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Manufacturer's Name & Add: M/s KEI INDUSTRIES LIMITED Client: DMRC Limited

Unit-1: SP-919/920, RIICO Industrial Area, Ph-III, Bhiwadi, Rajasthan Contractor: Larsen & Toubro Construction
Unit-2: Plot-A 280/281/282, Chopanki (Bhiwadi), Rajasthan Project: E & M DMRC PHASE-3 (CE-09 LOT 2)
Ref. Standard: Generally Confirming to BS: 6724 & BS: 7846
S.No.
Component and
Operation
Characteristics
Type of
Check
Quantum of check
Reference
Documents
Acceptance Norms Test Procedure
Format of
record
Agency Remarks
1 2 3 4 5 6 7 8 9 11
M C
1.0
1. Conductor Resistance Elect. 100 % Drums
BS EN:
60228/Appd. Data
Sheet
Annexure A Annexure-1 T.C. P R
2. H.V.at room Temparature Elect. 100 % Drums
BS: 7846/Appd.
Data Sheet/BS:
6724
3.5 kV for 5 min Annexure-2 T.C. P R
1. Conductor Resistance Elect. **One sampe per
size
BS EN:
60228/Appd. Data
Sheet
Annexure A Annexure-1
T.C. P W
2. Thickness of Insulation & Sheath Meas. "
BS: 7846/ Approved
Data sheet/BS:
6724
Annexure A Annexure-4 T.C. P W
TESTS ON FINISHED CABLES
FAT for LT XLPE CABLES (FS AND NON FS)
10
**one sample
per size for
qty not less
than 2 km
Routine Tests 1.1
6724
3. Core Identification Visual "
Appd. Data
Sheet/DMRC Spec Annexure A
Visual Examination
& measurement T.C. P W
4. Armour wire diameter Elect. "
BS: 7846/BS: 6724
Annexure A Annexure-11 T.C. P W
5. Armour resistance test Meas. "
BS: 7846/BS: 6724
Annexure H Annexure-1 T.C. P W
6. Hot Set Test (for XLPE Only) Mech. " BS:7655 (1.3)
Elongation under Load-
175% (Max) &
Permanent Elongation
after cooling-15%
(Max0
Annexure-5 T.C. P W
7. Tensile Strength and %Elongation
for Insulation (before ageing)
Mech " BS:7655 (1.3)
12.5 N/sq mm (Min) &
200% (Min) Annexure-6 T.C. P W
8. Tensile Strength and %Elongation
for Sheath (before ageing)
Mech " BS:7655 (6.1)
10 N / sq mm (min) &
100% (min) Annexure-6 T.C. P W
9. H.V.Test at room temperature Elect. " " 3.5 kV for 5 min Annexure-2 T.C. P W
10. Corrosive and acid gas
generation for outer sheath
Chem. One sample per lot
irrespective
size/type
BS:7655(6.1) / IEC-
754(Part1/2)
Max. 0.5% Annexure-25
T.C. P W
Acceptance Tests 1.2
Page 1 of 5
Manufacturer's Name & Add: M/s KEI INDUSTRIES LIMITED Client: DMRC Limited
Unit-1: SP-919/920, RIICO Industrial Area, Ph-III, Bhiwadi, Rajasthan Contractor: Larsen & Toubro Construction
Unit-2: Plot-A 280/281/282, Chopanki (Bhiwadi), Rajasthan Project: E & M DMRC PHASE-3 (CE-09 LOT 2)
Ref. Standard: Generally Confirming to BS: 6724 & BS: 7846
S.No.
Component and
Operation
Characteristics
Type of
Check
Quantum of check
Reference
Documents
Acceptance Norms Test Procedure
Format of
record
Agency Remarks
1 2 3 4 5 6 7 8 9 11
M C
FAT for LT XLPE CABLES (FS AND NON FS)
10
11. Flammability Test fire
One sample per lot
irrespective
size/type
IEEE:383/IEC-332-1
Shall Pass
Annexure-26 & 27
T.C. P W
12. Smoke emission Thermal " ASTM-D-2843 Max 20% Annexure-24 T.C. P W
13. Oxygen index Thermal " ASTMD-2863 30 % Min. Annexure-23 T.C. P W
14. Temperature index Thermal " ASTMD-2863 280C Min. Annexure-23 T.C. P W
Category CWZ test as per BS: 6387
for FS cable
1. Resistance to Fire Alone
(Category C)
Fire One sample per lot
irrespective
size/type
BS: 6387
950
o
C for 3 hours
Annexure-30 & BS:
6387 Annexure. D,
D.2
T.C. P W
2. Resistance to Fire with water
(Category W)
Fire
"
BS: 6387
650
o
C for 15 Minutes
Annexure-30 & BS:
6387 Annexure. D,
D.3
T.C. P W
Acceptance Tests 1.2
D.3
3. Resistance to Fire with
mechanical shock (Category Z)
Fire
"
BS: 6387
950
o
C for 15 Minutes
Annexure-30 & BS:
6387 Annexure. D,
D.4
T.C. P W
1. Test on Conductor
a) Conductor Resistance Elect.
One sample per lot
irrespective
size/type
BS EN:
60228/Appd. Data
sheet
Annexure-A Annexure-1 T.C P R
2. Test for XLPE Insulation
a) Thickness measument Phy.
One sample per lot
irrespective
size/type
BS:
6724/BS:7846/BS:7
655(1.3)
Annexure A Annexure-4 T.C P R
b) Tensile strength & Elongation test
before ageing
Phy. " BS:7655(1.3)
12.5 N/sq mm (Min) &
200% (Min)
Annexure-6 T.C P R
c) Ageing In Air Oven Phy. " BS:7655(1.3)
Tensile Strength
variation 25% (max)
& Elongation variation
25% (Max)
Annexure-8 T.C P R
d) Hot Set Test -do- " BS:7655(1.3)
Elongation under Load-
175% (Max) &
Permanent Elongation
after cooling-15%
(Max0
Annexure-5 T.C P R
TYPE TEST 3.3
Page 2 of 5
Manufacturer's Name & Add: M/s KEI INDUSTRIES LIMITED Client: DMRC Limited
Unit-1: SP-919/920, RIICO Industrial Area, Ph-III, Bhiwadi, Rajasthan Contractor: Larsen & Toubro Construction
Unit-2: Plot-A 280/281/282, Chopanki (Bhiwadi), Rajasthan Project: E & M DMRC PHASE-3 (CE-09 LOT 2)
Ref. Standard: Generally Confirming to BS: 6724 & BS: 7846
S.No.
Component and
Operation
Characteristics
Type of
Check
Quantum of check
Reference
Documents
Acceptance Norms Test Procedure
Format of
record
Agency Remarks
1 2 3 4 5 6 7 8 9 11
M C
FAT for LT XLPE CABLES (FS AND NON FS)
10
e) Water Absorption Test (grav.) -do-
One sample per lot
irrespective
size/type
BS:7655(1.3) 1 mg/sqcm(Max) Annexure-10 T.C P R
f) Shrinkage Test Phy. " BS:7655(1.3) 4% (Max ) Annexure-9 T.C P R
