Rajasthan Northern Area Development

Project General

Power, Control and Instrument Cables

DECO-RX-E-SP-2002

Mustang Project Number 11338

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C3 October 18, 2007 Re-issued for construction SLK
C2 July 20,2007 Re-issued for construction JME SLK MA RSB
C1 July 19, 2006 Issued for Construction JME TGS SLK HPK HSN
81 April 18, 2006 Issued for Implementation JME TGS HPK SLK GHH HW
A2 March 10, 2006 Issued for Team Review SLK TGS HPK
Revision Date Description Prepared Checked Approved
 , Rajasthan Northern Area Development - Project General Document Number
Power, Control and Instrument Cables DECO-RX-E-SP-2002

TABLE OF CONTENTS
1.0 SCOPE ............ . .......... 3
2.0 DEFINITION OF TERMS ..... 3
3.0 STANDARDS ................ . ........................ 3
3.1 ....................................... 3
Bureau of Indian Standards (BIS or IS) ................. ..
3.2 International Electro-technical Commission (IEC) Standards ................... . ......... 3
3.3 British Standards (BS) for instrument cables ....... A
3.4 Regulations ............................. .. .... A
4.0 DESIGN CHARACTERiSTiCS ...................... . ......... A
4.1 Site Conditions .......................... .. .. ....... A
4.2 GeneraL... ............. .. ......... . ............ ............ A
4.3 High Voltage Power Cables: ....... 5
4.4 Low Voltage Power Cables: ........... 5
4.5 Control Cables: ......................... . ...... 6
4.6 Fire Resistant Power Cables ...... .. ...... 6
4.7 Instrument Cables ............................................... .. . ..... 6
5.0 QUALITY ASSURANCE AND SHIPMENT .................................... .. .......................... 8
5.1 Quality Requirements .................. . . ... 8
5.2 Cable Drums .. ...8
6.0 INSPECTION & TESTING. .. 9
6.1 Inspection ..................................................... .. ......... 9
6.2 Type Tests ........... .. ........ 9
6.3 Routine Tests .. ... 10
6.4 Acceptance Tests ............................ .. .... 10
6.5 Short Circuit Tests ............ . .. .. 10
7.0 VENDOR DOCUMENTATION .................. .. .10

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Rajasthan Northern Area Development - Project General Document Number
Power, Control and Instrument Cables DECO-RX-E-SP-2002
Revision I C3

1.0 SCOPE
This specification covers design, engineering, procurement of materials, manufacture, factory testing,
packing & forwarding, transportation and delivery at site of the following cables:

a. Single/multi core power cables from 660/1100V up to 33kV

b. 660V/1100V multi conductor control cables

c. Bundled pair and triad instrument cables

2.0 DEFINITION OF TERMS

2.1.1 Within this specification the following definitions shall apply:

2.1.2 COMPANY - The COMPANY means Cairn Energy India Pty Limited, and its subsidiaries or authorized
representatives.

2.1.3 VENDOR - The VENDOR is the party that manufactures and supplies equipment and services to perform
the duties specified by the COMPANY.

3.0 STANDARDS
3.1 Bureau of Indian Standards (BIS or IS)

a. IS 694 PVC insulated cables for working voltages up to and including 11 OOV

b. IS 1255 Code of practice for installation and maintenance of power cables upto and
including 33kV rating

c. IS 1554 PVC insulated (heavy duty) electric cables

d. IS 3961 Recommended current ratings for cables

e. IS 5831 PVC insulation and sheath of electric cables

f. IS 7098 Part 1 & 2 Cross linked polyethylene insulated PVC sheathed cables

g. IS 8130 Conductors for insulated electric cables and flexible cords

h. IS 10418 Drums for electric cables

i. IS 10810 Methods of tests for cables

j. OISD RP 149 Oil Industry Safety Directorate Recommended Practice for design aspects for
safety in electrical system

3.2 International Electro-technical Commission (IEC) Standards

a. IEC60227 PVC Insulated Cables of Rated Voltage up to and including 450/750V.

