WBPWD/EE-I/CKHED/eNIT39/25-26

Amount

HIGH-MAST LIGHTING

SITC of 12.5 M high mast lighting system covering design, manufacture, install, testing and commissioning of High Mast Lighting Systems complete in all respects including casting of foundations as per following specification (Make: Transrail/ Aster/ Crompton/ Bajaj)

APPLICABLE STANDARDS : The applicable codes followed for high mast designs are as follows: 1. TR. No.- 7: High Masts for Lighting and CCTV (2000 edition) of ILE, U.K, 2. IS 875 Part – III : Wind Loading 3. BS EN 10025, S355 : High Tensile Steel Sheets 4. BS EN ISO 1461 : Galvanization

A. HIGHMAST :

1. Structure details: The High masts shafts are generally 20 sided polygons & continuously tapered. The structural design of high masts should be carried out in conformation with the above code of practices followed internationally. This is very critical & important in view of the fact that design of mast may vary from one geographical location to the other due to the difference in wind speeds & the load on the mast.

2. Construction details: The high mast shafts are manufactured from high tensile steel plates of minimum yield strength of 355N/Sq. MM which should conform to BS EN 10025 , cut & folded to form a polygon section. The cutting of sheet before bending on press brake shall be by cold shearing method to avoid development of stresses in steel. The manufacturer has to submit spectro chemical test report of steel at the time of dispatch. Because of the ease of transportation, masts are fabricated in sections. These sections are joined at site by slip-stress- fit method & as per Technical Report No.7, the minimum over-lapping between two sections should be 1.5 times the diameter at penetration. Each mast shaft section have only one longitudinal weld and without any circumferential weld joint. The welding shall be submerged arc welding only. The welding procedure shall be certified by reputed agency like CEIL. The mast base flange are free from any incursion or lamination and provided with supplementary gussets between the bolt-holes to ensure elimination of helical stress concentration. A vandal resistant, weather proof, lockable door of suitable size is provided at the base of high mast to access comfortably the components at the base compartment for normal opearation & for maintenance. For the environmental protection of the mast, the entire fabricated masts shall be hot dip galvanized (internally & externally) as per BS EN ISO 1461standards or equivalent with average coating thickness of 85 microns. The galvanizing shall be done in single dipping. Double/ part dipping shall not be allowed.

3. Dynamic Loading of Mast: The mast structure shall be suitable for atleast wind speed of 50 M/sec to sustain an assumed maximum reaction arising from a wind speed as per IS 875 (3 second gust), and are measured at a height of 10 metres above ground level. The designed lives of the mast should normally be 25 years. Wind tunnel report from Indian reputed institute like IIT has to be submitted by manufacturer.

4. Luminaries Carriage: The lantern carriages are to be fabricated from 50NB ERW Class B-M.S. pipe 8 arm, welded in 2 section. Holes are to be provided in the bottom side of arm tubes to act as conduit for wires. The whole assembly is hot deep galvanised. A PVC lining is to be provided in the inner side of carriage to avoid any metal contact with mast surface. The lantern carriage should be designed for symmetrical arrangementas of 8 nos. luminaries & it’s control gear boxes. Junction boxes are provided on the carriage for terminating the trailing cable.

B. Raising and lowering mechanism:

1. Winch: The winch is comprised of double drum, completely self sustaining without the need for brake shoe, springs or clutches. There is a permanent oil bath for self-lubrication. The drums are to be properly grooved to provide a perfect seat for wire ropes. The Safe Working Load of winch is 750 kG & the gear ratio is 53:1. The winch is normally be operated by an electrical power tool of single speed 0.75 HP integral motor, however there is a provision for manual operation also by means of manual handle. The winches are type tested through reputed institutions like IIT as consultants and the type test reports are submitted along with offer. Winch shall be manufactured by mast manufacturer only.

2. Head Frame: The hot dip galvanized head frame is to be designed as a capping unit of the mast is of welded steel construction and provided with guides and separators between the ropes and cable. The LM6 Aluminium pulleys with bush bearing mounted through stainless steel shaft shall be suitable to accommodate wire ropes and multi core trailing cable. The head frame is provided with guides and stops with PVC buffer for the docking of luminaires carriage. The pulley assembly is covered by a hot dip galvanized canopy

3. Stainless Steel Wire Ropes: The stainless steel wire ropes are generally be of 6 mm dia, 7/19 construction with central core being stainless steel only. The grades of wire ropes are in accordance to AISI 316. The breaking load of each rope is not less than 2350 Kg giving a factor of safety of more than 5 for the system at full load as per the Technical Report No -7. The end construction of rope for the winch drum is fitted with copper talurit and for two continuous ropes, the end termination in luminaires carriage are with stainless steel thimble and copper splicing and for others with stainless steel thimble and bull dog grips. Two continuous wire ropes are normally used for in-tension systems which are more reliable & safe

