N_Arc Consulting IRCON

Lighting And Small Power

1.0 Introduction

This part of the GTR covers the substation internal & out door lighting system. The
Lighting shall be complete in all respects and any item not included in this
specification but essential for proper installation and functioning of the lighting system
shall be deemed to be included in the scope of the specification whether specifically
mentioned or not.

All equipment shall be thoroughly cleaned from packing materials, scales, rust, oil,
grease etc prior to commencement of the installation work.

All equipment shall be checked physically for the completeness of all components and
devices before taking up installation.

All equipment and accessories shall be installed strictly in accordance with the
manufacturer's instructions / drawings. Equipment supplied in sections or dismantled
condition shall be reassembled at site with all associated accessories as per the
manufacturer's instructions.

2.0 Recommended Codes & Standards

IS-732 : Code of practice for Electrical wiring installation

IS-3646 : Code of practice for Interior illumination
IS-3043 : Code of practice for earthing.

The erection and commissioning work under this contract shall conform to the above
codes and regulations of the statutory authorities. Nothing in this specification shall be
construed to relieve the contractor from his responsibility whether specifically
mentioned in this specification or price schedule or in the drawings or not.

3.0 Recommended Values of LUX Levels for illumination at various areas .

Sl. No Particulars Average Limiting Glare

Illumination level Index
‘Lux’
1. Control Rooms:

Vertical Control Panels 200 to 300 19

Rear of Control Panels 150 19
Control Desks 300 19
Switch House 150 25
2. Battery Room 150 -
3. Carrier Room 300 -
4. Office and Reception 300 19

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Sl. No Particulars Average Limiting Glare

Illumination level Index
‘Lux’
5. Cloak Rooms 100 -
6. Maintenance Room 300 25
7. Outdoor Transformer yard 50 -
8. SCADA Room 300
9 Engineers Room 200
10. Stairs 100 -
11. Corridors 70 16
12 Approach roads 30 -
13. Pathways 30 -
14. Car Parks 70 -
15. Store Room 100 -

4.0 General Requirements:

The scope of work for lighting shall cover the following areas.

The activities under the Scope of Work in this contract shall also include the following.

a) Design & Engineering of lighting system as per relevant standards &

specifications for the areas / buildings covered under this contract.

b) Supply, Installation, Testing & Commissioning of Light fittings, Lighting switch

boards / distribution boards.

c) Laying of cables, supply & erection of single compression glands and

terminations etc.

d) Testing and commissioning of the system.

e) Earthing of the individual/total system as per the specification/statutory

authorities requirements.

f) Any other work related to the above system as instructed by owner /

Engineer.

5.0 Installation (Indoor / Outdoor)

5.1 The lighting installation shall be integrated with the general building design to give a
better and modern appearance.

5.2 Light fittings shall be wired using PVC insulated aluminum conductor armoured cables
/ PVC insulated copper wire as per the schedules.

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5.3 The cables shall be terminated in the light fittings / distribution boards using single
compression type cable glands. The terminations shall be done with suitable copper
lugs. The terminations shall be done with proper care and with perfect finish by
considering safety and easy maintenance.

5.4 The total number of light points connected in each circuit shall not exceed 10 points or
800 watts whichever is maximum as per IS-732.

5.5 The light fittings shall be earthed by using the third core of the cable and no separate
earthing is permitted. However, the core earthing shall be connected to the main earth
bus at required intervals as per standards / statutory requirements.

5.6 Suitable size of junction boxes depending upon the circuit routing shall be used and
erected by the Contractor wherever required at no extra costs for both point wiring
and cable wiring. The scope includes the supply and erection of the junction boxes,
saddles, supporting frames, ERW/PVC conduits, cable clamps and other accessories
required and the prices shall be included in the cost of point wiring/cable wiring and no
extra price shall be payable to the contractor.

5.7 All the ERW conduits, Boxes wherever used shall be applied with 2 coats of synthetic
enamel paint to suit the colour of interior.

