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SPECIFICATION OF CABLES

1.

CABLE

1.1 General
This specification covers the design, manufacturer, factory tests, supply and
delivery of all powers, controls and instrumentation cables required for the entire
project.
1.2
1.2.1

Equipment to be furnished
The following cables shall be furnished in accordance with IEC publication
502 1983:
(a)
(b)
(c)
(d)

12 kV power cable
600 volt power cable
Control and instrumentation cable
Communication cable

1.2.2 The contractor shall be responsible for estimating and supplying the quantity
of various types and sizes of the cables. In course of actual execution if it is found that
additional cross-sections, types or quantities of cables are required than those indicated in
his proposal, the same shall be supplied without any additional charge to the employer.
The 12 kV major power cables required are attached as ANNEX to this section.
1.3

Design Requirements

1.3.1

12 kV power cable

(a) General
The 12 kV power cable shall be cross linked polyethylene insulated (XLPE),
screened and armored cable.
(b) Conductor
Conductor shall consist of stranded annealed copper wires. They shall comply
with IEC Publication. The maximum conductor temperature shall be 90 C.
(c) Current rating
The maximum current rating for the cable routes and conditions of installation
shall be stated for 12 kV power cable by the contractor.
(d) Anti-termite covering
Anti-termite protection shall be applied to the cable and shall consist of either a
non-magnetic metallic barrier or layer of nylon sheathing.

(e) Outer covering


The outer covering of the cable shall be extruded, continuous black PVC suitable
for the operating temperature of cable and shall meet the requirements of IEC
standard.
(f) Cable drum
Cable drum shall be non-returnable and shall be made of timber, pressure
impregnated against fungal and insect attack. Alternatively cable drum may be
made of steel suitable protected against corrosion.
(g) Outdoor and indoor termination
Outdoor and indoor terminations may be proposed under two forms i.e.:
1. Premolded terminations (Raychem/Denson make)
2. Taped terminations
Terminations for cables shall be provided in sufficient quantities for complete
installations of substations
.
(h) Jointing accessories
Cables shall be installed in maximum possible lengths and straight through
jointing between shorter lengths will not be permitted without the prior written
approval from the Client/Engineer. Jointing accessories for stranded copper
conductor cables shall be designed for indentation ferrules
(i) Voltage identification
The plastic over sheath shall be embossed with the name of the manufacturer,
number of conductors, the cross sections, and type of insulations followed by:
Electric cable 12,000 volts
(j) Phase identification
Phase identification for either triplexed or multiconductor cable shall be in
accordance with follows:
(a) Phase A (R) : Red
(b) Phase B (S) : Yellow
(c) Phase C (T) : Blue
1.3.2. 600 volt power cable
(a) General
The low voltage cables shall be 600V grade polyethylene (PE) insulated and
PVC sheathed. Low voltage AC power systems will be solid grounded neutral
with phase to phase voltage level of 400V and phase to neutral voltage of
230V AC system and 110V DC system.

(b) Conductor
Conductor shall consist of stranded annealed copper wires. They shall comply
with IEC publication. The cable is intended for use at normal conductor
operating temperatures not exceeding 75 C.
(c) Insulation
The electrically and thermally stable polyethylene insulation (PE) shall be
extruded onto the conductor so as to prevent contamination and voids in the
insulation.
(d) Current rating
The maximum continuous current rating for the cable routes and conditions of
installation shall be stated for low voltage power cable by the contractor.
(e) Jacket
The cable core assembly shall be covered with a flame retardative and
moisture resistant PVC jacket which is free-stripping from the insulation. The
overall jacket shall be clean, dry, and free of grease and shall be suitable for
ink or paint application.
(f) Anti-termite covering
Anti-termite protection shall be applied to the cable and shall consist of either
a non-magnetic metallic barrier or layer of nylon sheathing.
(g) Identification
(1) Each cable shall have a printed legend on the overall jacket with a
manufacturers name, voltage class, the number and size of
conductors, type of insulation.
(2) The colors for core identification and color sequence shall be in
accordance with fallows
- Single-core : Black
- Twin
: Red and black
- Three-core : Red, Yellow and Blue
- Four-core : Red, Yellow, Blue and black
1.3.3

Control and instrumentation cable


(a) General
All control and instrumentation cable shall be 600V grade as per IEC
multi conductor, color coded, PVC insulated armored cable. Each multicore cable shall have not less than 20 percent or 4 spare cores whichever is
the greater.
(b) Conductor

Copper conductor shall be stranded circular non-compacted copper


conductor of minimum cross-section of 2.5 sq. mm.
(c) Insulation
The electrically and thermally stable PVC insulation shall be extruded
onto the conductor so as to prevent contamination and voids in the
insulation.
(d) Assembly
(1) Multi-conductor cables shall be assembled in accordance with
applicable IEC standard.
(2) A flame retardate binder tape may be used underneath the overall
jacket of multiconductor cables, if required to achieve the desired flame
retardative characteristics. Tapes, if used, shall be non hygroscopic.
(e) Jacket
(1) The cable core assembly shall be covered with a flame retardative and
resistant jacket which is free-stripping from the insulation.
(2) The overall jacket shall be clean, dry and free of grease and shall be
suitable for ink or paint application.
(3) Cable jacketing and the interstices within the jacket shall be free of
water. Evidence of water shall be grounds for rejection of cables.
(f) Anti-termite covering
Anti-termite protection shall be applied to the cable and shall consist of
either a non-magnetic metallic barrier or layer of nylon sheathing.
(g) Identification
Each cable shall have a printed legend on the overall jacket, with the
manufacturers name, voltage class, the number and size of conductors,
and a unique number or code indicating the production run on batch. The
identification shall remain legible for the life of the cable.
1.3.4. Communication cable
(a) All cables and wirings shall have copper conductors and PVC
insulation and shall comply with IEC.
(b) Each communication cable shall be have not less than 20 percentage or
spare twisted pairs whichever is the greater. Cabling and wiring
installations shall be arranged to minimize the risk of fire and damage
which might be caused in the event of fire.

