801690/IMPROVEMENT TO EARTHING INFRASTRUCTRE AT MUKKUNNIMALA UNDER GE AF TRIVANDRUM

Amount

SCHEDULE 'A' PART - I (E/M Portion)

Supply, Installation, Commissioning and Testing of Maintenance Free Earthing system comprising of the following :-

Copper-Bonded Steel Earth Rod of 3-meter length and 17.2 mm diameter. Auger a hole of diameter 4 inches and 9 feet depth in the soil, placing the Earth rods into the augured hole, hammering the rods to 1 feet depth, and removing excavated material. Make: NVENT ERICO Cat Part No: CODE 613400 or techno-commercially equivalent of SIEMENS/HERGER complete all as specified and as directed by Engr-in-Charge. Brief features/ specifications of CBSE Rod are as follows:-

(a) The outer surface must be molecularly bonded with a uniform layer of 250-micron Copper, 99.9% pure electrolytic copper coating. (b) Rods have a high-carbon steel core and tip that provide superior strength when driving. A nickel interface must be provided between the copper and steel to avoid galvanic corrosion. Copper coating will not crack when bent or tear when driven (c) Must be capable of withstanding a fusing current of 25 KA @ 1 Sec. (d) Earth rod must comply with IEC 62305- 2, NBC 2010 and IEEE 80. Rod should be tested as per the IEC 62561- 2 /ANSI®/NEMA® GR1 standard. UL logo and control number, where applicable stamped on each rod for easy inspection after installation (e) Tensile strength greater than 80000 PSI on 12 mm. (f) High resistance to corrosion. (g) Material category number should be UL listed, Manufacturer Make, Part No and UL mark should be printed in each rod.

M&L for Ground Enhancement Material (GEM), Per Bag -11.33 Kgs , Conforming to IEC 62561-7 Standard, Premixing the GEM into slurry form using water( not more than 5 L to 6 L per bag), Pouring the GEM mixture using filling in the augured hole for earthing pits and for horizontal treatment of size 100mm x100mm for CBSC interconnection of size between earthing to earthing. Make ERICO Cat Part No: GEM 25A- 25-1lb or techno-commercially equivalent of HERGER/SIEMENS complete all as specified and as directed by Engr-in-Charge. Brief features/ specifications of the same are as follows:-

NOTE of 1.20:-(a) Must be a carbon-based, superior conductive material. (b) Resistivity must be less than 0.02 Ωm. (c) Must not cause corrosion to copper when in contact. (d) Must not expand or experience any shrinkage once set. (e) Must not depend on the continuous presence of water/moisture/salt to maintain its conductivity. (f) Must not decompose or leach out with time. (g) Must not contain hazardous chemicals as per IEC 62561-7 standard, TCLP Tested and EPA test method 1311. (h) Flexural and possess compressive strength as per the relevant standard. (j) Sulphur content must be less than 2%. (k) Must be in line with IEEE 80 clause 14.5.d. (l) Corrosion test shall be conducted on the material under both aggressive and non-aggressive conditions. (m) Installation Instruction and Material DATA sheet should be printed in each package. (n) Contactor has to ensure the installation procedure provided by OEM during the execution of work at site

M&L for Readymade PVC Heavy duty earth chamber (450 mm x 450mm ) with square cover and minimum 20 ton load bearing capacity, marking plate on top of the chamber cover and mentioning the earth resistance value on it including fixing Complete with all necessary fixing arrangements all as specified and as directed by Engr-in-Charge.

M&L for Readymade PVC Heavy duty earth chamber (450 mm x 450mm ) with square cover and minimum 5 ton load bearing capacity, marking plate on top of the chamber cover and mentioning the earth resistance value on it including fixing Complete with all necessary fixing arrangements all as specified and as directed by Engr-in-Charge.