4. Power Tool for Winch: Three phase, single speed, 6 pole high-powered integral motor of 0.75HP rating with mechanical tripping facility are to be provided at the base of mast to facilitate raising & lowering operation of luminaires carriage. The motors are to be coupled with the winch shaft through chain & sprocket. A mechanical torque limiter is to be mounted on motor shaft to stop transmission of motion from motor to winch in case of excess load and thus prevent the damage to winch and breakage of rope

C. Other Accessories:

1.Electrical System, Cable and Cable Connections: EPR ( Ethylene Propylene Rubber ) insulated & PCP ( Poly Chloro Propene ) sheathed copper conductors are used as trailing cable to transmit electric power from the bottom of high mast to the lantern carriage at top. The minimum size of trailing cable to be used is 5C X 4 Sq.mm; however the size of the cable depend on the total electrical load of the luminaries. Metal clad heavy duty plug & sockets of “Military Specifications (MS)”are used for terminating the above trailing cable. Wiring from junction box to luminaries are done by 3 core 1.5 sq. mm PVC insulated, PVC sheathed, copper flexible wires unless otherwise specified by the client. Suitable arrangement is provided in the base compartment to receive and terminate incoming power cable and MCB in a box for isolation of incoming power supply.

2. Earthing Terminals: Earth terminal using 12 mm diameter hot dip galvanized bolts are provided on the door stiffener of the mast for lightning and electrical earthing of the mast.

3.Lightning Finial: One number heavy duty hot deep galvanised lightning finial shall be provided for each mast. The lightning finial shall be minimum 1.2 metre in length and provided at the centre of the head frame. It should all be bolted solidly to the head frame to get a direct conducting path to the earth through the mast. It shall never be provided on the lantern carriage under any circumstances in view of safety of the system.

Supply & delivery of 8 Mtr long GI Hot Dip Galvanized in single Dip (65 micron DFT) Octagonal Pole (as per BSEN 10025) having Yield strength min-355 N/mm2 & Tensile Strength- 490-630N/mm2. The pole should be continuously tapered and shall have octagonal cross section, incl. 1.0 mtr angular (105º) arm-bracket (as approved by EIC) . It will consist of a pole-top loop-box having one 16A 4-terminal stud-type connector, one 250V 5A kit-kat fuse unit, one NL on porcelain insulator, as required for 4Cx10 sqmm Al cable in/out & outgoing connection to fitting, and pilferage & weatherproof, screwed cover. The galvanisation of pole conforming of BSEN ISO 1461 or equivalent incl. Base-plate having dimension 260x 260mmx16mm and 4Nos of M24X750mm long 'J' type EN 8 grade foundation bolts with nuts projected bolt length 125mm. (Make- Bajaj/Utkarsh/Transrail) as directed by EIC. a) Single arm type

Erection of above Octagonal GI (Hot Dip Galvanised in single Dip) Pole with Base Flange & foundation nuts, Bolts etc on CC (4:2:1) stepped foundation having (L-500mm x W-500mm x H-600mm) & (L-400mm x W-400mm x H-200mm) below the ground level and (L-300mm x W-300mm x H-200mm) above ground level including neatly cemented finish (3mm thick) above ground level incl. making hole by gas cutter machine on the pole suitable for alkathene/ polythene pipe entry for street light wiring with S&F earth bolt for eathing connection etc. & carriage of pole upto 1.6 Km from Store to work-site including filling up the pit with shifted soil and ramming properly as directed by EIC.

Supply of outdoor stand mounted feeder pillar with 32A TPN MCB incomer, single dial timer, 25A TP contactor for the automatic switching of luminaries, power tool control with 2 no 9A contactors and raise lower push button, Incoming 25 sq. mm and out going 16 & 2.5 sq. mm terminals.

Supply & fixing of Rectangular LED Flood Light luminaire with innovative thermal management, multiple optics option and equipped with IP66 protection (Make- Philips BVP283 LED240 CW FG SY5WB 200W V1/Wipro/Lighting Technology) as per direction of EIC

Construction of suitable shallow foundation with 1:2:4 concrete for the highmast considering the safe soil bearing capacity at site as 10 T/sqmtr at 2 metre depth with all materials and labour as directed by EIC.

