INDEX OF 66KV XLPE CABLES

S. No.

PARTICULARS

SCOPE

STANDARDS

CLIMATIC CONDITIONS AND LAYING CONDITIONS

DESIGN & TECHNICAL DETAILS

MATERIAL AND CABLE CONSTRUCTION

CABLE JOINTING ACCESSORIES

MANUFACTURING PROCESS

QUALITY ASSURANCE

TESTING

10

TESTS AT MANUFACTURERS WORKS

11

MARKING ON OUTER SHEATH

12

SEALING AND DRUMMING

13

STANDARD LENGTH AND QUANTITY TOLERANCE

14

DETAILS OF PAST EXPERIENCE

15

GUARANTEED TECHNICAL PARTICULARS

16

ABSOLUTE GUARANTEES

Annexure-I

DESIRED TECHNICAL PARTICULARS OF 66 KV XLPE CABLE

TECHNICAL SPECIFICATION FOR 66 KV XLPE CABLE

1.0 SCOPE
1.1

Scope includes manufacture, testing before dispatch and delivery FOR destination of
66 KV XLPE Power cable of size 1200mm2 as per BOQ conforming to IS 7098 for
66kV cable work of LILO of one circuit of 66kV Sector 23- Dhundahera line at
proposed 220kV s/stn. Sector 20 enroute proposed 66kV s/stn. HSIDC Udhog Vihar
(3.91kms) and LILO of one circuit of Daultabad- Sector 9 line at proposed 66kV s/stn.
Sector 4 Gurgaon (3.47kms).

2.0 STANDARDS:
2.1 Unless otherwise stated hereafter, rating, characteristics, test and procedures etc.
concerning the 66kV XLPE cable shall be preferably as per IS, IEC standards given
below and shall be in compliance with the latest edition or revisions thereof and
meeting the constructional details and testing requirement as stipulated in foregoing
also.
IEC-60228
IEC-60229
IEC-60230
IEC-60270
IEC-60287-1-1
IEC-60502
IEC- 60840
IEC-62067
BIS: 7098 (Part-3)
IEEE:48

Conductor for insulated cable.

Tests on cable over sheaths
Impulse tests on cables and their accessories.
Partial discharge measurements
Calculation of continuous current carrying capacity.
Power Cables with extruded insulation and their
accessories.
Power Cables with extruded insulation and their accessories
for rated voltage above 30 KV upto 150 KV.
Tests for power cables with extruded insulation for rated
voltage above 150 kV upto 500 kV.
XLPE Cable specification for working voltages from 66 kV
upto and including 220 kV.
Tests procedures and requirements for high voltage cable
terminations.

2.2 The 66 KV XLPE cable may conform to any other authorities standards, which
ensures an equal or better quality than the standard mentioned above. The bidder
must specifically indicate the standards to which the cable conforms and indicate all
deviations (if any) from the preferred IS/ IEC codes that affect performance and rating.
2.3 Compliance of the 66 KV XLPE cable manufactured with the provisions of this
specification does not relieve him of the responsibility of furnishing 66 KV XLPE cable
and accessories of proper design, electrically and mechanically suited to meet the
operating guarantees at the specified service conditions.
2.4 If there are, in the opinion of the bidder, any conflicts between these codes and this
specification, these contradictions shall be brought to the attention of the owner.
3.0 CLIMATIC CONDITIONS AND LAYING CONDITIONS
The XLPE Power cable shall be suitable for continuous & satisfactory operation under
following conditions:Page-1

3.1 Climatic Conditions:i)

ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)

Peak ambient temperature in shade

Maximum average ambient temperature in 24 hours
period in shade
Min. ambient air temperature in shade
Maximum temperature attainable by an object exposed to
sun
Maximum relative humidity
Minimum relative humidity
Average number of thunder storm days per annum
Average number of rainy days per annum
Average annual rainfall
Number of months of tropical Monsoons conditions.
Maximum wind pressure
Altitude not exceeding

50oC
40oC.
(-) 5 oC.
55 oC
100%
10%
40
100
10 to 100 cm
4 months
100 kg/Sq.mm
1000 M

3.2 Conditions of Laying:i)

ii)
iii)
iv

Laid directly in ground / metaled road.

Installed outdoor in free air in vertical position.
Drawn into underground ducts in RCC trench.
Laid through special arrangement for crossing of Bridge/Nala

3.3 Condition of installation of XLPE cable:

i)
Ground Temp.

35o C

ii)

Maximum conductor temp.

90o C

iii)

Air temperature

50o C

iv)

Depth of RCC trench

1.5 m. approx.

v)

Formation

1 Ckts. in trefoil with spare

vi)

Bonding of metallic sheath

vii)
viii)

Number of 3 phase circuits

Thermal Resistivity of soil

Single point/ Both end/Cross

Bonding (as applicable)
Ckt-I
150o C cm/W or as per site
conditions

4.0 DESIGN & TECHNICAL DETAILS

4.1 Single Core XLPE cable suitable for 66 KV nominal system shall have construction as
under:
The cable shall be made of Segmental type (Milliken as per table2 of IEC:60228) for
size of 1200mm2 of 66kV, electrolytic grade Aluminium tapped with semi conducting
tape. Conductor screening shall be with extruded semi conducting thermosetting
compound layer. The cable shall be insulated with completely dry cured XLPE
insulation; Insulation screening for non-metallic part shall be with extruded semiPage-2

conducting thermosetting compound layer. Taping with semi conducting water

swellable tape shall be provided for longitudinal water sealing. Screening for metallic
part shall be with corrugated Aluminum or Lead Alloy E sheathed in combination with
bedding of semi-conducting tape(s) followed by annealed copper wires screen and
taped with open helix copper tape binder, if required followed by suitable non-metallic
tape binder and overall extruded black, PE or PVC sheath with outer conductive
coating. Power cable shall conform to the IS 7098(Part-III)/ IEC and foregoing paras
of this specification.
4.2. The covering shall be watertight, electrically insulated, rodent proof and vermin proof.
4.3 The offered XLPE cable for 66 KV earthed system shall meet the technical particulars
indicated in Annexure-I
4.4 The XLPE Cable shall be suitable for use where combined ambient temperature and
temperature rise due to load result in conductor temperature not exceeding 90 Deg C
under normal operation and 250 Deg C under short circuit conditions.
4.5 Offered XLPE cable end termination as well as jointing kits shall be of rated short
circuit current of 31.5 kA for duration of 1 second for 66 kV system.
4.6 The XLPE cables shall be designed to withstand the mechanical, electrical and
thermal stresses under the steady state and transient / fault conditions and shall be
suitable for proposed method of installation.
4.7 The cable shall be suitable for underground buried installation with uncontrolled back
fill and some of areas to be flooded by water in rainy season.
4.8 The sheath voltage under full load conditions shall not exceed the voltage specified /
allowed in relevant standards for safety of personal as well satisfactory working of
cable. Sheath shall be solidly grounded at suitable locations with / without SVL.
Bidder must indicate details of configuration proposed along with sufficiency
calculation with the bid so as to limit induced voltage of sheath within 65 V.
4.9 The charging current of the cable shall be as low as possible.
4.10 The XLPE cable shall be capable of withstanding the normal stress associated with
transportation, erection, reeling and unreeling operations without getting deformed.
4.11 The XLPE cable shall be used on System Voltage of 66 KV for 3-phase AC earthed
system. The cables shall be suitable for continuous operation at a power frequency
voltage 10% higher than system voltage.
4.12 Repaired cables shall not be acceptable.
5.0 MATERIAL AND CABLE CONSTRUCTION:5.1 Conductor:
5.1.1The Milliken segmental type shall be made of Aluminium complying to the
requirements of flexibility Class-2 of IEC-60228 / IS: 8130. The conductor shall have
high compactness & smooth surface finish.
Page-3