Note for Ser item No 1 to 1.40: (i) Contractor has to carryout soil resistivity and soil conductivity test and submit the report for the same before starting of the work and rate for the same deemed to be included in the quoted rate (ii) Augering of 100mm dia bore shall be measured and paid separately under relevant items of the schedule (iii) Contractor has to make MoU with the supplier for supervision till handing over of site to the user and rendering their support till guarantee period. (iv) Contractor has to obtain Genuineness certificate of the material from the supplier/Vendor certificated from IEC or equivalent Accredited lab (v) Contractor has to obtain minimum of 25 years of Guarantee certificate on Bond paper from vendor upon its performance (vi) The contractor has to make MoU with vendor for carrying out quarterly inspection during and after installation of earth pits for checking its healthiness till the period of Guarantee/Warranty and rate for the same deemed to be included in the quoted rate. The vendor and contractor are collectively responsible for rectification of defect in case of unhealthy of earth resistance value at any stage of Guarantee and Warranty period. (vii) Independent testing point shall be provided on each earthing and rate for the same deemed to be included in the quoted rate.

M&L for 10mm copper bonded steel Round conductor, having a minimum copper bonding thickness of 254 microns with continuous copper coating, conforming to IEC62305 and tested as per IEC 6251 Edition 2.0 standard. The conductor shall be UL listed, with a low carbon steel core for improved flexibility, high conductivity, and excellent corrosion resistance. The surface shall not crack or tear when bent, making it suitable as an earth lead or equipotential bonding conductor. Work includes excavation in hard rock or any type of soil to a depth of 150mm and width of 100mm for laying the ground conductor wherever required, for treating the horizontal conductor using GEM material, removing excavated material outside the MOD Premises, and refilling the trenches with soft soil in areas having hard rock after completion of horizontal treatment. Make ERICO Cat part No; CBSC 10 or Techno-commercially equivalent of HERGER/SIEMENS, complete in all respect as specified and as directed by the Engineer-in-Charge. Note:- The GEM material required for treatment or embedding on the CBSC shall be measured and paid separately under relevant items of this schedule.

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S & F Clamp Holder made up of 304 grade SS with SS bolt and nut at every 1 m distance of round conductor. The clamp should be suitable for copper-bonded steel Conductor of size 10mm. Make ERICO Cat Part No: CSS 10 or techno-commercially equivalent of HERGER/ SIEMENS complete all as specified and as directed by Engr-in-Charge.

M & L for SS terminal connector for termination of equipment body/ Panel body/ Neutral connection with suitable size of CBSC 10mm round conductor by mechanical means using nuts, bolts and all other accessories complete as directed by Engr-in-Charge. Make ERICO Cat Part No: BCR10T or techno-commercially equivalent of HERGER/ SIEMENS complete all as specified and as directed by Engr-in-Charge. Note: Terminals of existing earth pits shall be cleaned for proper contact with CBSC and cost for the same deemed to be included in the quoted rate.

M & L for Cadweld Materials for Connections between Ground Rod with CBSC conductor by Exothermic reaction. Connections to be made with a semi-permanent graphite mould, which shall hold the conductors to be welded. Weld metal must be a mixture of copper oxide and aluminium, should be compliant with IEEE 80 standards and tested as per IEEE 837 -2014 standard. Make ERICO Cat Part No: 150 PLUS F20 or techno-commercially equivalent of HERGER/ SIEMENS complete all as specified and as directed by Engr-in-Charge. Note:- The rate quoted shall be inclusive of the manpower and material required for making Cadweld and nothing shall be paid extra for the same.

M & L for 300 x100 x 3 mm common bus bar of copper material for earth connection with suitable base clamps & insulators, providing DD universal pattern for 12 nos of holes for connections. Make ERICO or techno-commercially equivalent of HERGER/ SIEMENS complete all as specified and as directed by Engr-in-Charge. Note:- The size of each hole shall be 10mm dia for insertion of CBSC.

