VOLUME IIA TECHNICAL SPECIFICATION

SECTION 5.1

1.1KV GRADE POWER AND CONTROL CABLES

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VOLUME IIA TECHNICAL SPECIFICATIONS

SECTION - 5.1 1.1KV GRADE POWER AND CONTROL CABLES

Clause No. 1.0 2.0 2.1.0 2.2.0 2.3 2.4 2.5 2.6 2.7.0 Particulars REQUIREMENTS FOR 1.1KV GRADE CABLES TECHNICAL CODES AND STANDARDS TECHNICAL REQUIRMENTS L.T. PVC POWER CABLES L.T. PVC CONTROL CABLES VOID CABLE DRUMS TESTS

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VOLUME - IIA Section 5. 1 (1. 1 KV Grade Power & Control Cables) 1. 1.0 REQUIREMENTS FOR 1.1 KV GRADE CABLES: Qualifying Requirement : Please refer Volume - 1 Section IFB Clause 11.0 1.1 GENERAL: The bidder shall quote for cables for entire scope of work. Following are the preferred sizes of cables to be used in the project and the cable vis a vis the purpose f or which to be used in indicated in part I of 3 of volume - II i.e., Technical specifications. PVC POWER CABLES (ALUMINUM CABLES): 4C x 95mm 4C x 25 mm 2C x 10mm 2C x 70mm PVC CONTROL CABLES (STANDARD COPPER CABLES): 2C x 2.5 mm 10C x 2.5 mm 19C x 2.5 mm 4C x 6 mm 4C x 10 mm 4C x 25 mm 1.2 Successful bidder shall prepare entire laying and termination schedules in accordance with criteria stipulated at Clause 1.3 below along with final cable quantities required and the same shall be submitted in advance for Owner's approval. CRITERIA FOR SELECTION OF POWER & CONTROL CABLES:

1.3

1.3.1 Aluminum conductor P V C insulated armoured power cables shall be used for main power supply purpose from L T Aux. Transformers to control room. 1.3-2 Aluminum conductor P V C insulated armoured power cables shall be used for various other applications in switchyard area / control room except for control / protection purposes. 1.3.3 For all control / protection instrumentation purposes P V C insulated armoured control cables of minimum 2.5 sq. mm. size with stranded copper conductors shall be used. 1.3.4 The size of the Power & Control and power cables for various purposes have been indicated in part 1 of 3 of Technical specifications. The bidder has to asses the quantities and indicate in the bid proposal sheets. In some cases tentative quantities have been indicated. These can be reassessed and indicated by bidder.

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The Bidder may offer other than sizes specified, in such case and for other application where sizes of cables have not been indicated in the specification, sizing of power cables shall be done keeping in view continuous current, voltage drop and short circuit consideration of system. Relevant calculation shall be submitted by the bidder during detailed engineering for Purchaser approval. The successful bidder has to finalize the cable schedules based on the site conditions and the schemes quoted, which are to be approved by owner payment for control and power cables will be made quantities of both power and control cables indicated in the bid proposal sheets and quantities finalized as per cable schedules WHICHEVER is LOWER 1.3.5 While preparing cables schedules for control / protection purposes following shall be ensured : Separate cables shall be used for AC & DC Separate cables shall be used for DC1 & DC2 (only for 220KV Station) For different cores of CT, CVT, & VTs separate cables shall be used. At least one (1) core shall be kept as spare in each copper control cables up to 9C size where as minimum no of spare cores shall be two (2) for control cables of 10 cores or higher size. For control cabling, 2.5 sq. mm copper cables shall be used for connections. For CT & VT circuits 6 &10 sq. mm copper control cables shall be used, respectively. 2.0 TECHNICAL:

2.1.0 CODES & STANDARDS The design manufacture testing and performance of cables covered under this specification shall comply with latest edition of the following standards including amendments: IS:7098 XLPE insulated PVC sheathed cables (Part-I) for working voltage up to & including 1100 Volts . ISS130 Conductors for insulated electrical cables & flexible cords. IS:5831 IS:3975 IS:10418 IS: 1554 PVC insulation & sheath of electrical cables. Mild steel wires strips & tapes for arm armoring of cables . Specification of drums for electric cables PVC insulated (heavy duty) electric cables for working voltage (part-I) up to and including 1100 V. Measuring & minimum oxygen concentration to support 2683 candle like combustion of plastic(oxygen index).

ASTMD

2.1.2 Cables complying with other internationally accepted standards such as IEC, VDE, JPCEA etc., will also be considered if they ensure performance & constructional features equivalent or superior to standards listed above In such a case.The Bidder shall clearly indicate the standard /

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standards adopted and furnish a copy of English version of the latest revision of the standard(s) along with the tender & shall clearly bring out the salient features for comparison. 2.1.3 In case of any conflict between the referred specifications codes or standards & this technical specifications, the latter shall prevail to the extent of such difference. 2.1.4 1.1 KV grade power & control cables to be supplied under this package shall be ISI approved & marked as such. Non-compliance of above shall not be accepted.