5.1.2 The minimum number of wires in conductor and D.C. resistance shall be as per tableII of IEC-60228 / IS: 8130. The grade and quality of the Aluminium used for the
conductor shall be as per IEC/IS standard.
5.1.3 The material & nominal area of conductor shall be as per BOQ.
5.2

Conductor Screen:

5.2.1 The conductor screen consisting of semi conducting compound layer shall be
provided over the conductor by extrusion which will not only eliminate the risk of
electric discharge at the interface between conductor and insulation but will also
present a very smooth protrusion free interface with the insulation to eliminate any
localized stress concentration. The screen shall be firmly bonded to XLPE
insulation.
5.2.2 The minimum thickness of extruded conductor screen shall be 1.0 mm. The outer
surface of the conductor screen shall be circular and free from irregularities. A nonhygroscopic semi-conducting tape, if required, shall be applied to the conductor
under extruded layer to prevent penetration of compound in to the conductor
interstices.
5.3

Insulation:-

5.3.1 The insulation composed of a special super clean grade layer of cross linked
polyethylene (XLPE) shall comply with the requirement of IS-7098(Part-III)/ IEC. The
insulation shall be applied by extrusion over the conductor screen and vulcanized
using dry curing process to form a compact homogeneous body free from micro
voids and contaminants.
5.3.2 The eccentricity of insulation should not be more than 10%.
5.4

Insulation Screening:

5.4.1 The insulation screening shall consist of two parts, namely, non-metallic and
metallic.
5.4.2 Non-Metallic Part (extrusion):5.4.2.1 A non-metallic insulation screen of semi-conducting compound similar to conductor
screen (clause 5.2) for similar purpose shall be applied directly over the insulation
core by extrusion and shall be continuous and cover whole surface area of
insulation. It shall be firmly bonded to the insulation.
5.4.2.2 The minimum thickness of extruded insulation screen layer shall be 0.8 mm, the
ovality of the core shall be not more than 5%.
5.4.3

Non-metallic part (taped)-Longitudinal water barrier:

5.4.3.1 Under-sheath, water barrier shall consist of a synthetic semi-conducting moisture

swellable layer (non woven synthetic tape with suitable water swellable absorbent
tape with suitable overlap) covering the whole surface area of the insulation screen.
The barrier shall restrict longitudinal water penetration under the metallic sheath.
The nominal thickness of water swellable tape shall be 0.3 mm.
Page-4

5.4.3.2

The semi conducting compound and the semi conducting tape shall be
compatible with the insulating material and suitable for the operating
temperature of the cable.

5.4.4

Metallic Part Radial Water Barrier:The metallic sheath of Aluminium sheath or Lead alloy E shall be provided over
the non-metallic part of the insulation screening. Metallic sheath, together with
copper screen (if required) shall be able to withstand short circuit current of
31.5 kA for duration of 1 second for 66 kV system. The details of metallic
sheaths are as under:

5.4.4.1

Lead alloy E Sheath:

i)

The lead alloy sheath shall have composition as per IS: 692. The lead alloy E
Sheath shall be extruded using a continuous screw press and shall be free from
all extrusion defects. The nominal thickness of lead alloy E sheath shall be as
per IEC-60502-2 / IS: 7098 (Part-3).
The bedding over the Metallic sheath shall be of semi-conducting tape(s)
Copper wire screen of annealed plain copper wires with gap shall be Helically
applied over the Radial Water Barrier lead alloy metallic sheath.

ii)

An open helix copper tape binder shall be applied over the copper wire screen.
The nominal thickness of the tape shall not be less than 0.1 mm. The minimum
thickness shall not fall below the nominal value by more than 10%. Suitable
non-metallic binder tape may also be applied over the copper screen to prevent
the penetration of the outer sheath in to the screen.

5.4.4.2

Corrugated Aluminium Sheath:i)

When the corrugated aluminium sheath is used, it shall be applied by

extrusion/seam-weld and then passing through a corrugating head. The
corrugating head contains rotating dies to form the valleys between the ribs
like sine wave and produce to correct diameter of sheath to fit over the
insulation. The sheath shall be free from pinholes flaws and other
imperfections.

ii)

Anti-corrosive compound shall be applied over the aluminium sheath.

5.5

Outer Sheath:-

5.5.1

The outer sheath shall consist of an extruded layer of black, PE or PVC type
ST-2 as per IEC/IS-7098 (Part-3)

5.5.2

The nominal thickness of outer sheath shall not be less than the value
calculated as per the recommendation of IEC 60502-2/IS-7098 (Part-3). The
outer sheath shall be of sufficient hardness to discourage termite and rodent
attack.
Page-5

5.5.3

Outer conductive coating / layer:

The outer conductive layer shall be of Graphite coating applied at works. This
conductive layer / coating must facilitate testing of the non-metallic outer
sheath. This test is important to ensure the physical integrity of the cable from
time to time be it at the factory, after transportation, directly after laying upon
completion of the installation.

6.0

CABLE JOINTING ACCESSORIES

6.1

The cable jointing accessories shall include the end terminating kits, straight
through joints. These shall be rated for 31.5KA for 66 kV system. The sheath
voltage under full load conditions shall not exceed 65V specified / allowed in
relevant standards for safety of personal as well satisfactory working of cable.
The sheath shall be solidly grounded.

6.2

The cable terminations shall be fire resistant. The components of kits shall have
flame retardant property.

6.3

All the cable sealing end/end termination kits and straight through joints shall be
either pre-molded or Heat shrinkable type upto 66kV level complete with
accessories from reputed manufacturer of proven design which has already
been extensively used and fully type tested. The make of termination kits and
straight through joints shall be got approved from HVPNL before bringing in
use.

6.4

The joint shall preferably be built up from the same material as the main cable
and shall have electrical and mechanical withstand capabilities same as or
better than the main cable. The joints shall be suitable for tropical climatic
conditions. The straight through joints shall be suitable for underground buried
installation with incorporated back fill and chances of flooding by water. The
straight through joints should be absolutely impervious to the entry of water.
The manufacturer shall use the proven technology and design to prevent entry
of water or any other liquid inside the straight through joints and cables.

6.5

The end termination shall be outdoor anti-fog type and shall be of porcelain
type with accessories. The outdoor terminal should be suitable for heavily
polluted atmospheric conditions with minimum creepage distance of 25 mm/kV
and protected creepage distance of not more than 50% of the total creepage
distance. The cable end terminals for terminating the cables shall be fully
compatible with the cables to be supplied. Field tests of sealing end terminals
shall be made in conjunction with the cables after installation of the cables and
terminals.

6.6

The testing of cable termination, sealing ends and straight through joints shall
be as per IEC-62067. All the type tests, sample tests and routine tests shall be
as per IEC-62067.

6.7

The cable termination and straight through joints shall bear guarantee for five
(5) years from the date of commissioning. Any defect noticed in the kit shall be
attended by the bidder immediately but not later than 24 hours on getting the
complaints and if required shall be replaced and installed free of cost, otherwise
the same will be arranged at the bidders risk and cost.
Page-6

7.0

MANUFACTURING PROCESS:

7.1

XLPE cable should be processed in a modern triple head extrusion

manufacturing line. XLPE extrusion and curing through Vertical Catanery
Vulcanisation system (VCV) or horizontal MDCV or CCV will be used to ensure
circularity and concentricity of the extruded layers around the conductor.

7.2

The conductor screen, insulation and insulation screen shall be extruded in one
simultaneous triple extrusion process (Clause 14.2.1 of IS: 7098-3) through
common triple crosshead. The extruders and triple crosshead shall be
designed to prevent stagnation of materials to eliminate hot spots and ensure
smoothness of the conductor screen and screen surfaces. Insulation thickness
should be controlled on-line using X-ray monitoring system.