M & L for Potential Equvalization Clamp (PEC100) of ATEX approved and suitable for use in potentially explosive atmospheres. The Weather proof enclosure is suitable for direct burial and Gas Discharge Tube (GDT), all other accessories as directed by the Engr-in-Charge. Make ERICO Cat Part No: PEC-100 or techno-commercially equivalent of HERGER/ SIEMENS complete all as specified and as directed by Engr-in-Charge. Note: Terminals are connected at either end using a suitable copper lugs and an SS Bolt/Nut and cost for the same deemed to be included in the quoted rate

M & L for cutting the existing hard standing/PCC/WBM road at a depth not less than 150MM x 100mm in width for laying of copper bonded steel conductor complete including, returning, filling in finishing the top surfaces by providing cement concrete (1:3:6) type C2 (using 24mm graded stone aggregate) 10 cm thick on top, PCC surface finished to a uniform smooth surface, bottom filled with excavated earth complete all as specified and directed by Engr-in-Charge. Note:- The rate quoted deemed to be included the cost of making good surface of the road/Hard standing/PCC/WBM

M &L for Boring of holes in the hard rock size of 4" dia and 9 feet depth by using suitable Augar technology and arranging the air compressor with rig unit, in and around the Radar building, Power Plant Building, the substation area or any other locations as decided by Engr-In-Charge/ GE and removing rubbish off the premises complete all as specified and to the entire satisfaction of the Engr-In-Charge.

Supply, Installation, Commissioning and Testing of air terminal system of Collection Volume Method (CVM) with the following accessories for the location Radar Building, Power plant Area, HQ Building, Transmitter tower of Mukkunnimala Tech area :-

Dynasphere lightning conductor made of stainless steel as per IEC 61024. The Air terminal shall be placed using the " Collection Volume Method / Field Intensification Method" placement methodology as specified in IEEE‐998. Make ERICO Cat Part No: D/SMKIVSS or techno-commercially equivalent of SEIMENS/ HARGER complete all as specified and as directed by Engr-in-Charge. Brief features/ specifications of the same is as follows:- aa) Impulse Tested, atleast for 40 KA both +ve and -ve , 8/20 micro-second, resistance between the terminal tip and the sphere should be minimum 10 MΩ before and after the test. ab) Free from Corona effect. ac) The dome must be insulated from the rod but connected to ground via a dynamic variable impedance. ad) The center grounded electrode tip shall be at least 20mm diameter. ae) The terminal must be isolated from the structure using an insulated support mast making an isolated lightning protection system.

2.3 M elevation pole made of FRP Mast with a dia of 60 mm with a SS-U Bolt to fix the unit. Make ERICO Cat Part No: FRP-2.3M or techno-commercially equivalent of SEIMENS/ HARGER complete all as specified and as directed by Engr-in-Charge.

5 M elevation pole made of AL(aluminium) Mast with a dia of 60mm and additional supporting mast for 2.3 M FRP MAST with IN-LINE COUPLING to fix the unit. Make ERICO Cat Part No: 5-ALU /INLINE CUP or techno-commercially equivalent of SIEIMENS/HERGER complete all as specified and as directed by Engr-in-Charge.

Guy wire support and all required fixing equipment's. Make ERICO Cat Part No: IGUYKIT7MGRIP complete all as specified and as directed by Engr-in-Charge. Note for serial item No. 11 to 11.40:- (i) The rate quoted deemed to be included the rate of all fixing arrangements, civil work and any other works required for effective functioning of the system. (ii) The contractor has to install and the system as per OEM instructions and recommendations and cost for the same deemed to be included in the quoted rate.

Supply & Laying of ERICORE down conductor cable, shall be designed with low impedance and low inductance to minimize voltage built up due to lightning impulses. The down conductor shall be designed with the shielded copper conductor with inner insulation, conductive sheathing all concentrically arrange to withstand impulse voltage of 250KV peak, between core and screen with characteristic impedance of <12 Ohms (W) and inductance of <40 nH/m. The outer diameter of down conductor copper cable of size 37mm with copper section minimum 50 sq.mm.