b. IEC60228 Conductors of insulated cables

c. IEC60229 Tests on cable over sheaths with special protective function

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Power, Control and Instrument Cables DECO-RX-E-SP-2002
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d. IEC60287 Electric cables- Calculation of current rating

e. IEC 60331-31 Test for electric cables under fire conditions - Circuit integrity - Part 31
Procedures and requirements for fire with shock - Cables of rated voltage up
to and including 0,6/1 kV

f IEC 60332 Tests for electric cables under fire conditions

g. IEC60502 Power cables with extruded insulation and their accessories for rated voltages
from 1kV up to 30kV

3.3 British Standards (BS) for instrument cables

a. BS 5308-1 Instrumentation Cables. Specification for Polyethylene Insulated Cables.

b. BS 5308-2 Instrumentation Cables. Specification for PVC Insulated Cables.

c. BS 7846 Electric Cables. 600/1 OOV Armoured Fire Resistant Cables having
Thermosetting Insulation and Low Emission of Smoke and Corrosive Gases
when affected by Fire.

3.4 Regulations

3.4.1 The equipment shall be in conformance to the statutory regulations as per COMPANY document DECO-
RX-PM-SOW-0024.

3.4.2 All cables shall be of a type already tested by Central Mining Research Institute (CMRI), Dhanbad and
approved by Chief Controller of Explosives (CCE)/Directorate General of Mines Safety (DGMS)I
Directorate General Factory Advice Service & Labour Institute (DGFASLI), as required, for use in
specified gas group locations. BIS marking is mandatory

3.4.3 In case cables to be used are type tested by other reputed agencies outside India, the vendor shall
approach applicable statutory bodies specified above and get it approved by them for use in the specified
area of utilisation prior to bidding.

4.0 DESIGN CHARACTERISTICS

4.1 Site Conditions

4.1.1 Cables shall be designed for rated performance at extreme site conditions as specified in Project General
Information Sheets (DECO-RX-J-SP-2002)

4.2 General

4.2.1 The cables suitable for both direct buried and cable tray installation in high ambient climate.

4.2.2 Maximum conductor cross section area for multi core cables is 300mm 2 and 630mm 2 for single core.
2 2
4.2.3 Minimum conductor size for power is 4mm and 2.5mm for lighting and control.

4.2.4 The cable voltages ratings for various systems with'ln the plant shall be as follows:

a. 19/33kV (Uo/U) rated high voltage (HV) cables for 33kV (Earthed) system

DECO-RX-E-SP-2002
 Rajasthan Northern Area Development - Project General Document Number
Power, Control and Instrument Cables DECO-RX-E-SP-2002

b. 11/11 kV (Uo/U) rated high voltage (HV) cables for 11 kV (Unearthed) system

c. 6.6/6.6kV (Uo/U) rated high voltage (HV) cables for 6.6kV (Unearthed) system

d. 1.1kV rated low voltage (LV) power cables for 415V system

e. 660V rated low voltage (LV) power and control cables for 240/230V system

f. 300/500V rated low voltage (LV) 'Instrument cables for motor sensors

4.2.5 Outer sheath of all cables used shall have the following properties

a. It shall be flame retardant type conforming to category AF as per IS: 10810

b. The cable shall have a low smoke property. The minimum Oxygen Index shall be 29 per IS :
10810-58

c. Outer sheath shall be moisture and UV resistant as per IS: 10810 IIEC 60229

d. Fire resistant properties of cables shall be as per IEC 60331-31

4.2.6 Short circuit withstand capabilities of cable shall be as follows:

a. 33kV outgoing cables 16kA for 0.5 Sec

b. 11 kV incom ing and outgoing cables 50kA for 0.5 Sec

c. 6.6kV incoming and outgoing cables (circuit breaker protected) 40kA for 0.5 Sec

d. 1.1 kV power cable between PMCCs, if any 65kA for 1 Sec

2
e. 6.6kV and 1.1kV cables protected by fuses shall be able to withstand the maximum 1t let
through energy of fuse.