7.3

The cross linking, curing and cooling shall be carried out in one operation and
shall be a dry curing process under high pressure to eliminate the formation of
voids in the insulation and contaminations in the dielectric.

7.4

Process conditions such as curing and cooling temperature, production speed

etc. shall be closely monitored during manufacture to ensure a good degree of
cross-linking through the whole insulation.

7.5

The manufacturing process shall be desired to eliminate irregularities like

protrusions, voids and contamination etc. to ensure the long-term reliability of
the cable.

7.6

Loading of the extruder in the manufacturing plant shall be performed entirely

closed and dust proof. The entire line of processing should be controlled from a
computerized central control console. Contamination shall be avoided by use
of a fully enclosed material handling system. To avoid contamination XLPE
Granules must be transported using gravitational material feeding system.

8.0

QUALITY ASSURANCE:-

8.1

Raw materials used for manufacture of cable shall be of highest quality and
material received by manufacturer should be checked / tested to ensure that it
meets manufacturers material specification. The materials shall be clean and
packed in moisture and dust proof packing.

8.2

As the Quality control of EHV XLPE cables while manufacturing is very critical
so expert supervision is required for raw material testing, in process checks and
also for final testing. A specially trained quality assurance team should be in
place for maintenance of the quality at an optimum level at the plant. Complete
details of manufacturing process along with details of automatic manufacturing
plant, shall be furnished by bidder in the bid.

8.3

Quality assurance plan indicating test /checks of raw material, process of

manufacturer and final inspection with customer hold point shall be submitted to
the purchaser for approval.

Page-7

9.0
9.1
9.1.1

TESTING:GENERAL:This schedule gives tests to be carried out on 66 KV, single core XLPE type
cables. The schedule of tests to be followed shall be generally as per IS7098(Part-3)/ IEC 62067/ IEC-60840 (For 66 KV cable).

9.1.2

The facilities available for site tests shall be clearly and implicitly brought out in
the Bid. The site tests shall be carried out during and after laying/installation by
the supplier.

9.1.3

This test schedule can be modified at the discretion of the purchaser to omit or
to include additional tests. Power frequency test shall be carried out at a
frequency of 50 Hz.

10.0
10.1

TESTS AT MANUFACTURES WORKS:The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC62067/
IEC-60840 (For 66 KV cable).

10.2

ROUTINE TESTS:The following shall be carried out as routine test:

a)
b)
c)

Conductor Resistance Test

Partial discharge Test
High Voltage Test

10.3

ACCEPTANCE TESTS:The following tests shall be carried out as special tests:

a)
Conductor Resistance Test
b)
Test for dimension of Insulation
c)
Hot Set Test for Insulation
d)
Test for thickness of metallic Sheath.
e)
Partial Discharge Test.
f)
High Voltage test.
g)
Measurement of Capacitance.

10.4
10.4.1

TYPE TEST(s):The cables offered should be fully type tested. Type test reports (not more than
seven years old reckoned from the date of bid opening in respect of all the type
tests carried out as per relevant IEC/ IS standards from Govt./ Govt. approved
reputed test house shall be submitted along with the bid.

10.4.2

The bidder must have all testing facilities available at their works for testing the
material as per clause 8 above. Detailed list of testing equipment along with
relevant tests must be furnished with the tender other wise offers is likely to be
ignored.

11.0
11.1

MARKING ON OUTER SHEATH:The following particulars shall be marked on cable outer sheath:
Manufacturers name/ or trade name
Voltage grade viz. 38/66 KV.
Cable size ( no. of core x conductor cross section)
Year of manufacture.
Purchasers name i.e. HVPNL
Page-8

11.2

The spacing between one set of marking and the beginning of the next on the
legend shall not exceed 150 mm.

11.3

Besides above, progressive sequential marking of length shall also be provided

at every one meter, which shall be clear and legible sequential length working
by embossing/ engraving/printing.

12.0

SEALING AND DRUMMING:-

12.1

Immediately after the works tests, both ends of every length of cable shall be
sealed by means of heat shrinkable end caps.

12.2

Cables shall be wound on metallic drums. All the drums shall be arranged to
take a round spindle and be legged with strong closely fitting wooden battens
so as to prevent damage in the cable. Each drum shall bear an identification
number permanently stenciled or branded on the outside of the flange.

12.3

Cable reels shall be of rugged construction, with a drum diameter of ample

dimensions to accommodate the single conductor. Manufacturer shall be
responsible for any damage to the cables during transit. Changes in the shape
of the cable during transit shall not result in deformation in metallic drum.
The cable drum/ reel shall carry the following information clearly marked on
one flange of the drum.

12.4

Manufacturer's name, Brand or trade mark.

Conductor of cable.
Type of cable and voltage grade.
Size of cable.
Length of cable on the drum.
Direction of rotation of drum (by means of an arrow).
Net weight
Gross weight.
Year of manufacture.
Confirming to IEC/IS No
Purchase order details.
Name of owner.
Name of consignee.
13.0

STANDARD LENGTH AND QUANTITY TOLERANCE:-

13.1

The Standard length of cable shall be Minimum 500m. to 750m. However,

based upon the production capacity, the successful bidder may offer the larger
length of the cable in order to optimize the No. of Mid-span joints (subject to
safety & ease of cable during wounding on drum, transportation & its
erection). Also the delivery length of cable shall match with the location of
jointing bays as described in Erection part. The line-wise detailed survey
shall include the loops in between the route & at both ends of s/stns. The
successful bidder shall give an undertaking in this regard for the offered length.
No negative tolerance in length shall be permitted.
The sufficient loop of 66kV D/C line cables shall be taken at upcoming
66kV s/stn. Udhog Vihar (HSIDC), the tentative length of loop for bidding
purpose has been considered as 100m.
Page-9

14.0

DETAILS OF PAST EXPERIENCE: -

14.1

The details of past orders executed by

the relevant schedule.

15.0

GUARANTEED TECHNICAL PARTICULARS:-

15.1

The bidder shall furnish guaranteed technical particulars of cable in the relevant
schedule enclosed

16.0

ABSOLUTE GUARANTEES:-

16.1

All commissioning tests and performance tests shall be treated as absolute

guarantee and in the event of failure in any of such test(s) the bidder shall take
steps to rectify/replace/modify at his cost the defective components(s),
assemblies. The equipment after such rectification/repair shall be re-tested at
bidder cost at site.

16.2

The satisfactory performance of materials supplied shall be Guaranteed as

indicated in Commercial bid document. Technical Parameters of the cable shall
be as stipulated in Annexure-I:

the bidder shall be indicated in

Annexure - I
DESIRED TECHNICAL PARTICULARS OF 66 KV XLPE CABLE
S. No.

Particulars

Technical Details

Cable

Single Core, Aluminium

Conductor XLPE cable
Conforming to IEC 60502,60840/
IS 7098(part-3) amended up to
date.
66 KV 10% kV, 50 Hz 3%
72 kV
YES

Applicable standard
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
v)

System voltage & frequency

Highest System Voltage
Suitable for earthed system
CONDUCTOR
Material
Nominal cross-sectional area
Construction of conductor/flexibility
class
Shape and formation
Approx overall diameter of
conductor

Milliken segmental type

1200mm2
Class-2, IEC 228 / IS: 8130
Very well compacted
to be indicated

Page-10

6.
i)

CONDUCTOR SCREENING
Material & type

ii)
iii)
7.
i)

Grade
Thickness
INSULATION
Material

ii)

Nominal thickness of insulation

8.
A

INSULATION SCREENING
Non-metallic part(extruded)
Material

i)
ii)
iii)

i)
ii)
C
i)
ii)
iii)
D
E

Grade
Min. thickness.
Non-metallic part (taped)
longitudinal water barrier over
insulation screen.
Material
Min. thickness
METALLIC SHEATH
Material
Min. Thickness(mm)
Short Circuit Current Withstand
[Metallic sheath, together with
copper screen (if required)]
Bedding over lead sheath
CONCENTRIC COPPER WIRE
SCREEN (IF REQUIRED)
Material and type

i)
Min. area (Sq. mm)
ii)
9.

