Replacing of existing earth wire with the new OPGW
in 400 kV Overhead Transmission Line Peja 3 Ribarevine (Kosovo part)
March, 2012 Operator Sistemi, Transmisioni dhe Tregu SH.A. Transmission, System and Market Operator J.S.C. Operator Sistema, Prenosa i Trzista A.D.
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Table of Contents
Specifications .......................................................................................................................................... 1 1. Plant Description ........................................................................................................................ 4 1.1 Location of the Overhead Lines ................................................................................................. 4 1.2 Route Description ....................................................................................................................... 4 1.3 Line Conditions ........................................................................................................................... 5 1.4 Climatic Conditions ..................................................................................................................... 5 2. Scope of Supply and Services ................................................................................................... 6 2.1 Scope of Works .......................................................................................................................... 6 2.1.1 Provision of OPGW on existing 400 kV Overhead Line Peja 3 - Ribarevine .................... 6 2.1.2 Replacement of Earthwire by OPGW in 400 kV OHL Peja 3 - Ribarevine ........................ 7 2.2 Optical Groundwire ..................................................................................................................... 8 2.2.1 Design ................................................................................................................................ 8 2.2.2 Sag and Tension Requirements ...................................................................................... 11 2.2.3 Tests ................................................................................................................................ 12 2.2.4 Splicing and Joint Boxes .................................................................................................. 14 2.2.5 Spare Parts and Tools ..................................................................................................... 16 2.2.6 Packing, Shipment, Transport ......................................................................................... 16 2.2.7 Clamps and Fittings for OPGW ....................................................................................... 17 2.2.8 Tests of OPGW and Fittings ............................................................................................ 19 2.2.9 Test for OPGW/OPGW and OPGW/OPUG Splicing ....................................................... 21 2.2.10 Stockbridge Dampers ...................................................................................................... 21 2.3 Construction, Stringing, Commissioning .................................................................................. 22 2.3.1 General ............................................................................................................................ 22 2.3.2 Safety and Supervision .................................................................................................... 22 2.3.3 Site Preparation and Facilities ......................................................................................... 24 2.3.4 Supervision, Erection and Checking of Work on Site ...................................................... 26 2.3.5 Responsibility of Contractor ............................................................................................. 26 2.3.6 Route Clearance .............................................................................................................. 27 2.3.7 OPGW Stringing .............................................................................................................. 28 2.4 Fibre optic link .......................................................................................................................... 36 2.4.1 General ............................................................................................................................ 36 2.4.2 Power Budget Calculations .............................................................................................. 36 2.4.3 Connectors ....................................................................................................................... 36 2.4.4 Optical Main Distribution Frame ...................................................................................... 36 2.5 Final Checking and Testing ...................................................................................................... 37 2.6 Hand-Over Date ....................................................................................................................... 38 PART 2: TECHNICAL DATA SCHEDULES ........................................................................................... 39 Table 1: Technical Data - 400 kV OPGW Earthwire ...................................................................... 40 Table 2: Technical Data - 400 kV OHL Accessories for OPGW .................................................... 42 Table 3: Technical Data - Supporting Documents ......................................................................... 43 Table 4: Technical Data - Dampers ............................................................................................... 44 Table 5: Technical Data - Connection Clamps for OPGW Connection to Tower Steel Structures 44 PART 3: PRICE SCHEDULES............................................................................................................... 46 1. Price Fixing ............................................................................................................................... 46 1.1 General ..................................................................................................................................... 46 1.2 Pricing ....................................................................................................................................... 46 3 2. Cost of Items Not Specifically Indicated ................................................................................... 49 3. Handling of Price Schedules .................................................................................................... 49 3.1 Price Schedule "Contract Summary - Definite Works" and "Contract Summary - Optional Works" ................................................................................................................................................ 49 3.2 Factory Acceptance Tests ........................................................................................................ 49 4. Signing of Price Schedules ...................................................................................................... 50 PART 4: LIST AND PRICES FOR RECOMMENDED SPARE PARTS .................................................... 1 PART 5: LIST OF SPECIAL TOOLS (WITH COMMENTS ON EXISTING) ............................................. 1 PART 6: LIST OF CONTRACTOR'S MANPOWER ................................................................................. 1 1. Project Management .................................................................................................................. 1 2. Work Force ................................................................................................................................. 1 PART 7: LIST OF CONTRACTOR'S MACHINERY AND EQUIPMENT .................................................. 1 PART 8: DEVIATIONS FROM TENDER / CONTRACT DOCUMENTS AND ALTERNATIVES (SPECIFICATIONS) ................................................................................................................................ 1 PART 9: LIST OF SUBCONTRACTORS ................................................................................................. 2
4 1. Plant Description
1.1 Location of the Overhead Lines
The project area is located in the North Western part of Kosovo and has an altitude of below 1660 m (from tower no.12(189)) and below 600 m (from tower no.35(166)). Transmission line routes are in a valley where vegetation is mainly in cultivated plots. It is believed that no agricultural machines or irrigating systems are used so far which could be disturbed by the line construction.
Material can be transported by ship to the port of Durres in Albania. The road E851 runs from Bar to Pristine from where materials may be transported to the project area over local roads.
1.2 Route Description
The existing line route goes over a valley with rolling hills as presented in Fig.1. The drawing is based on Google Earth map and on the mini-project of the 380 kV Kosovo B - Titograd transmission line.
Therefore, the Contractor shall, based on his own route optimization, carry out his own final line survey on the basis of the proposed line route, taking into account modifications as requested by the Employer. The Contractor shall provide a topographical layout survey (GPS-based) for the Employer's approval.
Fig. 1.
For telecom purposes this part of line will be equipped with optical fibre ground wire (OPGW). 5 1.3 Line Conditions
Common line conditions are summarized as follows: a. Climatic conditions: Weather-related loads on towers, conductors, earthwires, insulator sets etc., are the same for the 400 kV line. b. Insulation: The entire line is considered to be relatively clean though in industrial and major cities and partly along main traffic routes. There is moderate pollution from industrial and traffic atmospheric waste. In regions outside these areas, air pollution is small or non-existing. Taking into account future industrial growth, a specific creepage distance of 20 mm/kV (pollution class II as per IEC 60815) is specified and included in the schedule of minimum technical requirements (Part 2, Technical Data Schedules). c. Corrosion protection: The following measures are applicable: All structural steel parts shall be protected by hot-dip galvanizing, according to ISO 1461 by a zinc coat of 610 g/m (86 m) for the steel members and 500 g/m (70 m) for bolts, nuts and washers. For the OPGW steel wires, no galvanized steel will be accepted; only aluminium-clad steel (ACS) shall be used. d. Soil conditions: The line will cross over rolling hilly and plain areas with good soil conditions, generally stiff, with changing water level. Therefore, foundation types specified in chapter 4.6 cover limited foundation types. However, the foundation types shall be established on the basis of soil investigations carried out by the Contractor.
1.4 Climatic Conditions
Kosovo has a moderate continental climate with hot summers and cold winters.
Air Temperature During the year, the average monthly temperatures vary between -17 C in January and 24.6 C in July. The daily temperature difference between average maximum and average minimum varies between 5 C in winter to 11 C in summer. Extreme ambient shade temperatures recorded in Kosovo are: Absolute maximum +40 C Absolute minimum -40 C.
Relative Humidity The average relative humidity varies between 51 and 90%. During winter, the average relative humidity is higher than during summer. Absolute maximum of relative humidity in Kosovo is 100%.
Wind In Kosovo, Eastern and South-eastern winds prevail. Occasionally, these winds blow very strong. Average wind speed varies between 1.5 and 3.5 m/s. Maximum wind gust speed is 35 m/s occurring at any temperature but without additional loading due to ice.
Precipitation Rainfall occurs during the entire year. The average monthly rainfall in Kosovo varies between 40 and 90 mm. More rainfall occurs during late spring and early summer than during the rest of the year.
Isokeraunic Level The number of thunderstorm days in Kosovo is up to 40 days per year.
6 Seismic Conditions According to the modified Mercalli scale (MCS), the intensity is between 7 and 8 points. All electromechanical equipment shall be designed to resist earthquake loads resulting from accelerations specified in the reports of the Seismic Institute for each particular location.
Solar Radiation The total heat received by a surface is 800 W/m.
2. Scope of Supply and Services
This chapter describes the extent of contract works assigned to various construction activities under the Contract. The project will be implemented based on a "plant and build design contract" (turn-key contract) - FIDIC 1999.
The works and services to be performed by the Contractor shall comprise design, manufacture, shop tests, packing, transport, insurance, any charges incurred up to delivery up to the state border, landing charges, transport to the site, insurance, site clearing and levelling, infill, fencing, drainage, civil construction works, erection of equipment, site testing, submission of documentation, commissioning, defect liability and everything necessary to leave the plant complete and in full working order at the expiration of the defects liability period in accordance with provisions of the contract.
The Contractor is bound to provide complete works even if the equipment / parts or sections or works to be done are not specifically mentioned but are required to complete the works to be operational.
The proposed final arrangement and works is given for indication only. The Contractor shall study:
the position of the towers of existing overhead line, layout plans, operational scheme in this part of the system, availability of the shutdown, and prepare the most suitable arrangement.
Before completing the study and as part of the design, the Contractor shall prepare the step-by-step changeover procedure, indicating in detail the sequence of proposed construction activities. Utmost consideration shall be given to the duration of shutdowns, which shall be kept to a minimum. The solution shall be coordinated and agreed with the Employer.
Route and basic design elements in this connection shall be submitted well in advance for approval by the Project Manager to avoid delays in construction.
The plant and build design contract comprises the sections as described below.
2.1 Scope of Works
2.1.1 Provision of OPGW on existing 400 kV Overhead Line Peja 3 - Ribarevine
For telecommunication purposes, an OPGW shall be provided and installed in the existing 400 kV line, Peja 3 Ribarevine, from Peja 3 Substation until tower no. 12 near to the border with Montenegro.
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2.1.2 Replacement of Earthwire by OPGW in 400 kV OHL Peja 3 - Ribarevine
In order to install the OPGW, one existing earthwire in 400 kV OHL between tower no. 12, near border with Montenegro and Peja 3 Substations should be dismantled and replaced by new OPGW.
The Contractor should dismantle the existing 126.1 mm steel earthwire and shall install OPGW 126.1 mm with 48 fibres of G.655 with total length of 28,100 km, from the tension tower no 12 to the gantry of Peja 3 Substation. Some allowance for slack span to the Peja 3 Substation's shall be included, thus giving a total OPGW length of about 28,500 km.
Table 1: Existing Earthwire Characteristics and Weather-Related Factors
Unit Earthwire Cross section mm 126.1 Diameter mm 14.5 Weight of wire kg/km 842.1 Modulus of elasticity kg/ mm 16,200 Coefficient of linear expansion 1/C 13*E-06 Weather-related loading Ice load for (earthwire & conductors) kg/m 0.18 d Max. design tension of earthwire kp/ mm 21 Max design tension of conductor kp/ mm 8
The Bidder shall study and propose OPGW type having similar properties providing the same sags, hence mid-span clearances shall remain the same. The proposed OPGW shall be fully compatible with contracted OPGW in CGES with characteristics described in Anex B of this document, extracted from the Agreement for the Installation of the OPGW cable and telecommunication equipment in the 400 kV Interconnection Line SS Ribarevine SS Peja 3, up to the border with Montenegro.
An as-built mini-manual is available and will be handed over to the Contractor upon contract award. The Contractor should, based on this mini manual:
survey the line as per the requirements detailed in this document, Prepare and submit sag and tension calculations for approval before ordering the OPGW, Dismantle existing earthwire and install OPGW, All other requirements of the specification are applicable for carrying out the works, as built documents etc.
The OPGW shall be extended up to Peja 3 Substation gantry where the Contractor, upon successful optical domain time reflection test (OTDR), should connect OPGW to the terminal joint box. OPGW termination box shall be installed at the base of the substations' gantry structures. A jumper shall be provided with a slack span of sufficient length to be terminated at the substation entry equipment. Connection to the substation optical entry point with be realised with OUG cable.
