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: TECHINCAL SPECIFICATION FOR H.T.POWER CABLE AND ACESSORIES












TECHNICAL SPECIFICATION
FOR
H.T.POWER CABLE
AND ACCESSORIES




REV.
NO.

CONCEPT ENGINEERING
PROJECTS PVT. LTD.
DOCUMENT NO. : CEPL/SPEC/EL/DOC14

DESCRIPTION

CEPL/SPEC/EL/DOC14

TOTAL SHEETS :

REV. 0
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CONTENTS


1.0

2.0

SCOPE...3

SERVICE CONDITION.....3

3.0
CODES & STANDARDS..4

4.0
GENERAL CONSTRUCTION.....5

5.0
DESIGN CRITERIA..6

6.0
TECHNICAL REQUIREMENT....7

7.0
CABLE SELECTION & SIZING..11

8.0
CABLE ACCESSORIES...12

9.0
INSPECTION,TESTING AND ACCEPANCE..........12

10.0 PACKING AND DESPATCH....18

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1.0

2.0

3.0

SCOPE
This specification along with data sheets covers requirements for design, manufacture,
Testing at work and supply of XLPE insulated FRLS Aluminium Medium & High Voltage
cables and Cable Jointing/Termination Accessories for medium and High Voltage
System.

Abbreviations:

ASTM
:
American Society for Testing and Materials
BIS

:
Bureau Of Indian Standards.
BS

:
British Standard
IS

:
Indian Standard
IEC

:
International Electro technical Commission
NEMA
:
National Electrical Manufacturers Association

EPR
:
Ethylene Propylene Rubber
FR

:
Flame Retardant
HR PVC :
Heat Resistance Polyvinyl Chloride
PVC
:
Polyvinyl Chloride
UV

:
Ultra Violet
XLPE
:
Crosslinked Polyethylene

SERVICE CONDITION
The Equipment to be supplied against this specification shall be suitable for satisfactory
continuous operation under the following tropical conditions.

i) Ambient Temp.
50 C






ii) Humidity

95%






iii) Max. Wind Pressure
150KMPH

iv) Rain fall

50mm/hr

v) Temperature

33C


CODES & STANDARDS

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: TECHINCAL SPECIFICATION FOR H.T.POWER CABLE AND ACESSORIES

All standards, specifications and codes of practice referred to herein shall be the latest
editions including all applicable official amendments and revisions as on date of
opening of bid. All the cables and cables jointing & termination accessories shall
conform to the requirements of the following standards and codes :
IS:7098 (Part II)

Specification for Crosslinked polyethylene insulated PVC sheathed


cables. PartII: For working voltages from 3.3 KV upto and including
33 KV.

IS : 3975

Low Carbon Galvanized steel wires, formed wires and tapes for
armouring of cables.

IS : 4905

Methods for random sampling.

IS : 5831

PVC insulation and sheath of electrical cables.

IS : 8130

Conductors for insulated electrical cables and flexible cords.

IS : 10418

Specification for drums for electric cables.

IS : 10810

Methods of tests for cables.

IS:3961(PartI)

Recommended current ratings for cables:part2 PVC Insulated


and PVC sheathed heavyduty cables.


IS : 6380 Specification for Elastomeric Insulation and sheath of E

Electric cables.
IS:10462(Part1)
IS : 209

IS : 13573

Fictitious calculation method for determination of dimension of


protective coverings of cables: Part1 Electrometric and
thermoplastic insulation cables.
Specification for Zinc.
Joints and termination for polymeric cables for working Voltages
from 6.6KV up to and including 33KV.



IEC: 227

PVC insulated electric cables

IEC: 183

Guide for selection of HV cables

IEC: 885

Electric test methods for electric cables

IEC: 12381

Power cables

IEC: 6033121

Test for electric cable under fire conditions circuit integrity


Procedures and requirements Cables of rated voltage up and
including 0.3/1.0KV.


IEC: 603323 Test on electric cables under fire conditions.
IEC754 (PartI)
CEPL/SPEC/EL/DOC14

Tests on gases evolved during combustion of electric cables.


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: TECHINCAL SPECIFICATION FOR H.T.POWER CABLE AND ACESSORIES

IEC332

NEMAWC70

Tests on electric cables under fire conditions. Part3: Tests on bunched


wires or cables (CategoryB).

Standard for Non Shielded Power cables rated 2000V or less for
the distribution of Electrical energy.


NEMAWC53

Standard test, methods for Extruded dielectric Power, Control,


Instrumentation and portable cables for test.