OUTER SHEATH
Material

i)
ii)
10.
11.
12.

Min. thickness of outer sheath

Conducting layer over outer
sheath
Approx overall diameter of cable
(mm)
Approx. weight per meter of cable
(kg/m)

Extruded, semi conducting

compound layer.
As per IEC/IS
1.0 mm
Cross linked polyethylene(XLPE)
As per 7098 (Part 3)

Extruded semi conducting

Compound layer.
As per IEC/IS: 7098 (Part 3)
0.8 mm

Synthetic Non-woven semi

conducting Water swell-able tape
As per standard.

Corrugated Aluminium / Lead alloy

E sheath IS 692
Conforming to IEC 60502/ IS: 7098
(Part 3)
31.5 kA for one Second

Semi conducting tape(s)

Annealed plain copper wires applied

helically with gap followed by open
helix of copper tape binder
This and lead alloy E sheath shall
meet earth fault current of 31.5kA for
a duration of 1 second.
Extruded Layer of Black PE or PVC
type ST-2 as per IEC-60502 / IS:
7098 (Part 3)
As per standard
Graphite coating
To be indicated
To be indicated
Page-11

13.
14.

15.

16.
i)

ii)

17.
18.
19.
20.
21.

Recommended minimum
installation radius.
Maximum D.C. Resistance of
conductor at 90 deg C in ohm/km.
Continuous current rating for each
circuit when laid in ground in trefoil
formation and other condition
given in specification.
Maximum allowable temperature
for cable and accessories.
At rated full load and at site
conditions.
The conductor temperature after a
short circuit for one second shall
not exceed (with conductor
temperature at start of short
circuits as 900 C).
Basic impulse insulation level
(1.2/50 micro second wave)
Power frequency withstand voltage
Symmetrical Short circuit rating for
one second duration for lead
sheath and copper screened
combined/ Aluminium Sheath
Drum Length
Expected cable life.

To be indicated
As per standard
To be indicated

90 Deg C
250 Deg C

As per Standard
As per Standard
31.5 kA for 1 Sec.

AS per Clause No.-13.0

35 years.

Page-12

INDEX OF ERECTION OF 66KV XLPE CABLES

S. No.

PARTICULARS

SCOPE

ROUTE SURVEY

STATUTORY CLEARANCES

CABLE HANDLING

DAMAGE TO PROPERTY

CABLE ROUTE MARKERS / CABLE JOINT MARKERS

DEPTH OF LAYING OF CABLES

PAYING OUT THE CABLE

SAND BEDDING

10

BACK FILLING

11

WARNING TAPE

12

PREVENTION OF DAMAGE DUE TO SHARP EDGES

13

ROAD, RAIL & CANAL CROSSINGS

14

TRENCH LESS DIGGING

15

JOINTING BAY

16

TOOLS & PLANTS

17

BENDING RADIUS

18

JOINTING AND TERMINATION OF CABLES

19

SUMPHOLES

20

TENTS/ COVERS

21

PRECAUTIONS BEFORE MAKING A JOINT

22

MEASUREMENT OF INSULATION RESISTANCE

23

IDENTIFICATION

24

MAKING A JOINT

25

CABLE TERMINATIONS

26

CABLE TERMINATING STRUCTURES

27

EARTHING

28

TESTS AFTER INSTALLATION

SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS

ERECTION PART

TECHNICAL SPECIFICATION OF LAYING, ERECTION, TESTING & COMMISSIONING

OF CABLES:1.0
1.1

Scope: Complete installation, laying, testing and commissioning of the cable of the D/C lines shall
be the responsibility of the bidder. Four runs of the cable per circuit shall be laid as per
the tentative route plan enclosed. The scope for installation work shall, therefore include,
but not limiting to: 1. Route survey for the entire route length under the scope of work.
2. Clearances from relevant Local Authorities for laying of cables. All the protective
measures for laying, protection and for smooth working of all the cables as per statuary
norms/standards to be followed/ensured by the bidder for its safe and smooth operation
in future.
3. Laying of cables under scope as per specification. At most of the route length, the
cables shall be laid through Trench-less technology at depth of 2.5m to 3.0m.
4. Measurement of Thermal resistivity of soil. The value of thermal resistivity will be
intimated to field office.
5. Transportation of cable drums & other material.
6. All civil works required for laying of the cables, which shall include design, construction
materials and labours. Manholes shall be provided at every proposed joint location for
jointing bays. The bidder shall identify the location of the joint bays after carrying out
detailed survey of the cable route and excavation of the trial pits. The delivery lengths of
the cables shall match the location.
7. Laying & installation of cables in ducts, in HDPE pipes and through Trench less method of
required strength for various crossings, in air at terminations at the tower, at varying
depths due to obstructions, construction of cable jointing bays.
8. Supply of HDPE pipe of required strength of ISI mark shall be 1.5 times of Cable. The
HDPE pipes are required for crossing of roads/ Bridge/Railways/culverts/water courses/
Nala/ Sewerage pipe lines/Oil /Gas pipe lines and for Trench-less system. The pipes to be
filled with sand/suitable material after cabling in Road crossing .
9. Supply & Erection of terminal structures including foundations between the line for
supporting cable end terminations, it shall include the supply of Earthing material,
Earthing of each cable, post insulators for cable support, civil foundation design,
construction material and labours etc.
Page-1

10.

The cables will be terminated on the cable termination structures in the s/stn. premises
and the cable will be terminated on the tower at the point of connection with Overhead line.
Where the cable is to be terminated on the tower (tower will be erected
departmentally), the LAs will have to be mounted on the tower by making suitable
arrangement and the independent earthing of LAs mounted on the tower and of each
cable shall be got done to the satisfaction of Engineer-incharge. The size of
galvanised flat to be used for earthing of LAs shall be 75X12mm.

11.

Termination of cables at both ends. Suitable loops shall be provided at both ends.

12.

It shall be the responsibility of the contractor to terminate the fourth (spare) run of the
cable at the terminal structures in such a way that it shall be possible to connect it to
all the three phases of conductor by changing jumpers only. However this spare cable
shall be connected to nearest conductor to avoid theft/moisture in-gress. Necessary
bonding of the cable screen shall be done by the supplier.

13.

Tentative Quantity of LAs shall be as per BOQ attached. The drawings of LAs shall be
got approved from HVPNL .

14.

Cable markers as per statutory requirements shall be provided all along the route at a
maximum distance of 100 meters and other important locations. Also the location of
the underground cable shall be clearly indicated on the marker.

15.

The bidder shall make his own arrangement for boarding & lodging of his men
engaged in the work.

16.

Training of HVPNLs Engineers & jointers.

17.

The laying of cables shall be through proposed densely populated residential/industrial

area. Therefore, utmost precautions shall be taken for erection of cables by the
contractor for safety of the public. All the bidders are strongly advised to visit the site
through field office and acquaint themselves with the topography, infrastructure,
crossings involved etc. before submitting the bids. Suitable protection of XLPE cables
and Public property shall be ensured to the satisfaction of Engineer-incharge. The
successful bidder shall be fully responsible for providing all equipment, materials,
system and services specified or not, but are required to complete the erection and
successful commissioning of 66 KV cable complete in all respects. The cost of
carrying out such works, shall be deemed to be included by the bidders in the last
column of Supply & Erection portion. Nothing Extra shall be paid later-on on this
account except for the variation in the quantities of the items shown in Supply &
Page-2

18.