M&L for Upper termination kit suitable for cable mentioned in item NO 12 is of low inductance, low impedence cable to connect LA should withstand upto 310 KV with all accessories all as specified and directed

S & F Beam clamp holder made up of 304 grade SS with SS bolt and nut at every 1 m distance of round conductor including other fixing accessories which is necessary for the system. Make ERICO Cat Part No: ERICORE 36MM OD complete all as specified and as directed by Engr-in-Charge.

Supply, Installation, Commissioning and Testing of Maintenance Free Radial -MAT Earthing system comprising of the following:

Copper Bonded Steel Earth Rod of size 5 feet x 5/8 inch diameter of 4 Nos, earthing system required excavation of 100 mm width x 150 mm depth x 5000 mm length to be made al four sides as Square pattern Mat radials should be 10 meters apart, Auger 4 Nos hole of diameter 4 inch and 5 feet depth in the soil, Placing the Earth rods in to the augured hole, hammering the rods to 1 feet depth, Readymade FRP Heavy duty earth chamber (450mm x 450mm) Top Cover with minimum 25 ton load bearing capacity, removing excavated material. Complete all as specified and as directed by Engr-in-Charge. Brief features/ specifications of CBSE Rod are as follows:- (a) The outer surface must be molecularly bonded with a uniform layer of 250-micron Copper, 99.9% pure electrolytic copper coating. (b) A nickel interface must be provided between the copper and steel to avoid galvanic corrosion. (c) Must be capable of withstanding fusing current of 20 KA. (d) Earth rod must be in compliance with IEC 62305- 2. (e) Tensile strength greater than 80000 PSI on 12 mm. (f) High resistance to corrosion. Note:- (i) The rate quoted deemed to be included the rate of making 4 Nos bore of 100 mm dia and 5 feet depth (ii) The contractor has to install and the system as per OEM instructions and recommendations

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10 mm Copper Bonded Steel Round Conductor, minimum copper bonding shall be 254 microns having continuous coin form, the conductor core consists of a low-carbon steel grade for improved flexibility. The copper surface of the conductor should provide high conductivity and corrosion resistance properties, well‐suited as a lightning protection conductor in accordance with the IEC 62305‐3 Edition 2.0 standard. Including excavation 150mm X100mm and 30 cm depth for laying round conductor, removing excavated material, return filling. Make ERICO Cat Part No: CBSC - 10MM complete all as specified and as directed by Engr-in-Charge.

S&F Lightning Event Counter, Installed on down conductor, Non resettable mechanical counter, Non electronic without battery or external power source, IP67 enclosure, Triggering impulse < 2 KA, 8/20 micro second, Warning sticker should be provided near to the Down conductor in a visible place. Make ERICO Cat Part No: LEC-IV or techno-commercially equivalent of SEIMENS/ HARGER complete all as specified and as directed by Engr-in-Charge.

Design Supply, installation, testing and commissioning of 21 MTR height triangular shaped hot dip galvanised steel lattice tower, fabricated from mild steel conforming to IS: 2062 and galvanized as per IS: 2629/ IS : 4759 with a minimum uniform zinc coating of 85 microns, suitable for outdoor installations for installing active type lightning arrester complete with footing /foundation as per approved structural design and drawing.