DIN53387

Artificial weathering and ageing of plastics and elastomers by


exposure to filtered xenon are radiation.



BS: 7846

Electric cable600/100V armoured fire resistance cables having


thermosetting insulation and low emission of smoke and corrosive
gases when affected by fire.


ASTMD 2843 Standard test method for density of smoke from the burning or
decomposition of plastics.

The cables and accessories shall also confirm to the provisions of Indian Electric Rule
and other statutory regulations, as applicable.

In case of any contradiction between various referred Standard /specification /data


sheet and statutory regulations, the following order of priority shall govern:

Statutory regulations
Data Sheets
Job Specifications
This Specification
Code and Standards.


4.00 GENERAL CONSTRUCTION

4.01 The cables shall be brand new and in good condition. These shall be suitable for laying
in trays, trenches, ducts, conduits and underground buried installation with
uncontrolled backfill and possibility of flooding by water and chemical. Extra PVC /
Rubber end caps for each XLPE Cable size shall be supplied.

4.02 Sequence marking of the length of the cable in meter shall be provided on the outer
sheath at every one meter.

The embossing/engraving shall be legible and indelible.

Cable identification: Cable identification shall be provided by embossing on every meter
on the outer sheath the following:

a)
Manufacturers name or trademark
b) Voltage grade
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4.03

4.04

4.05

c)
Year of manufacture
d) Type of insulation and outer sheath e.g. XLPE/HRPVC/FRLS as applicable.
e)
No. of core and size of cables.
f)
ISI Mark
g)
Word FRLS at every 5 meter (if applicable)
h)
Screen fault Current 300A for 2Sec.

The overall diameter of the cables shall be strictly as per the values declared by the
manufacturer in the technical information subject to a maximum tolerance of 2mm up
to overall diameter of 60mm and 3mm for beyond 60mm.

PVC/Rubber end caps shall be supplied free of cost for each drum with a minimum of
eight per thousand meter length. In addition, ends of the cables shall be properly sealed
with caps to avoid ingress of water during transportation and storage.

The cable meant to be used in mining area under the Jurisdiction of DGMS shall comply
with the requirements as specified in the job specification /Datasheet.

DESIGN CRITERIA

5.00

5.01.1 The cables will be used for connection of power circuits of the system. All the power
cabling as required and specified in Scope of cables shall be carried out by the
contractor. Actual cable sizes will be selected by the Contractor. Number of different
sizes selected will be kept to a minimum for optimization.

5.01.2 Cables shall be generally laid on ladder type cable trays or drawn through rigid steel
conduits.

5.01.3 For continuous operation at specified rating, maximum conductor temperature shall be
limited to the permissible value as per relevant standard and/or this specification.

5.01.4 The insulation and sheath materials shall be resistant to oil, acid and alkali and shall be
tough enough to withstand mechanical stresses during handling.

5.01.5 Armouring shall be single round wire / strip of galvanized steel for multi core cables
and aluminum for single core cable as per the relevant standards.

5.01.6 The outer sheath shall have fire resistant low smoke (FRLS) characteristics and shall
meet the requirements of additional tests specified for the purpose.

5.01.7 Core identification for multi core cable shall be provided by color coding.


5.01.8 Cables shall be so designed and manufactured that no damage occurs during handling,
transit, storage, installation under any operative conditions which they may be
subjected to.

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5.01.9 HT XLPE FRLS power cables shall be manufactured by triple extrusion dry cure (CCV)
process using nitrogen.

5.1.10 Minimum value of volume resistivity for XLPE insulation shall be 1.0 x 1014 ohmscm at
27 C and 1.0x1012 ohmscm at 90 C.

5.1.11 Maximum continuous operating temperature shall be 90 C under normal operation and
250 C under short circuit condition.

5.1.12 The fire survival cable shall meet the following additional requirements:

i)
The insulation shall be of EPR or equivalent material with glass mica tape below
or above insulation.
ii)
Unless otherwise specified the cable shall meet requirement of circuit integrity
test for a minimum period of 3 hours at max. Temperature of 950 C.
5.1.13 All cables shall meet the fire resistance requirement as per categoryB of IEC
332 (Part3).