4.3 High Voltage Power Cables:

4.3.1 Multi-core power cables will be of stranded copper conductor, conductor screening, XLPE insulation and
semi-conductor insulation screening formed by triple extrusion process, copper screening, extruded PVC
inner sheathed (ST2), galvanized steel wire armoured, overall flame retardant low smoke (FRLS), UV
resistant extruded PVC sheathed (ST2)

4.3.2 Single core power cables will be of stranded copper conductor, conductor screening, XLPE 'Insulation and
semi-conductor insulation screening formed by triple extrusion process, aluminium wire armoured, overall
FRLS, UV resistant extruded PVC sheathed (ST2) cables
0
4.3.3 Rated for continuous operation at 90 C conductor temperature.

4.3.4 Core identification of multi-core cables is by coloured strip applied on the core.

4.4 Low Voltage Power Cables:

4.4.1 Multicore power cables will be of stranded copper conductor, XLPE insulated, extruded PVC inner
sheathed (ST2), galvanized steel wire armoured, overall FRLS, UV resistant extruded PVC sheathed
(ST2)

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Power, Control and Instrument Cables DECO-RX-E-SP-2002

4.4.2 Single core power cables will be of stranded copper conductor, XLPE insulated, aluminium wire
armoured, overall FRLS, UV resistant extruded PVC sheathed (ST2) cables

4.4.3 Lighting cables will be of stranded copper conductor, PVC insulated (Type A), extruded PVC inner
sheathed (ST1), galvanised steel wire armoured, overall FRLS, UV resistant extruded PVC sheathed
(ST1 ).

4.4.4 For street lighting, 3C1 Omm' cable shall be used.

4.4.5 Color coding to new harmonized core identification:

a. Black (1 core)

b. Red-Black (2 cores)

c. Red-Yellow-Blue (3 cores)

d. Red-Yellow-Blue-Black (4 cores)

e. Red-Yellow-Blue-Black-Grey (5 cores)

4.5 Control Cables:

4.5.1 Control cables will be of single core copper conductor, PVC insulated (Type A), extruded PVC inner
sheathed (ST1), galvanised steel wire armoured, overall FRLS, UV resistant extruded PVC sheathed
(ST1)

Core identification shall be colour coded as per IS 694 I IEC 60227

4.6 Fire Resistant Power Cables

4.6.1 Fire resistant cables will be of multi core copper conductor, Mica tape with overlap as fire resistant layer
Extruded XLPE insulated per IEC 60092-351, Braid of copper wires designed to act as collective screen,
overall Fire Resistant, UV resistant Extruded orange halogen free polyolefine, SHF1 sheath as per
60092-359.

4.6.2 The cables shall be tested for fire resistant properties 750°C for 3 hours tested as per IEC 60331-31

4.6.3 Core identification of multi-core cables is by coloured strip applied on the core as per IS 694 I IEC 60227

4.7 Instrument Cables

4.7.1 Type 1 - Flame Retardant Paired Tray Cables for PCS, PECS or Telecom service

a. .75, 1.5 and 2.5 mm', BS5308 Part 1 Type 2, IEC 60332-3, plain stranded copper, XLPE insulated,
twisted pairs, LSOH inner jacket, SWA, LSOH black outer jacket (blue for IS applications),
300/500V, 90"C rating.

b. Single Pairs will have overall screen only.

c. Multipairs will be 2, 5, 10, 20, 30 or 50 sets with individual and overall screens.

d. Pair Identification: blue-black numbered.

4.7.2 Type 2 - Flame Retardant Triad Tray Cables for PCS, PECS or Telecom service

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Rajasthan Northern Area Development - Project General Document Number
Power, Control and Instrument Cables DECO-RX-E-SP-2002
Revision I C3

a. . 75 or 1.5 mm', BS5308 Part 1 Type 2, IEC 60332-3, plain stranded copper, XLPE insulated, twisted
triads, LSOH inner jacket, SWA, LSOH black outer jacket (blue for IS applications), 300/500V, 90°C
rating.

b. Single Triads will have overall screen only.

c. Multitriads will be 5, 10 or 20 sets with individual and overall screen.

d. Triad Identification: blue-brown-black numbered.

