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| 1 | SCOPE OF WORK: Design, Fabrication, Transport, Supply, Installation, Testing and Commissioning of the Complete Lighting System, using Raising and Lowering type of High Mast Towers but excluding ‘Civil Foundation Works for High Mast Pole & Feeder Pillar’. | SCOPE OF WORK: Design, Fabrication, Transport, Supply, Installation, Testing and Commissioning of the Complete Lighting System, using Raising and Lowering type of High Mast Towers but excluding ‘Civil Foundation Works for High Mast Pole & Feeder Pillar’. |
| 2 | HIGH MAST SHAFT: | HIGH MAST SHAFT: |
| 3 | CONSTRUCTON: High Mast Shaft shall be of continuously tapered, polygonal cross section, presenting a good and pleasing appearance and shall be based on proven In-Tension design conforming to the standards referred, to give an assured performance, and reliable service. 12 Metre ‘High Mast Shaft’ in SINGLE section suitable for wind velocity as per IS: 875 part-III, Hot Rolled sheet steel conform to IS 2062 / BS EN 10025 or Equivalent. | CONSTRUCTON: High Mast Shaft shall be of continuously tapered, polygonal cross section, presenting a good and pleasing appearance and shall be based on proven In-Tension design conforming to the standards referred, to give an assured performance, and reliable service. 12 Metre ‘High Mast Shaft’ in SINGLE section suitable for wind velocity as per IS: 875 part-III, Hot Rolled sheet steel conform to IS 2062 / BS EN 10025 or Equivalent. |
| 4 | 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, weatherproof door, provided with a heavy-duty double 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 such as to avoid buckling of the mast section under heavy wind conditions. | 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, weatherproof door, provided with a heavy-duty double 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 such as to avoid buckling of the mast section under heavy wind conditions. |
| 5 | LANTERN CARRIAGE: | LANTERN CARRIAGE: |
| 6 | FABRICATION: A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fittings and control gear boxes. 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 (in symmetrical arrangement) and the control gear boxes, and also have a perfect self balance. The Lantern Carriage shall be fabricated in two halves 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 protective PVC 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 galvanised after fabrication. | FABRICATION: A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fittings and control gear boxes. 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 (in symmetrical arrangement) and the control gear boxes, and also have a perfect self balance. The Lantern Carriage shall be fabricated in two halves 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 protective PVC 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 galvanised after fabrication. |
| 7 | 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. | 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. |
| 8 | HEAD FRAME: The head frame which is to be designed as a capping unit of the mast shall be of welded steel construction galvanised both internally and externally after assembly. 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-corrosive material, and shall be of die cast Aluminium Alloy (LM-6). Pulley made of synthetic materials such as Plastic or PVC are not acceptable. 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 galvanised internally and externally. Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not dislodge 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. | HEAD FRAME: The head frame which is to be designed as a capping unit of the mast shall be of welded steel construction galvanised both internally and externally after assembly. 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-corrosive material, and shall be of die cast Aluminium Alloy (LM-6). Pulley made of synthetic materials such as Plastic or PVC are not acceptable. 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 galvanised internally and externally. Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not dislodge 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. |
| 9 | RAISING AND LOWERING MECHANISM: For the installation and maintenance of the luminaires 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. | RAISING AND LOWERING MECHANISM: For the installation and maintenance of the luminaires 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. |