5.1.14 The eccentricity of the core shall not exceed 10% and ovality not to exceed 2%.
The eccentricity shall be calculated as :
tmax tmin
x 100
t max
and the ovality shall be calculated as
dmax dmin
x 100
d max
Where tmax/tmin is the maximum/minimum thickness of insulation and dmax/d
min is the maximum / minimum diameter of the core.
***************************************************************************************
6.00

TECHNICAL REQUIREMENT
All High voltage cables for use on high voltage system shall be heavyduty type, 3.3kv up
to 33KV systems and with stranded Aluminium/copper conductor, Conductor Screened
with Extruded semiconducting compound, XLPE Insulated, Insulation Screened with
extruded semiconducting compound with copper tape (0.3KA for one sec.), cores laid
up, inner sheath of PVC tape, galvanized steel flat strip armoured and Flame retardant
low smoke (FRLS) overall PVC sheathed cable designed to with stand all mechanical,
electrical and thermal stresses develop under steady state and transient operating
conditions.
Cable conforming to IS: 7098/II/85 with latest amendments unless specified otherwise
in data sheet.

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6.01 Conductor

6.01.1 Stranded, compacted circular aluminium conductor of H2 grade and conductor
flexibility class conforming to class2 of IS: 8130 (1984).

6.01.2 Aluminium conductor used in power cables shall have tensile strength of more than
100n/mm2. Conductor shall be multi stranded.

6.02 Conductor Screening


6.02.1 All cables rated 3.8/6.6 kV and above shall be provided with both conductor screening
and insulation screening. The conductors shall be provided with nonmetallic extruded
semi conducting screen.

6.02.2 The metallic screen of each core shall consist of copper wires or tape with minimum
overlap of 20%. However, for single core armoured cables, the armouring shall
constitute the metallic part of the screening. The metallic screen of each core shall be
capable of carrying the system earth fault current 300A for 2sec. Method of curing for
cables shall be "dry curing / gas curing / steam curing".

6.02.3 Cross linked semiconducting compound extruded in the same operation as the
insulation.

6.03 Insulation

6.03.1 The core shall be with Cross linked polyethylene (XLPE) compound dry cured applied
over the conductor by extrusion over screed conductor.

6.03.2 It shall be free from voids and shall withstand all mechanical and thermal stresses
under steady state transient operating conditions. It shall confirm to the properties
given in Table1 of IS 7098(part2)/

6.03.3 The Thickness of insulation and the tolerance on thickness of insulation shall be as per
Table 2 of IS: 7098(Part2).

6.03.4 Cross linked polyethylene (XLPE) insulation shall be suitable for continuous conductor
temperature of 90 Deg. C and short circuit conductor temperature of 250 Deg. C,
overload conductor temperature of 130 Deg. C.

6.04 Insulation Screening

The insulation screen shall consist of non metallic extruded semiconducting compound
in combination with non magnetic metallic copper screen not less than 0.1mm. Unless
specified otherwise, the copper screen for all the three cores together shall be capable of
carrying the single line to ground fault current value and the duration specified in the
data sheet.

6.05 Core Identification
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6.05.1 Three (3) core cables, core identification shall not be done with different colouring of
XLPE insulation, but with natural colour with coloured strips applied on the cores or by
numerals printing on the cores.

6.05.2 Cores of the cables of upto 5 cores shall be identified by colouring of insulation.
Following colour scheme shall be adopted.
1 core Red, Black, Yellow or Blue
2 core Red & Black
3 core Red, Yellow & Blue
4 core Red, Yellow, Blue and Black
6.06

6.07
6.07.1

6.07.2
6.07.3
6.07.4
6.07.5

6.08
6.08.1

Laying up of cores:

Cores shall be laid up together as per IS 7098 Part 2 (1985).
Inner Sheath

The inner sheath shall be applied over the laidup cores by extrusion and shall be
HRPVC compound inner sheath confirming to type ST2 of IS: 5831/1984. Such inner
sheath shall be provided by pressure extrusion process with filler.
The minimum thickness of inner sheath shall be as per IS 7098 Part2 (1985)

In Single core cables, there shall be extruded inner sheath between insulation metallic
screen and armouring..

Distinct extruded PVC inner sheath of black colour as per IS 5831 shall be provided for
all cables.

The Thickness of insulation and the tolerance on thickness of insulation shall be as per
Table 2 of IS: 7098(Part2).

The cable cores shall be laid up with fillers between the cores wherever necessary. It
shall not stick to insulation and inner sheath. All the cables, other than single core
unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per
IS: 5831.

Armour

Unless otherwise specified all cables shall be provided with armour. for multicore
cables, the armour shall be by single round galvanised steel wires the calculated
diameter below armouring does not exceed 13mm and by galvanised steel strips where
this dimension is greater than 13 mm. Requirement and methods of tests for armour
material and uniformity of galvanization shall be as per IS3975 and IS10810(Part
41).The dimension of armour shall be as per method (b) of IS 7098 (Part2).