ERECTION OF THE ABOVE High Mast Installation as per directionof E.I.C

Earthing with 65 mm dia GI pipe (TATA-Medium)x 3.0 Mts. long and 1 No. 50 mm x 6 mm galvanized (Hot Dip) steel strip (4 Mts. long), 20 mm dia x 125 mm long galvanized bolt, double nuts, double washers including finishing both ends by making holes etc. and S & F 65 mm dia GI pipe (ISI-Medium) protection (3 Mts. long) to be filled with bitumen partly under the ground level and partly above ground level to an average depth of 3.65 Mts incl. connection to High Mast earth terminal with 25x3 mm GI flats with materials & labour. (2nos per mast required) as to GS.

COMPOUND LIGHTING

Supply & Fixing of 90Watt Outdoor type Street light fittings (Make- Philips BRP333 LED110 CW R5C FG PSU S1 V1/Wipro/Lighting Technology) as per direction of EIC

S/F Fixing of Greenline Street light ( Make-Phillips,Model No:-BRP032 P LED75 CW SLR PSU GR SPDWipro/Lighting Technology) as per direction of EIC,LED fittings on wall including S/F 40 mm dia 1.5 mtr long GI pipe(ISI) arm bracket with 40 mm x 10 mm MS clamp incl.painting as per GS including S/F the adjustable MS frame on wall & as per direction of EIC.

Supply & fixing of 120 Watt out door type LED flood light fittings Make: Philips BVP282 LED120 CW FG SY5WB 100W V1 /Wipro/Lighting Technology) as per direction of EIC

Supply & Fixing of 78W LED Street light (Make- Philips BRP 501 LED CW RSC/Wipro/Lighting Technology) as per direction of EIC on existing GI pipe(ISI) arm bracket

Supply & fixing of 36 Watt out door type LED Flood Light fittings (Cool White) (Make- Philips BRP331 LED36 CW R5N PC PSU S1 V1/Wipro/Lighting Technology) as per direction of EIC

CABLING & WIRING

S/F of LED Light controll with sequencial Digital Timer(412631) incl. S/F of 1 no. 40 A Contractor(412545) ( 1 NO & 1 NC), 32 A SP MCB 1No. with necess. Connection 3x2.5 cu wire as reqd. which fixed in (2+6) way SPN MCB DB concealed in wall as req. as per instruction of EIC( make- Legrand ).

Supplying and Fixing SS water proof looping cable box size having 200X150X 100 mm as per GS.(I-2) (16-A)

S/D following sizes PVC insulated Cu wire (Finolex/RR Kabel/Polycab/Mescab) in 20mm dia PVC rigid conduit pipe (Precision) to power points as follows incl. making connections as to G.S.:-

3 x 1.5 mm² in 20mm dia PVC rigid conduit pipe

2 x 2.5 & 1x 1.5 mm² in 20mm dia PVC rigid conduit pipe

2 x 4 & 1x 2.5 mm² in 20mm dia PVC rigid conduit pipe

Supply & drawing of 1.1 kV grade 4-core 16sqmm XLPE/Ar. Al. cable in underground trench 460 mm wide x 760 mm average depth, with brick protection on the top of the cable with 8 (eight) Nos. bricks per metre, including filling the space between the brick & cable and also the trench with shifted soil, leveling up and restoring surface duly rammed as directed by EIC.

Supply and laying of 1.1 KV grade 2 core 6 sq mm armoured aluminiunm conductor cable on wall including S/F shaddle ( Make-NICCO/Gloster/Crystal)

Supplying and fixing compression type cable gland for 4 core 16sqmm. Cable complete with brass gland, brass ring & rubber ring for dust & moisture-proof entry of XLPE armoured cables & Finishing of the XLPE insulated armoured cable ends by cable sockets and insulated tapes etc., including supplying sockets, tapes etc. and making connection to switch, BDB and BBC as directed by EIC.

Supplying and fixing compression type cable gland for 2 core 06 sqmm. Cable complete with brass gland, brass ring & rubber ring for dust & moisture-proof entry of XLPE armoured cables & Finishing of the XLPE insulated armoured cable ends by cable sockets and insulated tapes etc., including supplying sockets, tapes etc. and making connection to switch, BDB and BBC as directed by EIC.

Supply & drawing 40mm dia heavy gauge spl. Quality alkathene /polythene pipe for passing the cable from U.G. trench to pole/ pillar box through pole / pillar box brick foundation as directed by EIC.

Rate should be quoted incl. of all taxes and cess.

Defect Liability period : 1 year

R L COMPANY (BID ID -6923675)

MODERN TECHNO CORPORATION (BID ID -6920673)

KANJILAL and SONS (BID ID -6900613)

BAPPA CONSTRUCTION (BID ID -6939836)