2.1.5 However, if cables to be, supplied under this package are manufactured outside India confirm to other internationally accepted equivalent or superior standards the above specification not be applicable . 2.1.6 The Indian Standards mentioned in Clause 2.1 can be obtained from: Bureau of Indian Standards Manak Bhavan, 9. Bahadur Shah Zafar Marg, NewDelhi - 110002. INDIA.

2.2.0 TECHNICAL REQUIREMENTS: 2.2.1 GENERAL 2.2.1.1 The cables shall be suitable for laying in racks, ducts, trenches, conduits & underground buried installation with uncontrolled back fill & chance of flooding by water. 2.2.1.2 They shall be designed to withstand all mechanical, electrical & thermal stress under steady & transient operating conditions. 2.2.1.3 The Aluminum / Copper wires used for manufacturing the cables shall be true circular in shape before stranding should be uniformly of good quality, free from defects . All aluminum used in the cable shall be of H2 grade. The fillers & inner sheath shall be of non-hygroscopic, & shall be softer than insulation The outer sheath must be fill reluctant suitable for the operating temperature of the cable. Progressive sequential marketing of the length of the cable in meters. Every one-meter shall be provided on the outer sheath of all cables. Only galvanized round steel wire armour shall be used for multicore cables. G.S.strip armour shall not be accepted for these cables. The cables shall have outer sheath of a material with an oxygen index of not less than 29 & a temperature index of not less than 250 C. All the cables shall pass fire resistance test as per IS:1554(part-1). The P V C cables insulated cables shall be capable of withstand in a conductor temperature of 160 C during a short circuit.

2.2.1.4

2.2.1.5

2.2.1.6

2.2.1.7

2.2.1.8 2.2.1.9

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2.2-1-10 2.2-1-11

Repaired cables shall not be accepted. Allowable tolerance on the overall diameter of the cables shall be plus or minus 2 mm. The normal current rating of PVC insulated cables shall be as per IS 3961.

2.2-1-12 2.3

L.T. PVC Power Cables.

The P V C ( 70C ) insulated 1100V grade power cables shall be of FR type clause category, conforming to IS:1554 (part-I ) its amendments, read along with this specification & shall be suitable for steady conductor temperature 70 C. The conductor shall be stranded Aluminum. The insulation shall be extruded P V C to type-A of IS : 5831. A distinct inner sheath shall be provided in all multi-core cables. For multicore armored cables, the inner sheath shall be of extruded P V C. The, outer sheath shall be extruded PVC to type ST-1 of IS : 5831 for all cables . Where armouring is specified for single core cables the same shall be of aluminium wires /strips. 2.4 L.T. PVC Control Cables:

2-4. 1 The 1100 grade 70 C control cables shall be of FR type Clause category confirming to IS : 1554 ( Part-I ) & its amendments, read along with this specification The conductor shall be stranded copper. The insulation shall be extruded PVC to type A of IS:5831. A distinct extruded inner sheath shall be provided in all cables. The fire retardant over sheath shall be extruded P V C to type ST-1 of IS : 5831 & shall be grey in color except where specifically advised by the owner to be black. 2.4.2 Cores shall be identified as per IS:554 for the cables up to five (5) cores & for cables with more than five(5) cores the identification of cores shall done by printing legible Hindu Arabic Numerals on all cores as per clause 10.3 of IS :1554(Part-1). 2.50 VOID

2.6.0 CABLE DRUMS 2.6.1 Cables shall be supplied non-returnable wooden or steel drums of heavy construction & drum shall be properly seasoned sound & free from defects. Wood preservative shall be applied to the entire drum. 2.6.2 Standard lengths for each size on power & control cables to be supplied by bidder shall be 500/1000 meters. The cable length per drum shall be subject to a tolerance of plus or minus 5% of the standard length. The owner shall have the option of rejecting cable drums with Shorter lengths. However, the total quantity of cables after taking into consideration of all cable drum of each size shall be within tolerance of 2%. 2.6.3 A layer of waterproof paper shall be applied to the surface of the drums over the outer most cable layer. 2.6.4 A clear space of atleast 40 mm shall be left between the cables & the lagging. 2.6.5 Each drum shall carry the manufacture's name, the owner's name, address, contract number & type, size & length of the cable, net & gross weight stenciled on both sides of drum. A tag containing the same information shall be attached to the leading end of the cable An arrow &. suitable