g) Insulation resistance constant Elect. " BS:7655(1.3) 3.67 Mohms-km Annexure-31 T.C P R
3. Test on Inner Sheath / bedding
a) Thickness measument Phy.
One sample per lot
irrespective
size/type
BS: 6724/BS:7846 Annexure A Annexure-4 T.C P R
b) Tensile strength & Elongation test
before ageing
Phy. " BS:7655 (6.1)
10 N / sq mm (min) &
100% (min)
Annexure-6 T.C P R
c) Corrosive and acid gas test Chem. "
BS:7655(6.1) / IEC-
754(Part1/2)
Max. 0.5% Annexure-25 T.C P R
4. Test on Armour Wire 4. Test on Armour Wire
a) Measurement of dimensions Phy.
One sample per lot
irrespective
size/type
BS: 6724/BS:7846 Annexure A Annexure-11 T.C P R
b) Mass of Zinc Coating Phy. " BS: 6724/BS:7846 BS: 6724/BS:7846 Annexure-16 T.C P R
c) Wrapping test for galvanized
wire
Mech " BS: 6724/BS:7846
No cracks on Zinc
coating
Annexure-14 T.C P R
d) Armour Resistance Test Elect. " BS: 6724/BS:7846 Annexure-H Annexure-1 T.C P R
5. Test on Outer Sheath
a) Thickness measument Phy.
One sample per lot
irrespective
size/type
BS: 6724/BS:7846 Annexure A Annexure-4 T.C P R
b) Tensile strength & %Elongation at
break
Phy. " BS:7655 (6.1)
10 N / sq mm (min) &
100% (min)
Annexure-6 T.C P R
c) Ageing In Air Oven Phy. " BS:7655 (6.1)
Tensile Strength
variation 40% (max)
& Elongation variation
40% (Max)
Annexure-8 T.C P R
Page 3 of 5
Manufacturer's Name & Add: M/s KEI INDUSTRIES LIMITED Client: DMRC Limited
Unit-1: SP-919/920, RIICO Industrial Area, Ph-III, Bhiwadi, Rajasthan Contractor: Larsen & Toubro Construction
Unit-2: Plot-A 280/281/282, Chopanki (Bhiwadi), Rajasthan Project: E & M DMRC PHASE-3 (CE-09 LOT 2)
Ref. Standard: Generally Confirming to BS: 6724 & BS: 7846
S.No.
Component and
Operation
Characteristics
Type of
Check
Quantum of check
Reference
Documents
Acceptance Norms Test Procedure
Format of
record
Agency Remarks
1 2 3 4 5 6 7 8 9 11
M C
FAT for LT XLPE CABLES (FS AND NON FS)
10
d) Water immersion test Phy.
One sample per lot
irrespective
size/type
BS:7655 (6.1)
Tensile Strength
variation 30% (max)
& Elongation variation
30% (Max)
Annexure-6 &
BS:6469 -99.1 Cl.
14.0
T.C P R
e) Pressure test at high temperature Phy. "
BS:7655 (6.1)(Table
2)
Max Indentation-50%
Annexure-18 T.C P R
f) Cold Impact Test Mech "
BS:7655 (6.1)(Table
2)
No cracks. Annexure-19 T.C P R
g) Bending test at - 15 C Mech "
BS:7655 (6.1)(Table
2)
No cracks. Annexure-20 T.C P R
h) Cold elongation test at - 15 C Mech "
BS:7655 (6.1)(Table
2)
30 % (min) without
break
Annexure-21 T.C P R
i) Tear resistance Test Mech " BS:7655 (6.1) 5 N/mm(min) Annexure-22 T.C P R i) Tear resistance Test Mech " BS:7655 (6.1) 5 N/mm(min) Annexure-22 T.C P R
j) Corrosive and acid gas test Chem. "
BS:7655(6.1) / IEC-
754(Part1/2)
Max. 0.5% Annexure-25 T.C P R
5. Test on complete cable
a) H.V.Test at room Temperature
Elect.
One sample per lot
irrespective
size/type
BS: 7846/Appd.
Data Sheet/BS:
6724
3.5 kV for 5 min Annexure-2 T.C P R
b) Abrasion test Elect. "
BS: 7846/BS: 6724
No sign of cracks Annexure-28 T.C P R
c) Compatibility test Elect. " BS: 7846/BS: 6724
Tensile strength-12.5
N/sq mm(min) &
Elongation at break-
200% (min) and
Tensile strength
variation 25%(max)
& Elongation
variation25%(Max)
Annexure-29 T.C P R
d) Insulation resistance constant of
sheath
Elect. " BS:7655(6.1) 0.0035 Mohms-km Annexure-32 T.C P R
Page 4 of 5
Manufacturer's Name & Add: M/s KEI INDUSTRIES LIMITED Client: DMRC Limited
Unit-1: SP-919/920, RIICO Industrial Area, Ph-III, Bhiwadi, Rajasthan Contractor: Larsen & Toubro Construction
Unit-2: Plot-A 280/281/282, Chopanki (Bhiwadi), Rajasthan Project: E & M DMRC PHASE-3 (CE-09 LOT 2)
Ref. Standard: Generally Confirming to BS: 6724 & BS: 7846
S.No.
Component and
Operation
Characteristics
Type of
Check
Quantum of check
Reference
Documents
Acceptance Norms Test Procedure
Format of
record
Agency Remarks
1 2 3 4 5 6 7 8 9 11
M C
FAT for LT XLPE CABLES (FS AND NON FS)
10
LSZH Poperties (for LSZH Compound only)
1. Corrosive and acid gas generation
for outer sheath
Chem. One sample per lot
irrespective
size/type
BS:7655(6.1) / IEC-
754(Part1/2)
Max. 0.5% Annexure-25
T.C. P R
2. Smoke emission Thermal
"
IEC-61034 70% Min. light
transmission
Annexure-24 T.C. P R
3. Oxygen index Thermal " ASTMD-2863 30 % Min. Annexure-23 T.C. P R
4. Temperature index Thermal " ASTMD-2863 280C Min. Annexure-23 T.C. P R
5. Flammability Test fire " IEEE:383/IEC-332-1
Shall Pass
Annexure-26 & 27
T.C. P R
Category CWZ test as per BS: 6387
for FS cable
1. Resistance to Fire Alone
Fire
One sample per lot
irrespective
BS: 6387
950
o
C for 3 hours
Annexure-30 & BS:
6387 Annexure. D, T.C. P R
1. Resistance to Fire Alone
(Category C)
Fire irrespective
size/type
6387 Annexure. D,
D.2
T.C. P R
2. Resistance to Fire with water
(Category W)
Fire "
BS: 6387
650
o
C for 15 Minutes
Annexure-30 & BS:
6387 Annexure. D,
D.3
T.C. P R
3. Resistance to Fire with
mechanical shock (Category Z)
Fire "
BS: 6387
950
o
C for 15 Minutes
Annexure-30 & BS:
6387 Annexure. D,
D.4
T.C. P R
Legends-W - Witness; R - Review; P - Perform, M - Manufacturer, C - Client/Third Party Inspection Agency
T.C - Test Certificate
(For KEI INDUSTRIES LIMITED)
Page 5 of 5
KEI INDUSTRIES LIMITED



