INSPECTION REPORT FOR GEMSCAB LT CABLES (3CX300, 3CX120)

CABLE MANUFACTURING UNIT: PATHREDI, NEAR BHIWADI, DIST. ALWAR, RAJASTHAN DATE OF INSPECTION: 18/04/2012 CABLES ABOVE 16mm2 BOTH IN Al & Cu ARE MANUFACTURED IN BOTH PVC AND XLPE INSULATION. LT CABLES INSPECTED: 1.1kV kV grade Al conductor XLPE insulated.

CONSTRUCTION Conductor: Conductors are made from electrolytic grade aluminium / copper conforming to IS:8130, and are Compact circular or Compact shaped, Solid / Stranded circular. Insulation: GEMSCAB XLPE cables use specially made from high grade cross-linked polyethylene for insulation by extrusion process. Core Identification : The cores are identified by different colours: Single core Red, Black, Yellow, Blue or natural Two core Red and Black Three core Red, Yellow and Blue Four core Red, Yellow, Blue and Black Three and half core Red, Yellow, Blue and reduced neutral core in Black. Laying Up : In multicore cables, cores are laid-up as per the above colour scheme, interstices are filled wherever necessary to make the laid-up cores circular. Inner sheath: Laid-up cores are bedded over with thermoplastic material for protection against mechanical and electrical damage. Armoring: Armoring is provided over the inner sheath to guard against mechanical damage. Armoring is generally of galvanised steel wires or strips (in single core cables used in AC system armoring is by non-magnetic hard drawn aluminium wires / strips). Round steel wires are used where the diameter over the inner sheath does not exceed

13 mm, flat steel strip armor is used above 13 mm dia. Round wire of different sizes can be provided against specific request. Outer Sheath: Specially formulated heat resistant black PVC compound conforming to the requirement to type ST2 of IS:5831-1984, extruded to form the outer sheath. A. B. C. D. Max. Conductor Temperature for continuous operaton : 90C Ambient Air Temperature : 40C Max. Conductor temperature during short circuit : 250C Type of Installation i. 3 Core Cable Installed Independently Three cables in Trefoil ii. Single Core Cables Touching each other

Process Flowchart

Tests & procedures 1. High voltage test: Electrical equipment must be capable of withstanding overvoltages during operation. The applied voltage must be of approximately sinusoidal shape and of any frequency between 25 and 100 Hz. It must be increased gradually to the full value and maintain continuously for 15 minutes between conductors and between each conductors and sheath. Insulation resistance test: During the short-time test, the MegOhm Meter is connected directly across the equipment being tested and a test voltage is applied for about 60 seconds. Because temperature and humidity can affect the readings, the measurements should preferably be made above the dew point at standard temperature, about 20 C/68 F. For equipment rated above 1000 volts, the expected resistance should increase to one megohm per 1000 volts applied. FRLS Test i) HCL Gas Emission Test- All PVC Compounds when decomposed due to fire emit gaseous fumes, which are basically corrosive in nature. This is entirely due to the ingredients used in the formulations. These fumes, if containing higher amounts of corrosive gas i.e. Hydrochloric Acid Gas, may damage various instruments and equipments in the vicinity of fire. More and more stress is being given these days to control this content in reasonable limits. A sample of cable compound is subjected to controlled rate of heat for a certain period and the decomposed gases are collected in alkaline solutions. Such alkaline medium is then analysed to estimate the HCL evolved. ii) Oxygen and Temperature Index Tests Oxygen index is the measurement of oxygen content at which the vertically held sample when ignited ceases to burn off its own within 3 minutes. This is a relative measure of combustion resistance of materials in the context of atmospheric oxygen. Temperature Index is the temperature at which the vertically held sample ceases to burn off on its own within 3 minutes at an Oxygen concentration of 21% i.e. atmospheric air. iii) Smoke Generation Test Optical method is most practiced to measure the amount of smoke generated while burning the sample. A fixed dimension sample of material is put to flame of specified intensity for 4 minutes and the percentage obscuration on an optical path is measured a 15 seconds interval. A graphical plot of such measurements evaluates the average smoke density. This area integration method is only the quantitative indication of smoke generation by the PVC compound.

2.

3.

Test Reports
Samples were selected for Acceptance Test as per IS: 7098/Pt-II/1985 & IS: 7098/Pt-I/1988. Following test was conducted:Size & Type: 3C x 300 Sq.mm. A2XFY 1.1KV FRLS Cable S.No a) Test Detail Test on conductor i) Resistance test at 20C ii) No. Of wires Test for Thickness i) Insulation vi) Inner sheath vii) Armour (Aluminium Wire) viii) Outer Sheath ix) Overall cable diameter x) Outer Sheath cover Physical test for insulation i) Tensile strength ii) Elongation at break iii) Hot set test (at 200 3C for 15 min) a) Elongation under load b) Permanent Elongation Physical test for outer sheath i) Tensile strength ii) Elongation at break Unit Specified Value Red Ohm/Km Nos. 0.100 Max 37 Observed Value Yellow Blue 0.0988 37 0.0986 37

0.0987 37

b)

mm mm mm mm mm

1.8 Approx 0.60 Min 4.0 x 0.8 10% 2.2 Min 53.0 Approx Black 12.5 Min 200 Min

1.82

1.87

1.86

0.69 3.74 to 3.95 x 0.82 to 0.87 2.39 53.38 Black 17.40 550 16.9 565 17.2 555

c)

N/ mm %

% % N/ mm %

175 Max 15 Max 12.5 Min 150 Min

65 1.65

75 1.80 16.4 270

70 1.75

d)

e) f) g) h)

Oxygen Index Test Temperature Index Smoke Density Rating HCL gas emission test

% deg C % %

29 min 250 60 max 20 max

32.9 415 51.88 12.86