8 2.2 Optical Groundwire
2.2.1 Design
Electrical and Mechanical Requirements The Contractor shall carry out all works in a skilled manner and in compliance with modern methods of engineering. In addition, the Contractor shall obey all applicable regulations regarding the manufacture and delivery of the goods and shall follow all instructions issued by the Employer / Employer's Representative. The OPGW shall be based on an ACS (aluminium clad steel) wire construction or on a composite construction of AAC wires with ACS wire reinforcement, in order to fulfil the requirements regarding mechanical strength, conductivity for lightning discharge and short circuit current resistance, corrosion resistance and protection of the optical fibres. The OPGW construction shall be suitable for incorporation of 48 optical fibres G.655 for 400 kV overhead line groundwire replacement. The OPGW shall possess a good electric conductivity allowing to support the single phase short circuit currents, a good conductivity for an effective screening and reduction of induced voltages into nearby telecommunication lines and other conductive objects (pipes, fences, etc.), a good mechanical performance allowing proper sag correlation with the phase conductor, a good corrosion resistance efficient protection of the optical fibres a long lifetime. An aluminium clad steel (ACS) conductor with a minimum ACS cross-section or an aluminium alloy (AAC/ACS) conductor or a technically equivalent alternative shall be supplied for the OPGW. The Bidder shall propose the type of armouring he intends to apply taking into account state-of-the-art practice. The Bidder shall demonstrate suitable operation experience and have type test records for the types of OPGW proposed. It is recommended that ordering of OPGW lengths on drums should consider the line lengths between designated and approved joint box positions for minimizing OPGW waste.
Basic Standards conductor for overhead lines EN 50182 optical fibre cable IEC 60794-1-1 IEC 60794-1-2 IEC 60794-4 IEEE Std 1138 ITU-T Recommendation G.655 ITU-T Recommendation G.652 IEC 60793-1-1 IEC 60793-1-2 IEC 60793-1-3 IEC 60793-1-4 IEC 60793-1-5 If the Contractor wishes to base his Bid on standards or codes other than those specified e.g. such authoritative standards appropriate to the country of manufacture, he may do so, provided that he submits with his Bid complete data about the standards or codes applied and confirms in his Bid that such standards or codes meet, as a minimum, the requirements of the designated standards. The Contractor shall submit with and as a part of his Bid a tabulated list of the differences between the standards or codes applied and those designated herein. Alternative standards or codes are subject to approval by the Employer / Employer's Representative. 9 The OPGW shall be suitable for service in the specific climate with the main characteristics as specified in the Part 2, Technical Data Schedules. The Bidder shall enter the main design data and performances of the OPGW in the Technical Data Schedules. All these data shall be proven by means of calculations and tests as specified.
OPGW Structure
Structure The OPGW shall be composed of stranded metallic wires over a central fibre optical core or shall include optical fibre containing stainless steel tubes in one of the inner wire layers of the conductor. The construction of the OPGW shall be so that the optical fibre shall not be firmly constrained against other fibres, strength members, moisture barrier compound or any other components in order that the fibre strain is de-coupled from the strain in other components when the OPGW is under tension. The Bidder shall fully detail the composition of the optical fibre unit including heat shielding material and maximum temperature rating of the materials. Moisture ingress is not permitted into the optical fibre unit, and Bidders are to provide details on how to achieve this.
Optical Core Design Individual optical fibres or groups of fibres shall be contained in protective tubes. These tubes shall form the fibres' secondary protection (the coating being the primary protection). The optical core design shall be based upon the loose tube principles. This means that the cable design shall provide a strain margin. The optical core design shall prevent longitudinal fibre transport in the loose tubes. A water block shall prevent longitudinal water penetration of the optical core and individual tubes. A metallic screen that shall prevent ingress of water or moisture to the optical tube/core. The tube shall be made of metal. Elongation of the tube caused by cable elongation shall be in proportion to such cable elongation. The inside of the tube shall be smooth. In case the steel tubes are with welded seam, no welding debris shall be left inside the tube. Lengths of tube shall not be welded together; i.e. there must be no transverse welds. If transverse welds are to be accepted (only in agreement with the Employer) the location of the weld in the tube and its position in the actually delivered cable should be indicated. The tube shall be free of pinholes. The tube shall not deform and shall continue to fulfil its function when subjected to the following: the electrical, thermal and mechanical loads stated in this generic technical requirements, the high-frequency (>1 Hz) and low-frequency (<1 Hz) vibrations occurring in the high-voltage line, use with the prescribed suspension and tensioning equipment and vibration dampers, all regular and permissible conductor assembly processes, Non-circularity of the tube shall be 5%.
Water ingress prevention screen A clear water-blocking compound (gel) shall be used around the optical fibre to prevent the ingress of moisture and other impurities. The water-blocking compound shall retain its characteristics up to the rated fault current temperature. The requirements of the water blocking compound are as follows: it shall not inhibit movement of the fibre within the tubes; it shall be compatible with other used materials it shall remain pliable and maintain its water resistance over the operating temperature range and over the OPGW service life it shall be free of air entrapment and shall not cause H 2 gas generation over the operating temperature range and service life and shall be dermatological safe. The Bidder shall provide full details of the water blocking compound (gel), including the method of removing the compound prior to cleaving and fusion splicing.
10 Manufacturing The OPGW shall be of a design and construction so as to ensure long service life with high economy and low maintenance costs. They shall be suitable in every respect for continuous operation at nominal parameters as well as in transient operating conditions, under the climatic conditions prevailing on the site. All materials used under this contract shall be of the best quality, and workmanship shall be of the highest class throughout, with the designs and dimensions of all parts such that the stresses to which the OPGW are subjected shall not distort or damage them under the most severe conditions encountered during installation and in service. There shall be no joints or splices in any optical fibre in a reel length of the complete optical cable. The OPGW Manufacturer shall be ISO 9000 quality assurance system certified and shall prove a minimum experience in successful supply of similar OPGW of 10 years. Special attention shall be paid to the OPGW stranding process to ensure the necessary tightness between different layers in order to avoid slippage or relative movement of strands or cage formation during stringing. The ACS wires of the OPGW shall have a conductivity of 20% IACS. The aluminium coating shall be smooth, clean, of uniform thickness and free from defects. For the ACS part, no joints are permitted in individual ACS wires after the cladding of the steel wires. The Contractor shall ensure that the design and construction of the OPGW is such that the tolerances stated in the specified standards and in these technical requirements will be observed and verified in the Manufacturer's works. The particulars and guarantees specified in Part 12, Technical Data Schedules shall be guaranteed within the tolerances permitted by the relevant standards, these data and conditions being part of the Contract. If the guaranteed values are not achieved, the Employer / Employer's Representative may reject the said part of the goods at the Contractor's expense. If the electrical resistance per kilometre of OPGW on any drum exceeds the guaranteed resistance set out in Part 12, Technical Data Schedules, the Employer / Employer's Representative may then reject any drum found faulty in this respect.
Optical Fibres For 400 kV line the OPGW shall have 48 fibres according to ITU-T G.655 recommendation, with characteristics as specified in Part 2, Technical Data Schedules. No joints shall be allowed in any fibre in any drum length. Discontinuities may only be accepted while from both ends of the cable, at 1550 nm wavelength, the difference is less than 0.05 dB/km for every fibre in every drum, provided by ODTR proves. The Bidder shall state the refractive index of the optical fibres at 1550 nm and all basic parameters of the proposed fibre.
Fibre Coating The optical fibres shall be coated with a tight outer UV-hardened acryl protective coating having a nominal diameter of 250 m 10 m. The coating shall be easily mechanically removable over a length of up to 50 mm for the purpose of cleaning, cleaving and fusion splicing. Each fibre shall be colour coded to facilitate fibre identification. These coatings shall be coloured and shall not degrade the optical cladding/core neither mechanically nor optically. The optical fibre coating material shall not generate H 2 gas around the optical fibres that will increase the optical loss as specified above over the designed life span of the optical fibre. The Bidder shall supply details of the methods employed to minimize the generation of H 2 gas. The Bidder is to provide details of the coating material, dimensions and minimum bending radius of the coated fibre. All coatings / colours shall be compatible with fusion splices utilizing the light inject 11 detect (LID) method and profile alignment method.
2.2.2 Sag and Tension Requirements
The OPGW shall be strung considering the following maximum tension / stress criteria:
Everyday tension condition: At the yearly average temperature (10C), with no wind, the every day stress (EDS) shall not exceed 20% of the calculated breaking load / stress or EDS load recommended by the Manufacturer.
The existing 400 kV overhead line has been designed for the following maximum tension in the most unfavourable conditions (-20C with wind or -5C ice load without wind) that shall be considered while replacing the existing earthwire by new OPGW.
Table 2 Proposed OPGW Tension Parameters
Voltage Exiting Earthwire New OPGW Max Tension Notes kV Size daN/ mm
Kp/ mm
400 kV existing 126.1 mm 20.6 21.0 as existing E/W 400 kV new New OPGW 126.1 mm
According to Manufacturer's recommendation
Note: The value of max tension in Kp/ mm are designed one whereas those in daN/ mm are calculated as equivalent
Maximum load condition: For the maximum load condition, which can be: maximum design wind, or reduced wind and ice load, or minimum temperature,
The OPGW shall have, within the adopted limit state design method, the following partial safety factors: partial safety factor for actions: 1.35 partial material safety factor: 1.85. This is equivalent to a limitation to 40% of the breaking load within the classical global safety factor method. The OPGW shall be suitable for stringing on spans up to 600 meters in 400 kV and 450 m in 110 kV overhead lines, with sags coordinated to those of the conductor. The following sag correlation condition has to be observed: For the nominal span under every day condition the final OPGW sag shall not exceed 90% of the phase conductor sag. The Contractor shall supply data (initial and final) for the OPGW stringing calculated for different line spans in a chart or tabulated form, sag and tensions for the temperatures between +80 and -20C with temperature creep correction. Before starting the delivery of the goods, the Contractor shall submit the detailed OPGW length calculation for the line, according to the actual sections, spans and differences in levels. The Bidder is required to state the maximum tension to which the OPGW may be strung without affecting the optical properties of the fibres and to retain efficient operation of the communication link. The Bidder is to provide details on the handling and installation techniques of the OPGW, in particular, 12 the precautions and methods to be taken to prevent damage to the optical fibres. Any special equipment or techniques required shall also be given, particularly with respect to: stringing sheave minimum diameter, anti-twist requirements, bull wheel diameter for stringing tensioner.
2.2.3 Tests
General Test programmes shall be prepared and submitted to the Employer / Employer's Representative for approval. Tests dates shall be announced in time to allow the participation of the Employer / Employer's Representative if requested. A test report has to be submitted to the Employer / Employer's Representative for approval within two weeks after test performance.
Type Test Tests shall be performed in accordance with IEC 60794-4 and IEC 60794-1-2. Type tests certificates may be accepted provided that tested OPGW structure corresponds to the offered one. In addition, the following tests referring to fibre optic cable shall be performed: For the optical fibre (before assembly): - Mode field diameter test - Cladding diameter and non-circularity test - Core/cladding concentricity error test - Tensile strength test - Tensile proof test - Micro bending sensitivity test - Torsion test - Flexing test - Abrasion test - Blocking test - Spectral-attenuation cutback test - Chromatic dispersion test - Cut-off wavelength test - Point defects test - Min./max. temperature test - Accelerated oxygen aging test - Temperature-shock test - Temperature-cycling test - Temperature dependence of attenuation test - Fungus resistance test For the completed fibre optic cable: - Overall diameter measurement - Optical cable length measurement - Vibration test - Bend, low and high temperature test - Cyclic flexing test - Impact test - Compressive loading resistance test - Tensile loading and bending test - Spectral-attenuation cutback test - Chromatic dispersion tests 13 - Cut-off wavelength test - Ambient light susceptibility test - Optical crosstalk test - Backscatter light test - Salt spray (corrosion) resistance test - Accelerated oxygen Aging test - Temperature humidity cycling test - Snatch test
Stress-strain One sample of OPGW, not less than 10m long, shall be subject of a stress-strain test complete with the fittings. The test shall be undertaken in accordance with IEC 61089, Annex B. The measuring techniques shall be in accordance with IEC 60794-1-1. There shall be no visual change to the OPGW strands after the test and the fibre strain must be less than 0.05% at 85% of the UTS of the cable.
Tensile Performance The test shall be undertaken in accordance with the load conditions specified in IEC 61089, Annex B. The measuring techniques shall be in accordance with IEC 60794-1-2. There shall be no permanent change in the fibre attenuation at the specified wavelength after the test, while the change in attenuation during the test shall be less than 0.05 db/km from zero load to 85% of the UTS of the cable.