Note: (i) Contractor shall carry out soil investigation test in terms of laid down in IS specification and accordingly the contractor shall submit structural design & drawing of the lattice tower duly vetted by any IIT/NIT or any other Govt Engineering colleges to the CWE for approval within 30 days from the date of commencement of work. (ii) The tower shall be structurally designed to with stand wind velocity not less than 180 km/hr as per MET section data and data available with Indian meteorological department with gust factor of 1.2 and adequate safety margins. Tower to be designed as per IS 800 and IS 875 including complete structural analysis for wind loading and load combinations (iii) The quoted rate also deemed to be included the rate of the following provisions a) Segmented tower sections of 3m length with all bracing, cleats, base plates, stiffeners and galvanised high tensile nuts and bolts for complete assembly b) Grillage type RCC Foundation as per structural design as per OEM’s recommendations including site clearing, excavation, PCC, centering, reinforcement (Fe500), M20 grade concrete, and embedded anchor bolts as per approved design drawings. c) Hot dipped galvanised steel vertical step ladder, securely fixed to the tower legs, with anti slip rugs (spacing not exceeding300mm) complete withintegrated vertical fall arrest system or safety lifeline. d) Maintenance platform at the tower top (minimum 1.2m x 1.2m) made of anti slip galvanized steel chequered plate of size 6mm grating including 1.0 m high hand rails on three sides and toe guards for safety. e) Provision and installation of Guy ropes using galvanised steel wire ropes (minimum 16 mm dia 6 x 19 construction) complete with deadman anchors or grouted anchor rods, turnbuckles, thimbles and guy clamps. Guying to be done at two or more levels with a guy radius as per structural requirements f) Provision for Aviation obstruction light at the top of the tower mounted securely on the maintenance platform including necessary cable routing provisions from tower base to top for power supply including control arrangements with MCBs. g) Complete painting of the structure with one coat of epoxy primer and two coat of epoxy + PU paint all as specified and directed h) Approval certificate from the concerned authority for the detailed drawing of 180 kmph wind velocity for 21 mtr height tower (j) This work includes complete installation including lay out marking, assembly, vertical alignment, guy tensioning, torquening of bolts, inspection, testing and commissioning of the tower at site, using necessary equipment, scaffolding, cranes or derricks and manpower etc (k) This includes transportation, loading/ unloading, tools, consumables, safety equipments and compliance with all statutory norms complete in all respects as per drawings, technical specifications and directions of the Engineer-in- charge.

Supply, installation, commissioning and testing of Power line surge protection system comprising the following

Point of Entry Protection at Main panel , for Enhanced Din Rail Surge Protector Triggered Spark Gap (TD) Technology operating voltage 480V, Maximum Surge rating 130KA @ 820Micro second with LED Status indication per mode, 3Ph 150KA/PH, 240V, TT contacts as per UL 1449 edition &IEC 61643-1 Provide over current protection for the surge unit with suitable IP- rated enclosure Make :ERICO Cat part No: TSG 11302s or techno commercially equivalent of SIEMENS/ HERGER complete all as specified and directed by Engr-in- Charge

Transient surge filter (TSF) with the Transient Discriminating (TD) Technology at the point of UPS Panel maximum current rating of 20 A, maximum surge rating of 20kA, 8/20µS, Maximum continuous operating voltage of 440V, Low let- through voltages on the critical line to neutral mode, the system should be under UL registered, IEC Compliant, compact, serviceable solution for protection of UPS which is feed to PLC controllers, SCADA systems, motor control centers and other process control systems, Replaceable surges module reduces down time and un protected time during maintenance, Provide over current protection for the surges unit with suitable IP rated enclosure all as directed Make : ERICO Cat part No: TSF 20A-240V or techno commercially equivalent of SIEMENS/ HERGER complete all as specified and directed by Engr-in- Charge

Supply, installation, commissioning and testing of Data line Surge protection system comprising the following

Local Antenna Network(LAN) Surge protector, Rugged, metallic enclosure provides both environmental and electrical shielding, up to CAT6 and POE(Power Over Ethernet) protection in one product, simple, bi-directional installation, Nominal discharge current for L-L 150KA, 8/20µs, L-N 10KA µs. Maximum frequency 250 MHZ(no data loss) the unit is mounted on Din rail all as specified and directed Make : ERICO Cat part No: LAN- RJ45 C6P or techno commercially equivalent of SIEMENS/ HERGER complete all as specified and directed by Engr-in- Charge