Erection portion. After award of contract, its Design/Drawings will be got approved
before execution of work.

19.

The design of all type of crossings is in the scope of the bidder and work

shall

be

started only after getting the design / Drawings approved from HVPNL.
2.0

Route Survey
The bidder shall fully familiarize himself with the site and route conditions etc. The
complete design and detailed engineering shall be done by the contractor. The survey
shall be conducted for underground routes to finalize the route and paths for the
underground cable. Contractor shall arrange information about existing under ground
facilities for the proposed routes. To do so as built drawings or route index diagram
for various services viz water works, electric supply utilities, telecom services, public
health, Gas/oil authorities etc. may be collected from the concerned authorities. In
case details are not available, the contractor shall assess suitably by conducting
enquiries and surveys. The contractor shall prepare and submit the final survey report
showing all the details enroute for HVPNL approval.

3.0

Statutory Clearances
The contractor shall coordinate on behalf of owner, for obtaining necessary clearances
for laying of cable and carrying out excavation/ digging work from the authorities on
behalf of the Employer and provide requisite copies of information maps, survey report
etc. to the authorities. The employer shall assist the contractor in obtaining such
clearances by providing the authority letter or any other relevant document. The
contractor shall ensure quick and speedy clearances in order to implement the project
within stipulated schedule. In case the authorities have some objections on certain
sections of routes proposed and are unwilling to provide clearances, the contractor
shall propose an alternate route, promptly carrying out the survey and submit specific
survey report for that and reapply for clearance after taking into account the
comments/objections of the authority. The clearance of the Chief Electrical inspector
under Electricity laws shall solely be in contractors scope.

4.0

CABLE HANDLING
The inspection of cable on receipt, handling of cables, paying out, flaking, cushioning
with sand or sieved compacted soil, back-filling, providing and fixing joint markers,
route indicators, and all necessary precautions that are required shall be carefully
planned and in general conform to IS 1255-1983 or its equivalent.

5.0

DAMAGE TO PROPERTY
The contractor shall take all precautions while excavation of trench, trial pits & drill for
trench-less laying etc., to protect the public and private properties and to avoid
accidental damage. Any damage so caused shall be immediately repaired and brought
to the notice of the Employer.
The contractor shall bear all responsibilities and liabilities and shall bear all costs of
the damages so caused by him or by his workman or agents.
Page-3

6.0

CABLE ROUTE MARKERS/CABLE JOINT MARKERS

Permanent means of indicating the position of joints and cable route shall be
fabricated supplied and erected.
Markers provided shall be as per the field requirement, if the route passes through
open fields, markers should be conspicuously visible above ground surface.
The marker should incorporate the relevant information. The name of the owner,
voltage, circuit & Danger sign. The drawing of marker is enclosed with the bid.

7.0

DEPTH OF LAYING OF CABLES

Depth of laying of cables shall be 1.5m for directly buried cables ( trench method) and
2.5m-3.0m in Trench-less method Laying at varying depths due to obstructions/site
conditions may be accepted subject to field office approval during detailed
Engineering. The typical cross-section drawing of trench is enclosed with this
specification.

8.0

LAYING OUT THE CABLE

The excavated cable trench shall be drained of all water and the bed surface shall be
smooth, uniform and fairly hard before laying out the cables. The cables shall be rolled
in the trench on cable rollers, spaced out at uniform intervals. The laying out process
must be smooth and steady without subjecting the cable to abnormal tension or
scratches. The cable being laid out shall be smoothly and evenly transferred to the
ground after proving the sand cushion. The cables shall never be dropped. Suitable
size cable stocking pulling eye shall be used for pulling the cable. While pulling the
cable by winches or machines, the tension loading shall be by tension indicator and
shall not exceed the permissible value for the cable..
The cable end seals shall be checked after laying and if found damaged shall
immediately be resealed. Sufficient number of heat shrinkable cable end sealing caps
shall be stocked at site stores for testing and jointing work. The integrity of the outer
sheath shall be checked after the cable is laid in position.
The sealing of power cable ends during the storage, execution & completion of jointing
work shall be in the scope of successful bidder. Under no circumstances, the cable
ends shall be kept open. The amount due to damages done because of
water/moisture ingress OR penetration in the cable / conductors during execution shall
be recovered form successful bidder. It shall be responsibility of successful bidder to
repair OR replace free of cost without affecting the completion schedule.

9.0

SAND BEDDING:
The cable shall be completely surrounded by well-compacted sand (River bed sand) to
such a thickness and of such size that the cable is protected against damage.
Precast RCC slabs in M-20 of size 500X300X65mm for 66kV and shall be provided for
protection of the cable by covering the cable as per drawing enclosed. Every pre-cast
slab shall carry the engraved words as- HVPNL 66kV.
Page-4

10.0

BACK FILLING:
Normally back filling shall consist of the material earlier excavated. However, bigger
stones or pieces of rock should be removed & shifted at approved locations of Local
Authority. The compaction of Earth filling shall be ensured by the contractor 95% of
the Proctor density.

11.0

WARNING TAPE:
A pre-warning, Red colour plastic/PVC tape, 250 mm wide 100 microns thick shall
be laid at approx. 0.4 m above the cable specified depth, throughout the cable route.
The tape shall carry the legend printed in black continuously as under CAUTION
HVPNL, 66000 V CABLES.

12.0

PREVENTION OF DAMAGE DUE TO SHARP EDGES

After the cables have been laid in the trench and until the cables are covered with
protective covering, no sharp metal tool shall be used in the trench or placed in such a
position that may fall into the trench.
Straight and curved rollers used shall have no sharp projecting parts liable to damage
the cable.
While pulling through pipes and ducts, the cable shall be protected to avoid damage
due to sharp edges.
The cables shall never be bent, beyond the specified bending radius.

13.0

ROAD, RAIL & CANAL CROSSINGS

The road, Rail & Canal crossing should be done by HDPE pipes of required strength
of diameter not less than 1.5 times the cable diameter.

14.0

Trench less Digging:

If required, trench-less digging shall be used for all roads crossings and through
congested Urban streets of HUDA/industrial area. The various methods of trench less
digging such as hand/manual auguring (up to 15m), impact moling (from 16m to about
40-50m). HDD (above 40-50m) shall be adopted based on the soil/site conditions and
the requirement and exact method for trench less digging shall be finalised during
detailed engineering as per actual site/soil condition.
The contractor shall propose the exact methods and procedures for
implementation of trench less digging at various crossings taking into
consideration the following guidelines, for approval by the Employer:a)
b)
c)
d)
e)
f)
g)

Excavation and backfilling of trial pits and verification of soil condition.

Excavation of entry and Exit pits.
Erection of drill machined drilling of pilot hole.
Placement and driving hand augur.
Placement and carrying out impact moling.
Reaming and widening of bore holes in steps (if required).
Pulling of product pipe.
Page-5

15.0

JOINTING BAY
Manholes shall be provided at every proposed joint location for jointing bays. The
bidder shall identify the location of the joint bays after carrying out detailed survey of
the cable route and excavation of the trial pits. The delivery lengths of the cables shall
match the location.
In case of underground portion, the joint bays should have a flat and level surface
lined with bricks and properly plastered. The retaining walls on all sides to the required
height shall be of brick/stone masonry. The top of the wall shall have a cement
concrete band 1:2:4 with 20mm size aggregate all-round. The top shall be covered
with pre-fabricated RCC slabs and with an inspection cover. Al the bottom in a corner,
a sump-pit shall be made for bailing out water.
The contractor shall submit design and drawing of Jointing bay for HVPNL approval.
All works shall be carried out under supervision of the engineer in charge or his
representative.