Crush and Impact The tests shall be undertaken in accordance with the recommendations of IEC-60794-4 and IEC 60794-1-2. The crush test shall be undertaken by applying to the OPGW a 10 kN load for 1 min. via a 100 x 100 mm movable flat plate. There shall be no measurable permanent change in the fibre attenuation at the specified wavelength, while any temporary change in attenuation shall be less than 0.1 db. The impact test shall be undertaken by dropping a 4 kg weight from a height of 150 mm onto the end of a 20 mm diameter steel mandrel placed on the OPGW. After 20 repeated applications, there shall be no measurable change in fibre attenuation at the specified wavelength, while any temporary change in attenuation shall be less than 0.1 db.
Temperature Cycling The optical performance under temperature cycling shall be tested in accordance with IEC 60794-1-2, with TA and TB as stated in Part 12, Technical Data Schedules and the duration of 4 hours. The test should be undertaken twice.
Water Ingress The optical sub-unit shall be tested for water ingress in accordance with IEC 60794-1-2.
Short Circuit Current One sample of OPGW, not less than 10 m long, shall be subject to a short circuit current pulse. The short circuit current pulse specified in Part 2, Technical Data Schedules shall be applied within less than 1 s after the conductor's initial temperature has been raised to the specified value. During the test, the temperature of the optical sub-unit shall be measured, the temperature immediately after the current pulse shall be less than the specified temperatures. The test shall be performed three times with an interval of 30 min. Optical alteration of the test fibres shall be monitored continuously. After the third impulse, the OPGW shall be dismantled and the optical cable examined throughout its length for any signs of deterioration.
14 Lightning Strike The test shall consider both an initial stroke and a power follow through. The test conditions shall be Class 0 according to IEC 60794-1-2. The test shall be carried out on a sample of OPGW, not less than 2 m long. The acceptance criteria shall be that calculated residual strength OPGW is not less than 90% of the original stated ultimate tensile strength. Any damaged strands shall be assumed to be broken.
Sample Tests Tests for aluminium-clad steel wires/aluminium alloy wires shall be carried out in accordance with the requirements of IEC 61232/ IEC 60889. Samples taken on random from the OPGW drums ready for shipment against each batch shall be tested for overall diameter, the lay length and lay ratio of layers, lay directions and DC resistance in accordance with IEC 61089 or EN 50182 at the factory by the manufacturer which may be witnessed by the Employer / Employer's Representative. In addition, attenuation shall also be measured on each fibre of above mentioned sample drums of OPGW with OTDR.
Routine Tests OPGW on all drums shall be tested for mechanical tests including measurement of overall diameter of OPGW, measurements of thickness of Al and ACS wires, diameter of tube, wrapping test of Al and ACS wires, check of surface quality and OPGW weight, checking of lay length and lay ratio of layers, checking of lay directions, breaking load test of OPGW and DC resistance measurement in accordance with IEC 61232, IEC 60889, IEC 61089 or EN 50182 at the factory by the Manufacturer as routine tests. In addition the following routine tests shall be performed: Attenuation on each fibre of all OPGW with OTDR at the factory by the Manufacturer as routine test, Fibre point defects test, Fibre attenuation test, Fibre microbend test, Cut-off wavelength test, Chromatic dispersion test.
Optical Fibres Optical fibres shall be type tested in accordance with the requirements of ITU-T G655/G652 and IEC 60793, as appropriate. Routine tests regarding attenuation OTDR shall be carried out according to IEC 60793-1 at the factory by the Manufacturer.
2.2.4 Splicing and Joint Boxes
On the substation gantries (connection between OPG and OPUG) and at every 3 to 5 km on tension towers (connection of OPGW sections) shall be implemented by means of joints in terminal joint or through joint boxes.
At the tension towers not provided with joint boxes, the Contractor shall provide suitable attachment fittings to by-pass the tower without any additional joint. The prescribed minimum bending radius shall be observed at all angle points. If necessary, special tandem or multiple stringing blocks have to be used for stringing the OPGW at angle points.
The joint through boxes shall be of the "hood" type with encapsulated cable entry. They shall be 15 mounted within the framework of the transmission towers above the anti-climbing device. The OPGW access to the casing should be via entry ports in the base, properly sealed to prevent moisture ingress. Same joint through may be used as terminal box for jointing OPGW with OPUG in substitution gantry by applying of appropriate glands in entry ports or a different design used according to manufacturer recommendation.
The Bidder shall present in his Bid detailed description and drawings of the OPGW / OPGW and OPGW / OPUG jointing procedure and devices. He is responsible for the operational continuity of the optical fibre system considering that the interface point between line and underground cable is the joint casing at the gantry. All documents supplied by the Contractor shall be submitted to the Employer / Employer's Representative for approval before starting of the Manufacture.
Weatherproof units shall be provided for the joint boxes (casings). The joint boxes shall include all necessary hardware to terminate, protect and fix the spliced fibres. Optical losses shall be no more than 0.08 dB on an average per splice, and no single splice loss shall exceed 0.10 dB. Each splice shall have a spare fibre length of approximately 1 m or more. A finished splice shall be supported within the joint box by suitable clips or restraints. It shall be possible to remove and replace the splice in the support device without risk of damage to the splice or fibre.
The inlets of the joint boxes shall be sealed with thermo-shrink plastics. The outer material of the box shall be oil-resistant and metallic, preferably aluminium. The enclosure is to be re-enterable and re- sealable without detriment to the integrity of the enclosure and optical fibres. Enclosure re-entering and sealing shall not require power tools and shall use only a minimum number of special tools.
The Bidder shall provide detailed specifications for mechanical and optical aspects of all joints, splices and end sealing arrangements for the individual parts and/or complete system. The Bidder shall submit with his Bid a calculation of the total attenuation (overall losses) for the complete telecommunication link considering all splices, fibre aging, etc. The total alternation shall be a guaranteed value.
The quality and performance of all joints shall achieve the mechanical requirements over its design life.
The Bidder shall describe in detail the proposed method of jointing the optical fibre, both during manufacture and installation.
The Contractor shall provide detailed drawings showing the location of all joints. Each joint shall be uniquely numbered.
As part of the jointing procedure, the Contractor shall monitor the optical performance of each joint using an optical time domain reflectmeter. Upon completion of jointing and prior to sealing, the joint casing an estimate of joint loss and measurement of the total fibre attenuation shall be made. If the total fibre loss is projected to exceed the designed installation loss, the joint shall be broken and rejoined until the specified performance is achieved.
If local injection and detection techniques are used to measure the attenuation, any necessary fibre bends shall not affect the physical properties of the fibre and shall not shorten its life span. The fusion splice tray shall not have any sharp edges or protrusions that may damage the optical fibre. Number tags for fibre and tube identification are to be included.
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2.2.5 Spare Parts and Tools
Spare Parts Spare OPGW quantities, as per the Part 3 Price Schedules shall be delivered together with the last scheduled dispatch and shall be provided in continuous lengths on non-returnable steel drums as specified. The Bidder shall enter the corresponding prices in these price schedules and carry the sub-total to the Summary. For any additional quantities that may be ordered after the date of the taking-over certificate, the prices will be subject to adjustment. The spare OPGW have to be adequately protected against humidity, corrosion, etc. and packed and treated in such a manner as to be suitable for storage in the climatic conditions at the site, for an indefinite period. They shall be delivered on steel drums provided with identification labels including also type and quantity. The spare OPGW shall be delivered to the Employer's stores, and delivery will not be deemed completed until the packing material has been checked by the Employer / Employer's Representative. The taking-over will take place after delivery to the Employer's store and the taking-over certificate will be signed by the Employer / Employer's Representative.
The Bidder shall also fill in the list as per Part 14 Recommended Spares for maintaining the fibre optic link over its expected lifetime. Those spare parts shall not be included in the Summary of Part 13 and the list shall not be binding. The Employer may purchase all or part of these recommended spares.
Tools The special tools and test equipment needed to maintain the fibre optic link over its expected lifetime may be included.
The Bidder shall fill in the list as per Part 5 Recommended Special Tools for maintaining the fibre optic link over its expected lifetime. Those spare parts shall not be included in the Summary of Part 3 and the list shall not be binding. The Employer may purchase all or part of these Special Tools.
2.2.6 Packing, Shipment, Transport
The OPGW shall be delivered and shipped on stoutly constructed timber or steel drums as specified, and lapped with protective covering across the whole width of the drum. The OPGW shall be shipped in continuous lengths clearly marked by the manufacturer. The packing for the corresponding spare parts shall comply with the requirements specified for long time storing.
All drums with OPGW shall have a layer of waterproof wax paper or plastic sheet which must be safe against chemical reactions. It shall be laid around the barrel under the OPGW, another one shall be laid over them and under the lapping. Drums shall be securely fastened around the perimeter and shall be suitable for rolling on the flanges without causing damage to the OPGW.
The disposal of all empty drums shall be the responsibility of the Contractor.
The following information shall be clearly written in indelible paint on both flanges of each drum:
contract title and reference number; Manufacturer's name; 17 lifting instructions and limitations; direction of rolling.
An aluminium or painted metallic marking plate shall be fixed to each drum clearly showing the following data:
type and size; length; gross and net weight; batch and drum numbers; stranding date; main dimensions of the drum; correct direction of rolling.
The Contractor shall submit a sketch or drawing showing the full details of drum design and the details of the proposed method of impregnation and lagging of the inner drum surfaces with approved tarred paper or equivalent material. The minimum length of the OPGW on drums is subject to the Employer's / Employer's Representative's approval.
2.2.7 Clamps and Fittings for OPGW
2.2.7.1 General
All clamps and fittings shall comply with the requirements of this Biding Document and must be approved by the Employer / Employer's Representative. They shall be suitable for the OPGW type proposed by the Contractor. The Contractor shall ensure close and continuous liaison between the manufacturers of OPGW, clamps and fittings so that the equipment will be perfectly adapted. The detailed design of OPGW suspension and tension hardware shall be coordinated with the manufacturer of the OPGW. The installation techniques and procedures shall be submitted to the OPGW manufacturer and his written approval for the complete design and materials intended to be used with the approved OPGW type will be presented to the Employer / Employer's Representative before the final approval for the hardware and OPGW will be granted.
All clamps and fittings except for vibration dampers shall be supplied by the same manufacturer. Splitting up of the supply of clamps and fittings will not be permitted.
Besides, the Contractor shall assure perfect fitting of the OPGW set attachment armatures (connecting hardware) to the tower steel construction. The design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion of the contact surfaces and to maintain good electrical contact under service conditions.
At all suspension, tension towers and substation gantries, the OPGW shall be electrically connected to the steelwork by means of jumpers of the same size and material as the OPGW as well as by means of suitable fittings.
The earthwire connections to the towers (connecting hardware, earthing connections) shall withstand the single-phase fault current shown in Part 2, Technical Data Schedules without suffering damage and this performance must be checked in accordance with the requirements. The Employer / Employer's Representative may require tests to be carried out to demonstrate the short circuit characteristics of each type of connection-to-tower set. The cost of such tests shall be borne by the 18 Contractor.
All ferrous parts of the assemblies component elements and of the accessories for conductors and OPGW shall be hot dip galvanized according to ISO 1461.
The split pins of all clamps and fittings shall be of stainless steel.
The suspension towers will be equipped with suspension sets and the tension towers with tension sets. All sets shall be designed for the OPGW selected type and for the mechanical loads and loading conditions shown below as well as the safety factors given in Part 2, Technical Data Schedules:
OPGW dead weight design spans as specified maximum wind speed maximum ice load ice load with reduced wind maximum working stress in the OPGW.
Particular care shall be taken during manufacture of clamps and fittings and during subsequent handling to ensure smooth surfaces free from burrs and sharp edges.
2.2.7.2 Suspension Assemblies
Armour grip suspension clamps shall be used for OPGW. The clamp body shall be of high-tensile strength corrosion-resistant aluminium alloy and shall preferably be forged or cast. For cast clamp body, an additional reinforcement shall be foreseen. The spiral rods shall also be of aluminium alloy and shall not have diameters of less than 4 mm.
The material of the clamps should satisfy the norms EN 1559 for aluminium alloy castings and EN 1562 for malleable cast iron.