ANNEXURE-1- CONDUCTOR / ARMOUR WIRE RESISTANCE TEST

SIGNIFICANCE :-Control the resistance to meet the system design parameters. Resistance
depends on conductor dimension and construction, conditions, temperature
and resistivity. Resistance is expressed in terms of ohms per kilometer
corrected to 20 deg.c
TEST SPECIMEN :- Full drum length.
APPARATUS :- Digital Micro Ohm Meter/Double Kelvin Bridge
TEST PROCEDURE :-
1. Connect the instrument with the specimen/drum.
2. Measure the resistance of the conductor/armour/drain wire at ambient temp.
3. Calculate the measured resistance to the standard temperature & standard length.
CALCULATION:-
R20 = (Rt x Kt x 1000)/L
Where R
20
= Resistance at 20
0
C
Rt =Measured resistance of L meter of cable at t
0
C in ohms.
Kt = Temperature correction factor for resistance at the temp. of t
0
C
L = Length of cable in meters
t = Temperature of conductor at the time of measurement
Value of temperature correction factor
Kt = 1 / [1+0.004(t 20)]
= 250 / (230+t)
0.004 is constant-mass temperature coefficient of resistance at 20 deg c for copper and
aluminium . For steel the same to be taken as 0.005.
PERFORMANCE :-
The corrected value should not exceed the appropriate values given in the
IS:8130 / BS:6360/IEC-60228.


KEI INDUSTRIES LIMITED -



ANNEXURE-2-HIGH VOLTAGE TEST
SIGNIFICANCE :-The higher voltage stress is applied for a short duration to ascertain that
the cable will withstand the voltage imposed on it when it will be in
service.
TEST SAMPLE :- Full drum length or 3.0 meters minimum length is taken as a sample.
APPARATUS :- High voltage source and water bath.
TEST PROCEDURE :-The high voltage source is connected to the sample under the test as given
below.
A) UPTO FOUR CORE CABLES:
S/c core= 1 against E 2 core= 1 against 2+E
2 against 1+E
3 core= 1 against 2+3+ E 4 core= 1 against 2+3+4+E
2 against 1+3+ E 2 against 1+3+4+E
3 against 1+2+ E 3 against 1+2+4+E
4 against 1+2+3+E
MULTICORE CABLES
A) All odd numbered cores of all layers against all even numbered cores of all layers.
B) First core against last core in each layer concerned if in at least one layer the total no. of cores
is odd and greater than one, otherwise not required.
C) All odd numbered layers against all even numbered layers.
D) Test Voltage:- Cables against IS:1554(Pt-1)/IS:7098(Pt-1):-3 kV ac for 5 minutes
BS:7846/6724 : 3.5 kV ac for 5 minutes.
1. For multi core and single core armoured cable the test is conducted at ambient
temperature. For unarmoured single core cables it is immersed in water at ambient
temperature and duration of immersion is as per applicable standard. For performing
test at elevated temperature the duration and temperature of the water shall be as per
applicable standard.
2. PERFORMANCE :-
No break down of insulation should be there during the test.
KEI INDUSTRIES LIMITED



ANNEXURE-4-MEASUREMENT OF THICKNESS OF INSULATION ,
SHEATH AND OVERALL DIAMETER
SIGNIFICANCE :-The thickness of insulation or sheath has been specified on the basis of
voltage stress and/or mechanical forces , the covering is expected to
withstand in service. The measurement of such thickness determines the
limits of such dimension to ensure that the requirement of the
specification are satisfactorily met.
TEST SAMPLE :- Test specimen shall be of 300 mm approx. The specimen should be prepared
in a manner suitable for different type of measurements. Wherever
required the slice to be cut for measurement.
APPARATUS :- Micrometer (0.01 mm LC), Vernier caliper ( 0.01 mm LC), Graduated
magnifying glass (0.01 mm LC).
PROCEDURE :-
1. Overall diameter to be measured at three places and two reading to be taken at right angle.
The avg. of these six reading to be taken to determine the overall dia.
2. For round core/cable piece diameter over and below the insulation/sheath is measured at
three places and at right angle at each place. The measured avg. dia below
insulation/sheath to be subtracted from the avg. of the dia. above insulation/sheath and the
difference divided by two.
3. The minimum thickness is determined by taking minimum value at a point.
4. For sector shaped core the measurement to be made at each (three) corner and three at the
centers of the faces. It is to be ensured that the minimum at a point measurement has to be
in these six readings. All the six readings to be added and divided by six to get the avg.
value.

PERFORMANCE :-
The test specimen should meet the requirements of relevant IS/IEC/BS standard.

KEI INDUSTRIES LIMITED
ANNEXURE-5-HOT SET TEST
SIGNIFICANCE :-This test method serves as a means for determining weather or not the
material has been cross-linked.
TEST SPECIMEN :- Test specimen may be of two types, dumb-bell or tubular. Whenever
possible dumb-bell type test specimens shall be used. Where the sample
size is so small it is not possible to cut a dumb-bell , circular specimen
are used. Approx.100 mm long sample is taken in case of tubular
specimen.
APPARATUS :- Thermostatically controlled with controlled air flow (Rate of change of
air flow 8 to 20 changes per hr.) oven, scale, Dumb-bell cutting die,
Instrument to measure thickness to an accuracy of 0.01mm. Grips &
Thermometer.
PROCEDURE :-
1. The samples are marked to a 20mm guage length.
2. The test pieces are fixed with jaws and suspended in the oven at a temperature specified
in the relevant standard. Weights are attached to bottom grips to exert a force of
20N/cm
2
.


3. After 15 minutes in the oven the distance between the marker lines is measured. The
force is then removed and the test piece is left to recover for 5 minutes at the same
temp.
4. The test piece is then removed and allowed to cool slowly to ambient temp., after which
the distance between marker lines is measured again.
CALCULATION :-
The % hot set elongation(Elongation under load)=(B-A)*100/A
Permanent Set % = (C-A)*100/A
Where A= Initial Length B= Length measured after 15 minutes
C= Length after cooling
PERFORMANCE :-
The test specimen should meet the requirements given in IS:7098(Pt-1) & BS:7655-(1.3).