16.0

TOOLS AND PLANTS

The successful bidder shall have all necessary tools, plant and equipment to carry out
the survey and cable installation work.
The bidder are instructed to give all the details of equipment at their disposal, to carry
out the work successfully and speedily.

17.0

BENDING RADIUS:
The minimum bending radius of XLPE insulated cables are as follows:
Cable

Bending radius

Single Core

20 x D

D means the overall diameter of the completed cable.

18.0

JOINTING AND TERMINATION OF CABLES

The cable jointing personnel and his crew shall have good experience in the type of
joints and terminations that are used. The jointing work shall commence as soon as
two or three lengths of cables have been laid. All care should be taken to protect the
factory-plumbed caps/ seals on the cable ends and the cable end shall be sealed
whenever the end is exposed for tests.
Jointing of cables in carriage ways, drive ways under costly paving, under concrete or
asphalt surfaces and in proximity to telephone cables and water mains should be
avoided whenever possible.
Sufficient over lap of cables shall be allowed for making the joints.
The joint bay should be of sufficient dimensions to allow the jointers to work with as
much freedom of movement and comfort as possible. Sufficient space should be kept
below the cable to be jointed.
The joints of different phases shall be staggered in the jointing bay.
Page-6

19.0

SUMPHOLES
When jointing cables in water logged ground or under unforeseen rainy conditions, a
sumphole should be made at one end of the joint bay, in such a position so that the
accumulated water can be pumped or baled out by buckets, without causing
interference to the jointing operation.

20.0

TENTS/ COVERS
An enclosure or suitable protection cover shall be used in all circumstances wherever
jointing work is carried out in the open irrespective of the weather conditions. The joint
shall be made in dust free, moisture free and clean atmosphere.

21.0

PRECAUTIONS BEFORE MAKING A JOINT

The cable end seals should not be opened until all necessary precautions have been
taken to prevent circumstances arising out of rainy/ inclement weather conditions,
which might become uncontrollable.
If the cable end seals or cable ends are found to have suffered damage, the cables
should not be jointed, without tests and rectification.

22.0

MEASUREMENT OF INSULATION RESISTANCE

Before jointing, the insulation resistance of both sections of cables shall be checked.

23.0

IDENTIFICATION
The identification of each phase shall be clearly and properly noted. The cable shall be
jointed as per the approved design. Each cable shall have identification for phase at
joint bays.

24.0

MAKING A JOINT
Comprehensive jointing instructions should be obtained from the manufacturer of
jointing kits and meticulously followed.
The materials used in the joints like ferrules, screen/sheath continuity bonds, lugs etc.,
shall be of good quality and conform to standards. The jointing tools shall be
appropriate and as per the requirement of jointing HV XLPE cables.

25.0

CABLE TERMINATIONS
The preparation of the cable end for installing the terminations and the precautions to
be taken before fixing the terminations shall be followed as in the case of the cable
jointing procedures.
The instructions furnished by the termination manufacturer shall be strictly followed:
At cable terminating end, the following provisions for supply and erections are to be
included:
A sufficient length of spare cable shall be left in the ground, for future needs.
Page-7

The cable shall be properly fastened using non-metallic clamps.

The spare cable shall be connected to its nearest cable on load so as to avoid its theft
and moisture ingress.
Appropriate labels shall be fixed identifying the phase circuit, voltage and date of
commissioning etc., on the cable supporting structure.
26.0

CABLE TERMINATING STRUCTURES

The terminating structure being provided shall be of bidders standard design as per
requirement of cable end sealing, porcelain bushing etc.
The mounting structure shall be fixed on the cement concrete foundation, the design
and drawings of which shall be submitted to Employer for approval and acceptance
during the course of detailed engineering.
After fixing the end termination, the cable shall be fixed to the support, with nonmagnetic material clamps to the required height securely.The mounting structure
includes the supports for cable end boxes, post insulators, link boxes and any other
structure required for the intent of the contract. All steel sections used shall be free
from all imperfections, mill scales, slag intrusions, laminations, fillings, rust etc. that
may impair their strength, durability and appearance. All materials shall be of tested
quality only.

27.0

Earthing:Bidder shall carry out the earthing of sheath/ screen at the cross bonding points as
well as at the ends of cable using insulation sheath bonding (earthing) cable of
required size through link boxes with/ without surge voltage limiter at cross-bonding
points and terminal substations. Earthing shall be as per relevant standards. The
sheath /screen shall bound in the earth station through disconnecting type link boxes.
Screen continuity by using tinned copper mesh and earth continuity by tinned copper
braids of appropriate size shall be provided for transfer of screen/earth in straight
through joints.
All the LAs to erected on the towers shall be properly earthed through 75X12mm GI
strip to the satisfaction of field office.

28.0

TESTS AFTER INSTALLATION

All tests as prescribed in IEC-60840: 1999 shall be performed after installation
able.

of
Page-8

SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS

1.0 EXCAVTION
1.1

The specification covers excavation for cable trenches, ducts, structural foundation,
jointing bays.

1.2

The contractor shall control the grading in the vicinity of all excavations so that the
surface of the ground will be properly sloped or diked to prevent surface water from
running in to the excavated area during construction.

1.3

The excavation shall include the removal of all materials required to excute the work
properly and shall be made with sufficient clearance to permit the placing, inspection
and setting of forms and completion of all works for which the excavation was done.

1.4

The sides and bottoms of excavation shall be cut sharp and true. Under cutting shall
not be permitted. Earth sides of excavations shall not be used in lieu of form work for
replacement of concrete unless authorized by the Engineer where the limititations of
space for large excavation necessitate such decision.

1.5

When machines are used for excavation th last 300 m,m before reaching the required
level shall be excavated by hand or by such equipment that will leave the soil at
required final level in its natural condition.

1.6

The bottom of the excavation shall be trimmed to the required level and when carried
below such level by error, shall be brought to level, by filling with lean concrete of 1:4:8
Mix at contractors cost.

1.7

All excavation for installation of underground facilities shall be open cuts.

1.8

The excavations for foundation where specified shall be carried out at least 75 mm or
as specified in relevant drawing below the bottom of the structure concrete and then
be brought to the required level by placing lean concrete of 1:4:8 mix or as specified
with aggregate of 40 mm nominal size.

1.9

When the excavation requires tracing, sheeting, shoring strutting etc. the contractor
shall submit to the Engineer in charge drawings showing arrangement and details of
proposed installation and shall obtain the approval from the Engineer in charge before
proceeding with the work.

1.10

The contractor shall have to constantly pump out the water collected in the pits,
trenches due to rain, sub soil, springs etc. and maintain dry working conditions at no
extra cost to the owner.

2.0 DISPOSAL OF EXCAVATED EARTH

2.1

The contractor shall arrange to transport the surplus excavated earth by mechanical
transport. It shall however be ensured that no stacked/disposed shall be as directed
by the Engineer-in-charge.
Page-9

2.2

3.0

However the contractor shall take all precautions at the site of excavation for keeping
the free flow of vehicular and human traffic and to avoid inconvenience in general. The
soil transported for disposal shall be stacked, leveled and dressed neatly.

BACK FILLING MATERIALS

3.1. The backfilling of excavated trenches around foundation shall consist of one of the
following materials as the Engineer-in-charge may direct in each location.
i) Selected sieved earth from excavated soil.
ii) Selected sieved earth brought from borrows area.
iii) Sand filling (sieved).
3.2 Filling shall be done after the concrete or measonry work has fully set and its curing
completed.
3.3 The contractor shall fill in and around any work until it has been properly reinstated and
approved by the Engineer-in charge.