The neoprene or other non-metallic material shall have good resistance to aging and be capable of withstanding temperatures between -20C and +40C without changing essential properties. The material shall have adequate resistance to the effects of ultra-violet radiation, ozone or pollution factors. The rotational axis of the clamp shall be in the longitudinal axis of the OPGW to avoid unacceptable distortion of the OPGW due to unbalanced longitudinal loads. The Contractor shall ensure by appropriate design a suitable performance of the clamp-conductor assembly by wind induced vibration.
In addition to the suspension clamp, connecting hardware is required for a suitable mechanical and electrical connection to the tower. The Contractor is responsible to supply the complete set of the suspension assembly.
2.2.7.3 Tension Assemblies
OPGW attachments to tower shall be of helical grip type consisting of two helical parts (fittings), one for OPGW protection and the other one as actual dead-end fitting. Preformed helical dead-ends shall have "cabled loop" eyes. The material of the spiral rods shall be high-tensile strength aluminium clad 19 steel.
The material of the clamps should satisfy the norms EN 1559 for aluminium alloy castings and EN 1562 for malleable cast iron.
The protection part is defined to protect the OPGW against radial forces produced by the high longitudinal tensions during operation. The protection part must be laid in the opposite direction of the outer layer of the OPGW, and the dead-end part must be laid in opposite direction to the protection part. The grip strength shall be at least 95 % of the ultimate tensile strength of the OPGW.
The tension attachment devices must correspond to the OPGW type and dimensions. The protection part must be longer than the tension (dead-end) part, and the length must be sufficient to install vibration dampers. The number and diameter of the spiral rods of the two parts are generally different but must be coordinated to meet the operational requirements.
2.2.7.4 Mid Span Joints for OPGW
The OPGW shall not be jointed in the spans.
2.2.8 Tests of OPGW and Fittings
2.2.8.1 General
Test programmes shall be prepared and submitted to the Employer / Employer's Representative for approval. The date of tests shall be announced in time in order to allow participation of the Employer / Employer's Representative, if requested. A test report has to be submitted to the Employer / Employer's Representative for approval within two weeks after test performance.
The joints for OPGW (joint enclosure and splices) are subject to the requirements of IEC 61073, IEC 61300 and shall be tested as specified in the documents. The mechanical tests specified in IEC 61073-1, par. 4.5, shall be performed.
2.2.8.2 Clamps and Fittings for OPGW
The OPGW suspension and tension attachment-to-tower sets shall be tested for mechanical and thermal performance as for the OPGW specified above. These are in particular:
tensile load test clamp bolt tightening test unbalanced load test aeolian vibration test fault current test.
The joints for OPGW (joint enclosure and splices) are subject to the requirements of IEC 61073, IEC 61300 and shall be tested as specified in the documents. The mechanical tests specified in IEC 61073-1, par. 4.5, shall be performed.
The test procedures shall follow the recommendations of CIGRE, TF 22.11.03, Guide for Fittings for Optical Cables on Transmission Lines, Part 2A, Testing Procedures (published in ELECTRA No. 188, 20 February 2000).
The tensile test shall be agreed with the OPGW Manufacturer, and the optical attenuation shall be measured. The clamp bolts have to be tightened according to the recommended moments and the OPGW shall be visually checked afterwards.
The vibration test shall be coordinated with IEC 60794.
The Bidder shall demonstrate the adequacy of the grounding connection to the fault current by test date, field experience or calculation.
The costs for these tests are deemed to be included in the bid price.
2.2.8.3 Splice Boxes for OPGW
The OPGW fittings and the hardware for OPGW/OPGW and OPGW/OPUG joints used in this contract shall be subjected to type tests.
The Bidder shall nominate in the Technical Data Schedules the type tests he proposes for the OPGW/OPGW and OPGW/OPUG joints. Joint box type tests shall include a water immersion test for proving the joint water tightness and seals, with measurement of attenuation variation of the splice and loss characteristic in an assembled joint at the start and end of a 7 days immersion period. Type test certificates may be submitted to the Employer / Employer's Representative for approval.
The costs for these tests are deemed to be included in the Bid Price.
2.2.8.4 Final notes and OPGW fittings thermal stability
In addition to the tests mentioned above, particular tests have to be carried out on the insulator sets and insulator units:
corona test; radio interference test; thermal stability test (OPGW).
The tests referring to the insulator sets have to be carried out on completely equipped sets, with all clamp and fitting parts, installed in their characteristic working position and having attached also an agreed length of conductor or conductor bundle. The costs for these tests are deemed to be included in the bid price.
Thermal Stability Tests for OPGW fittings Thermal stability of the OPGW suspension and tension attachments to tower shall be verified according to the procedures recommended in IEC 61854. If requested by the Employer / Employer's Representative, a thermal stability tests shall be carried out as type tests in the Manufacturer's works or in specialized laboratories on the OPGW suspension and tension attachments to tower. Each attachment set type shall be completely installed in its typical working position together with a sufficient OPGW wire length in order to allow for a simultaneous test (OPGW and attachment set). Each set type will be submitted to a cycle of 3 tests with different test parameters as shown below: 21
Table 3: Thermal Stability Test Parameters for OPGW Suspension and Tension Attachments
Short Circuit Current 400 kV Lines Test Type to be Selected Duration 1 7 1.0 sec. 2 10 0.5 sec. 3 22 0.1 sec.
Oscillograms of the short-circuit currents and voltages applied during tests shall be recorded. Photographs shall also be taken from the tested object before and after test. The tests shall be considered as successful if no damage of the earthwire or to the attachment sets occurs. The fault current supply circuit and the arrangement of the tested object shall be subject of the Employer's/ Employer's Representative's approval.
2.2.9 Test for OPGW/OPGW and OPGW/OPUG Splicing
After installation of the OPGW/OPUG but before splicing, the optical fibres shall be tested regarding attenuation. Furthermore, OPGW/OPUG joints shall be tested to prove compliance with the specified performances (attenuation), including OTDR tests.
2.2.10 Stockbridge Dampers
2.2.10.1 Requirements
Vibration dampers of stockbridge type shall be installed at all OPGW suspension and tension points and shall be mounted on armour rods. Minimum two dampers per span shall be provided; one damper per span is not permitted. The exact number of dampers shall be determined by a damping study which is included in the scope of work. The Contractor shall submit all data and calculations regarding the characteristics, number and placement of the vibration dampers to be used for the various ranges of spans. The calculations shall cover the range of 1 to 7 m/s wind velocity, the typical OPGW tensions (EDS) and the range of span lengths. All calculations shall be performed under the responsibility of the Contractor and shall be subject to approval by the Employer / Employer's Representative.
Regarding the damping characteristics of the vibration damper, the Contractor shall guarantee that close to the suspension clamps as well as to the damper own clamp, the conductor stains due to the wind induced vibrations are kept within acceptable limits over the entire range of possible frequencies. The Contractor shall guarantee, by means of corresponding calculations, that the bending strain of the conductor will be restricted to maximum of 150 m/m and the damper clamp velocity will not exceed 0.1 m/s.
The damper clamps shall be of forged aluminium alloy or cast and shall be designed to ensure that dampers do not cause damage to the OPGW for which they are used.
The damper clamp shall be dimensioned to keep the necessary distance between the first vibration damper and the mouth of the suspension clamp on OPGW, taking into account the installation on the OPGW or on the armour rods. 22
For bolted clamps, the clamping bolts shall be of steel having a minimum tensile strength of 800 N/ mm. They shall be designed to facilitate an easy damper mounting. The screws shall be locked in an approved manner. The washers shall be made of stainless steel.
Elastomers or other non-metallic materials if used shall have good resistance to aging and shall be capable of withstanding temperatures between -20C and +40C without change of essential properties. The materials shall have adequate resistance to the effects of ozone, ultra-violet radiation and air pollution over the entire temperature range.
The dampers shall be designed to exclude water collection. If this is not possible, they shall have drainage holes with a minimum diameter of 6 mm.
All ferrous parts of the damper elements shall be corrosion protected.
2.2.10.2 Tests
Stockbridge dampers shall be type and sample tested in accordance with IEC 61897 (Requirements and Tests for Stockbridge Dampers). The test procedure shall be agreed with the Employer / Employer's Representative in order to ensure the requirements specified or other approved requirements. Tests shall not cause damage to the OPGW to which the test dampers were applied. Tests of sliding forces shall be applied for bolted damper clamps only.
Tests of the electrical and mechanical characteristics of the stockbridge dampers shall be covered in Part 3, Price Schedules.
2.3 Construction, Stringing, Commissioning
2.3.1 General
The following chapters contain the requirements and conditions for the preparation of access roads, route clearing, tower pegging, preparation of tower locations, foundation works and erosion protection, tower erection, conductor and OPGW stringing and sagging works as well as final commissioning.
The Contractor has to develop a suitable planning and has to suitably split the line length into several sections, which have to be treated separately and simultaneously in order to meet the target completion date. For each operation, the necessary number of teams shall be determined based on average productivity.
The Contractor shall have available competent and experienced supervisors on site at all times during construction / erection works, so that the building quality is achieved as per requirements set out in these bidding documents.
2.3.2 Safety and Supervision
The Contractor shall prepare a report on safety on site in line with the regulations of the country and submit it to the Employer for approval.
2.3.2.1 Safety of Personnel
23 Methods of carrying out the work and qualification of specialists, irrespective of particular requirements herein, shall conform to high quality standards. Generally accepted practice requirements and practice of high-skill work of the mentioned type shall be observed in any respect. The Employer shall be satisfied with the quality of all works and shall confirm this. However, such confirmation shall not relieve the Contractor from his responsibilities or obligations.
When carrying-out the works, the maximum safety, consistent with good construction and erection practice, must be observed by the personnel engaged in this contract.
This refers to the works on preparing ditches for foundations, especially shuttering or and tower assembly and erection.
If tower lifting method is used the particular care shall be taken that during tower raising the workers not engaged in the lifting operations are moved to a safe area.
Since construction and erection in some parts of the line will be carried out in the area of existing and energized high voltage lines, additional measures shall be taken to protect the personnel against induced voltage. These measures shall apply during installation of conductors and OPGW.
All works on conductors and wire cables stringing in dangerous areas shall be performed strictly observing "Safety rules for construction and erection works on or nearby operating transmission lines".
Additional safety measures in carrying-out construction and erection works on crossings are as follows:
1) Road crossings: the time of beginning, duration and technology of safe works on conductors and wire cables mounting when crossing a highway shall be agreed on with the organization operating this highway; when carrying out the works, the attendance of a representative of this organization is mandatory unless denied in writing is obtained. in places of traffic, the conductors and wire cables shall be run-out on a scaffolding of at least of 6.0.m a height. at the moment of conductor stringing, care shall be taken to keep people away from and under the conductors and wire cables; at a distance of 100 m on both sides of the scaffoldings, the mounting crew foreman shall place workers with red flags to warn or stop the transport if necessary. places of work shall be marked with "safety first" signs; conductor stringing shall not be performed in fog with low visibility, in icing and wind with a speed over 10 m/s.
2) Electrified railroad crossings: to ensure safe works on suspension of conductors and wire cables, temporary towers shall be installed based on reinforced concrete posts of at least 20 m height with horizontal arms. These posts shall be buried into the ground to a depth of 3 m. Temporary towers shall be installed in distance of 15 m from the permanent railroad, 10 kV OHTL or communication line servicing the railroad. They shall be dismantled, after the works are completed; to prevent disruption of train schedule, the total time required for mounting of OHTL conductors and wire cables crossing railroads shall be divided into possibly equal periods during which the works shall be performed in intervals between freight and passenger trains; when performing the works, the railroad contact conductors and 10 kV OHTL conductors 24 shall be deenergized; three days prior to commence the work a request for disconnection of 10 kV OHTL shall be filed to the relevant authorities operating the railroad, and a permission for carrying out the work shall be obtained. The work shall be carried out only when attended by representatives of the railroad services.
3) Communication line crossings: safety technology for conductors stringing over aerial communication line crossings without line rearrangement shall be agreed upon with the respective authorities operating the communication line; stringing of conductors and OPGW over communication line without the line rearrangement shall be performed only with the written permission of the this communication line operator and in the presence of its representative. In this case scaffolding arrangement, their dimensions and place of erection shall be agreed with the line operator. The contractor shall be fully responsible for any damage that may occur due to the line erection works and shall perform all required repairs to restore the line to its previous technical and operational status.