5.8 All the light fittings shall be controlled from the indoor/outdoor/emergency local
distribution boards / individual single pole switches and these boards shall be
mounted at a height of minimum 1500 mm above the finished floor level.

5.9 All sockets shall be fixed at a height of minimum 1200 mm from finished floor level
with synthetic enamel painted MS box.

5.10 The minimum clamping distance of saddles/clamps shall not exceed 450mm and
good workmanship shall be maintained.

5.11 The supports structure required for fixing light fittings, control gear, switchboards, DBs
etc., and any other support structures/frame work shall be included in the scope of
erection of the item/lighting system and no extra price will be payable to the
contractor.

5.12 All the junction boxes, bends shall be of reputed make recommended in enclosed list
and suit the colour of the conduit used.

5.13 All the necessary civil works connected with the lighting installation shall be done by
the contractor only. No extra payment will be made on any account and co-ordination
with civil contractor is also the responsibility of the contractor.

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5.14 All cable termination shall be done with properly sized copper sockets and suitable
type of glands.

5.15 All cable armour and glands should be earthed with No.14 SWG copper by using
correct size of copper sockets from earth bus.

5.16 The switches used shall have proper identification markings to the load which they are
controlling.

5.17 Whenever the contractor is required to work in coordination with false ceiling if
necessary and other interior décor work, care shall be taken and prime importance
shall be given before installation of light fittings and sockets etc., in those areas, and
prior approval shall be obtained from owner/consultant.

5.18 For identifying the circuit no. at local control panel / LDB suitable Nomenclature for the
boards/panels shall be painted with black paint on white back ground containing
description, feeder details and cable size etc.

5.19 The rate quoted for cables shall also include the cost of the clamps, screws, painting
suitable for wall/structure, wall chipping, plastering and finishing it with existing colour
shade etc.

5.20 Surface / concealed conduit system shall be adopted using PVC conduits / ERW
conduits / PVC casing and capping for all the areas mentioned in the scope of work
with suitable inspection type (PVC/MS) Junction box shall be used to facilitate drawing
of wires / ease of maintenance.

i) Each circuit shall have separate conduit outgoing from DBs for power.

ii) Two circuits of same phase may be taken in a single conduit for lighting
alone.

5.21 The minimum size of the conduits shall not be less than 19 mm and thickness shall
not be less than 2 mm. The size of wires/conduit shall never exceed the limits
specified in the relevant standards. PVC casing and capping shall be supplied with
necessary bends, junction boxes and other accessories as required. It shall be
suitable for interior decor colour and neatly fixed with proper screws etc.

5.22 Fan points shall have concealed wiring and 12 mm dia GI hook with anchor fastener
for open wiring. Fans shall be suspended with MS conduit pipe and finally finished
with two coats of paint to suit the colour specified by owner/consultant after
completion.

5.23 Switches for fan and lighting points shall be mounted at 1500 mm above finished floor
level with 14 SWG sheet steel box and cover plate shall be hylam / perpect sheet
3mm thick which shall match with interior wall colour. (The color shall be checked with
Owner/Consultant at the time of erection).

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5.24 All 15A/20A socket shall be fixed at 1500mm from finished floor level in a suitable MS
box generally but to suit the site condition/owners requirement.

5.25 All MS boxes wherever specified shall be applied with 2 coats of anti-corrosive primer
and finished with two coats of paint of interior wall colour.

5.26 Light fittings shall be attached to ceilings and wall with proper dropper to an elevation
required by Owner / Consultant. Where fittings are to be suspended, MS conduit pipe
suspended units shall be employed with ball & socket arrangements and finally
finished with two coats of white paint.

5.27 Earth continuity shall be maintained throughout the entire wiring installation with
separate earth continuity conductors of copper and ultimately connected to a common
earth terminal at the distribution board with PVC sleeves (Only inside the DB). All the
MS boxes and DB's shall also be earthed.