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6.08.2 For three (3) core cables: Single galvanized steel strip armor conforming to IS: 3975 /
1988.



6.08.3 For Single Core Cables:
Armour shall be of Non magnetic material consisting of single hard drawn aluminum
round wires conforming to H4 grade of IS: 8130 / 1984.

For single line core armoured cables, armouring shall be of aluminium wires. For
multicore armoured cables armouring shall be of galvanised steel as follows:

Calculated nominal dia of cable under
armour

Size and Type of armour

i)

Upto 13 mm

1.4mm dia GS wire

ii)

Above 13 & upto 25mm

0.8 mm thick GS formed wire/1.6 mm dia


GS wire

iii)

Above 25 & upto 40 mm

0.8mm thick GS formed wire/2.0mm dia GS


wire

iv)

Above 40 & upto 55mm

1.4 mm thick GS formed wire/2.5mm dia


GS wire

v)

Above 55 & upto 70mm

1.4 mm thick GS formed wire/3.15mm dia


GS wire

vi)

Above 70mm

1.4 mm thick GS formed wire/4.0 mm dia


GS wire

6.08.4 The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum
resistivity of 0.028264 ohmsq.mm/mtr at 20 deg.C. The types and sizes of aluminium
armouring shall be same as mentioned for galvanised steel above.

6.08.5 The gap between armour wires / formed wires shall not exceed one armour wire /
formed wire space and there shall be no cross over / overriding of armour wires /
formed wires. The minimum area of coverage of armouring shall be 90%. The breaking
load of armour joint shall not be less than 95% of that of armour wire / formed wire.
Zinc rich paint shall be applied on armour joint surface of GS wires/formed wires.
For mining cables, the size and type of armour shall be such that the combined
conductance of armour shall equivalent to 75 % of the conductance of largest conductor
of the cable.

6.08.6 For mining cables, the size and type of armour shall be such that the combined
conductance of armour shall equivalent to 75 % of the conductance of largest
conductor of the cable.

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6.09 Outer Sheath




6.09.1 The outer sheath for the cables shall be applied by extrusion and shall be of HRPVC
FRLS compound conforming to the requirements of type ST2 compound as per IS:
5831/1984 shall be provided over armour.
6.09.2 All cables covered in this specification shall be flame retardant (FR) unless specified
otherwise in the data sheet. The outer sheath of cables shall possess flame propagation
properties meeting requirements as per IS 10810 (Part62) category AF.

6.09.3 The minimum and average thickness of iouter sheath for unarmoured cables and
minimum thickness of outer sheath for armoured cables shall be as per


IS : 7098 (Part2).

6.09.4 Outer sheath shall be of PVC black in colour. In addition to meeting all the requirements
of Indian standards referred to, outer sheath of all the cables shall have the following
FRLS properties.
(a.) Oxygen index of min. 29 (Test method as per IS 10810 Part58)
(b.) Acid gas emission of max. 20% as per IEC754 (PartI)
(c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per
ASTMD2843.

6.10

7.0

Discharge free construction:



Inner conductor shielding/screening, XLPE insulation and outer core shielding
/screening shall be extruded in one operation by special process (i.e. triple extrusion
dry cure process) to ensure that the insulation is free from contamination and voids and
perfect bonding of inner and outer shielding with insulation is achieved. The bidders are
requested to elaborate the manufacturing technique adopted by their manufacturers to
achieve this motive.


CABLE SELECTION & SIZING

HT Power cables shall be sized based on the following considerations:

a)
Rated current of the equipment

b)
The voltage drop in the cable, during motor starting condition shall be limited to
10% and during full load running condition it shall be limited to 3% of the rated
voltage. And for welding and hoisting cable voltage drop shall be 15% during
running and starting shall be 5%.

c)
Short circuit withstand capability

Derating Factors

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Derating factors for various conditions of installations including the following shall be
considered while selecting the cable sizes:

a)
Variation in ambient temperature for cables laid in air
b)
Grouping of cables
c)
Variation in ground temperature and soil resistivity for buried cables.

Cable lengths shall be considered in such a way that straight through cable joints is
avoided.

8.0
CABLE ACCESSORIES

8.0.1 The termination and straight through jointing kits for use on the systems shall be
suitable for the type of cables offered as per this specification and shall meet
requirements of IS 13573.