4) Operating transmission line crossings: the Contractor's personnel shall arrange for and attend safety training to get acquainted with safety regulations being in force in the line operator organization. The Contractor shall propose site arrangement scaffolding and their dimensions and locations for the line mechanical protection during stringing operation. The arrangement shall be approved by the line operator. The works should not start without permit to work signed by the line operator. prior to commencing stringing operation, all towers under the project within in the stringing section should be earthed. stringing may commence only upon the existing line de-energisation and suitable grounding in place. The grounding of existing line shall be performed by the operator's crew demonstrating the absence of voltage while installing grounding. the working areas shall be marked with warning signs.
2.3.2.2 Compliance with Rules and Regulations
All equipment and materials supplied and all work carried out shall comply in all respects with the requirements of the rules and regulations as well as of acts in force in the country of the Employer and applicable to the contract works.
2.3.2.3 General Particulars and Guarantees
The works shall comply with the general particulars and guarantees stated in contract documents. All working methods employed and all plant and equipment supplied under this contract shall be approved by the Employer. The Contractor shall be responsible for any discrepancies, errors or omissions in the general particulars and guarantees.
2.3.3 Site Preparation and Facilities
The Contractor shall prepare the site to perform his duties in efficient and smooth way. The facilities described here do not cover all but only a main features necessary to be provided. 25
Part 7 chapter 7 describes requirements for the Employers'/Employer's Representative facilities.
2.3.3.1 Office Accommodation
The Contractor shall provide for himself such buildings as may be necessary for office accommodation for his site staff during the construction period. The cost of these shall be included in the contract price.
2.3.3.2 Living Accommodation
The Contractor shall make his own arrangements with regard to accommodation for his expatriate and locally recruited staff during the construction period. All dwellings and buildings existing or erected for this purpose by the Contractor shall comply with local regulations with regard to construction, water supply, sanitation and other requirements.
Temporary construction camps shall be provided with proper sanitation and other necessary facilities. All accommodation shall be removed by the Contractor when no longer required. After the removal of accommodation, the ground shall be left in a clean and tidy condition.
2.3.3.3 Medical Services
The Contractor shall make his own arrangements where medical services may be required for his repatriate and locally engaged staff.
2.3.3.4 Water, Electricity, Drainage Sewage, Fencing, etc.
The Contractor shall provide all ancillary facilities as required to keep site bin sound technical operational and sanitary conditions
2.3.3.5 Staff Transport
The Contractor shall provide at his own expense all necessary transport for his personnel and materials.
2.3.3.6 Storage Facilities
The Contractor shall make his own arrangements for storage area and shall obtain the approval of the Employer for the places along the line route where he intends to store materials. Such places shall not be outside the authorized area unless special arrangements are made with the owners of adjacent property. The Contractor shall provide any necessary protection and safeguarding of the materials in the areas allocated to him. The handling and storage of any equipment at the site shall be at the risk of the Contractor and without responsibility to the Employer. The Contractor is to arrange the protection of these materials against vermin attack, corrosion and mechanical damage during storage.
The site storage area shall be prepared with adequate hard standing for the orderly storage of conductor drums, tower steel, insulators and fittings so that the material will not be damaged by the effects of adverse weather during storage. Materials and equipment packed in flammable crates or drums shall be stored in such a manner as to avoid any damage arising from fire.
2.3.3.7 Compressed Air 26
The Contractor shall make his own arrangements for a supply of compressed air if required for the execution of the contract works.
2.3.3.8 Lifting Facilities
The Contractor shall make his own arrangements to purchase or provide lifting facilities required for materials and equipment handling and transport on the site.
2.3.4 Supervision, Erection and Checking of Work on Site
All works on site included in this contract shall be supervised throughout by a sufficient number of qualified representatives of the Contractor who have thorough experience of the erection and commissioning of similar works.
The Contractor shall verify from time to time which portions of the site works the Employer desires to check, but such checking shall not relieve the Contractor from the liability to complete the works in accordance with the contract or exonerate him from any of his guarantees.
If the Employer proves that the Contractor will be unable to complete any section of the works in the stipulated time, the Contractor shall mobilize its staff/personnel to carry out works outside normal working hours to catch up the scheduled time. For this extra work, the Contractor is not entitled to claims for any extra expenses unless the delay is due to causes for which the Contractor is entitled to an extension of time under the conditions of contract. If the Employer proves defective works, the Contractor shall, after the completion of works, keep on site supervisory staff of such number and for such periods as the Employer may require to remedy the revealed defects in the shortest possible time.
The Contractor shall keep all the site including office/living accommodation storage, canteen (if any) in reasonably clean conditions, removing all waste material resulting from the works as it accumulates. On completion of the construction, the site is to be left clean and tidy to the satisfaction of the Employer. Any damage done to buildings, structures and plant or property belonging to the Employer shall be made good by the Contractor at his expense.
2.3.5 Responsibility of Contractor
Until each section of the works has been taken over or deemed to have been taken over under the conditions of contract, the Contractor shall be entirely responsible for such sections of the works under construction and during testing.
During the period of maintenance, the Contractor shall ensure that a competent representative is available at the site for the purpose of carrying out any work of maintenance for which the Contractor is responsible.
Any work which may be required from the Contractor in pursuance of his obligations under the conditions of contract shall be carried out so as to interfere as little as practicable with the normal operation of the energy system. Works on the site shall be carried out at such time and during such hours as the Employer may require.
27 Works shown in the drawings and not mentioned or described in the technical requirements, or works described in the technical requirements and not shown in the drawings shall nevertheless be deemed included in the contract, and their fulfilment shall be included in the contract price.
2.3.5.1 Contractor's Employees
The Contractor shall fulfil all his obligations in respect to accommodation, feeding and medical facilities for all personnel he employs in accordance with the requirements of the statutory labour regulations of Kosovo. The Contractor shall be responsible for the behaviour on site of all personnel employed by him.
2.3.5.2 Control of Subcontractors
The Contractor shall be responsible for specifying the quality assurance requirements applicable to subcontractors and suppliers, for reviewing the implementation of subcontractors' quality assurance arrangements and for ensuring compliance with the requirements.
The Contractor shall ensure that all appropriate technical information is provided to subcontractors and suppliers. The Contractor shall, for the supply of items, plant and equipment (including those subcontracted) arrange for suitable protection for the products at all stages including delivery and installation on the site.
The Contractor shall submit for information a detailed programme defining the basis of control to be applied to each subcontract or supply order.
2.3.6 Route Clearance
Wayleave for the line (subject to the negotiations between Employer and authorities / landowners) will be provided by the Employer to enable the Contractor to carry out the contract works. Before the Contractor commences work on any property, he will obtain from the Employer the explicit permission and if applicable a wayleave schedule giving details on any special requirements of the owners concerned. The Contractor shall give adequate notice of commencement of work to the landowners.
2.3.6.1 Removal of Obstacles
As the danger of bush fires does exist, scrubs and trees (particularly pine trees) have to be cleared from the line corridor. Where clearing is necessary, the following requirements shall be observed:
Fruit trees and crops shall not be removed at all. The Contractor shall take the necessary precautions to avoid damage to these crop trees when carrying out the easement clearing. The compensation or consequences caused by any damage which in the opinion of the Employer could be avoided, shall be borne by the Contractor. Other trees and tall scrub shall be cleared to a distance of 25 m on either side of the centreline of the route. Trees and bushes shall be cut down to a height of not more than 0.5 m above ground level and not removed by bulldozer. In addition, tall trees outside the cleared area shall be trimmed by the Contractor to such a height that while falling the distance of 2 m from the conductors shall be kept. No tree may be cut without the explicit permission of the Employer. Roots and other plants shall not be removed to prevent excessive surface erosion.
The Contractor shall take all appropriate precautions when clearing vegetation in the vicinity of public 28 buildings, streams, roads and private houses. The streams embankment should be restored/reinforced to avoid future erosion. Fallen trees shall be removed from these areas immediately after clearing. Any damage caused by carelessness, ignorance and over-sight shall be compensated by the Contractor.
The necessary permission for the removal of obstructions such as fences, buildings, telecommunication and power lines will be in the responsibility of the Employer. No obstruction may be removed without the explicit permission of the Employer.
2.3.6.2 Re-Clearing
Before issuing the final acceptance certificate or at the time agreed by the Employer, the Contractor shall have re-cleared the vegetation within the easement to the standard specified.
2.3.6.3 Crossing of Obstacles
The Contractor shall, at his own expense, make any necessary arrangement and take the necessary precautions where the route crosses buildings, telecommunication and power lines, orchards, gardens, railways, antiquities or other obstructions or ground over or across where erection cannot be carried out without precautions that require scaffoldings or roof protections.
These arrangements, supported by calculations and drawings for each crossing, should be presented in a suitable document and shall be for the approved by the Employer / Employer's Representative.
The Contractor shall provide all necessary scaffolding and the like for the crossing of telecommunication or power lines, roads, railways, buildings or other obstacles. The Contractor shall advise the Employer in each case of the scaffolding he proposes to use. Drawings of the proposed scaffoldings shall be submitted to the Employer / Employer's Representative for approval (see also chapter 2.3.7.4).
2.3.7 OPGW Stringing
2.3.7.1 Handling and Storage
Whether in storage and during handling, all OPGW reels shall be kept clear off the ground and in clean conditions. Contact with any substances likely to damage the materials and reels shall be avoided.
The Contractor shall take adequate precautions during handling, storage and installation to prevent kinking, twisting, nicking or other damage to the materials and reels. The conductors and OPGW shall never be dragged over the ground or any other rough surface.
Suitable precautions shall be taken to avoid dropping down of reels during loading or unloading from vehicles.
2.3.7.2 Stringing Plan
At least one month before stringing commences, the Contractor shall give due consideration to all the factors involved and shall submit to the Employer / Employer's Representative for approval a fully detailed stringing schedule, stating locations of earthwire drums, tensioners and pullers, the proposed position of mid-span joints, together with temporary reinforcement of towers or their crossarms and all 29 other relevant information required for the stringing operations, including the maximum tensions to be used during running out of pilot wires and OPGW.
2.3.7.3 Tools and Equipment
Tools and equipment shall conform to IEEE Standard 524 (Guide to the Installation of Overhead Transmission Line Conductors) and to the conditions as specifically described hereunder.
Reel Stands Reel stands shall be strongly constructed and reel brakes shall be provided. Braking of the OPGW reels during stringing shall be positively controlled and shall be applied in a manner which avoids damage to the conductor or OPGW or to the reels.
Pilot Wire Pilot wires shall be made of non-twist steel wire. The pilot wire shall be strong enough for stringing work. The Contractor shall be responsible for clearing a narrow passes way (about 2 m wide) along the centre line of the line route for laying out the pilot wire manually.
Powered Puller The powered puller shall have a capacity of not less than the maximum stringing tension of the OPGW. The puller system shall have a powered winch with transmission gears for changing speed during stringing work.
Tension stringing equipment Tension stringing equipment shall be of neoprene or Teflon lined bull wheel type. The bull wheel brake or brake control shall be designed such that when the maximum tension is obtained, the tension will be held constant so long as the brakes are left at this setting. The tensioner shall be equipped with earthing conductor through device. The bull wheel diameter and lining material shall be approved by the Employer / Employer's Representative. A neoprene or Teflon lining material, at least 6mm thick, would be acceptable.
Compressors for Joints and Dead End Connector Assemblies Suitable hydraulic compressors equipped with pressure gauges and dies or other approved types shall be used for tension joints and compression dead-end connections. This shall thoroughly satisfy the requirements for jointing of the conductor.
Length meter A length meter for measuring the OPGW during stringing shall be provided and may be part of either the powered puller or the tension stringing equipment.
2.3.7.4 Crossing of Roads, Power Lines etc.
Scaffolding shall be provided over roads, power and communication lines, houses etc. The cost of all scaffolding shall be included in the stringing price.
The scaffolding which is used to cross specified low, medium and high voltage power lines shall be of such dimensions and allow such clearances that the power lines being crossed may remain in operation during construction of the new transmission line unless stringing is made over the crossing. Shut-downs on the lines to be crossed will be given for stringing however their duration shall be kept to the minimum. Such restrictions in building and use of the scaffolds shall not be grounds for claiming additional costs. 30
The scaffold shall be designed to withstand the maximum design wind speed, except that a reduced return period will be accepted. Consideration shall also be given to impact loading by dropping of the upper phase conductor. The scaffold shall consist of square mesh nylon nets attached to steel wire ropes running perpendicular to the lower line route, carried by metal scaffolding at 3 m intervals. The nets shall be attached to the catenary wires by means that do not require the presence of any persons on the net or the catenary wires whilst the lower line is alive. An additional movable walk net laid over the mesh nets may be used whilst the lower line is dead. Normally steel or aluminium tubular scaffolding should be used.
