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ANNEXURE-1 to the TENDER ENQUIRY NO.: DPS/AMPU/ELE/354 Complete Technical Specifications of the of HIGH MAST SYSTEM

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ANNEXURE-1 TO THE TENDER ENQUIRY NO.: DPS/AMPU/ELE/354 Complete technical specifications of the of HIGH MAST SYSTEM Design, manufacturing, supply and delivery at AMD,ER ,Khasmahal, Jamshedpur on FOR basis and Erection and Commissioning of High mast lighting, 20 Mtrs. height shaft with single dip hot galvanized, lantern carriage, double drum internal winch motor, trailing steel wire rope, control panel, head frame along with 08 Nos. of 200 watts LED flood light fitting complete along with aviation light on top of the high mast - 01 No. Note: Erection & Commissioning: The supplier must do the Erection, Commissioning of all the supplied High mast Lighting systems at location AMD,ER, Khasmahal, Jamshedpur ( Site will be earmarked by AMD authority) by constructing of suitable foundation considering the safe soil bearing capacity at site as 10T/sqmtr at 2 Mtrs depth with all materials and labours, including installation of mast feeder pillar by grouting stand on the concrete with all material and labours. Page 1 of 11 TECHNICAL SPECIFICATION HIGH MAST SYSTEM Height of mast : 20 Meter No. of sections : Two Material construction : S 355 grade as per BS-EN10 025 Base dia. and top diameter (A/F) : Top : 150 mm, Bottom : 460 mm Plate thickness & section Length : Top : 4 mm, Bottom : 5 mm Cross section of Mast : 20 side polygon Standard for of galvanization : As per BS EN ISO 1461 Size of opening and door at base : 1200 x 250 mm Diameter of base plate : 670 mm Thickness of base plate : 25 mm Lightning protection finial : G.I single spike of length 1200 mm Max.wind speed : 62.5 m/s Number of foundation bolts : 8 nos. PCD of foundation bolts : 590 mm Type / diameter / length of foundation bolts : TS 600 / 32 mm dia / 850 mm long LUMINAIRES CARRIAGE Material of construction : 50 NB ERW Class B - M. S. Pipe Diameter of carriage ring (mm) 710 mm (ID) Construction 6 Arm Welded, 2 sections Load carrying capacity 12 Luminaire TRAILING CABLE Conductor Copper, 5 core, 4 sq mm Insulation EPR insulated PCP sheathed No. of circuits per mast One WINCH/ POWER TOOL Grade / construction AISI 316, 7/19 construction Number of ropes Two continuous Diameter (mm) 6 mm Braking load capacity 2350 kg x 2 Page 2 of 11 EQUIPMENT SPECIFICATION HIGH MAST LIGHTING GENERAL: The scope of this specification also covers the manufacture, transport, installation, testing and commissioning of the complete lighting system, using Raising and Lowering type of High mast Towers, including the Civil Foundation Works. AMD will only provide the supply point. However, all items required for the safe and efficient operation and maintenance of the lighting system including the high mast, whether explicitly stated in the following pages or not shall be included by the Contractor. HIGHMAST STRUCTURE: The High mast shall be of continuously tapered, polygonal cross section, at least 20 sided. Presenting a good and pleasing appearance and shall be based on proven In Tension design conforming to the standards specified, to give an assured performance, and reliable service. The mast shall be with decorative type umbrella and suitable for wind loading as per IS 875 Part 3 1987. CONSTRUCTION: The mast shall be fabricated from steel plates, cut and folded to form a polygonal section, welded and shall be telescopically jointed by welding/stress fit method. The procedural weld geometry and the workmanship shall be exhaustively tested on the completed welds. Mast can be fabricated in multiple sections of length approximately 10 metres. Thus a 20 M shall be delivered in two sections. No site welding or bolted joint shall be done on the mast. The minimum Overlap distance shall be 1.5 times the diameter at penetration. The mast shall be provided with fully penetrated flange, which shall be free from any lamination or incursion. The welded connection of the base-flange shall be fully developed to the strength of the entire section. The base flange shall be provided with supplementary gussets between the bolt holes to ensure elimination of helical stress concentration. For the environmental protection of the mast, the entire fabricated mast shall be hot dip galvanized, internally and externally. The thickness of galvanizing shall be a minimum of 85 microns. DOOR OPENING: An adequate door opening shall be provided at the base of the mast and the opening shall be such that it permits clear access to equipment like winches, cables, plug and socket etc. and also facilitate easy removal of the winch. The door opening shall be complete with a close fitting, vandal resistant, weather-proof door provided with a heavy duty internal lock with special paddle