8.0.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the
manufacturers mark of origin.

8.0.3 The kit shall include all stress grading insulating and sealing materials apart from
conductor fittings and consumable items. An Installation instruction sheet shall also be
included in each Kit.

8.0.4 The contents of the accessories kit including all consumable shall be suitable for storage
without deterioration at a temperature of 45 C ,with shelf life extending to more than 5
years.

8.01 TERMINATING KITS

The terminating kits shall be suitable for termination of the cables to an indoor
switchgear or to a weatherproof cable box of an outdoor mounted transformer/motor.
For outdoor terminations, weather shields/sealing ends and any other accessories
required shall also form part of the kit. The terminating kits shall be from one of the
makes/types mentioned in the data sheet.

8.02 JOINTING KITS

The straight through joining kits shall be suitable for installation on overhead trays,
concrete lined trenches, and ducts and for underground burial with uncontrolled
backfill and possibility of flooding by water and chemicals. These shall have protected
against rodent and termite attack. The inner sheath similar to that provided for cables
shall be provided as part of straight through joint..The jointing kits shall be from one of
the makes/types mentioned in the data sheet.

9.0 INSPECTION, TESTING AND ACCEPTANCE

9.0.1 The cables shall be tested and inspected at the manufacturers works. All the materials
employed in the manufactures of the cable shall be subjected, both before and after
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manufacture, to examination, testing and approval by customer/Owner. Manufacture


shall furnish all necessary information concerning the supply to customer /Owner
inspectors. The inspector shall have free access to the manufacturers work for the
purpose of inspecting the process of manufacture in all its stages and he will have the
power to reject any materials, which appears to him to be of unsuitable description or of
unsatisfactory quality. The vendor shall give at least 2 week advance notice to the
purchaser, regarding the date of testing to enable him or his representative to witness
the test.

9.0.2 Type and acceptance tests shall be carried out on 1 drum selected on random basis, out
of every 10 or less number of drums of each type and size of cable of each lot. Size shall
mean area of cross section in sq.mm read in conjunction with the number of cores. Type
shall mean type of insulation, outer sheath, volt grade FRLS/FS etc.

9.0.3 All tests shall be witnessed by owners representative. All the standard Type, Routine &
acceptance tests as per IS or other relevant standards shall be witnessed by owners
representative.


9.01 TYPE, ROUTINE & ACCEPTANCE TESTS ON CABLE:

After completion of manufacture of cables, type, routine and acceptance tests shall be
performed strictly as per relevant IS & other applicable standards amended upto date.

9.01.1 ROUTINE TESTS:

The following tests shall be carried out as Routine tests on each and every drum
length of cable, as per IS 7098 (Part 2) / 1985.

a) High Voltage Test
b) Conductor Resistance Test
c) Partial discharge test (for screened cables) on full drum length.

9.01.2 ACCEPTANCE TEST:

The following test shall be carried out as Acceptance Test in the presence of MSPGCL
Inspecting Engineer on samples taken from the delivery lot. One drum out of every 10
number of drums or less shall be selected at random sampling basis in each lot for the
Acceptance Tests which shall be carried out at manufacturers /suppliers cost.
a) High Voltage Test
b) Conductor Resistance Test
c) Tensile / wrapping test.
d) Partial discharge test (In screened cables).
e) Insulation Resistance/Volume resistivity test
f)
Measurement of thickness of insulation and sheath and other dimensions
g) Tensile strength & elongation at break for insulation & sheath.
h) Hot set test on XLPE insulation
i)
Flammability test as per Swedish standard SS: 4241575 ClassF3 (Swedish
Chimney test)
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j)
k)
l)
m)

Acid gas generation test as per IEC7541.


Smoke density test as per ASTMD2843/1977
Oxygen index test as per ASTMD 2863/1977
Temp. index test as per ASTM2863/77


TYPE TESTS:

9.02

9.02.1 The type test as per applicable standards as given below shall be conducted on one
drum selected on random basis out of every 10 drums or less of each type and size of
cable (In presence of MSPGCL representative). In case, facilities of any of the type tests
are not available at the works of the supplier, then such type tests shall be carried out
by the supplier at independent recognized Govt. approved laboratory at the cost of
supplier.

9.02.2 Tensile test (for aluminium) as per IS: 8130

9.02.3 Wrapping test (for aluminium) as per IS: 8130
Note: In the case of compacted circular & shaped conductors these tests shall be
carried out before compacting/shaping for ensuring use of H2 grade aluminium.