(c) For telephone type cables, conductor wires of less than 0.6 sq. mm.
shall not be used. Where twin or quad make up is required in any cable,
the cores shall be uniformly twisted and the lays arranged such that
crosstalk is reduced to a minimum.
(d) No conductor smaller than 32/0.2mm (1 sq. mm), or having less than
three strands shall be used for interconnecting cabling except in the case of
telephone extensions. All cables shall have insulation which will withstand
the highest temperature to be experienced in service.
(e) Each conductor of a multicore cable shall be readily identified by a
number marker tape or, in the case of telephone type cables, color
insulation.
1.4.1

Special Requirements
Small cut piece lengths of cable will not be accepted. Cables up to 500 meters in
length or approved by Client/Engineer shall be of one length shipped in a drum of
adequate size. For higher quantities, multiple lengths/drums may be shipped
subject to the approval of Client/Engineer.

1.5 Drawings, Data & Manuals


The following information shall be furnished along with the Tender.
(a) Manufacturers leaflets giving constructional details, dimension and
characteristics of different cables.
(b) Current rating of cables including de-rating factor due to grouping, ambient
temperature and type of various installation.
(c) Write-up with sketches illustrating the manufacturers recommendation for
splicing, jointing and termination of different types of cables.
(d) Type test report of all types of power, control and instrument cables. The Tenderer
shall clearly describe the type and routine tests to be performed on cables.
(e) Drum length for each type of cable.
1.6 Tests
1.6.1

Routine and design tests


Routine test in accordance with the provisions of Test requirements in
IEC standard Publication 502 1983 shall be carried out for each drum
of cable.
Type test (both electrical and non-electrical) and Electrical tests after
installation as per IEC publication 502, Section Three article 16,17 and 18
shall have to be carried out to prove the general qualities and design of a

given type of cable and for the purpose of acceptance of the lot. The test
certificate shall be approved by Owner/Engineer before shipment.
The following tests shall be included in the routine test by the
manufacturer at the factory as minimum requirements for this
specification:
(a)
(b)
(c)
(d)
(e)

Construction inspection
Conductor resistance test
High voltage test
Insulation resistance test
Physical and aging test for insulation and jacket

1.6.2. Field tests


After installation at site, cables shall be subjected but not limited to the following
tests:
(a) Measurement of insulation resistance
(b) DC dielectric test
1.7

Performance guarantee
The performance figures quoted on schedule of Technical Data shall be
guaranteed within the tolerance permitted by relevant standards and shall become
a part of the contract. In case of failure of the cables to meet the guarantee, the
employer reserves the right to reject the equipment. The contractor shall have to
rectify the defect at no extra cost to the employer and without delaying the
commissioning schedule.

ANNEX

(12 kV XLPE - Power cables for - SUHEP)


1. From each Generator terminals in KIOSK to 12 kV VCB in MV Room in
P/H 1 run of 400 sq. mm; 3 core Armored Cu Cable.
2. From each Generator terminals in KIOSK to Excitation panel in P/H - 2
runs of 16 sq. mm; 2 core Armored Cu Cable
3. From 12 kV VCB panel in MV Room to 3x4.25 MVA; 11/66 kV Single
phase Power Transformers in Switchyard 2x3 runs of 500 sq. mm; 1 core
Armored Cu Cable.
4. From Single phase Power transformers 11 kV terminals; in making Delta
connections on 11 kV side 3x1 run of 500 sq. mm; 1 core Armored Cu
Cable.
5. From 12 kV VCB panel in MV Room to 1 MVA; 11/11 kV, Isolating
transformer (Delta side) in Switchyard 1 run of 25 sq. mm; 3 core
Armored Cu Cable.
6. From 12 kV VCB panel in MV Room to 250 kVA; 11/0.4 kV, 3 phase Dry
Type Station Service transformer in the P/H 1 run of 25 sq. mm; 3 core
Armored Cu Cable.
7. From 12 kV VCB panel in MV Room to Outgoing feeder line; first pole
(200 kVA; 11/0.4 kV, 3 phase Head works transformer) 1 run of 25 sq.
mm; 3 core Armored Cu Cable.
8. From each Generator Neutral to NGR panel 1x2 runs of 16 sq. mm; 1
core Armored Cu Cable.
9. From Isolating Transformer (Y- Side) Neutral to Grounding 1 run of 25
sq. mm; 1 core Armored Cu Cable.
10. From Isolating Transformer (Y- Side) Terminals to segregated 12 kV VCB
panel in MV room 1 run of 25 sq. mm; 3 core Armored Cu Cable.
11. From Generator 1 and 2 (Y- Side) Terminals to segregated 12 kV Dynamic
Braking panels in line with NGR Cubicle 2 runs of 35 sq. mm; 3 core
Armored Cu Cable.