DATA Line Krone Protector with high speed Data line protector, 40 VDC, simple installation in to Krone LSA disconnect block, it should be provided with both L-L and L-PE protection modes for comprehensive protection , Maximum continuous operation voltage 40VDC and Surge rating 20 KA@ 8/20µa, Frequency 0-12 MHz. it should be a Multistage protection. The enclosure materials should be thermoplastic under UL94V-0 all as specified and directed Make : ERICO Cat part No: HSP-10K-230 or techno commercially equivalent of SIEMENS/ HERGER complete all as specified and directed by Engr-in- Charge

Material and labour for High density Poly ethylene ( HDPE) Pipes of size 50mm pressure rating 6 Kgf/sqcm for protection of cables/ cu strips etc all as specified and as directed.

Supply, installation, testing and commissioning of 50mm dia GI Pipe light grade for laying of cable in surface/road crossing complete all as specified and as directed.

Material and labour for PCC 1:3:6 type C1 with 20mm graded aggregate for coping complete including necessary form work complete all as specified and directed

Taking down old unserviceable earthing pits any type complete all as directed.

Taking unserviceable earth conductor of any type complete all as directed.

Note for serial item No. 1 to 17.2:- The contractor has to visit the site before quoting of rate since the site is located on hill top at Mukkunnimala. The complete works of the Earthing / Lightning protection system shall be done through OEM only (OEM Shall be approved by GE concerned). Contractor should submit MOU for execution of entire work with OEM (approved by GE) before commencement of work Design/Drawing/ Technical specifications of the complete earthing & lighting protection system showing the layout including dimensions is to be submitted by the contractor in consultation with OEM (approved by GE) strictly keeping in view the actual ground requirements & the same is to be got approved from Engr-in-Charge &GE . Any items missed out in technical specifications but technically required for efficient working of the system is deemed to be included in the unit quoted rates. The contractor /Firm is required to visit the site prior to quoting of the subject items/work so as to ascertain the actual ground requirements. Any further query at a later date shall not be entertained & responsibility of the same shall rest on the contractor/firm. The cost of making the disturbed surfaces good (Substation yard Stones and gravel, Walls, Pavement etc) is deemed to be included in the unit quoted rate of relevant items. On testing if the desired earth resistance is not found according to the relevant Indian Standards it is to be re done at his own cost to the entire satisfaction of Engr-in-Charge.

Note for serial item No. 1 to 17.2:-(Contd...) Repair/ Preventive maintenance of the complete earthing & Lightning protection system is to be got done from the OEM /Sister Concern/Channel partner only by the contractor for the entire defect liability period i.e two years from the certificate date of completion & the cost of the same is deemed to be included in the unit quote rates. The contractor has to take the proper survey at site for the position of existing cable routing for electrical as well as communication and water line.If any damage to any electrical/communication cables or any pipelines or any other installations occur during execution of the work, then the same shall be made good by the contractor to the entire satisfaction of the concerned & the cost of the same is deemed to be included in the unit quoted rates. If any damage to any electrical/communication cables or any pipelines or any other installations occur during execution of the work then the same shall be made good by the contractor to the entire satisfaction of the concerned & the cost of the same is deemed to be included in the unit quoted rates. The contractor should submit a detailed Report of Test results (Air terminal, Lightning Event Counter and Grounding) from OEM after completion of work and same is to be certified from Engr-in-Charge & GE. Testing of the entire earthing system shall be conducted by the contractor at an interval of 3 months (on a quarterly basis) in presence of OEM and user concerned. The test report shall be duly signed by the user and submitted by the contractor for the entire guarantee period and cost for the same deemed to be included in the quoted rate. The contractor shall stand Guarantee to the Government for period of 10 Years immediately on completion of work for effective performance of earthing system and maintain resistance value earthing provided to the location as per standards for equipment, lightning arrester, power and DG Neutral. For giving guarantee, the contractor has to deposit security amount as 10% of total value of BOQ item No 1 to 1.40 of earthing for 10 years Purchase Voucher &Manufacturer’s test certificates to be submitted in original to the Engr-in-Charge.

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