KEI INDUSTRIES LIMITED



ANNEXURE-6-TENSILE STRENGTH AND ELONGATION FOR
INSULATION & SHEATH
SIGNIFICANCE :-This test is carried out to ensure that the insulation and sheath have requisite
tensile strength and elongation the mechanical stresses imposed during
manufacturing and installation of cables.
TEST SAMPLE :- Test specimen may be of two types, dumb-bell or tubular. Whenever possible
dumb-bell type test specimens shall be used. Where the sample size is so
small it is not possible to cut a dumb-bell , circular specimen are used.
Approx.100 mm long sample is taken in case of tubular specimen.
APPARATUS :- Tensile testing machine, Dumb-bell cutting die, Analytic weighting balance,
mechanical Instrument to measure thickness to an accuracy of 0.01mm
PROCEDURE :-
1. Both types of specimen are marked at 20 mm to measure elongation at break.
2. The area of the sample is determined as given below:-
Area of the test specimen(In mm):
Tubular Test Specimen: A=3.14(D-t)*t
Where D= Diameter of tube in mm t= thickness of the tube in mm
Dumb-bell Test Specimen: A=W*t
Where W=Width of the dumb-bell in mm t= thickness of the dumb-bell in mm
3. The tensile strength and elongation at break of the samples are determined on the Tensile
Testing Machine simultaneously.
4. The marker lines shall be closely followed and elongation shall be determined by measuring
the distance between the two marker lines at the instant of break.
5. The breaking load is also noted from the scale and tensile strength and percentage
elongation is calculated.
Tensile Strength= Breaking Load/Area
Elongation at break=( Length at break-Original length)*100/Original length
PERFORMANCE :-
The test specimen should meet the requirements given in IS:7098(Pt-1) & BS:7655.6.1/7655.1.3
KEI INDUSTRIES LIMITED



ANNEXURE-8-THERMAL AGEING IN AIR OVEN TEST
SIGNIFICANCE :- This test makes an assessment of change in tensile strength and elongation of
materials on subjecting them to accelerated ageing in air. The severity of
exposures, in both time and temperature, determine the extent and type of
changes that takes place.
TEST SPECIMEN :- Test specimen may be of two types, dumb-bell or tubular. Whenever possible
dumb-bell type test specimens shall be used. Where the sample size is so
small it is not possible to cut a dumb-bell , circular specimen are used.
Approx.100 mm long sample is taken in case of tubular specimen.
APPARATUS :- Thermostatically controlled with controlled air flow (Rate of change of air
flow 8 to 20 changes per hr.)Ageing oven, Tensile testing machine, Dumb-
bell cutting die, Instrument to measure thickness to an accuracy of 0.01mm.
PROCEDURE :-
1. The samples are suspended vertically in an ageing oven at the specified temperature in the
relevant specification.
2. After the end of ageing period samples are taken out and cooled down at room
temperature for 16 hrs.
3. Test for Tensile Strength and Elongation at break is carried out on these samples as well as
on the samples without ageing.
4. Variation among the before ageing samples and after ageing samples is calculated.
CALCULATION :-
Variation in T.S=(T.S before Ageing T.S after ageing)*100/T.S before ageing
Variation in Elong.=(Elong. before Ageing Elong. after ageing)*100/Elong. before
ageing
PERFORMANCE :-
The test specimen should meet the requirements given in IS:7098 (Pt-1) / BS:7655.(6.1) &
BS:7655.(1.3)
KEI INDUSTRIES LIMITED

ANNEXURE-9-SHRINKAGE TEST
SIGNIFICANCE :-The extruded polymeric materials may have residual strain which is relieved on
heating causing shrinkage. Purpose of this test is to determine such
shrinkages so that this may not cause any problem in terminations when
cable gets heated due to energization.
TEST SAMPLE :- Sample of approx. 220mm is taken . In case of test on insulation, this shall be
stripped of all covering over the insulation. The insulation or sheath is cut
down to a length of 200 mm measured to a accuracy of 0.5 mm.
APPARATUS :-Electrically operated and thermostatically controlled heating oven. Scale
having least count 0.5 mm
PROCEDURE :-
1. The sample is kept in the oven horizontally at the specified temp. and for a specified duration
in the relevant specification.
XLPE: 130deg.c for 1 Hour
2. After the period the sample is taken out and cooled down.
3. The shrinkage of the insulation or sheath is measured with an accuracy of 0.5mm.
%age Shrinkage=(L1-L2)*100/L1
PERFORMANCE :-
The test specimen should meet the requirements given in the IS:7098(Pt-1)/BS7655.1.3/7655.6.1/7655-
3.1.







KEI INDUSTRIES LIMITED



ANNEXURE-10-WATER ABSORPTION TEST(Gravimetric)
SIGNIFICANCE :-This test is done to ascertain the quantity of water absorbed when the
insulation or sheath of cable laid underground comes in contact with water
or moisture.
TEST SPECIMEN :- Slices of 0.6 to 0.9 mm thickness shall be ground or cut from the insulation or
sheath with surface approximately parallel and free from roughness.Test
pieces 80 to 100 mm long and 4 to 5 mm wide shall be punched out of the
slices.
Number of specimen Three (3).
APPARATUS :-Thermostatically controlled vacuum oven, balance 0.1mg accuracy,
desiccator.
PROCEDURE :-
1. The test pieces are dried in an oven for 24 hours at 70 2 deg C under vacuum at residual
pressure of 1mbar.After this treatment the samples are cooled in a desicator.
2. The dried samples are weighed to the nearest 0.1 milligram(W1) and placed in a container
of distilled water at the specified temperature for the specified temperature.
3. After this period the samples are taken out and cleaned with dry cloth or filter paper. The
specimens are reweighed (W2)
CALCULATION :-
Water absorbed ,mg/sq. cm = (W1 W2)/A
A= Surface area of test specimen
For tubular specimens, A= 2*3.14(D-t)x(L+t)/100 sq. cm
For dumb-bell specimens, A=1256+(180t)/100 sq. cm
PERFORMANCE :-
The test specimen should meet the requirements given in IS:7098(Pt-1)/BS:7655-1.3.