4.0 BACK FILLING FOR CABLE TRENCH

4.1 Back filling shall be done in horizontal layers of thickness not exceeding 300 mm
thickness, free from pockets with careful watering where necessary for compaction. The
backfill shall be riddled earth free from materials likely to cause damage to the cables.
4.2 The thermal backfill surrounding the cable shall be as per the design approved by the
owner.

5.0 SPECIFIATION FOR CEMENT CONCRETE

5.1 For the cement concrete, plain or reinforced for general use, requirement of concrete for
nominal mix, strength and quality pouring at all levels, from works, protection covering,
finishing, admixture, inserts, curing etc. the provision of the latest revision of IS:456 shall
be complied with, unless permitted otherwise by any other Indian Standard codes, shall
form the part of the specification to the extent applicable within specification. The cement
used shall comply with IS:12269 (OPC).

6.0

CURING AND PROTECTION OF CONCRETE

All fresh concrete shall be covered with the layer of an absorbent material and kept
constantly wet for a period of seven days or more from the date of placing concrete.
The immature concrete shall be protected from the damages and contamination that
would impair the strength of the concrete.

7.0 PRECAST RCC ITEMS

7.1

7.2

The concrete mix for the various types of pre-cast units shall confirm to IS: 456. The
aggregate shall be mixed by weight and water cement ratio shall be controlled to
obtain the dense concrete and the strength required. The reinforcement shall be as
per the design approved. The curing shall be carried out for the period of minimum
seven days from the date of casting and precast element shall be cured by flooding
with water of minimum 25 mm depth over the element for the period mentioned above.
All the pre-cast element shall be marked, appropriately as specified.
Page-10

8.0 FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as
per approved drawings.

9.0 BOLTS, NUTS AND WASHERS

Standard bolts, nuts an washers shall be used in all works. These should be
galvanized in accordance with IS: 5358.

10.0 PAINTING
Outdoor Kisok for link boxes etc., shall be painted with anticorrovise paint and red
oxide as primer and two coats of enamel paint. The boxes should be appropriately
labeled as per installation at site regarding the S.No., location, type caution
board/danger.

11.0 MATERILAS USED IN CABLE LAYING

Specification in brief on the materials used in installations of the underground cables,
like RCC precast cable protection covers, precluded cement concrete blocks for cable
route. Joint indication, cable and mounting structures joints bays, earthing and other
miscellaneous materials are given below. All materials shall conform to relevant
standards and shall be approved by the Engineer in charge.

12.0 RCC PRE CAST CABLE PROTECTION COVERS

These should be fabricated as per the design supplied by the contractor and approved
by HVPNL. The reinforcement cement concrete should be in the proportion 1:1.5:3 of
20 mm and down size aggregate and steel reinforcement of 8 mm diameter conform to
IS 1786 for deformed and cold twisted steel rods should be used and cured as per
Civil Engineering standards. The covers should carry the legends HVPNL 66 KV
Cables as the case may be. The covers should be free from burrs and projecting
edges so that may be easily laid to butt.

13.0 CABLE ROUTE MARKERS/JOINT MARKERS

13.1
13.2

13.3

Permanent and durable type, cable route markers/joint indicating blocks should be
provided as per the design approved by the purchaser.
The Reinforced cement concrete block should be made by the wet process and all the
concrete shall consists of one part cement, one and a half part sand, three parts
aggregates of size 20 mm and down.
The marking block should be given a smooth cover surface or cement mortar and shall
have the appropriate legends, 5 mm deep engraved on them as HVPNL 66 CABLE
Ckt.- I OR HVPNL 66 KV CABLE Ckt.- II, HVPNL 66 KV CABLE or as the case may
be.

Page-11

14.0 PIPES
14.1

14.2

HDPE pipes of ISI mark, of approved diameter and thickness, of good quality shall be
used for formation of cable ducts. All sundry materials like coupling, collars, and caps
to cover the pipe ends before cable is pulled in shall be provided.
The bidder shall furnish the design drawings of foundations, foundation anchor bolts,
and design calculations etc. of these structures.

15.0 SAND
15.1

15.2

Sand supplied for backfill shall be river sand, free from flakes, dust, earth, organic
matter and large pebbles and stones and should be free from any chemical
contaminats likely to have corrosive action on the cable coverings. The sand should
be sieved through a mesh to remove all large stones and pebbles. The sand shall be
properly graded and shall conform to IS:383 for concreting work.
The owner will decide on the requirement of the use of sand depending on the
availability of the excavated earth to be used for backfill. The sand should be used
with the approval of the owner as a backfill.

16.0 QUANTITIES
16.1

16.2

The quoted price shall also include supply of all material transportation charges, taxes,
duties, Octoroi and tole tax, labour, construction, plant and equipment and fixture,
fittings and all temporary and permanent works necessary for satisfactory completion
in all respects.
If the owner is directed by the Engineer in charge to excavate to a lower level than that
indicated in the drawing, such additional excavation shall not be paid for & will be
deemed to be included in the quoted rates.

16.3 LEAD AND LIFT

The rates quoted for all items of works shall include all lifts and leads wherever
applicable unless otherwise specified.

16.4 BY MECHANICAL TRANSPORT

The rate for this item shall include loading, carriage, unloading, stacking and dressing
etc. complete. In no case the excavated soil shall be stacked up to the distance of 1.5
Mtrs. From the edge of excavation or one third the depth of excavation whichever is
more.

Page-12

16.5

The contractor shall be responsible for estimates, assumptions and conclusions

regarding the nature of the materials to be excavated and difficulty of making and
maintaining of required excavations and performing the work required as shown on the
drawing and in accordance with these specifications. Cofferdams, sheeting, shoring.
Draining, dewarering etc. shall be furnished and installed as required and the cost
therof shall be included in the rate quoted. The contractor shall be held responsible for
any damage to any part of the work and property caused by collapse of sides of
excavation. The materials can be salvaged if it can be done with safety for the work
and structure and as approved by the Engineer in charge.

16.6

However, no extra claim shall be entertained for material not salvaged or any other
damage to contractors proper as the results of the collapse. He shall not be entitled to
any claim for redoing the excavations as a result of the same.

17.0 ROAD CUTTING

The road cutting, whether of cement concrete/ asphalt or macadam road surface shall
be taken after obtaining approval for cutting from the civic authorities, traffic police,
telephone authorities and work should be planned to be completed in the shortest
possible time. Where necessary work shall be planned during night or light traffic
periods.

18.0 ROAD CROSSING

HDPE pipes shall be used for cable. Pipes diameter should not be less than 1.5 times
the cable diameter.

19.0 FOOTPATH CUTTING

The slabs, kerb- stones, on the roads shall be removed and reinstated without
damage.

20.0 REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfill all joints and
cable positions should be carefully plotted and preserved till such time the cable is
energized and taken over by the Engineer. The protective covers shall then be
provided, the excavated soil riddled, sieved and replaced. It is advisable to leave a
crown of earth not less than 50 mm and not more than 100 mm in the centre and
tapering towards the sides of the trench.
20.1

The temporary reinstatement of roadways should be inspected at regular intervals,

more frequently in rainy season and immediately after overnight rain for checking
settlement and if required the temporary reinstatement should be done.

Page-13

20.2

After the subsidence has ceased the trench may be permanently reinstated and the
surface resorted to the best possible condition.

20.3

The road surface being cement concrete, asphalt or tarred macadam, resurfacing will
be done by the civic authorities at owners cost. The fixing of markers etc. shall be coordinated by bidder.

20.4

All works shall be carried out under supervision of the Engineer in Charge or his
representative.