9.02.4 Conductor Resistance test as per IS: 8130.

9.02.5 Test for armour wire/strip as per IS: 3975


9.02..6 Test for thickness of XLPE Insulation and HRPVC, FRLS sheath:
Requirements and methods of tests for the thickness of insulation,
outer sheath shall be as per IS: 7098 (Part2).

9.02.7 Tensile strength and elongation test for insulation & sheath:
This test shall be carried out as per IS: 7098 Part2 for XLPE cable.

9.02.8 Ageing test for insulation and sheath:
The method of test shall be as per the relevant IS standard. The period of test shall be
168 hours (7 days). At the end of the ageing period, the tensile strength and
elongation test shall be carried out as per Sr. No.(6) above. The value obtained must
not differ from the corresponding values obtained before ageing by more than + or
25% in case of XLPE compound.

9.02.9 Loss of mass test for HRPVC, FRLS sheath:
This test shall be carried out as per IS 583/1984 012 IEC 540 & IEC 502, on cables of
all voltage grades. The maximum permissible loss of mass is 2 mg/sq.cm for PVC.

9.02.10 Shrinkage test for XLPE insulation & HRPVC FRLS sheath:
This shall be carried out as per IS: 5831 1984 for sheathed and as per IS 7098 (Part
2) 1985 for XLPE insulation.

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9.02.11 Hot deformation test for HRPVC, FRLS sheath:


This shall be carried out as per IS: 5831 / 1984.

9.02.12 Cold Impact test for HRPVC, FRLS sheath:
This shall be carried out as per IS: 5831.

9.02.13 Heat shock test for HRPVC,FRLS sheath :
This test shall be carried out as per IS 5831 / 1984 and IEC 540 and
IEC 502 & sheath shall pass the requirements of this test.

9.02.14 Thermal stability test for HRPVC, FRLS sheath:
This test shall be carried out on cables as per IS 5831 / 1984 and IEC
540 and cables shall pass the minimum requirements of 80 minutes for sheath.

9.02.15 Hot set test for XLPE Insulation:
This test shall be carried out as per IS: 7098 Part1 and Part2 and cable shall pass the
requirements given therein.

9.02.16 Test for bleeding and blooming of Pigments for HRPVC, FRLS Sheath :

This shall be carried out as per IS: 5831 / 1984.

9.02.17 Fire Resistance Test
This test is compulsory and shall comply with the relevant clause of
applicable IS.

9.02.18 Partial Discharge Test for XLPE Cables:
The partial discharge test for XLPE insulation shall be carried out as
per IS:7098 (PartII).

9.02.19 Bending Test for XLPE Cables:
The test method and test requirement shall be as per IS: 7098 (PartII).
On completion of this test, the sample shall be subjected to partial
discharge measurement and comply with the requirements given in
above subclause 17.

9.02.20 Insulation Resistance / Volume resistivity
As per IS 7098 Part2 / 1985.

9.02.21 Dielectric Power Factor Test
As per IS 7098 Part2 / 1985.

9.02.22 Heating cycle test for XLPE Cables:
This test shall be as per IS: 7098 (PartII)

9.02.23 High Voltage Test
This test shall be performed as per the relevant Indian Standard 7098
Part 2 / 1985.
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9.02.24 Test for Rodent & Termite Repulsion Property of Sheath:
Test for Rodent and termite repulsion properties Test shall be conducted to note the
presence of rodent and termite repelling chemical in PVC compound. Normal
procedure is that a few chippings of PVC compound are slowly ignited in a porcelain
dish in a muffle furnace at about 600 C The resulting ignited ash is boiled with a
little ammonium acetate solution (10%). A drop of aqueous sodium sulphide solution
is placed on a thick filter paper and it is allowed to soak. The spot is touched with a
drop of above extract. A black spot indicates the presence of anti termite & rodent
compound.

9.02.25 Impulse Withstand Test
As per IS 7098 (2) (amended upto date).

9.02.26 Accelerated water absorption test for insulation: As per NEMAWC70 (for PVC
insulated cables) and as per NEMAWC53(for XLPE / EPR insulated cables). Test
certificates with respect to this test (not older than one year) from recognized testing
laboratory to be furnished for review by customer/owner before dispatch clearance
of cables. In case test certificates are not available, test is to be conducted by vendor at
his own cost in any recognized test laboratory or in house testing laboratory, before
dispatch clearance of cables. Sampling for this test is to be done randomly once for
each order, provided type of insulation remains same.