| 10 | WINCH: The winch shall be of completely self-sustaining type, without the need for brake shoe, springs or clutches. Each driving spindle of the winch shall be positively locked when not in use, gravity activated PAWLS. The capacity, operating speed, safe working load, recommended lubrication and serial number of the winch shall be clearly marked on each winch. The gear ratio of the winch shall be 53:1. 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 6 to 8 turns of rope remains on the drum even when 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 or by an integral power tool. It shall be possible to remove the double drum after dismantling, through the door opening provided at the base of the mast. | WINCH: The winch shall be of completely self-sustaining type, without the need for brake shoe, springs or clutches. Each driving spindle of the winch shall be positively locked when not in use, gravity activated PAWLS. The capacity, operating speed, safe working load, recommended lubrication and serial number of the winch shall be clearly marked on each winch. The gear ratio of the winch shall be 53:1. 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 6 to 8 turns of rope remains on the drum even when 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 or by an integral power tool. It shall be possible to remove the double drum after dismantling, through the door opening provided at the base of the mast. |
| 11 | STAINLESS STEEL WIRE ROPE: The suspension system shall essentially be without any intermediate joint and shall consist of only non-corrosive stainless steel of AISI 316 or better grade. The stainless-steel wire ropes shall be of 7/19 construction, the central core being of the same material. The overall diameter of the rope shall not be less than 6 mm. The breaking load of each rope shall not be less than 2350 kg. Giving a factor of safety of over 5 for the system at full load as per the TR-7 referred to in the beginning of this specification. The end constructions of ropes to the winch drum shall be fitted with talurit. The thimbles shall be secured on ropes by compression splices. Two continuous lengths of stainless-steel wire ropes shall be used in the system and no intermediate joints are acceptable in view of the required safety. No intermediate joints/terminations, either bolted or else, shall be provided on the wire ropes between winch and lantern carriage. | STAINLESS STEEL WIRE ROPE: The suspension system shall essentially be without any intermediate joint and shall consist of only non-corrosive stainless steel of AISI 316 or better grade. The stainless-steel wire ropes shall be of 7/19 construction, the central core being of the same material. The overall diameter of the rope shall not be less than 6 mm. The breaking load of each rope shall not be less than 2350 kg. Giving a factor of safety of over 5 for the system at full load as per the TR-7 referred to in the beginning of this specification. The end constructions of ropes to the winch drum shall be fitted with talurit. The thimbles shall be secured on ropes by compression splices. Two continuous lengths of stainless-steel wire ropes shall be used in the system and no intermediate joints are acceptable in view of the required safety. No intermediate joints/terminations, either bolted or else, shall be provided on the wire ropes between winch and lantern carriage. |
| 12 | EARTHING TERMINALS: Suitable earth terminal using 12 mm diameter stainless steel bolts shall be provided at a convenient location on the base of the Mast, for lightning and electrical earthing of the mast. | EARTHING TERMINALS: Suitable earth terminal using 12 mm diameter stainless steel bolts shall be provided at a convenient location on the base of the Mast, for lightning and electrical earthing of the mast. |
| 13 | POWER TOOL FOR THE WINCH: A suitable, high-powered, electrically driven, internally mounted power tool, with manual over ride shall be supplied for the raising and lowering of the lantern carriage for maintenance purposes. The speed of the power tool shall be to suit the system. The power tool shall be single speed, provided with a motor of the required rating. The power tool shall be supplied complete with suitable control. | POWER TOOL FOR THE WINCH: A suitable, high-powered, electrically driven, internally mounted power tool, with manual over ride shall be supplied for the raising and lowering of the lantern carriage for maintenance purposes. The speed of the power tool shall be to suit the system. The power tool shall be single speed, provided with a motor of the required rating. The power tool shall be supplied complete with suitable control. |
| 14 | LIGHTNING FINIAL: One number heavy duty hot dip galvanised lighting finial with copper spike on top shall be provided for each mast. The lightning finial shall be minimum 1.2 M in length and shall be provided at the centre of the head frame. It shall be bolted solidly to the head frame to get a direct conducting path to the earth through the mast. The lightning finial shall not be provided on the lantern carriage under any circumstances in view of safety of the system. | LIGHTNING FINIAL: One number heavy duty hot dip galvanised lighting finial with copper spike on top shall be provided for each mast. The lightning finial shall be minimum 1.2 M in length and shall be provided at the centre of the head frame. It shall be bolted solidly to the head frame to get a direct conducting path to the earth through the mast. The lightning finial shall not be provided on the lantern carriage under any circumstances in view of safety of the system. |
| 15 | AVIATION OBSTRUCTION LIGHTS: Suitable Aviation Obstruction Lights of reliable design and reputed manufacturer shall be provided on top of each mast. | AVIATION OBSTRUCTION LIGHTS: Suitable Aviation Obstruction Lights of reliable design and reputed manufacturer shall be provided on top of each mast. |