KEI INDUSTRIES LIMITED



ANNEXURE-11-MEASUREMENT OF DIMENSIONS OF ARMOUING
MATERIAL
SIGNIFICANCE :-The measurement of dimensions used for armouring of electric cables, as taken
out from the finished cable, without removing the Zinc coating.
TEST SAMPLE :- Test specimen shall be of 300 mm approx. it shall be free from scratches ,dents
and other external irregularities.
APPARATUS :- Micrometer-(0.01 mm LC), Vernier caliper-(0.01 mm LC), Graduated
magnifying glass-(0.01 mm LC).
PROCEDURE :-
1. Test specimen is drawn from the finished cable & shall made reasonably straight.
2. The test specifimen shall be marked at three equidistant points ( say 50 mm) from the ends
and at the middle.The set of measurements made at these points shall be recorded and used
to determine the average.
3. The measurements shall be made in the following manner.
a. Wire At each marked point diameter shall be measured in two directions at right
angles to each other.
b. Strip At each marked point outer width shall be measured with outside arms of
varnier caliper or by micrometer, the thickness shall be measured by micrometer and
radius by curvature gauge.
CALCULATION :-
a. For Diameter of Wire- Average Value = (X + Y) / 6
b. For Dimensions of Strip Average Value = ( P1 + P2 + P3 ) / 3
PERFORMANCE :-
The test specimen should meet the requirements of relevant IS / BS standard.

KEI INDUSTRIES LIMITED



ANNEXURE-14-WRAPPING TEST ON ARMOUR WIRE
SIGNIFICANCE :- To determine the ductility of the wire as the armour should not
break or split off while undergoing axial twists during manufacturing
as well as laying of the cables.
APPARATUS :-Mandrels equal the diameter of wire and fifteen times the thickness
of the strip i.e 12 mm. 0.5 mm
TEST SAMPLE :- Sample shall be a piece of wire 200 mm long cut from the outer end
of the coil after discarding a minimum length of 300 mm.
PROCEDURE :-
The test specimen shall be wound in a closed helix (minimum three turns) around a cylindrical
mandrel having a diameter 15 times the nominal diameter of wire, keeping the vaulted side of the
wire outside and subsequent straightened.
PERFORMANCE :-
The wire should withstand without breaking or splitting on being wrapped and
subsequently straightened.


KEI INDUSTRIES LIMITED

ANNEXURE-16-MASS OF ZINC COATING ON STEEL ARMOUR
SIGNIFICANCE :- This test is carried out to ascertain whether requisite amount of zinc
has been deposited on the material by finding the mass of the zinc
coating.
APPARATUS :-Weighing balance having least count 0.01 gram. Beaker 500 ml &
Micrometer 0.01 mm LC
TEST SAMPLE :- Wire/strip sample not less than 250 mm .In case of smaller sizes of
wire, mass of the sample shall be not less than the diameter of the wire
in mm multiplied by four as a guide to the length of wire.
PREPARATION OF TEST SOLUTION :-Dissolve 20 grams of antimony trioxide or 32 grams of
antimony trichloride in one litre of concentrated hydrochloric acid
STRIPPING SOLUTION :-By adding and mixing well 5 ml of the antimony chloride solution to
every 100 ml hydrochloric acid.
PROCEDURE :-The sample to be cleaned in a organic solvent i.e trychloroethylene and then by
spirit/alcohol and dried thoroughly.
Weigh the clean test piece to 0.01 gms. The sample to be bent or coiled to complete immersion in
the test solution. Immerse the sample in the convient volume of stripping solution until the
evolution of hydrogen ceases. Take out the specimen, wash in running water, wipe off well with
clean soft cotton cloth, dry it fully and weigh the stripped specimen to the nearest 0.01 gms.
In case of wire, the diameter of the wire shall also be taken to the nearest 0.01 mm by taking the
avg. measurement.
FORMULA FOR CALCULATION :-
For round wires :- Mass of Zn coating in gm/m
2
: ( M
1
-M
2
/M
2
) x d x 1965
For steel strip :- Mass of Zn coating in gm/m
2
: ( M
1
-M
2
/M
2
) x K
K 2571 for 4x 0.8 mm size & 4383 for 6.1 x 1.4 mm size
For tapes :- Mass of Zn coating in gm/m
2
: ( M
1
-M
2
/A

) x 10
6
M
1
Mass of original sample M
2


Mass of stripped solution
d- Dia of stripped wire A- Coated area of original test specimen
PERFORMANCE :-
The wire/strip should meet the requirement of the relevant standard.

KEI INDUSTRIES LIMITED
ANNEXURE-18-PRESSURE TEST AT HIGH TEMPERATURE
SIGNIFICANCE :- Sheaths tends to soften when exposed to a high temp.over a sufficient period.
In that condition when they are subjected to mechanical pressure they
have the tendency to get deform resulting in reduction in thickness which
will impair their functional utility. This test is carried out to check
whether they have sufficient resistance to such deformation.

TEST SAMPLES :- For each core to be tested , three adjacent pieces shall be taken from a
sample having a length of 250 mm to 500 mm. the length of each pieces shall
be 50 mm to 100 mm.

TEST APPARATUS :- Indentation Device (heating oven. Hot pressure test apparatus with
loading weights and a varnier caliper having least count 0.01 mm)
TEST PROCEDURE:- 1) The test specimens are placed on the pressure test apparatus. the force
is applied perpendicular to the axis of the test specimen and the blade shall also be perpendicular
to the axis of the pin or tube. The formula for calculation of force is:
F = k 2 D * t - t
2


Where D is the mean diameter over sheath or insulation and diameter over laid up cores in
case of sector shaped cores.t is the average thickness of the test specimen. k is the constant
value of which is as follows.
k= 0.6 for flexible cords and flexible cables and cables for fixed installations where dia of core or
sheath is upto 10 mm.
k= 0.6 (where dia of core or sheath is less than or equal to 15 mm ) for fixed installation.
k= 0.7 (wher dia of core or sheath is greater than 15 mm) for fixed installations.
The calculated force is rounded off downwards by not more than 3%.
2) The specimen is kept in a heating oven at the specified temperature and for the period in the
relevant applicable standard.
3) After the specified period is over the specimens are taken out of the oven and cooled in cold
water.
4) The thickness on the point of impression and at a distance of about 10mm on both sides of the
impression is measured.
CALCULATION %age thickness retained = T
1
/ T
2
* 100
Where T
1
= thickness at the point of impression (indentation)
T
2
=Thickness at the point 10 mm away from the impression.