5.28 Each circuit shall have separate neutral wire from DB to the final point. The neutral
shall not be looped in middle from one circuit to another circuit. For each circuit the
circuit main shall also be a part of point wiring. The neutral wire shall also be brought
to all the switch boxes whether socket points shall be provided in the switch box or
not. Two lights controlled by one switch (stair case point) shall also be considered as
one point only.

5.29 Cables above ground shall be adequately supported in steel brackets or shall be
clipped or cleated direct to the wall depending upon the number of cables. No extra
payment allowed to claim in steel weight basis. On multiple cable runs, the cables
shall be neatly grouped and where bends are required, additional clipping shall be
used.

5.30 All cable armour and glands, MS boxes shall be earthed with No. 14 SWG Cu.
properly sized sockets from earth bus.

5.31 The distribution boards shall be as per the make approved by Owner / Engineer. The
Distribution boards shall be of factory made only and fabricated boards not
acceptable.

5.32 For all wires / cables / PVC pipes, ISI mark certificates shall be produced.

5.33 Light/fan point shall also include the 5A switch for each point.

5.34 Colour codes for wiring shall be used as follows:

Piece - Ash
'R' phase - Red
'Y' phase - Yellow

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'B' phase - Blue

Neutral - Black
Earth - Green

For identifying the circuit no. at local control panel suitable labels shall be marked.
The phase wire from the single phase DB shall have the respective phase color code
upto the switch.

6.0 Type of Wiring

Area Type Details

1) Control room substation Unarmoured cable 3C 2.5 Sqmm PVC

unarmoured cable
650 / 1100 V grade

2) Yard lighting Armoured cable 4C. 10 Sqmm PVC AL

1100 V grade.

7.0 Type of Control of Lighting

a) Control room - MCB in DB

b) Yard - Contactor with timer switch

8.0 Lighting

Type of light fitting:

a) Switch gear / Room - Surface mounted, Industrial type 2x 36 /

40W with high lumen output cool light
fluorescent lamps Philips make or of
approved make

b) Control Room / Engineers Room - Decoration type 2x36/40W with high

lumen output cool light fluorescent
lamps of Philips make or approved
make

c) Battery Room - Surface mounted corrosion proof light

fitting with 2x36 / 40W with high Lumen
output cool light fluorescent lamps of
Philips make or of approved make)

d) Other areas & corridor - Batten fitting with 1x 36 / 40W cool day
fluorescent lamps of

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Philips make or of approved make)

e) Yard lighting - Heavy duty flood light fitting 1x250 HP

HPSV lamp with separate cast
aluminium control gear box. of Philips
make or of approved make

f) Entrance to the Sub station - Post top lantern with 1x70W building
HPSV lamp of Philips or of approved
make).

9.0 Flood Light Fitting

The flood-light fittings required for area lighting shall be as specified below:

Industrial weather – proof type wide beam flood-light fittings suitable for 1x250 W
HPSV lamp shall be of cast aluminium housing having brightened anodized spun
aluminium reflector with toughened front glass, fitter with neoprene rubber gasket,
cast aluminium back plate accommodating lamp holder assembly, mounting bracket

and porcelain lamp holder. The fittings shall be supplied complete with 2mm thick
sheet steel weather proof control gear box incorporating ballast, power factor
improvement capacitor and igniter fully wired.

10.0 Post-Top Lantern

The decorative post top lanterns for mounting on low height steel tubular poles shall
be suitable for 70 W sodium vapor lamp. The fittings shall be made of cast
aluminium, stove enameled, having opal acrylic diffuser bowl, spun aluminium canopy
and built in control gear accommodating ballast, power factor improvement capacitor
etc.

11.0 Fluorescent Fittings

Fluorescent fittings shall be supplied complete with copper wound ballast, starter, bi-
pin spring loaded holder and power factor improvement capacitor, fully wired suitable
for fluorescent tube lamps.

The fluorescent lighting fittings shall be as specified below:

a) Mounting rail type fluorescent fittings (HPF) suitable for single / twin 36/40W
fluorescent tube lamp to be suspended or mounted on ceiling having heavy
gauge sheet steel cover for the channel.

b) Industrial type fitting (HPP) with rejection suitable for Twin 36/40W fluorescent
tube lamps to be suspended or mounted on ceiling.