21.0 MAINTENANCE OF SITE CONDITIONS

The contractor shall be clean the completed cable route and shall remove all surplus
and waste materials, empty cable reels etc. preferably the same day but not later than
the next day after the particular work is completed.

Page-14

Bill of material of LILO of one circuit of 66kV Sector 23- Dhundahera line at proposed 220kV
s/stn. Sector 20 enroute proposed 66kV s/stn. HSIDC Udhog Vihar .
(Supply Portion only)
Sr. No.

Description

Unit

Total Quantity

1.

66kV 1200 mm2 Single Core

Aluminium
Conductor Milliken type , XLPE insulated Cable
as per technical specification
End Terminations as per technical specification
suitable for above cable

Mtrs.

3910X8

No.

16

3.

Galvanised End Termination Structures with Nuts ,

Bolts, washers etc.

No.

Indicative quantity of Link Box with SVL

( to be decided as per requirement)

No

Indicative quantity of Link Box with-out SVL

( to be decided as per requirement)

No

1 x 240, Copper Conductor, PVC insulated,

Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs

200

66kV LAs alongwith earthing material.

No.

10

Terminal Connectors including Hardware fitting &

conductor etc.

No.

Lot

11

Mtr.

3550X8

12

Supply of HDPE pipes required for various

crossings including passing of XLPE cable with
trench less in HUDA Sector streets/Industrial area.
Tentative No. of Straight Through Joints

No.

64

12

Spare Straight Through Joints

No.

12

Any other items not specified above but are

required to complete the job in all respect.
( Break-up to be specified by the bidder)

No.

Lot

2.

Note:1. It is specific for all the bidders to visit the office of SE/ TS, Gurgaon to see the site
constraints before finalising / submitting the bids.
2. The said work involves the route through residential area/Industrial area for which Trenchless digging shall be got done as per Technical specification.
3. The above mentioned length of cable involves the tentative loop of 100m for enrouting the
said line at proposed 66kV s/stn. HSIDC Udhog Vihar.
4. To lessen the no. of Straight through joints, the length of cable shall be judiciously
selected keeping in view the safety of the cable by the successful bidder during detailed
survey.
5. The route length / Quantities of 66kV line shown above is tentative & may vary.

Bill of material of LILO of one circuit of 66kV Sector 23- Dhundahera line at proposed 220kV
s/stn. Sector 20 enroute proposed 66kV s/stn. HSIDC Udhog Vihar .
( Erection Portion only)
Sr.
No.
1.

Description

Unit

Quantity
360

Detailed Survey, Laying of Double Circuit Running

1200 mm2 Aluminium Milliken Conductor 66
circuit
KV cable in trefoil formation with one spare for Length
each Circuit (6+2), installation of Straight
(6+2)
Through joint, and complete Civil works in all
Mtrs.
respect on through rate basis as per technical
specification with trench method (directly
Buried).
Detailed Survey, Laying of Double Circuit Running
1200 mm2 Aluminium Milliken Conductor 66
circuit
KV cable in trefoil formation with one spare for Length
each Circuit (6+2), installation of Straight
(6+2)
Through joint, and complete Civil works in all
Mtrs.
respect including using of HDPE pipes &
Manholes for jointing Bays on through rate
basis as per technical specification with
Trench-less method.
Nos.
Installation End Terminations including link
boxes, earthing, Terminal connectors etc. and
their Structures / Foundations. This shall also
include erection of Hardware fittings &
conductor
Installation of LAs alongwith their earthing.
Nos.

Testing & Commissioning

Lot

Lot

Any other items not specified above but are

required to complete the job in all respect.
( Break-up to be specified by the bidder)

LS

Lot

3550

16

Note:1. It is specific for all the bidders to visit the office of SE/ TS, Gurgaon to see the site
constraints before finalising / submitting the bids.
2. The said work involves the route through residential area/Industrial area for which Trenchless digging shall be got done as per Technical specification.
3. The above mentioned length of cable involves the tentative loop of 100m for enrouting the
said line at proposed 66kV s/stn. HSIDC Udhog Vihar.
4. To lessen the no. of Straight through joints, the length of cable shall be judiciously
selected keeping in view the safety of the cable by the successful bidder during detailed
survey.
5. The route length / Quantities of 66kV line shown above is tentative & may vary.

Bill of material of LILO of one circuit of Daultabad- Sector 9 line at proposed 66kV s/stn.
Sector 4 Gurgaon.
(Supply Portion only)
Sr. No.

Description

Unit

Total Quantity

1.

66kV 1200 mm2 Single Core

Aluminium
Conductor Milliken type, XLPE insulated Cable
as per technical specification
End Terminations as per technical specification
suitable for above cable

Mtrs.

3470X8

No.

16

3.

Galvanised End Termination Structures with Nuts ,

Bolts, washers etc.

No.

Indicative quantity of Link Box with SVL

( to be decided as per requirement)

No

Indicative quantity of Link Box with-out SVL

( to be decided as per requirement)

No

1 x 240, Copper Conductor, PVC insulated,

Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs

200

66kV LAs alongwith earthing material.

No.

10

Terminal Connectors including Hardware fitting &

conductor etc.

No.

Lot

11

Mtr.

1000X8

12

Supply of HDPE pipes required for various

crossings including passing of XLPE cable with
trench less in HUDA Sector streets/Industrial area.
Tentative No. of Straight Through Joints

No.

56

12

Spare Straight Through Joints

No.

12

Any other items not specified above but are

required to complete the job in all respect.
( Break-up to be specified by the bidder)

No.

Lot

2.

Note:1. It is specific for all the bidders to visit the office of SE/ TS, Gurgaon to see the site
constraints before finalising / submitting the bids.
2. The said work involves the route through residential area for which Trench-less digging
shall be got done as per Technical specification.
3. To lessen the no. of Straight through joints, the length of cable shall be judiciously
selected keeping in view the safety of the cable by the successful bidder during detailed
survey.
4. The route length / Quantities of 66kV line shown above is tentative & may vary.

Bill of material of LILO of one circuit of Daultabad- Sector 9 line at proposed 66kV s/stn.
Sector 4 Gurgaon.
( Erection Portion only)
Sr.
No.
1.

Description

Unit

Quantity
2470

Detailed Survey, Laying of Double Circuit 1200 Running

mm2 Aluminium Milliken Conductor 66 KV cable in
circuit
trefoil formation with one spare for each Circuit Length
(6+2), installation of Straight Through joint, and
(6+2)
complete Civil works in all respect on through rate
Mtrs.
basis as per technical specification with trench
method ( directly Buried).
Detailed Survey, Laying of Double Circuit 1200 Running
mm2 Aluminium Milliken Conductor 66 KV cable in
circuit
trefoil formation with one spare for each Circuit Length
(6+2), installation of Straight Through joint, and
(6+2)
complete Civil works in all respect including using
Mtrs.
of HDPE pipes & Manholes for jointing Bays on
through rate basis as per technical specification
with Trench-less method.
Nos.
Installation End Terminations including link boxes,
earthing, Terminal connectors etc. and their
Structures / Foundations. This shall also include
erection of Hardware fittings & conductor
Installation of LAs alongwith their earthing.
Nos.

Testing & Commissioning

Lot

Lot

Any other items not specified above but are

required to complete the job in all respect.
( Break-up to be specified by the bidder)

LS

Lot

1000

16

Note:1. It is specific for all the bidders to visit the office of SE/ TS, Gurgaon to see the site
constraints before finalising / submitting the bids.
2. The said work involves the route through residential area for which Trench-less digging
shall be got done as per Technical specification.
3. To lessen the no. of Straight through joints, the length of cable shall be judiciously
selected keeping in view the safety of the cable by the successful bidder during detailed
survey.
4. The route length / Quantities of 66kV line shown above is tentative & may vary.