9.02.27 The normal sequence of the electrical tests shall be as per Clause 16.1.1 of IEC
502/1978 and / or as per IS 7098 Part 2 / 1985. All the tests listed herein shall be
applied successively to the same sample.

9.02.28 The inner sheath of the XLPE insulated cable shall be subjected to all the tests
applicable for PVC sheath as per IS 5831 / 1984.

The following special tests to be performed on the cables as per sampling plan. These
tests are required to be witnessed by customer/Owner before dispatch of cable.

9.03 SPECIAL TEST

9.03.1 Special Test on HRPVC FRLS materials
All the sizes of XLPE power cables of the FRLS HRPVC sheathed type shall pass
following special test requirements.

9.03.2 Oxygen/Temperature Index test on sheath material:
This test shall be carried out as per American National Std. ASTMD 2863/77. The
minimum oxygen index shall be 29 at room temperature. For determination of the
temp. Index, the oxygen index test shall be carried out at different temperature upto
250C. However, the test shall be carried out by extrapolation method beyond
temperature at which the material of sheath may start deformation. The min/ temp.
Index (i.e. the temperature at which the oxygen index is minimum 21) shall be 250C
generally as per BICC Hand Book Chap6.

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9.03.3 Acid gas emission test on sheath material:


This test shall be carried out as per IEC Std. 7541. The maximum acid gas emission
shall be less than 20 by weight.

9.03.4 Smoke density test on sheath material:
This test shall be carried out as per American National Standard ASTMD2843/1977
and also as per UITP method (3M cube test on finished cable sample). The ASTM test
method is compulsory. For passing this test, the requirement of light transmission
shall be minimum 40% after the test.

9.03.5 Flammability test on finished cable sample:
Flammability tests on finished cable as per the requirements of IEEE383, IEC3321
and Swedish standard SS 4241475 clause F3. Smoke generation by sheaths under fire
as per ASTM D 2843. The cables shall meet the requirements of light transmission of
minimum 40% after the test. The test shall be carried out by extrapolation method
beyond temperature at which the material of sheath may start deformation as per
BICC handbook chapter6 on cable in fire. Acid gas generation by sheaths under fire as
per IEC7541 and the minimum acid gas generation shall be less than 20% by weight.
Each type of cable shall also be subject to the following additional type test at works.

This test shall be carried out as per the following method:

Swedish Std.SS:4241475 ClassF3 This test known as Swedish Chimney test


is compulsory.

IEEE std. 3831974 This test known as the vertical tray flame propagation
test shall be conducted if insisted by purchaser.

IEC Std: 3321. The cable should meet the requirement of all the above
standards.

IS10810 (Part 61&62). The acceptance criteria for tests conducted shall be
as under.
Part61 The cable meets the requirement if there is no visible damage on the
test specimen within 300mm from its upper end.
Part62 The maximum extent of the charred portion measured on the test
sample should not have reached a height exceeding 2.5 m above the bottom
edge of the burner at the front of the ladder.

9.03.6 Test for Resistance to Ultra Violet Radiation:
This test shall be carried out as per DIN 53387 or ASTMG154 on outer sheath. The
retention value of Tensile strength and ultimate elongation after the test shall be
minimum 60% of tensile strength and ultimate elongation after the test shall be
minimum 60% of Tensile strength and ultimate elongation before the test. Test
certificates with respect to this test (not older than one year) from recognized testing
laboratory to be furnished for review by EIL before dispatch clearance of cables. In case
test certificates are not available, test is to be conducted by vendor at his own cost in
any recognized test laboratory or in house testing laboratory, before dispatch clearance
of cables. Sampling for this test is to be done randomly once for each order, provided
outer sheath remains same.

9.03.7 Accelerated water absorption test for insulation:
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As per NEMAWC70 (for PVC insulated cables) and as per NEMAWC53(for XLPE /
EPR insulated cables). Test certificates with respect to this test (not older than one
year) from recognized testing laboratory to be furnished for review by
customer/owner before dispatch clearance of cables. In case test certificates are not
available, test is to be conducted by vendor at his own cost in any recognized test
laboratory or in house testing laboratory, before dispatch clearance of cables. Sampling
for this test is to be done randomly once for each order, provided type of insulation
remains same.


9.03.8 Dielectric retention Test:

The dielectric strength of the cable insulation tested in accordance with NEMAWC70
at 75 1C shall not be less than 50% of the original dielectric. Strength (for PVC
insulation cables).Test certificates with respect to this test (not older than one year)
from recognized testing laboratory to be furnished for review by customer/owner
before dispatch clearance of cables. In case test certificates are not available, test is to
be conducted by vendor at his own cost in any recognized test laboratory or in house
testing laboratory, before dispatch clearance of cables. Sampling for this test is to be
done randomly once for each order.