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c) Corrosion resistant fluorescent fittings (HPF) suitable for twin 36/40W

fluorescent tube lamps suitable for suspended or mounted on ceiling.

d) Wide spread, decorative recessed mounting florescent fittings (HPF) suitable

for twin 36 / 40W fluorescent tube lamps, together with stove enamelled sheet
steel mirror assembly and all accessories.

12.0 Bulk Head Fittings

Bulk head, weather-proof fittings for use in covered porches, surrounding the switch
gear room shall be suitable for direct fixing to wall/ceiling and to accommodate upto
100W incandescent lamp.

14.0 Lighting Poles for Substation

Lighting poles shall be of 9m height swaged steel tubular, welded with

300x300x10mm thick MS plate at the base. Poles shall be buried to a depth of not
less than 1.5m below ground level embedded in concrete foundation. Foundation shall
be to a depth of 150mm below base plate and shall have PCC upto 450mm above
ground level ith coping.

A junction box made of 14G MS sheet steel of size not less than 200x175x100mm
shall be fixed at 750mm above ground level. This junction box shall house necessary
terminal blocks to terminate 16/25 sqmm cable and a 16A porcelain rewireable fuse.
Junction box shall have entry for 2nos of 40mm dia GI pipes for cables and threaded
at junction box end and shall be buried upto a depth of 750mm below ground level.
Junction box shall have hinged door.

Emergency light fitting which shall be fitted in the pole below flood light fitting. The
wiring shall be made separately from the DC source. The emergency fitting shall be of
flood light fitting with GLS lamp and the protection class of IP: 54.

15.0 Lighting Distribution Board (LDB)/Emergency Distribution Board

i. The LDB shall be fabricated out of 2mm thick Sheet steel and suitable for
mounting on walls. The cover of the DB shall have male female type hinges
and 90° rotation knob to close and open. The door shall be provided with
continuous synthetic rubber gasket to make the board complete dust proof.

ii. TPN lighting distribution board shall be with incomer controlled by 4 pole MCB
+ ELCB 100 MA and outgoings each controlled by MCB (SPN) as required

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iii. The MCBs shall be so mounted inside the enclosure that their operating
knobs project out of the enclosure for easy operation. Emergency DB shall
have rotary type switch.

iv. Two earthing terminals, one inside the board and one outside the board shall
be provided.

v. The DB shall be internally wired, provided with knock out, with incomer at
bottom entry and outgoing circuits at top.

vi. Suitable name plates for the board and circuit nos. of all outgoing feeders
shall be provided.

vii. Sufficient No. of blank plates shall be provided to cover the openings in the
DBs.

16.0 Accessories

a. Control Switches, Receptacles Etc.

(i) The control switches, receptacles, junction boxes, etc. shall conform to
relevant Indian Standards or equivalent specifications.

17. Lamps

(i) GLS lamps if specified shall be provided with bayonet caps and shall be of
'Clear' type unless otherwise specified.

(ii) The fluorescent lamps if called for, shall be 'Day-light colour' type unless
otherwise specified and it shall be with features to avoid blackening of lamp
ends.

(iii) The lamps shall be suitable for use in any burning position. Restrictions, if
any, shall be clearly stated.

(iv) The lamps shall be capable of withstanding small vibrations and the
connections at lead in wires and filaments / electrodes shall not break under
such circumstances.

18.0 Spare Parts

Whether included in the manufacturer's recommendation or not, unit prices of the

following items shall be quoted together with the suggested quantities and catalogue
numbers.

- Each type of lamp

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- Each type of control switch

- Each type of receptacle
- Each type of control box
- Each type of reflector
- Each type of junction box
- Ballast for high pressure sodium Vapour lamps
- Power factor improvement capacitors
- Box for accommodating control gear of HPSV lamps
- Starters

The unit prices shall not however be limited to the above items. The bidder may
recommend additional spare items for which unit prices shall be furnished.