Scaffold design shall duly consider safety requirements with particular respect to accidental contact with live conductors during construction, use and removal.
The scaffold, including foundations, shall be designed and constructed to ensure stability during the erection and removal, and also at times when work has ceased for any reason including adverse weather conditions. The foundations shall be suitable for soil characteristic at site. The scaffold shall extend at least 5 m either side of the outermost conductors of the upper line. A maximum of 2 m of this distance may be provided by means of catchers. Catchers shall be provided at each end of each scaffold support. The catchers may be vertical or inclined to a maximum angle of 45 from the vertical.
They shall be capable of withstanding the specified impact loads without excessive distortion that would permit a falling conductor to approach or touch a live line.
The upper parts of the scaffold shall be provided with soft wood rubbing boards or otherwise protected in an approved manner to prevent damage to the conductors resting on or being drawn over the guard. Soft wood poles may be used for this purpose. The height of these boards shall be sufficient to prevent the conductor damaging the nylon net. To avoid damaging the conductors, no object other than non-metallic lashing or the catchers shall protrude above the rubbing boards.
The scaffolds shall be constructed to prevent unauthorized access or climbing by the use of barbed wire anti-climbing devices, fences or other means approved by the Employer. The scaffolding shall be lit with red warning lamps during the night if erected within 2 m from a highway or footpath without fencing.
Where possible, the resistance to earth of the scaffold shall be less than 10 ohms. Bonding the scaffold to the earthing systems of either the live line or the line under construction normally is not acceptable. In the former case, a nearby line fault could cause the scaffold to become live. In the latter case, a fault between the live line and the scaffold could cause components of the line under construction to become alive, particularly as its earthing system may not be complete. The earth rods should normally be driven into the ground 1.0m out of the scaffold's structure perimeter.. The rods should be securely connected electrically and mechanically to the scaffold structure by flexible copper or aluminium leads with minimum cross-sections of 64 mm or 100 mm respectively.
Drawings of the scaffold, complete with details of the clearance plates and earthing arrangement, together with supporting, calculations shall be submitted to the Employer / Employer's Representative for approval.
2.3.7.5 Stringing OPGW
The Contractor shall ensure the Manufacturer's instruction for specific stringing requirements.
31 Stringing and sagging of OPGW shall be done in accordance with the detail system design which is subject to approval by the Employer prior to commencement of any field works.
OPGWs shall be kept off the ground at all times when the OPGW is in motion. Tension stringing of all OPGWs shall be continuously controlled.
The Contractor shall take special care that the OPGWs are not dragged on the ground at any time during erection or come into contact with any obstacles such as walls, fences or buildings, etc.
OPGW drums shall be closely examined before pulling commencement, and all nails and other items that could damage the OPGW shall be removed. During stringing, the OPGW drums shall be supervised at all times, and the OPGW shall be inspected for defects while it is being pulled off the drum. Watchmen shall be positioned at critical structure locations to ensure a smooth stringing operation.
The OPGW tension during stringing operations shall be kept as low as possible, consistent with keeping the conductor at safe distance from the ground whilst in motion. At no time will the tensions be allowed to exceed 1.5 times of the permissible installation tension.
All stringing equipment shall be properly anchored and shall be positioned in such a way that towers and fittings will not be overloaded. OPGW reels shall be securely anchored during stringing operations, and reel jacks shall be of the self-braking type to prevent OPGW overrun. OPGW pulling equipment shall be such as to ensure a continuous steady pull. Every precaution shall be taken to prevent damage to the OPGW. Clamps and other devices used for handling the OPGW during erection shall allow no slippage or relative movement of strands or layers and shall not pinch or deform the OPGW.
Cable rotation shall be avoided during the installation of the OPGW in sections.
During the installation of the OPGW through the tower, cable rotation as caused by stretching out of the OPGW and kinking shall be avoided.
The OPGW shall be strung prior to stringing of the conductors. The OPGW shall be strung for whole line sections, without joints. The tools and equipment used shall be earthed.
The OPGW shall also be sagged prior to sagging of the conductors.
Suspension clamps shall be installed such that the earthing bond wires all face the same direction and the ends of the bond wires shall be clamped to structures in a manner approved by the Employer / Employer's Representative.
Vibration dampers shall be installed on the OPGW based on the recommendations of the damper study, on the Manufacturer's recommendation and as approved by the Employer / Employer's Representative.
2.3.7.6 Earthing of Conductors, OPGW and Stringing Equipment
Conductors and OPGW shall be effectively earthed in an approved manner during running out at all places where men are working on them.
32 Sufficient earth to maintain safety shall be kept until the time of taking over. The position of each earth shall be recorded by the Contractor.
Conductor sheaves lined with neoprene or rubber shall have an electrical conducting path between their suspension points and the conductor or OPGW supported within them and shall run with minimum friction.
When stringing operations are carried out close to or over/under crossing energized lines, the Contractor shall take all precautions necessary to prevent accidents and injuries to persons and property due to induced voltage or physical contact.
The main method to protect the workers against electric current induced by an energized transmission line is reliable grounding of conductors (wire cables) of every line section as a whole and immediately at the spot, where installation works are carried out.
Prior to stringing of the conductor (wire cable), each drum shall be grounded by attaching the "earthing bushing" of the tensioner (breaking machine) and puller to the tower grounding.
The stringing works may not commence unless the earthing is completed otherwise the works shall be performed using dielectric gloves.
The strung conductor (wire cable) shall be grounded every time it is suspended onto the tower.
After completion of stringing the conductor from the drum the conductor (earthwire) shall be securely earthed and the last 5-6 turns of the conductor (wire cable) shall be manually removed from the drum using dielectric gloves.
When installing conductor compression joints both ends of the conductors shall be earthed
Earth conductors while Fixing earthing to conductors (wire cables) and removing it should be done only using an insulating rod or with dielectric gloves.
Prior to sag setting and clamping all conductors (wire cables) shall be grounded on all towers that runs close or cross the energized line.
The conductor (wire cable) pulled down for sealing of the tension clamp shall be grounded right at the place of sealing.
On angle-tension towers, the conductor loop shall be attached to the tension string close to the tension clamp, while the loop of the grounding wire cable shall be attached by the tension clamp.
Stubs of anchor towers shall be attached only after mounting works in adjacent anchor spans are completed. After completion of clamping the conductors (earthwire) shall be connected to the tower crossarm with temporary earthing wire.
Conductors (earthwire) temporary earthing shall remain until sagging/clamping is completed. Similarly installation of spacers and vibration dampers should be done with conductors (earthwires) temporarily earthed.
Upon completion of works the temporary earthing shall be removed in the reverse order i.e. first the temporary earth conductor shall be removed from the conductor (wire cable) using an insulating rod, 33 then it shall be disconnected from the grounding wire.
2.3.7.7 Repair of Damaged Conductors and OPGW
Any damage noticed or caused during handling/stringing to conductor or OPGW shall immediately be reported to the Employer / Employer's Representative whose decision to replace or repair will be final.
Repair of the damage shall be done in the manner indicated or approved by the Employer / Employer's Representative at the expense of the Contractor.
Damage is considered to be any deformity on the surface of the conductor which can be detected by eye or by touch. Damage includes, but is not limited to, nicks, scratches, abrasions, kinks, basketing, popped-out strands and broken strands.
When damage to the conductor and OPGW does not exceed two aluminium strands, either broken or nicked deeper than one-third of their diameter, repair sleeves may be installed. If more than two strands are broken, abraded or nicked deeper than one-third of their diameter, the damaged section of the conductor shall be cut out, whereas for the OPGW the whole section shall be replaced.
Where, in the opinion of the Employer / Employer's Representative, repairs are acceptable, these shall be made by careful smoothing with fine emery paper, and installing repair sleeves or cutting and installing compressed joints.
If there is repeated damage in the same or consecutive span, the whole conductor in these spans shall be replaced.
All damage caused by come-along and other gripping devices shall be repaired or cut out, as required by the Employer / Employer's Representative, before the conductor and OPGW are finally sagged.
Conductor and OPGW repair sleeves shall not be used without the permission of the Employer / Employer's Representative and will be granted only in exceptional circumstances. No repair sleeves shall be used in spans crossing over power lines of voltages higher than 1 kV, telecommunication overhead lines and buildings as well as in single span sections. To permit handling without damage to the conductor and OPGW, the Contractor may be required to rewind on new drums.
All repair works, replacing conductors or OPGW due to damage(s) shall be at the Contractor's expense.
2.3.7.8 Jointing of Conductors and OPGW
Tension and dead-end assemblies of OPGW shall be of helical grip type. When passing the tension towers, the OPGW shall go into the next helical grip of the next section until the joint box.
The Contractor shall ensure that no bird-caging, over-tensioning of individual wires or layers or other deformation or damage to the conductor or OPGW occurs. Cutting of conductors and OPGW layers shall be carried out with tools designed to prevent damage to underlying strands or optical fibre tubes.
The Contractor shall keep a record of each compression joint showing its location, date of assembly, resistance measurement records and name of the linesman responsible for the assembly. 34
Where records of the joints made by a particular linesman show a repeated performance below the required standard, the Contractor shall, at the request of the Employer / Employer's Representative, cease to employ him on jointing operations and immediately replace him with other qualified personnel and rectify the corresponding points at his own expense.
Jointing shall not be permitted in a span between two adjacent tension towers and when crossing or adjoining roads, power lines, telecommunication lines or buildings.
Jointing shall not be performed in rain or in the dark. To develop the rated mechanical strength and electrical conductivity, the installation of compression joints shall be carefully supervised to ensure that the joints are properly carried out.
2.3.7.9 Sagging
The Contractor shall at an early stage submit for the Employer / Employer's Representative's approval, the sag and tension calculations including temperature shift creep compensation for 10 years. The calculations shall prove that the conductors and OPGW initial and final tension stay within a limit guaranteed by manufacturer(s) and that the line components are not overloaded during stringing operation and OPGW is unduly exposed to aeolian vibration damage in the period following erection.
The maximum permissible initial tension shall be lower than the value provided and guaranteed by the OPGW manufacturer.
Generally, the "equivalent span" method shall be used for calculating tensions and sags, i.e., the tension in any section length is that which would apply to a single span of length equal to the square root of the sum of the cubes of the individual span lengths in the section divided by the sum of their lengths. However for line sections in hilly terrain, the Contractor shall, where directed by the Employer / Employer's Representative, adopt more rigorous method of analysis taking account influence length and weight span and of differences in support levels, swing of insulators with conductors in sheaves etc. and showing insulator offsets for clamping-in. The Contractor should assume the following tensions for calculation of sags: "Final tension" shall mean the horizontal tension in a conductor or OPGW after 10 years in service, which is considered the "final sag" of the conductor/OPGW under a given load and temperature condition. Final tension corresponds to final sag. "Initial Tension" shall mean the horizontal tension in a conductor or OPGW at the time of marking for making-off, which is considered the "final stage" of the conductor/OPGW under a given load and temperature condition, with allowance where appropriate for the conductor being supported in sheaves rather than in clamps. Initial tension corresponds to initial sags.
The final tensions assumed for selection of the tower heights, types, locations and conductor clearances shown in the profile drawings to be provided by the Contractor are indicated, along with the respective temperatures and loads as in Part 2, Technical Data Schedules. The tensions in the OPGW must be such that the sag is 10% less than that of the conductor under everyday stress condition.
The spans used for measurement of sag before clamping shall be, where possible, the longest level spans in the section of line being sagged. When sagging conductor or OPGW lengths over six spans, the sag shall be measured at least every 1500 m. In unusual situations, additional measurements may be requested by the Employer/Employer's representative.
35 The correct sag shall be measured by accurate sighting in the selected span. In cases where sighting is considered by the Employer / Employer's Representative as unsatisfactory, other method as required/directed shall be used.
The Contractor shall provide and use a reliable radio communication system for reliable communication between stringing personnel.