PERFORMANCE :-

The test specimen should meet the requirements given in BS: 7655-6.1


KEI INDUSTRIES LIMITED

ANNEXURE-19-COLD IMPACT TEST
SIGNIFICANCE :-This test is carried out to ascertain the suitability or withstand ability of the
thermoplastic insulating or sheathing materials at low temperature or frost
conditions.
This is an alternative test to cold bend test which is considered impracticable
for insulation or sheath whose dia. is larger than 12 mm.
TEST SAMPLE :- Specimen of complete cable or core with conductor in place 10 cm long.
APPARATUS :- Electrically operated thermostatically controlled cold chamber. A plain
testing anvil ( Plate having 10 mm thickness and 1 kg weight) , pipe (Inside
dia 16 mm and length 30 cm) and cylindrical hammer (200 gm in weight and
13 mm in dia. radius of curvature 300 mm)
PROCEDURE :-
1. The test specimen with anvil and hammer are kept in the cold chamber at the specified
temperature in the relevant specification for a period of not less than 2 hrs. and not more
than 3 hrs.
2. The specimen shall rest on the testing anvil throughout their whole length.
3. At the end of the period the sample is struck once in the center by the falling hammer
dropped from a height of 30 cm through the cylindrical pipe.
The test specimen immediately after cold impact treatment are to be examined for any cracks
or scales visible to the naked eyes.
PERFORMANCE :-
There should not be any cracks or scales.







KEI INDUSTRIES LIMITED



ANNEXURE-20-BENDING TEST
SIGNIFICANCE :-this test is carried out to ascertain the suitability or with standability of the
sheath at low temperature or frost conditions.
This test is applicable to specimen of diameter up to and including 12.5
mm.
TEST SAMPLE :- Specimen of complete cable or core (without any covering) with conductor
in place with sufficient length (150 times the dia. of specimen approx.)
APPARATUS :- Electrically operated thermostatically controlled cold chamber. Smooth
metal mandrels of circular cross section.
PROCEDURE :-
1. The apparatus with the test piece in position shall be maintained in the refrigerator at the
specified temp for the period of not less than 16h. the cooling period of 16 h includes the
time necessary for cooling down the apparatus.
If the apparatus has been pre cooled, a shorter cooling period is permissible but not less
than 4 h provided that the sample have attained the prescribed test temperature.
2. At the end of the specified period and immediately after removal from cold chamber test
specimen shall be wound round the mandrel.
3. The specimen still on the mandrel shall be examined for any cracks or scales visible to the
unaided eyes.
PERFORMANCE :-
There should not be any cracks or scales.







KEI INDUSTRIES LIMITED



ANNEXURE-21-COLD ELONGATION TEST
SIGNIFICANCE :-this test is carried out to ascertain the suitability or with standability of the
thermoplastic insulating or sheathing materials at low temperature or
frost conditions.
This test is applicable to specimen of diameter up to and including 12.5
mm.

TEST SAMPLE :- Each sheath to be tested shall be represented by two samples of suitable
length
APPARATUS :- The test shall be carried out on a normal tensile machine provided with a
cooling device or on a tensile machine installed in a cooling chamber ,
using a liquid as the refrigerant, the conditioning time shall be not less
than 10 min at the specified test temperature. If liquid mixture is used for
cooling, it shall not impair the insulation or sheathing material.
PROCEDURE :-
1. After any covering has been removed , the sheath shall be cut open in the direction of the
axis, after which the cores and fillers and others internal parts (if any) shall be removed.
2. Two dumb-bells from each sample shall be punched in the direction of the axis of each
sample, if possible two dumb-bells shall be punched side by side.
3. The tensile apparatus shall be of non-self tightening type, in both pre-cooled grips , the
dumb-bells shall be champed over the same length , the free length between the grips shall
be about 30 mm for both type of dumb-bells if the direct measurement of the distance
between the marker lines is to be made during the test.
4. The speed of separation of the grips of the tensile machine shall be 25 5mm/min.
5. The elongation shall be determined by measuring the distance between line, if possible or
between the grips at the moment of rapture.
PERFORMANCE :-
The minimum elongation without break shall be confirming to BS: 7846.


KEI INDUSTRIES LIMITED

ANNEXURE-22-TEAR RESISTANCE TEST
SIGNIFICANCE :-This test is carried out to ensure that the sheath has requisite strength to
withstand mechanical stresses while in service.
TEST SAMPLE :-The test specimen shall be cut from the sheath of the cable with the help of
the die. If required the sheath should be grinded to remove irregularties
before preparing the specimen. The thickness of the specimen should not
be more than 4.0mm and not less than 1.0 mm.
APPARATUS :- Tensile testing machine, sample cutting die & vernier caliper.
PROCEDURE :-
1. The thickness of the specimen is measured and the specimen should be conditioned at 27
deg. C for a period of not less than 3 hrs .
2. Test shall be made within 5 minutes of removing the specimen from the conditioning
chamber.
3. The halves of the split of the specimen are placed in the jaws of the tensile testing machine
and the jaws separated at the rate of 350 to 500 mm/minute till the specimen has been
ruptured.
4. The breaking load is noted down and the tear resistance is calculated as the formula given
below :-
Tear Resistance (N/mm) = Breaking Load/ Thickness of specimen.
PERFORMANCE :-
The sample should meet the requirement of the relevant applicable standard.







KEI INDUSTRIES LIMITED



ANNEXURE-23-OXYGEN/ TEMPRATURE INDEX
SIGNIFICANCE :- This test gives the indication of the flame resistance propagation. The
higher the oxygen index the higher the fire resistance.
TEST SPECIMEN :- Test specimen of flat rectangular type having 6.5 0.5mm width and
3.0 0.5mm thickness or the specimen having its original thickness are
prepared. Length shall be 70 to 150mm.
APPARATUS :- Oxygen Index. Test Apparatus with temperature controller and oxygen
and nitrogen cylinders.
PROCEDURE :-
1. The instrument is calibrated by setting zero while pouring nitrogen in the column and
by setting 100 while pouring oxygen in the column. Gas flow rate in the coloumn shall
be 10.6 litres/min.
2. The specimen is mounted on the specimen holding unit. The mixture of nitrogen and
oxygen is poured and the desired percentage of oxygen content are set on the oxygen
analyzer. Gas flow rate in the coloumn shall be 10.6 litres/min.
3. The ignition flame is applied till the specimen has burnt. If the specimen burns for
three minutes or longer or for a length of 50mm, the specimen shall be extinguished and
the concentration of oxygen shall be recorded.
4. If the specimen stops burning before three minutes or before 50mm concentration of
oxygen shall be taken as being low. In that case increase oxygen concentration and burn
the sample again. Repeat the process until the exact concentration of oxygen at which
the specimen burns either for 3minutes or 50mm is found out.
5. Four values are taken at different temperatures by setting the temperature of the
column through temperature controller and graph is extrapolated to find out the exact
temperature index (critical oxygen index).
PERFORMANCE :-
The min. oxygen index shall be 30% and temp. index 280 deg.c or as per the requirement of
the customer.



KEI INDUSTRIES LIMITED

ANNEXURE-24-SMOKE DENSITY RATING
SIGNIFICANCE :-
The assessment of smoke for evaluating the behavior of one or more burning electric cable assemblies
under fire conditions

TEST SAMPLES :- Length of cable 1000 50 mm to be straightened.