19.0 Drawings and Data

(i) As part of the proposal, the Bidder shall furnish relevant descriptive and
illustrative literature on lighting fixtures and accessories and the following
drawings / data for the respective lighting fixtures:

(ii) Dimensioned drawings

(iii) Mounting details, cable entry facility and weights

(iv) Light distribution diagrams (zonal and Iso candela)

(v) Light output Vs temperature curve

(vi) Lumen output Vs Voltage

(vii) Lighting Design Calculations

11 PRE-DESPATCH INSPECTION:-

Lighting equipment shall be subject to inspection by a duly authorized

representative of the IRCON International limited. Inspection may be made at any
stage of manufacture at the option of the purchaser and the Lighting equipment if
found unsatisfactory as to workmanship or material is liable to rejection. Supplier
shall grant free access to the places of manufacture to IRCON’s representatives at
all times when the work is in progress. Inspection by the IRCON or its authorized
representatives shall not relieve the supplier of his obligation of furnishing Lighting
equipment in accordance with the specifications. Material shall be dispatched after
specific MDCC (Material Dispatch Clearance Certificate) is issued by IRCON.

Following documents shall be sent along with material

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a) Test reports
b) MDCC issued by IRCON International limited
c) Invoice in duplicate
d) Packing list
e) Guarantee / Warrantee card
f) Delivery Challan

12. INSPECTION AFTER RECEIPT AT STORES:-

IRCON Inspectors will inspect the material received at IRCON store for acceptance.

13. GUARANTEE:-

The material shall be guaranteed for satisfactory performance for a period of 12 months
from the date of commissioning or 18 months from the date of receipt whichever is earlier.
Any supplies found defective during this period, as a consequence of bad design,
manufacturing or workmanship shall be replaced, free of cost, by you, within a mutually
agreed schedule.

14. QUALITY CONTROL:-

The bidder shall submit within two weeks from LOI, assurance plan indicating the various
stages of inspection, the tests and checks that will be carried out on the material of
construction, components during manufacture and after finishing, bought out items and
fully assembled component and equipment including drives. As part of the plan, a
schedule for stage and final inspection within the parameters of the delivery schedule shall
be furnished. The Purchaser’s / Consultant’s engineer shall have free access to the
manufacturer / sub-supplier’s works to carry out inspections.

15. MINIMUM TESTING FACILITIES:-

Supplier / Manufacturer shall have adequate in house testing facilities for carrying out all
routine tests & acceptance tests as per relevant International / Indian standards.

16. MANUFACTURING ACTIVITES:-

The manufacturer shall have adequate machinery for manufacturing conductors and
should have Quality Assurance Manual, which shall be approved by IRCON international
Limited.

17. SCHEDULE OF DEVIATIONS:-

The Bidders shall set out all deviations from this specification, clause by clause in this
schedule. Unless specifically mentioned in this schedule, the tender shall be deemed to
confirm the purchaser’s specifications. (Format is attached).

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Appendix - A
Project: Rail Coach Factory, Rae Bareli.

Bid Document No
Tender Notification No.

TECHNICAL DEVIATIONS

The following are the Technical Deviations and Variations from and Exceptions to the
specifications and documents for the subject package. These deviations and variations are
exhaustive. Except these deviations, the entire work shall be performed as per your specifications
and documents.
———————————————————————————————————————----
Vol./Clause Ref./Page No. As specified Technical deviation
in the specification and variations to the
specification
———————————————————————————————————————----

———————————————————————————————————————----

Date: (Signature)......................................
Place: (Printed Name)................................
(Designation)...................................
(Common Seal)................................
Note :

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i. Continuation sheets of like size and format may be used as per Bidder's requirements and
annexed to this schedule.
ii. The deviations and variations, if any, shall be brought out separately for each of the
equipment
iii. In the event of no deviation, the bidder shall mark "NO DEVIATIONS" in the description
column and duly sign.
iv. Deviations which are not specifically brought out in the above format are not valid.

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