All conductor and OPGW sagging shall be performed during daylight. Sagging operations shall not be permitted during heavy rains, during storms or high wind, or other adverse weather conditions which would impair the accuracy of the sagging.
The pulling and adjusting of the conductor or OPGW to the final sag position shall be done by means of a hand or power operated hoist and not by pulling directly with trucks or tractors.
The Contractor shall not apply final tension to any conductor or OPGW nor make off any conductor or OPGW except in the presence of the Employer / Employer's Representative. Complete responsibility for ensuring correct tensions will, nevertheless, remain with the Contractor.
After reaching the correct sag, the conductor and OPGW shall remain in the stringing sheaves for at lest 3 days before clamping may commence.
A sag tolerance in [m] of 0.01 x sag in [m], but not exceeding 0.15 m will be permitted provided all conductors in the span assume the same sag and the necessary ground clearance is obtained.
The spans adjacent to gantries of substations shall be slack spans.
Clearances between conductors and ground and between jumpers and all structures must be checked during erection and before handing over the line.
The Contractor shall keep a schedule recording all sagging operations showing details of the section, the sagging and checking spans, ambient temperature, pre-stress (where appropriate) initial and final sags, the date of sagging and clamping-in offsets. This record along with the record of compression fittings shall form part of the final records for the line and shall be handed over for approval to the Employer / Employer's Representative. The records shall be available for inspection at any time.
2.3.7.10 Clamping
All conductors and OPGW shall be accurately marked for clamping at all towers on the same day following final sagging.
Clamping offsets shall be calculated by the Contractor and shall be marked using a method approved by the Employer / Employer's Representative that will not damage the conductors and OPGW.
Preformed armour rods shall be installed at all points of conductor and OPGW suspension. Armour rods shall be carefully centred in the suspension clamp. Suspension clamps shall be installed and adjusted such that the insulator string in its final position and at EDS temperature hangs in a vertical plane through the axis of the structure.
If it becomes necessary to change the point of attachment of the suspension clamp by more than 70 mm either way from the mid point of the armour rods after they are installed, the rods shall be removed and reinstalled so as to centre on the point of attachment. Under such circumstances the 36 armour rods may be reused if not damaged.
The Contractor will not be allowed any additional compensation for such removal, re-installation, or replacement of armour rods where required.
2.4 Fibre optic link
2.4.1 General
The fibre optic system will comprise overhead line and underground fibre optic cable sections. The new fibre optic link shall operate at STM-1, STM-4 and STM-16 line rates at a wavelength of 1550nm.
2.4.2 Power Budget Calculations
The Contractor shall provide power budget calculations. The result of the power budget calculations shall indicate the maximum link length with the existing OLTEs in SS Peja 3 and SS Ribarevine, and shall take into account: Transmit power (dBm) Receive power (dBm) Equipment margin: 3 dB Cable margin: 0.03 x span length dB Fibre attenuation: As per Fibre Optic Cable Requirements Splicing loss: 0. 1 dB (1300nm) or 0.05 (1550nm) Quantity of splicing per km: Average of one splice/1.6 km Connector attenuation: 0.3 dB.
The Contractor shall take into account in the calculations the additional attenuation introduced by the optic head (connectors) and the station fibre optic cables (with splicing at the terminal junction box).
2.4.3 Connectors
The equipment in SS Peja 3 shall be connected through ODF with connectors having the following features:
insertion losses less than 0.3 dB, FC/PC type durability: 500 mating cycles at least, return loss: >40 dB, cable retention: 100 N.
2.4.4 Optical Main Distribution Frame
At SS Peja 3 fibre optic cable terminal site, an Optical Distribution Frame (ODF) shall be provided. The fibre optic cables shall be terminated at the OMDF, and the OMDF shall be used to interface the SDH line equipment to the fibre optic cables. The ODF shall be equipped to accommodate and terminate fibre optic cable of 48 cores. All fibre optic cables entering the OMDF shall be of all-dielectric construction. All cables containing non-dielectric components shall be terminated and earthed in a splice box external to the OMDF.
37 The following basic functions of the OMDF are required: circuit rerouting/jumping, circuit disconnection, patching and test connections, bridging measurements, terminating measurements.
Optical fibres shall be terminated on an OMDF properly labelled with waveguide pair number, destination or source, go or return, and it shall be possible to divert and connect each optical waveguide to the appropriate point on any terminating equipment.
2.5 Final Checking and Testing
2.5.1.1 Final Checking
Subsequent to the completion of the transmission line construction, the Contractor shall carry out final checking and testing works. Test programmes for all tests shall be prepared and submitted to the Employer / Employer's Representative for approval. The date of tests shall be announced in time in order to allow participation of the Employer / Employer's Representative. A test report has to be submitted to the Employer / Employer's Representative for approval within two weeks after test performance.
The final checking shall include, but shall not be limited to:
tightening of bolts and fixing of missing members to towers; remove all scaffolds and equipment and clear all debris and other rubbish from the site; restore surface damage, foundation subsidence and carry out erosion control measures, where directed by the Employer / Employer's Representative or as required by local authorities or regulations; remove all left-over materials at winch yards, drum yards and store yards; complete clearing of danger tree and tree re-clearing on the easement; re-conditioning and handing over of access roads which shall be used for maintenance purposes; check of completeness of all towers. measurement of the OHTL and communication (OPGW) parameters.
2.5.1.2 Testing
The Contractor shall be responsible for conducting the tests in the presence of and as instructed by the Employer / Employer's Representative. If any failure is detected, the Contractor shall locate and determine the cause of the failure and shall make any replacement or repair necessary or correct any errors in the installation to the satisfaction of the Employer / Employer's Representative and at no extra cost.
Prior to final tests before energizing the line the Contractor shall provide the Employer / Employer's Representative with a written statement that all personnel is withdrawn and all temporary erection earthing removed and the line is ready for energizing The Contractor if not done at the earlier stage shall provide all protocols of tests as required by this specification. Prior to energizing/hand-over of the completed line, the following (as a minimum) final tests shall be carried out:
38 For OPGW - The OPGW performances shall be measured between the joint boxes installed on the terminal gantries. The Contractor will be responsible for all necessary corrections should the test fail.
The link attenuation shall be measured for each fibre.
The total dispersion at 1550 nm shall not be larger than:
Ns x 0.06 + L x 0.25 on each fibre, where Ns = total number of splices in line; L = length of the OPGW measured between the joint boxes mounted on the terminal gantries (including the excess in length due to sags and joints).
Should any additional test be required to prove completeness of the works in accordance with the specification or statutory regulations the shall perform or assist in doing so by the Employers' staff by providing such labour, transport and other assistance as required without extra charge.
Telecommunication The Contractor shall be responsible for assisting in the testing of the telecommunication link between Peja 3 and Ribarevine Substations The corresponding programme shall be prepared during the implementation stage. However, the price of the works is deemed to be included in the Price Schedules.
2.6 Hand-Over Date
On completion of the final checking and testing, the Contractor shall deliver to the Employer / Employer's Representative a written statement certifying that the line is complete in every respect, that all earths placed by the Contractor have been removed and that every member of the Contractor's staff has been informed that nobody is allowed to work on the line unless a working permit to work is issued and signed by the Employer / Employer's Representative.
This is mandatory that as built drawings, all test protocols and tools required for maintenance of the OPGW on transmission line are handed over to the Employer before line is energized and considered as handed over.
Some minor spare materials or appliances that are not essential for the OPGW maintenance may be handed over at later stage however exact dates as agreed with the Employer shall be declared and signed by the Contractor.
39
PART 2: TECHNICAL DATA SCHEDULES
The technical data given in these schedules are considered to be
Guarantee data.
Thus, the Bidder shall sign and stamp every page of these schedules.
The technical data schedules are available on the CD as word file:
Technical data schedules.doc
They should be filled by the Bidder and be attached to the Bid.
Only the column "Data offered by Bidder" shall be filled, no changes shall be made to the other columns.
Any Bid where changes have been made in the original data will be rejected.
40 Table 1: Technical Data - 400 kV OPGW Earthwire
Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 400 kV 1. Manufacturer - to be specified 2. OPGW type / material - AL-ACSA 3. Standards for design (construction and material) IEC 60794-1-1 IEC 60794-1-2 IEC 60794-4 ITU-T G655, EN 50182 IEC 60104 IEC 61232 IEE Std.1138 IEC 60793-1-1 IEC 60793-1-2 IEC 60793-1-3 IEC 60793-1-4 IEC 60793-1-5
4. Code / name - to be specified 5. Stranding and wire diameters: 6. Aluminium-clad steel No/mm to be specified 7. Aluminium alloy No/mm to be specified 8. Design cross-sectional areas: 9. Aluminium-clad steel mm to be specified 10. Aluminium alloy mm - 11. Total mm 126.1 12. Tube: 13. Number: no. to be specified 14. Diameter: mm to be specified 15. Material: stainless steel 16. Mechanical Characteristics 17. Diameter mm <14.5 18. Weight kg/km <840 19. Ultimate breaking load min. kN 120 20. - Max. working stress N/mm 206 21. - EDS (15C, still air) N/mm 88 22. Max. tension for stringing N to be specified 23. Coefficient for linear expansion 1/C-E-06 13 24. Modulus of elasticity N/mm2 16,200 25. Standard delivery length per drum m to be specified 26. Gross weight per drum incl. conductor kg to be specified 27. Minimum bending radius for cable under tension (without incurring cable or fibre damage or optical attenuation increase) mm to be specified 28. Minimum allowable stringing sheave diameter mm to be specified 29. Operating temperature range C to be specified 30. Electrical Characteristics: 31. Maximum DC resistance (T = 20C) /km to be specified 41 Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 400 kV 32. Short circuit test: 33. - T initial C 40 34. - Fault current intensity kA 7 35. - Fault current duration s 1 36. - Maximum temperature of optical fibre unit C 150 37. Lightning strike: 38. - Current kA 30 39. - Charge transfer C 50 40. Temperature cycling: 41. - TA C -20 42. - TB C +40 43. Type test certificate for OPGW - yes 44. Proof of operation experience - yes 45. Fibre characteristics: No. of optical fibres in OPGW (type G655) 48 46. Fibre type ITU-T G.655: 47. Fibre excess length to be specified 48. Core diameter m 8.0-11 10% 49. Transmission wave length nm 1550 50. Mode field diameter at 1550 nm (including tolerances) m 10.5 0.7 51. Optical cladding diameter m 125 1 m 52. Cladding non-circularity % < 2 53. Core concentricity error m 0.8 m 54. Fibre coating: 55. - Material - to be specified 56. - Nominal diameter m 250+/-10 57. Cable attenuation: (maximum) 58. - for every fibre in every drum at optical wave length of 1550 nm dB/km 0.25 59. Joint attenuation for every fibre measured on the fully installed joint at optical wavelength 1550 nm:
60. - average dB 0.08 61. - maximum dB 0.10 62. Max. total dispersion: 63. - at optical wave length of 1530-1565 nm ps/km.nm 6 64. - at optical wave length of 1565-1625 nm ps/km.nm to be specified 65. PMD ps/km to be specified 66. Cable cut-off wavelength nm 1450 67. Core numerical aperture - to be specified 68. Min. life span years 30 69. Refractive index at 1550 nm - to be specified 70. Proof test 1 second % to be specified 71. Minimum bending radius mm to be specified
42 Table 2: Technical Data - 400 kV OHL Accessories for OPGW
Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 400 kV 1. Manufacturer - 2. Standard - 3. Parts made of steel or iron material are galvanised - yes 4. Kind of galvanisation hot dip 5. Quality and tests correspond to IEC 61284 6. Factory tests according to 7. Factors of safety 8. For OPGW tension assemblies: 9. Minimum failing load referred to max. tension load of OPGW, or % 10. Minimum failing load referred to failing load of OPGW % 95 11. For OPGW suspension assemblies: 12. Minimum failing load referred to max. simultaneous acting forces % 13. Slipping load kN 14. Tension assemblies for OPGW: 15. Manufacturer 16. Type 17. Kind of connection of OPGW 18. by means of helical grip type 19. Material used for helical grips: 20. Dead-end 21. Protection and suitable ??? for vibration damper installation
22. Suitable for cross sections mm 126.1 46.2 23. for Peja an (optional) Skenderaj 110 kV OH line mm 42.4 24. Suspension assemblies for OPGW 25. Manufacturer 26. Type 27. Kind of connection with conductor 28. Material used for helical grips: 29. clamp body 30. clamp protection 31. spiral wires 32. Suitable for cross sections mm 126.1 46.2 33. for Istog, Peja and (optional) Skenderaj 110 kV OHL mm 42.4 34. Joints: OPGW/OPGW and OPGW/OPUG 35. Manufacturer 36. Type 37. Variant A: Splicing along an OHL 38. Variant B: Terminal, at gantry 39. Number of cable entries 43 Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 400 kV 40. Locking facilities - yes 41. Splice spare length m 1 42. Outer box material oil-resistant and metallic
43. Enclosure complete with: 44. organiser tray or - yes/no 45. splice cassette - yes/no 46. - accommodation for multiple cassettes mm 200-300 47. - splice cassette suitable for heat shrinkable connectors yes 48. Temperature C 49. Humidity % 50. Class of protection IP 55 or better 51. Minimum allowed bending diameter of optical fibres 52. Type test for joint box yes
Table 3: Technical Data - Supporting Documents
Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 400 kV 1. Drawing of OPGW suspension assembly yes 2. Drawing of OPGW tension assembly yes 3. Drawing of OPGW suspension clamp yes 4. Drawing of OPGW tension clamp yes 5. Drawing of each OPGW (joint boxes, splices) fitting component yes 6. OPGW hardware and fitting supply reference yes 7. Drawing of OPGW cross section yes 8. Composition of optical fibre unit yes 9. Details about protection of moisture ingress yes 10. Details of water-blocking compound incl. method of removing the compound yes 11. Details of coating material, dimensions and min. bending radius yes 12. Proof of supply of similar OPGW for five years yes 13. Details on handling and installation techniques yes 14. Description/drawings of OPGW / OPGW and OPGW / OPUG jointing procedure and devices yes 15. Specification of mechanical/optical aspects of joints, splices and sealing arrangements yes 16. Description of jointing procedure yes 17. List of recommended spare parts yes 44 Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 400 kV 18. Manufacturers technical data / pamphlets yes
Table 4: Technical Data - Dampers
Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 400 kV 1. Vibration Dampers for OPGW 2. Manufacturer 3. Type 4. Material used for: 5. Counter weights 6. Elastic cable 7. Clamp body 8. Iron and steel parts galvanised yes 9. Kind of galvanisation hot dip 10. Quality corresponds to: 11. Weight of damper to be installed in 12. for OPGW for Istog an Peje 1 Lines 13. Distance of damper fixing point from next clamp, and in case two dampers are fixed, required distance between damper fixing points mm 14. for OPGW for Istog an Peje 1 Lines 15. Clamping bolt materials: 16. stainless steel - yes/no 17. galvanised steel - yes/no 18. tensile strength n/mm 80 19. tightening toque NM 44 20. Non-metallic material temperature withstand C 0-40 21. Max. bending stress of conductor m 150 22. Expected life of conductors years 100 23. Drainage hole diameter mm min. 6
Table 5: Technical Data - Connection Clamps for OPGW Connection to Tower Steel Structures
Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 110 kV 400 kV 110 kV 45 Minimum Requirements Data offered by Bidder Description Unit Data 400 kV 110 kV 400 kV 110 kV 1. Type 2. Kind of clamping - 3. Material used for clamp body - 4. Bolts - 5. Suitable for cross section: mm 6. for OPGW for Istog and Peje 1 Lines 7. Supporting Documents 8. Drawing of conductor spacer dampers - yes 9. Drawing of OPGW vibration dampers yes 10. Capability of vibration (conductor and OPGW) measurements yes/no
46 PART 3: PRICE SCHEDULES
1. Price Fixing
1.1 General
The project will be executed on a turn-key basis. Therefore, all prices quoted are fixed and firm, up to the date of issuing of the Performance Certificate for the Project.