| 16 | LED FLOOD LIGHT: Flood Light, powder coated pressure die cast aluminium body with built in or separate driver as per the requirement with Driver efficiency >85%, Input voltage: Input voltage: 140-270 Volt AC, frequency 50/60 Hz, Operating temp range -5 0C to 50 0C, internal surge protection of 5 KV L,N,E as per IEC 61000-4-5, Driver efficiency >85%,THD < 10% as per IEC 61000-3-2, P. F.≥0.95, IP-66,IK-10, CRI >70, under voltage and over voltage protection, EMI-EMC as per CISPR-15, lenses for beam angle 30 deg-120deg as per the application and the project requirement, suitable tilt able fitting, life time (LED, Driver & electrical circuitry) of minimum 50000 Burning Hours with 70% of initial Lumen maintained till life ends as per LM80 extrapolation IES TM-21-11 report, CCT 3000°K / 4000°K / 5700°K /6500°K (As per ANSI Bin), SDCM(Standard Deviation Colour Matching) <5, Maximum power consumption should not more than the specified rating and Fixture shall be of relevant BIS standard complete in all respect i/c external connections with 1.5 sq.mm FRLS/HFFR, PVC insulated copper conductor single core cable and earthing etc. as required with Minimum 5 year OEM warranty. System lumen efficacy ≥120 and <135 lm/Watt output LM79 & LM80 Test report and all testing required for LED fixtures as per BIS shall be submitted. Shape size and CCT shall be as approved by Engineer-in-Charge as per requirement. (Thermal management: heat sink of aluminium housing such that LED junction temperature shall not rise above 90°C). | LED FLOOD LIGHT: Flood Light, powder coated pressure die cast aluminium body with built in or separate driver as per the requirement with Driver efficiency >85%, Input voltage: Input voltage: 140-270 Volt AC, frequency 50/60 Hz, Operating temp range -5 0C to 50 0C, internal surge protection of 5 KV L,N,E as per IEC 61000-4-5, Driver efficiency >85%,THD < 10% as per IEC 61000-3-2, P. F.≥0.95, IP-66,IK-10, CRI >70, under voltage and over voltage protection, EMI-EMC as per CISPR-15, lenses for beam angle 30 deg-120deg as per the application and the project requirement, suitable tilt able fitting, life time (LED, Driver & electrical circuitry) of minimum 50000 Burning Hours with 70% of initial Lumen maintained till life ends as per LM80 extrapolation IES TM-21-11 report, CCT 3000°K / 4000°K / 5700°K /6500°K (As per ANSI Bin), SDCM(Standard Deviation Colour Matching) <5, Maximum power consumption should not more than the specified rating and Fixture shall be of relevant BIS standard complete in all respect i/c external connections with 1.5 sq.mm FRLS/HFFR, PVC insulated copper conductor single core cable and earthing etc. as required with Minimum 5 year OEM warranty. System lumen efficacy ≥120 and <135 lm/Watt output LM79 & LM80 Test report and all testing required for LED fixtures as per BIS shall be submitted. Shape size and CCT shall be as approved by Engineer-in-Charge as per requirement. (Thermal management: heat sink of aluminium housing such that LED junction temperature shall not rise above 90°C). |
| 17 | ELECTRICAL SYSTEM, CABLE AND CABLE CONNECTIONS: A suitable terminal box shall be provided as part of the contract at the base compartment of the high mast for terminating the incoming cable. The electrical connections from the bottom to the top shall be made by special trailing cable. The cable shall be EPR insulated and PCP sheathed to get flexibility and endurance. Size of the cable shall be 2 RUNS of minimum 5 cores 2.5 SQMM copper. At the top there shall be weather proof junction box to terminate the trailing cable. Connections from the top junction box to the individual luminaires shall be made by using 3 core 1.5 sq. mm flexible PVC cables of below mentioned make. Suitable provision shall be made at the base compartment of the mast to facilitate the operation of internally mounted, electrically operated power tool for raising and lowering of the lantern carriage assembly. The trailing cables of the lantern carriage rings shall be terminated by means of specially designed, metal clad, multipin plug and socket provided in the base compartment to enable easy disconnection when required. | ELECTRICAL SYSTEM, CABLE AND CABLE CONNECTIONS: A suitable terminal box shall be provided as part of the contract at the base compartment of the high mast for terminating the incoming cable. The electrical connections from the bottom to the top shall be made by special trailing cable. The cable shall be EPR insulated and PCP sheathed to get flexibility and endurance. Size of the cable shall be 2 RUNS of minimum 5 cores 2.5 SQMM copper. At the top there shall be weather proof junction box to terminate the trailing cable. Connections from the top junction box to the individual luminaires shall be made by using 3 core 1.5 sq. mm flexible PVC cables of below mentioned make. Suitable provision shall be made at the base compartment of the mast to facilitate the operation of internally mounted, electrically operated power tool for raising and lowering of the lantern carriage assembly. The trailing cables of the lantern carriage rings shall be terminated by means of specially designed, metal clad, multipin plug and socket provided in the base compartment to enable easy disconnection when required. |