No. of samples.: Outer dia. Of cable(D) No. of samples
>40 1
2O<D<40 2
10<ll<20 3

APPARATUS :- As per IEC-1034-1/BS EN 50268-2

TEST PROCEDURE:-
1.Clean the windows of the photometric system thoroughly.

2 Connect the computer with the instrument and turn on the photometric lamp. Set 100% light
transmission of the photometric system

3 Lay the samples in horizontal position and centered above the tray.

4 Set the description of the sample and the recording time of values on the computer.Pour 1 Litre 0.01
Litre of alcohol (ethanol-90 1 %,methanol-4 1%, water-6 1%)in the fuel trey .

5.Ignite the alcohol in the fuel trey start the air circulation ,close the door and also start the scanning of
values on the computer immediately.

6. Run the test up to there is no decrease in light transmission for 5 minutes during the period
after the fire source has extinguished or when the test duration reaches 40 minutes.

7 Record the minimum light transmittance.

8.After each test clean the windows of the photometric system to regain 100% light transmission.

PERFORMANCE :-
1. Record the minimum light transmittance which should not be less than 80%.
KEI INDUSTRIES LIMITED

ANNEXURE-25-CORROSIVE AND ACID GAS GENERATION

SIGNIFICANCE :- This test is carried out to check the amount of halogen acid gas evolved
during burning of cables which signifies the extent of corrosion that a
compound is capable of causing in an environment.

TEST SAMPLES :- As per IEC-754-2/BS 7655(6.1) 1000 mg 5 mg is weighed with
the help of an analytical balance having an accuracy of 0.1 mg from
the material to be tested. It shall be cut into small pieces.

APPARATUS :- As per IEC-754-2/BS 7655 (6.1)

TEST PROCEDURE:-
1. Clean the instrument thoroughly.
2. The weighed sample shall be evenly distributed put in a combustion boat.
3. Attach a wash bottle containing 1000 10 ml demineralized or distilled water having
pH value between 5 and 7 and conductivity less than 1,0 micro S/mm
4. Set the air flow rate between 200 to 300 LPM and keep constant during the test.
5. Set the temperature of the tube at 935 deg .c which is measured by a thermocouple placed
inside the tube in the middle of the furnace.
6. Insert the boat containing test pieces quickly inside the effective zone of the tube and
start the timer.
7. Continue the combustion procedure under the air flow for 30 minutes in the furnace.
8. After the test disconnect the wash bottle from the tube and the contents of the wash bottle
to be made upto 1000 ml.
PERFORMANCE :-

1. The pH value of the is determined by the help of a pH meter at room temp. by means
of a pH meter and it should not be less than 4.3 when related to 1 litre of water.
2. The value of conductivity should not exceed 10 micro S/mm when measured by means of a
conductivity meter.
3. If the above two requirements are met that means the material under testing has the
halogen and corrosive gases less than 0.5%
KEI INDUSTRIES LIMITED

ANNEXURE-26-FLAMMABILITY TEST (IEEE-383)
SIGNIFICANCE :- The propagation of flame does not take place even if its outer
covering and insulation have been destroyed in the area of flame
impingement where there are a number of cables are in service.

TEST SAMPLES :- Sample of 8 feet from the completed cable are taken.

APPARATUS :- The vertical tray configuration is recommended as the best arrangement to
establish whether or not a cable could propagate a fire. The tray should be vertical, metal, ladder
type,3 in deep, 12 in wide and 8 feet long. The tray may be bolted at the bottom to a length of
horizontal tray for support.

Ignition source :- Ribbon type gas burner shall be mounted horizontally such that the flame
impinges on the specimen midway between the tray rungs, so that the burner face is 3 in behind
and approximately 2 feet above the bottom of the vertical tray. The flame temp should be
approximately 1500
0
F when measured by a thermocouple located in the flame close to but not
touching the surface of the test specimen.
The pressure of the gas shall be 0.9 0.1 cm of water when measured at the supply side of the
venturi mixer. The air pressure shall be 5.60.5 cm of water measured at the air inlet.

Mounting of the sample :- Multiple lengths of cable should be arranged in a single layer
filling at least the center six inch portion of the tray with a separation
of approx. the cable diameter between each cable.

TEST PROCEDURE :-
Mount the samples on the ladder. Ignite the burner and allow it to burn for 20 minutes. Record
temperature at point of impingement throughout the duration of the test, length of time flame
continues to burn after gas burner is shut off, jacket char distance and distance insulation is
damaged.

PERFORMANCE :-
The test specimen should not be charred upto the total height of the sample.





KEI INDUSTRIES LIMITED

ANNEXURE-27-FLAMMABILITY TEST(IEC60332-1)

SIGNIFICANCE :- This test is carried out to verify that a cable retards flame in case of
fire and it is self-extinguishing when the source of fire is removed.

TEST SPECIMEN :- The test specimen of 60025mm long is taken from the complete cable.

APPARATUS :- Test chamber and burner as per IEC 60332-1),Stop watch, Scale ( L.C-
0.5mm)

PROCEDURE :-
1. Weigh the sample and calculate the time of burning with the following formula.
T=60+m/25
Where m= mass in grams of the cable sample corrected to a 600 mm length.

2. The sample is clamped vertically and positioned in the middle of the test chamber.
3. The source of heat should be a burner and it is arranged at 45
0
C and at 475 mm from the
bottom edge of top clamp.
4. Where the dia. of cable is greater than 50 mm two burners are applied in opposite the
direction.
5. The flame is applied for a continuous calculated period of T seconds.
6. After removal of the flame the period of burning of cable shall be noted.
7. After all burning has ceased, the surface of the sample shall be wiped clean, and the
distance between top of charred or affected portion from lower edge of top clamp shall
be measured.
PERFORMANCE :-
The test specimen should meet the requirements given in IEC60332-1






KEI INDUSTRIES LIMITED

ANNEXURE-28-ABRASION TEST
SIGNIFICANCE :- To ascertain the integrity of the extruded sheath when subjected to
abrasive wear during laying of the cables.
TEST SAMPLES :- A sample of approx. one meter of finished cable is taken.

APPARATUS :- As per BS:7846

TEST PROCEDURE :-
1. Place the sample straight and horizontal on the firm base under the mild steel blade at
right angle.
2. Calculate the force and apply.
FORCE CALCULATION
Overall dia of cable(mm) Force(N)
Above 10 up to 20 15
Above 20 up to 30 35
Above 30 up to 40 65
Above 40 up to 50 105
Above 50 up to 60 155
Above 60 up to 70 210
Above 70 up to 80 270
3. Drag the steel blade along the cable for a distance not less than 600 mm at a speed of
between 150 mm/s and 300 mm/s.
4. Reverse the direction of movement at the end of each pass to give 50 passes,25 in each
direction over the 600 mm test path.