The Employer reserves the right to order additionally or to reduce the supply of material and services up to an amount of plus/minus 15% of the total value of the contract price without changing of the unit prices. In this case, the contract price will be adjusted accordingly.
The items described herein shall remind the Contractor that the main costs be included in the prices. Nevertheless, the prices shall be made up in accordance with the general and special conditions and the technical requirements as laid down in these contract documents (Volumes 1 - 3).
1.2 Pricing
Price Contains "Supply, "Inland Transport and Storage", "Works / Erection / Commissioning" as described below.
Supply (CIP) Prices CIP are defined according to "Incoterms". This includes but is not limited to: the detailed engineering and design, all provisional and final documents required and specified including respective numbering system, manufacture and/or procurement, assembly, inspection and testing, final painting and/or galvanizing, packing and marking at the Contractor's workshops, delivery to site, special tools and special equipment required for any maintenance, inspection and repair / works of any item in the scope, all overhead costs of the constructor.
Inland Transport, Storage And Insurance All costs and expenditures for and connected with the inland transport of the material from the harbour or local place of manufacture to the erection site and subsequent storage, including unloading and intermediate storage, including responsible care-taking of the materials during transportation and storage, including insurance against loss and damage during inland transport and storage, i.e. covering the materials from the insurance cover during customs clearance and harbour handling till the material is covered by the erection insurance.
Works / Erection / Commissioning This includes but is not limited to: technical and other documentation and insurance until issuing of Performance Certificate, training on site (class courses and hands on), 47 intermediate site storage, complete erection including supply of all consumable and fixing materials required for completion of work, provision of all labour, necessary lifting and erection devices, all necessary costs for erection and civil works, all temporary site facilities, fire protection sealing for all cable openings in building walls and floors and switchgear openings through the bottom or top (as well as preliminary during erection works as well as permanently), complete labelling as required, all signs for the erection period and permanently necessary for warning of any danger, emergency hints, prohibition signs, application of corrosion protection during erection as necessary (e.g. zinc coating at cut and welded places of cable ways and final painting, carrying out commissioning, testing, in compliance with the contract requirements.
Bill of Quantities The prices shall include all costs incurred by the Contractor for the fulfilment of his obligations under the contract up to the expiry of the contract defects liability period. The prices shall cover all costs for services, works, testing, plant, documentation, materials and equipment specified in the bidding documents and all costs related to the works as set out in the bidding documents. Should, in the opinion of the Bidder, the items listed in the price sheets not cover all of the costs, services and works necessary for the fulfilment of his contractual obligations, the Bidder shall add such items on separate price sheets and explain in his proposal the reasons for such additional items. In any case it is understood that the prices quoted cover each and any costs, services and works under the contract. The costs for the following shall be included in the prices:
General Costs This includes but is not limited to: costs for permits to remove obstacles and way leaves, cost of land for temporary sites, cost for buying, leasing and/or exploitation of borrows, provision for security services at site and others expenses, services required to complete the works under this contract.
Design Phase This includes but is not limited to: Manufacturers shop design, preliminary design, main (or final) design, detailed (or elaborate) design (for execution), design calculation, studies, as-built design (or design of executed structure), drawing up, copying and distribution of construction documents, organization and holding of design review meetings including accommodation and catering for Employer's and Employer's Representative's personnel.
Preparatory Works This includes but is not limited to: topographical surveys, soil investigations, line route und profile survey.
48 Temporary Site Works This includes but is not limited to: temporary offices and living accommodations for Contractor's, Subcontractor's, Employer's and Employer's Representative's personnel, first aid facilities, site stores, open air storages, provision of electric power, fuel, drinking water, raw water, security and fire fighting equipment, collection, treatment and disposal of wastes and sewage, construction and maintenance of the necessary temporary access roads.
During Manufacturing This includes but is not limited to: manufacturing, workshop testing, corrosion protection and application of paint and coatings, packing, marking, labelling.
Transportation to Site This includes but is not limited to: loading, unloading, intermediate storage, as far as necessary, transportation by land, sea, river or air.
Erection and Construction This includes but is not limited to: provision of all auxiliary materials, site transportation facilities, lifting equipment, tools, on-site class and hand on testing, erection and construction staff, site testing equipment, facilities and laboratories, all costs and expenditures for the provision of sufficient and appropriate manpower required for the supervision of civil works and dismantling works, all costs for performing of erection and civil works.
Dismantling This includes but is not limited to: preparation of risk assessment, dismantling, sorting and packing, delivery dismantled equipment/material to KOSTT's store.
Site Office, Living Accommodation and Communication Facilities This includes but is not limited to: construction, fencing, road access and other necessary facilities, maintenance for whole duration of the project, Insurance of vehicles and their maintenance including running cost, stationeries and consumables, all communication facilities such as telephone, faxes, walkie talkies, radio links, computers and Internet LAN networks, copying and printing facilities, courier services.
Spare Parts and Special Tools The completion of the price sheet for spare parts and special tools is mandatory. The prices shall 49 cover the spares as set out in the general technical requirements and in the particular technical requirements. Recommended spare parts, as well as recommended equipment, tools and instruments, shall not be brought forward for inclusion in the Total Summary Price Schedule. The Bidder shall provide under the relevant price sheets his own bill of quantities for such spare parts, tools and equipment needed to meet the warranted reliability and availability performance requirements for the duration of the defects liability period plus the spares required for a period of three years starting at the end of the contract period. Alternative prices for certain items, if offered, shall not be brought forward for inclusion in the summary price schedules.
2. Cost of Items Not Specifically Indicated
The equipment/materials and works not specifically mentioned in the price schedules are deemed to be included in other quoted prices, so that the project is completed in every respect to serve the intended purpose.
3. Handling of Price Schedules
The price schedules should be carefully filled in accordance with the following explanations:
Both price schedules, definite works plus optional works, will form the basis for the evaluation of the Bids.
The optional works will be included in the final total contract price, if considered reasonable and permissible by the budget.
The Contractor shall be responsible to complete the price schedules, any items not filled will be considered as included in the final price. No price adjustment is permitted.
The prices for "Inland Transport" (Column 4) shall be included in Column 3 ("CIP Price Total"), but shall be separately listed in Column 4 for demonstration purposes.
3.2 Factory Acceptance Tests
Factory acceptance test will basically be attended by 2 (two) Employer's Representatives at a time of whole duration of the tests as scheduled by the Contractor.
Should different equipment be manufactured at the same premises, the FAT may be combined allowing necessary time to cover the inspection by one representative, otherwise more Employer's personnel should attend the test.
Six weeks prior to scheduled tests the Contractor shall submit proposal including list of tests and their 50 duration for Employer's approval. The Employer will then request the Contractor to include either one or two their representatives.
All cost including travel, accommodation, daily allowances, local transport etc shall be included in the price.
4. Signing of Price Schedules
The Bidder shall sign and stamp every page of the Price Schedules.
insert files:
price schedule - grand total.xls price schedule - definite works.xls
1 PART 4: LIST AND PRICES FOR RECOMMENDED SPARE PARTS
(Not applicable - included in Part 3.)
1 PART 5: LIST OF SPECIAL TOOLS (WITH COMMENTS ON EXISTING)
(Not applicable - included in Part 3.)
Part 16: List of Contractor's Manpower 16-1 1 PART 6: LIST OF CONTRACTOR'S MANPOWER
It is assumed that the manpower provided in this schedule will be assigned to the project. Any change needs the approval of the Employer or Employers representative.
1. Project Management
Position Name Project Manager Deputy Project Manager Site Manager Design Manager
2. Work Force
Please insert the work force you are planning to assign to the project during project implementation.
Position Name
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Part 17: List of Contractor's Machinery and Equipment 17-1 1 PART 7: LIST OF CONTRACTOR'S MACHINERY AND EQUIPMENT
The Contractor is obliged to list below all the required major machinery and equipment which will be used in the project
Item No. Description (Name, Type, Capacity, etc.) Year of Manufac ture Ownership (Own Equipment or Rented) If Rented, Please Insert Name of Renting Company 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
1 PART 8: DEVIATIONS FROM TENDER / CONTRACT DOCUMENTS AND ALTERNATIVES (SPECIFICATIONS)
It is assumed that the documentation, equipment, material, works, services and testing will conform to the Tender Documents in every respect, unless deviations are mentioned in this schedule.
Deviations mentioned in the text or drawings forming part of the Bid, but not contained in this list, will be considered as nil and void, and the respective works will be treated as fully in line with the requirements of these Bid documents.
Deviations from Specifications:
2 PART 9: LIST OF SUBCONTRACTORS
Item of Supply or Work Subcontractor / Supplier Country of Origin Reference List Added [Yes/No] Authorization Form Added [Yes/No]