9.04 TYPE TEST ON CABLE ACCESSORIES

Type test should have been carried out to prove the general qualities and design of a
given type of termination/jointing system as per IS13573.The type test certificates
from independent testing laboratory shall be submitted before dispatch.

10.0 PACKING AND MARKING


CABLE DRUM:

10.0.1 Cables shall be supplied in nonreturnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be covered
with waterproof cover. Both the ends of the cables shall be properly sealed with heat
shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water
during transportation, storage and erection. Wood preservative antitermite treatment
shall be applied to the entire drum. Wooden drums shall comply with IS: 10418.

10.0.2 Each drum shall carry manufacturer's name, purchasers name, address and contract
number, item number and type, size and length of cable and net gross weight stenciled
on both sides of the drum. A tag containing same information shall be attached to the
leading end of the cable. An arrow and suitable accompanying wording shall be marked
on one end of the reel indicating the direction in which it should be rolled.

10.0.3 The standard drum length for power cables shall not be less than 500 meters. The
length per drum shall be subjected to a maximum tolerance of +/ 5% of the standard
drum length. Approval from Owner shall be obtained for supplying cable drum with
shorter lengths.

10.0.4 Unless otherwise specified, cables shall be supplied in drum lengths as follows:
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MV Cables



: 1000 m
Multicore Power cables up to 6 mm2
2
Multicore Power cables from 10mm up to 300mm

: 500 m
Single Core Power cable up to 630 mm2

: 1000 m
Control Cables up to 61 Cores




: 1000 m

HV Power Cable Up to 11kV (E) Grade


: 500 m
Three Core cable up to 400 mm2
Single Core cables up to 400 mm2


: 1000 m
Single Core cables above 400 mm2 and up to 630mm2
: 750 m

HV Power Cables above 11kV (E) Grade and up to 33kV (E) Grade

: 350 m
Three Core cables up to 300 mm2 grade
Single Core cables up to 400mm2


: 1000 m
2
2
Single Core cables above 400 mm and up to 1000mm : 500 m

A tolerance of 3 % shall be permissible for drum. However overall tolerance on each size of
cable shall be limited to 2 % .Offers with short /nonstandard lengths are liable for rejection. If
nostandard drum lengths are specified in the data sheet, the same shall be supplied.





























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ANNEXUREI


Following is the list of HT Cables required:

3.8/6.6 KV (E) HT XLPE Three core Aluminium Conductor Cables.

Three Core Aluminium Conductor, XLPE Insulated, and Unarmoured & strip Armoured,
FRLS Cables conforming to IS: 7098 Part2/1985.

Sr.
Nominal Size of
Qty.
Unit
No.
Conductor
1
3 x 35 Sq.mm.
0
Mtrs.
2
3 x 50 Sq.mm.
0
Mtrs.
3
3 x 70 Sq.mm.
0
Mtrs.
4
3 x 95 Sq.mm.
0
Mtrs.
5
3 x 120 Sq.mm.
0
Mtrs.
6
3 x 150 Sq.mm.
0
Mtrs.
8
3 x 185 Sq.mm.
0
Mtrs.
9
3 x 240 Sq.mm.
0
Mtrs.
10
3 x 300 Sq.mm.
0
Mtrs.
11
3 x 400 Sq.mm.
0
Mtrs.

6.35/11 KV (E) HT XLPE Three core Aluminium Conductor Cables.

Three Core Aluminium Conductor, XLPE Insulated, and Unarmoured & strip Armoured,
FRLS Cables conforming to IS: 7098 Part2/1985.

Sr.
Nominal Size of
Qty.
Unit
No.
Conductor
1
3 x 35 Sq.mm.
0
Mtrs.
2
3 x 50 Sq.mm.
0
Mtrs.
3
3 x 70 Sq.mm.
0
Mtrs.
4
3 x 95 Sq.mm.
0
Mtrs.
5
3 x 120 Sq.mm.
0
Mtrs.
6
3 x 150 Sq.mm.
0
Mtrs.
8
3 x 185 Sq.mm.
0
Mtrs.
9
3 x 240 Sq.mm.
0
Mtrs.
10
3 x 300 Sq.mm.
0
Mtrs.
11
3 x 400 Sq.mm.
0
Mtrs.

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