4.7.3 Type 3 - Fire Resistant Paired Tray Cables for ESD or FGS service, tested in accordance with IEC
60331-31 (750°C for three hours).

a. .75, 1.5 and 2.5 mm', BS5308 Part 1 Type 2plain stranded copper, XLPE insulated, twisted pairs,
LSOH inner jacket, SWA, LSOH black outer jacket (blue for IS applications), 300/500V, 90°C rating.

b. Single Pairs will have overall screen only.

c. Multipairs will be 2, 5, 10, 20, 30 or 50 sets with individual and overall screens.

d. Pair Identification: blue-black numbered.

4.7.4 Type 4 - Fire Resistant Triad Tray Cables for ESD or FGS service, tested in accordance with IEC 60331-
31 (750°C for three hours)

a. .75 or 1.5 mm', BS5308 Part 1 Type 2 plain stranded copper, XLPE insulated, twisted triads, LSOH
inner jacket, SWA, LSOH black outer jacket (blue for IS applications), 300/500V, 90°C rating.

b. S'lngle Triads will have overall screen only.

c. Multitriads will be 5, 10 or 20 sets with individual and overall screen.

d. Triad Identification: blue-brown-black numbered.

4.7.5 Type 5 - Flame Retardant Paired Direct Burial Cables for PCS, PECS or Telecom service

a. 1.5 and 2.5 mm', BS5308 Part 2 Type 3, IEC 60332-3, plain stranded copper, XLPE insulated,
twisted pairs, PVC inner jacket, Lead Jacket, SWA, PVC black outer jacket (blue for IS applications),
300/500V, 90°C rating.

b. Single Pairs will have overall screen only.

c. Multipairs will be 2, 5, 10, 20, 30 or 50 sets with individual and overall screens.

d. Pair Identification: blue-black numbered.

4.7.6 Type 6 - Flame Retardant Triad Direct Burial Cables for PCS, PECS or Telecom service
2
a. 1.5 and 2.5 mm , BS5308 Part 2 Type 3, IEC 60332-3, plain stranded copper, XLPE insulated,
twisted triads, PVC inner jacket, Lead Jacket, SWA, PVC black outer jacket (blue for IS applications),
300/500V, 90°C rating.

b. Single Triads will have overall screen only.

c. Multitriads will be 5, 10 or 20 sets with individual and overall screen.

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d. Triad Identification: blue-brawn-black numbered.

4.7.7 Type 7 - Fire Resistant Paired Direct Burial Cables for ESD or FGS service, tested in accordance with
IEC 60331-31 (750°C for three hours).
2
a. 1.5 and 2.5 mm , BS5308 Part 2 Type 3 plain stranded copper, XLPE insulated, twisted pairs, PVC
inner jacket, Lead Jacket, SWA, PVC black outer jacket (blue for IS applications), 300/500V, 90°C
rating.

b. Single Pairs will have overall screen only.

c. Multipairs will be 2, 5, 10, 20, 30 or 50 sets with individual and overall screens.

d. Pair Identification: blue-black numbered.

4.7.8 Type 8 - Fire Resistant Triad Direct Burial Cables for ESD or FGS service, tested in accordance with IEC
60331-31 (750°C for three hours).

a. 1.5 and 2.5 mm', BS5308 Part 2 Type 3 plain stranded copper, XLPE insulated, twisted triads, PVC
inner jacket, Lead Jacket, SWA, PVC black outer jacket (blue for IS applications), 300/50DV, 90°C
rating.

b. Single Triads will have overall screen only.

c. Multitriads will be 5, 10 or 20 sets with individual and overall screen.

d. Triad Identification: blue-brawn-black numbered.

5.0 QUALITY ASSURANCE AND SHIPMENT

5.1 Quality Requirements

5.1.1 The tolerance in the length of cables shall be as per BIS. For instrumentation cables, it shall be as per BS.

5.1.2 All cables shall be of single continuous lengths, as far as possible.

5.1.3 Splices by VENDOR are not acceptable in individual cores of multi core cable.

5.1.4 Ends of the cables on each reel shall be sealed, in order to prevent entrance of moisture during shipment
or outdoor storage at site.

5.1.5 In addition to the details required as per BIS, the cable outer sheath shall be marked with the cable's
progressive length at every metre (zero point being the cable end at its inner coil on the cable drum) in
addition to the details required as per BIS.