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accompanying wording shall be mark-ed on one end of the reel indicating the direction in which it should be rolled. 2.6.6 Packing shall be sturdy & adequate to protect the cables, from any injury due - to mishandling or other conditions encountered during transportation, handling & storage. Both cables ends shall be scaled with good quality heat shrinkable caps so as to eliminate ingress of water during transportation & erection. 2.7.0 TYPE TESTS 2.7.1 All cables shall conform to all type routine & acceptance tests listed in the relevant-IS. 2.7.2 The type tests on cables shall be conducted on each type and size of cables offered. 2.7.3 Following type tests as per IS:1554(Part-I)-1988 including its amendments and additional type tests shall be carried out on 1.1KV grade PVC insulated cables: a. Tests on conductor a. Annealing test (for copper) b. Tensile test (for aluminium) c. Wrapping test (for aluminium) d. Conductor Resistance test. b. Test for armouring wires/strips c. Test for thickness of insulation and sheath d. Physical tests for insulation and outer sheath. i. Tensile strength and elongation at break ii. Ageing in air oven iii. Shrinkage test iv. Hot deformation, Loss of mass v. Heat shock test vi. Thermal stability. e. Insulation resistance f. High voltage test (water immersion test only a.c. test as per clause No. 16.3.1) g. High voltage test at room temperature h. Flammability test i. Oxygen index and temperature index test on outer sheath j. Short time current test on power cables of sizes 240 Sq. mm and above. i. On conductor(s) ii. On armours.

2.7.4 Following type tests as per IS:7098(Part-2)-1988 including its amendments and additional type tests shall be carried out on XLPE insulated HT cable up to 33KV earthed system: a. Tests on conductor i. Annealing test (for Copper) ii. Tensile test (for aluminium) iii. Wrapping test (for aluminium) iv. Resistance test. b. Test for armouring wires/strips c. Test for thickness of insulation d. Physical tests for insulation e. Physical tests for outer sheath

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f. g. h. i. j. k. l.

Partial discharge test Bending test Dielectric power factor test Heating cycle test Impulse withstand test High voltage test Oxygen index temperature index test on outer sheath

2.7.5 Following type tests as per IS:7098 (part-3)-1993 including its amendments and additional type tests and additional type tests shall be carried out on XLPE insulated HT cable from 66KV up to and including 220KV: a. Tests on conductor i. Annealing test(for copper) ii. Resistance test iii. Tensile test (for aluminim) iv. Wrapping test (for aluminium) b. Physical tests for insulation i. Test for thickness and dimensions of insulation ii. Tensile strength and elongation at break iii. Hot set test iv. Shrinkage test v. Thermal ageing in air oven c. Resistivity test for semi-conducting layers d. Test for concentric metallic screen: i. Test for concentric copper wire ii. Test for concentric copper tape e. Thickness of metallic sheath f. Test for armouring material: i. Dimensions. g. Physical tests for outer sheath: 1. Measurement of thickness 2. PVC sheath i. Tensile strength and elongation at break ii. Ageing in air oven iii. Loss of mass in air oven only for PVC sheath iv. Heat shock test v. Hot deformation test vi. Shrinkage test vii. Thermal stability 3.PE sheath. i. Carbon black content ii. Tensile strength and elongation at break before and after ageing. iii. Hot-deformation. h. Flammability test (for PVC outer sheathed cables only) i. Water tightness test j. 1. Thermal ageing on complete cable sample. 2. Tensile strength and elongation at break for insulation and outer sheath. 3. Resistivity test for semi-conducting layer

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k. l. m. n. o.

Bending test followed by P.D. test Dielectric power factor and capacitance measurement at ambient temperature Dielectric power factor measurement at elevated temperature Impulse withstand test followed by HV test. Oxygen index temperature index test on outer sheath.

2.7.6 Contractor shall submit type test reports as per clause No. 9.2 of Technical Specification, Section: GTR for which test conducted once are acceptance (i.e. The requirement of test conducted within last five years shall not be applicable) for the following: 2.7.7 1.1KV grade PVC insulated cables High voltage test (water immersion d.c. test as per clause No. 16.3.2 of IS: 1554 (Part-1)-1988) 1.1KV grade XLPE insulated cables a. Water absorption (gravimetric) test as per IS: 7098 (part-1)-1988 2.7.9 XLPE insulated HT cable from 66KV upto and including 220KV a. Load cycle test followed by P.D. measurement as per IS:7098 (part-3) 2.7.10 Terminating/jointing accessories as per IEC 60840:1999 a. Partial discharge test at ambient temperature; b. Heating cycle voltage test c. Partial discharge tests -At ambient temperature -At high temperature d. Impulse voltage test followed by power frequency test. e. Test of outer protection for buried joints. 2.7.8

2.7.11 The owner reserves the right to witness any or all the tests, for which at least 30 days advance notice, shall be given- by the contractor. 2.7.11.1 Ten(10) copies of all routine & type test results shall be submitted for approval before dispatch of the cables from the works. 2.7.12 Bound copies of complete test reports, ten ( 10 ) in number, shall be furnished along with the cables. These shall include complete reports & results of the type tests, acceptance tests routine tests.

2.7.13 The owner reserves the light to get the cable Type tests at his own expense for any further tests to verify the compliance with the specifications & to reject the cables in case they are found not satisfying the qualifying requirements as per relevant standards.

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