| 18 | POWER CABLE: A cable of size 4 C x 10 sq. mm Aluminium conductor, Armoured cable for power supply and 4 x 1.5 sq. mm Copper conductor Armoured cable for motor supply shall be provided from feeder pillar to the base compartment of the high mast. Cable shall be taken to the base compartment of the high mast through the provision made in the foundation. | POWER CABLE: A cable of size 4 C x 10 sq. mm Aluminium conductor, Armoured cable for power supply and 4 x 1.5 sq. mm Copper conductor Armoured cable for motor supply shall be provided from feeder pillar to the base compartment of the high mast. Cable shall be taken to the base compartment of the high mast through the provision made in the foundation. |
| 19 | HDPE PIPE: 04 Meter length HDPE pipe confirms to IS: 4984:2016 (5th Rev. or latest), of DIA. 63 MM shall be laid 750 mm below from the ground level for insert the power cable of 1.1 kV grade. HDPE pipe is required for entry of cable to the base compartment of the high mast through the provision made in the foundation. | HDPE PIPE: 04 Meter length HDPE pipe confirms to IS: 4984:2016 (5th Rev. or latest), of DIA. 63 MM shall be laid 750 mm below from the ground level for insert the power cable of 1.1 kV grade. HDPE pipe is required for entry of cable to the base compartment of the high mast through the provision made in the foundation. |
| 20 | FEEDER PILLAR (STANDARD IP65): Each mast shall be provided with a feeder pillar fabricated out of 14 SWG CRCA sheet and finished with two coats of red oxide primer and grey enamel paint of shade 631 of IS 5. The feeder pillar shall comprise of incoming suitable rating MCB, Standard Digital Timer, Contactor, Al busbar, incoming / outgoing terminals and control for the power motor. Feeder pillar shall be mounted on suitable foundation near to the mast. | FEEDER PILLAR (STANDARD IP65): Each mast shall be provided with a feeder pillar fabricated out of 14 SWG CRCA sheet and finished with two coats of red oxide primer and grey enamel paint of shade 631 of IS 5. The feeder pillar shall comprise of incoming suitable rating MCB, Standard Digital Timer, Contactor, Al busbar, incoming / outgoing terminals and control for the power motor. Feeder pillar shall be mounted on suitable foundation near to the mast. |
| 21 | EARTHING: Supply and providing 2 Nos (1 No for High Mast, 1 No for Feeder Pillar) of earth stations using G.I. earth plate 600 mm X 600 mm X 6 mm thick including accessories, and providing masonry enclosure with cover plate having locking arrangement and watering pipe of 2.7 Meter long etc. with charcoal/ coke and salt as required. | EARTHING: Supply and providing 2 Nos (1 No for High Mast, 1 No for Feeder Pillar) of earth stations using G.I. earth plate 600 mm X 600 mm X 6 mm thick including accessories, and providing masonry enclosure with cover plate having locking arrangement and watering pipe of 2.7 Meter long etc. with charcoal/ coke and salt as required. |
| 22 | MANUAL: 3 sets of both wiring/ connection diagram and O&M MANUAL shall be supplied at the time of supply of High Mast Pole. | MANUAL: 3 sets of both wiring/ connection diagram and O&M MANUAL shall be supplied at the time of supply of High Mast Pole. |
| 23 | WARRANTY: High Mast Lighting System including its parts & accessories shall be warranted for a period of 12 months from the date of successful completion of ‘Supply, Installation, Testing and Commissioning’. | WARRANTY: High Mast Lighting System including its parts & accessories shall be warranted for a period of 12 months from the date of successful completion of ‘Supply, Installation, Testing and Commissioning’. |
| 24 | LOADING & UNLOADING: Loading & Unloading of High Mast Pole is also in the vendor's Scope. The successful tenderer should arrange its own vehicles (cranes etc) and tools and tackles for carrying out the same. | LOADING & UNLOADING: Loading & Unloading of High Mast Pole is also in the vendor's Scope. The successful tenderer should arrange its own vehicles (cranes etc) and tools and tackles for carrying out the same. |
| 25 | TRAINING: Vendor shall impart a minimum of one day training on ‘Operation & Maintenance’ of High Mast Lighting System to HAL's personnel. The quote should be inclusive of training charges (if any). | TRAINING: Vendor shall impart a minimum of one day training on ‘Operation & Maintenance’ of High Mast Lighting System to HAL's personnel. The quote should be inclusive of training charges (if any). |
| 26 | Vendor shall employ qualified / experienced personnel for the work and shall be responsible for safety of the personnel engaged by them. Staff employed for the work should be provided with necessary PPE / safety appliances. | Vendor shall employ qualified / experienced personnel for the work and shall be responsible for safety of the personnel engaged by them. Staff employed for the work should be provided with necessary PPE / safety appliances. |