key. The door opening shall be carefully designed and reinforced with welded steel section, so that the mast section at the base shall be unaffected and undue buckling of the cut portion is prevented. Size of door opening shall be around 1200 x 250 mm and shall be strengthened, if required to avoid buckling of the mast section under heavy wind conditions. DYNAMIC LOADING FOR THE MAST: The mast structure shall be suitable to sustain an assumed maximum reaction arising from a wind speed as per IS 875 and shall be measured at a height of 10 metres above ground level. The design life of the mast shall be a minimum of 25 years. Page 3 of 11 LANTERN CARRIAGE: a) Fabrication A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fittings and control gearboxes. The Lantern Carriage shall be of special design and shall be of steel tube construction. The tubes acting as conduits for wires, with holes fully protected by grommets. The Lantern Carriage shall be so designed and fabricated to hold the required number of flood light fittings and the control gearboxes, and also have a perfect self-balance. The Lantern Carriage can be fabricated in two/three sections and joined by bolted flanges with stainless steel bolts and nylon type stainless steel nuts to enable easy installation or removal from the erected mast. The inner lining of the carriage shall be provided with suitable protective arrangement, so that no damage is caused to the surface of the mast during the raising and lowering operation of the carriage. The entire Lantern Carriage shall be hot dip galvanized after fabrication. The design shall provide a perfect balance for the lantern carriage during raising and to lowering also. b) Junction Box Weather proof junction box, made of Cast Aluminium shall be provided on the Carriage Assembly as required from which the inter-connections to the designed number of the flood light luminaires and associated control gears fixed on the carriage shall be made. c) Raising and lowering mechanism For installation and maintenance of luminaries and lamps, it will be necessary to lower and raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement shall be provided, with the winch fixed at the base of the mast and the specially designed head frame assembly at the top. Suitable end limit switches shall be provided to trip the winch motor at both top & bottom ends of the designed travel. Suitable thermal relay shall be provided to trip the mechanism in case of overload. d) Winch The winch shall be of completely self-sustaining type, without the need for brake shoe, springs or clutches. Individual drum also should be operated for fine adjustment of lantern carriage. The capacity, operating speed, safe working load, recommended lubrication and serial number of the winch shall be clearly marked on each winch. The winch shall be self-lubricating type by means of an oil bath and the oil shall be readily available grades of reputed producers. The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay, with no chances of rope slippage. The rope termination in the winch shall be such that distortion or twisting is eliminated and at least 5 to 6 turns of rope remains on the drum even then the lantern carriage is fully lowered and rested on the rest pads. It should be possible to operate the winch manually by a suitable handle and by an integral/ external power tool. It shall be possible to remove the double drum after dismantling through the door opening provided at the base of the mast. Also, a winch gearbox for simultaneous and reversible operation of the double drum winch shall be provided as part of the contract. The winch shall be type tested in presence of a reputed Institution and the test certificates shall be furnished before supply of materials. A test certificate shall be furnished by the Contractor form the original equipment manufacturer, for each winch in support of the maximum load operated by the winch. Page 4 of 11 e) Head Frame The head frame, which is to be designed as a capping unit of the mast, shall be of welded steel construction, galvanized both internally and externally. The top pulley shall be of appropriate diameter, large enough to accommodate the stainless steel wire ropes and the multi-core electric cable. The pulley block shall be made of non-corrodible material, like die cast Aluminium Alloy (LM-6). Self-lubricating bearings and stainless steel shaft shall be provided to facilitate smooth and maintenance free operation for a long period. The pulley assembly shall be fully protected by a canopy galvanized internally and externally. Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not dislodged from their respective positions in the grooves. The head frame shall be provided with guides and stops with PVC buffer for docking the lantern carriage.
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