5.2 Cable Drums

5.2.1 The cable drums shall comply in all respects as per IS: 10418.

5.2.2 Cables shall be supplied in non-returnable, new wooden drums.

5.2.3 Cable drums shall be so constructed as to have required mechanical strength so that the drum flanges
and other components do not break during transport, in actual use or in storage.

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5.2.4 The flanges and the outside surface of the barrel shall be free from protruding materials or projections or
unevenness capable of damaging the cable or hands of operator during rotation of drums.

5.2.5 Drum identification labels shall be attached to the outside & inside flanges of each cable drum with the
following details:

a. Reference of Indian Standard.

b. ISI certification mark

c. Drum identification number

d. Type of cable and voltage grade

e. Number of Cores and Cross sectional area

f. Cable quantity (metres)

g. Number of lengths on drum (if more than one).

h. P.O number and item number

i. Total weight of cable drum (kg)

j. VENDOR's name

k. Year of Manufacture

I. Direction of rotation of drum (by means or an arrow).

m. VENDOR's stock code number

6.0 INSPECTION & TESTING

6.1 Inspection

6.1.1 The COMPANY reserves the right to inspect cable manufacturing at various stages.

6.1.2 The VENDOR shall give 14 days advance notice of the date when the type f routines tests are to be
carried out to enable the COMPANY's representative to witness these tests.

6.2 Type Tests

6.2.1 The VENDOR shall furnish type test certificates for each type and voltage grade of cables along with the
bid for COMPANY's review. Type test performed beyond 5 years are not acceptable.

6.2.2 Type tests are required to be carried out from the first lot of supply on a sample of anyone size of cable
ordered for each voltage grade. All the tests in accordance with latest revision of relevant BIS flEC and
BS (for instrument cables), shall be performed on cable samples drawn by the COMPANY's
representative and will be witnessed by him.

6.2.3 In case facilities of any of any of the type test are not available at the works of the VENDOR, then the
VENDOR shall carry out such type test at the independent recognized laboratory at his own cost.

6.2.4 Type test certificates for these cables shall be furnished by the VENDOR.

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6.3 Routine Tests

6.3.1 All routine tests as per latest revision of relevant BIS / IEC and BS (for instrument cables) shall be carried
out on each and every delivery length of cable. The result shall be given in agreed test report format.
Partial discharge test must be carried out in a fully screened test cell. It is, therefore absolutely essential
that the manufacturer should have the appropriate type of facility to conduct the routine tests.

6.4 Acceptance Tests

6.4.1 All acceptance test as per latest revisions of relevant BIS / IEC and BS (for instrument cables) including
the optional tests and flammability test shall be carried out on sample taken from the delivery lot.

6.5 Short Circuit Tests:

6.5.1 The VENDOR shall also undertake to arrange for the short circuit test as a type test on anyone size of
each voltage grade i.e. on one size of 11 KV, earthed grade shielded XLPE cables ordered at a
recognized testing centre such as Central Power Research Institute (CPRI) at Bangalore / Bhopal at his
cost. If facilities for carrying out short circuit test are available at the VENDOR's works, and provided the
certification procedure is approved by the COMPANY, testing at the VENDOR's works will be acceptable.
Short Circuit test shall be witnessed by the COMPANY's representative.

6.5.2 The short circuit test shall be preceded and followed by the following tests so as to ensure that the
characteristics of the cable remain within the permissible limits even after if is subjected to the required
short circuit rating.
a) Partial Discharge Test.
b) Conductor Resistance Test.

7.0 VENDOR DOCUMENTATION

7.1.1 The VENDOR shall have to take approval of relevant drawings and data from the COMPANY in writing
before starting manufacture of any equipment. The VENDOR shall at his own cost rectify defects in any
manufacture done prior to the approval of drawings / data in accordance with the approved drawings/data
and the equipment shall be delivered within stipulated time.

7.1.2 Drawings, data, information and manuals shall be submitted as indicated below:

a. Technical data sheets, characteristic curves.

b. Tables showing current ratings at 50°C ambient, a.c. resistance, inductive reactance, shunt
capacitance, I't characteristics for the conductor

c. Tables showing I't characteristics and specific resistance for armouring at 50°C

d. Any other drawings & data as required for satisfactory operat"ion and maintenance.

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