PERFORMANCE :-

1. There should not any cracks or splits when examined without magnification reveals after
the test.

KEI INDUSTRIES LIMITED

ANNEXURE-29-COMPATIBILITY TEST

SIGNIFICANCE :-
This test is intended to determine whether the Insulation & Sheath are likely to deteriorate due to contact
with the outer component in the cable.

TEST SAMPLE :- Three pieces of complete cable about 200 mm long shall be taken, preferably froi
position close to that from which the samples for the tensile test without ageing

APPARATUS :- Thermostatically controlled with controlled air flow (Rate of change of air flow 8 to 20
changes per hr.), Ageing oven, Tensile testing machine, Dumb-bell cutting die, Instrument to measure
thickness to an accuracy of 0.01 mm.


PROCEDURE

I. The pieces of cable shall be suspended vertically and substantially in the middle of the oven at
least 20 mm away from any other piece and shall not occupy more than 2% of the volume of the oven

2. Age the test pieces for 7 days at (100 2 C) in the air oven.

3. Place a sheet of clean white blotting paper under each test piece in the oven to detect any
exudation which may drip from the cable

4. After completion of the ageing test, measure the tensile strength and elongation at break of the
insulation and sheath.

PERFORMANCE :-

Insulation & sheath shall conform to the requirement given in RS: 7846 & at the end of the test
period in oven, the blotting paper shall be free of strains.

KEI INDUSTRIES LIMITED

ANNEXURE-30-FIRE RESISTANCE TEST
SIGNIFICANCE :- The assessment of performance of the cable required to maintain
circuit integrity (ability to continue to operate in the designated
manner whilst subjected to a flame source for a specified period) when
subjected to fire conditions.
TEST SAMPLES :- As per BS:6387/ IEC-60331-Part-21- 1200mm length samples is taken
from finished cable & 100 mm of insulation, sheath and outer
coverings are removed at each end for electrical connection.
EQUIPMENT :- Test Rig :- Test rig comprising of a stand and two metal rings to
hold and support the sample at the middle portion as per the reference
standard.
Source of Electric supply A 3-Phase star connected transformer is used to supply the required
voltage as per the reference standard.
Ignition source :- Ribbon type gas burner used with L.P.G fuel .
Deviations in methodology:-The standard requires a air flow rate of 80+/-5 L/Min. and propane
gas flow rate of 5.0+/-0.25 litres/ min. In India, Propane Gas source is
not as commercially available as in Europe and America. The gross
Calorific value of Propane is approx. 2516 BTU/cu. ft ( 88.85
BTU/Litre) thereby requiring a flow rate of 5.0 L/minute .The fuel
which is commonly available in India is LPG( A mix. of Propane,
Butane and Propylene). The gross calorific value of LPG is 122 BTU/ L
which is more than gross calorific value of Propane. This requires a
flow rate of 3.62 L/ minute.
The detailed calculation for Gas:
Required 5 litre/Min.
5.0 Ltr/Min.*88.85BTU/Litre / 122 BTU/Litre = 3.64 Litre/ Minutes
Mounting of the sample :- The test samples is mounted on the supporting equipment with the
metal rings providing the support at the middle as per ref standard.
TEST PROCEDURE:-
Burner position :- The burner is positioned such that it is horizontally 70 +/-10mm
blow the lowest point of the test sample and approximately 45 mm
from the central vertical plane of the test sample.
Time of application of the flame & Test Voltage :- The test voltage of 1100Volts & Flame is
applied continuously for 3 hrs. at 950 deg.c, after which the flame is
extinguished but the cable is energized for a further 15 Min.

PERFORMANCE :-
Requirement :- I) The voltage is maintained and there should be no fuse failure.
II) The conductor should not rupture, i.e. the lamp should not extinguished.


KEI INDUSTRIES LIMITED

ANNEXURE-31 INSULATION RESISTANCE
SIGNIFICANCE :-It is desirable to have the insulation resistance as high as possible
consistent with acceptable mechanical, chemical and heat resisting
properties. This test is to detect the conductive impurities or mechanical
imperfections in the dielectric which affects the quality of the cable
which may be developed in the dielectric during the manufacturing
process.
TEST SAMPLE :-Sample of minimum three meters is taken and all the coverings upon the
cores
are removed. In case of multi core cables 5 cores taken from the finished cable shall be used.
APPARATUS :- Million Meg. Ohm Meter.
PROCEDURE :-
1. The sample is immersed in water at ambient temperature. Duration of immersion is
one hour.
2. The test specimen is connected to the million meg ohm meter. The conductor is
connected to the high voltage terminal and the screen/armour or water bath is earthed.
3. The value is taken after 1 minute of electrification of meg ohm meter. Similarly values
are also taken at elevated temperature.
CALCULATION:-
Volume resistivity = 2 L R / Log e (D/d)
R = measured insulation resistance
L = Length of the cable
D = Outer diameter of insulation
d = Inner diameter of insulation
Insulation resistance constant = L x R x 10
-11
/ Log10 (D/d)
= 10
-11
x 0.367 x Volume resistivity
PERFORMANCE :-
The corrected value should not exceed the appropriate values given in the
IS:5831-1984/IS:7098(Pt-1)-1988/BS:7655-1.3/BS:7655-3.1.
KEI INDUSTRIES LIMITED



ANNEXURE-32-INSULATION RESISTANCE CONSTANT
SIGNIFICANCE:-
It is desirable to have the insulation resistance as high as possible consistent with acceptable
mechanical, chemical and heat resisting properties. This test is to detect the conductive impurities
or mechanical imperfections in the dielectric which affects the quality of the cable which may be
developed in the dielectric during the manufacturing process.

TEST SAMPLE:- Sample of minimum Five meters of complete cable

APPARATUS :- Supply, Voltmeter, Suitable switch, Bath Tub, Galvanometer, Standard
resistance & Electronic Meg. Ohm meter (million).

PROCEDURE
1.The sample is immersed in water at (20 5 C). Duration of immersion is 12 h to 16 h, having a
length of about 250mm at each end projecting above the water.

2.Immediately after the conditioning period , immerse the core in water at ( 902
o
C)

3.After immersion for (120 10 min), test specimen is connected to the million meg ohm meter.
Apply a voltage of between 300Vand 500V (dc), between the conductor and the water.

4.The value is taken after 1 minute of electrification of meg ohm meter.
CALCULATION:-
Insulation Resistance Constant (K) = I R / 1000 * Log
10
(D/(d)
R = Insulation resistance of the length of the cable (MOhm)
I= Immersed length of the cable (m)
D = Outer diameter of Sheath (mm)
d = Diameter over armour (mm)
PERFORMANCE :-
The corrected value should not be less than the appropriate values given in the BS: 7655(1.3).

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