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STANDARDS
The most universal standardising authority for cables is the International Electro-
technical Commission (IEC), although comparatively little commercial business is
placed directly against the IEC standards. This arises because IEC standards cater for a
large variety of permissible options and serve mainly as a basis for the preparation of
national standards, which are usually prepared in accordance with the IEC require-
ments. Furthermore the IEC standards represent a consensus of national opinions and
hence take several years both to prepare initially and for agreement to be reached on
amendments. If all minor points were to be included, the time period for resolution
would be extremely lengthy, especially in dealing with new developments. Countries
such as the UK which have always been well to the fore in cable development are
therefore able to issue much more comprehensive and up-to-date standards.
This can be seen from the number of items in the lists below of the relevant IEC and
British Standards. Whilst it might have been of interest to include standards from other
countries, these tend to be even more numerous, e.g. in the USA where in addition to
national standards for materials and components there is widespread use by industry at
large of cable standards issued by four bodies: Underwriter's Laboratories (UL),
Association of Edison Illuminating Companies (AEIC) and jointly by the Insulated
Cables Engineers' Association and the National Electrical Manufacturers' Association
(ICEA/NEMA). In the UK some large organisations have separate specifications for
their own use but many adopt the available British Standards and only add any
requirements necessary for their particular purposes.
108
Cable Standards and Quality Assurance 109
55-1 Part 1 - T e s t s
55-2 Part 2 - Construction
I E C 92 Electrical installations in ships:
There are m a n y parts o f this standard, of which those
relevant are 92-3, 92-351, 92-352, 92-359, 92-373, 92-375
and 92-376
I E C 227 Poly(vinyl chloride)-insulated cables o f rated voltages up to
and including 450/750 V:
227-1 Part 1 - General requirements
227-2 Part 2 - Test methods
227-3 Part 3 - Non-sheathed cables for fixed wiring
227-4 Part 4 - Sheathed cables for fixed wiring
227-5 Part 5 - Flexible cables (cords)
227-6 Part 6 - Lift cables and cables for flexible
connections
I E C 245 Rubber-insulated cables o f rated voltages up to and
including 450/750 V
245-1 Part 1 - General requirements
245-2 Part 2 - Test methods
245-3 Part 3 - Heat-resisting silicone-insulated cables
245-4 Part 4 - Cords and flexible cables
245-5 Part 5 - Lift cables
245-6 Part 6 - Arc welding electrode cables
IEC 502 Extruded solid dielectric insulated power cables for rated
voltages from 1 kV to 30 kV
I E C 541 C o m p a r a t i v e information on I E C and N o r t h American
flexible cord types
IEC 702 Mineral insulated cables and their terminations with a
rated voltage not exceeding 750 V
702-1 Part 1 - C a b l e s
702-2 Part 2 - Terminations
I E C 800 Heating cables with a rated voltage of 300/500 V for
comfort heating and prevention of ice formation
I E C 1138 Cables for portable earthing and short-circuiting
equipment
Conductors
BS2627:1970 (1985) Wrought aluminium for electrical purposes. Wire
BS 3988:1970 Wrought aluminium for electrical purposes. Solid
conductors for insulated cables
BS4109:1970 (1991) Copper for electrical purposes. Wire for general electrical
purposes and for insulated cables and flexible cords
BS 5714:1979 (1987) M e t h o d of measurement of resistivity of metallic materials
BS 6360:1991 Conductors in insulated cables and cords
Miscellaneous
BS801:1984 (1991) Composition of lead and lead alloy sheaths of electric cables
BS 1441:1969 (1988) Galvanised steel wire for armouring submarine cables
BS 1442:1969 (1986) Galvanised mild steel wire for armouring cables
BS2897:1970 (1985) Wrought aluminium for electrical purposes. Strip with
drawn or rolled edges
BS 7450:1991 Method for determination of economic optimisation of
power cable size
BS 7454:1991 Method for calculation of thermally permissible short-
circuit currents, taking into account non-adiabatic heating
effects
BS 7540:1994 Guide to use of cables with a rated voltage not exceeding
450/750
BS 7769 Electric cables. Calculation of the current rating
Influence of C E N E L E C
CENELEC, the European Committee for Electrotechnical Standardisation, has an
important effect on the preparation and issue of new cable standards in Europe.
Membership consists of the electrotechnical standards organisations of the countries of
the European Union together with those of the European Free Trade Association
(EFTA) outside the EU. One of the main aims of CENELEC is to harmonise national
standards in order to remove technical barriers to trading. For cables the basic work is
done by a technical committee, TC20, on which all countries are represented. Working
groups are established for individual subjects. The activities of CE N E L E C embrace
a wide field of electrical equipment and regulations concerning its use, including
the harmonisation of rules for electrical installations, at present up to 1000 V. The latter
is covered by Technical Committee TC64, and the outcome of this committee's work
has an important bearing on the IEE Wiring Regulations, BS7671" 1992. Generally,
as for TC20 and TC64, the numbering of the CE N E L E C technical committees is the
same as for the IEC technical committees dealing with the same subjects and, because
of the correlation between the work of the two organisations, it is convenient for
representation for European countries to be the same, at least in part, in the
two bodies.
To achieve the aims, Harmonisation Documents or European Standards are
prepared taking account of IEC requirements and they are published after approval
by the technical committee and other overall committees. Subsequently, and within a
limited time scale, all member countries have to bring their national specifications
into line, without deviations (other than any which may be justified by special
national conditions, which should be only temporary, if possible). To date, in the
cable field, flexible cables and cords, mineral insulated cables and some types of
wiring cables have been harmonised. Harmonisation Documents have also been
produced for certain components or aspects which relate to all or several types of
cable, so that reference can be made to them in the documents for the cables. These
include Harmonisation Documents for conductors, test methods for thermoplastic
and elastomeric insulations and sheaths, the method of numbering of small cores
in cables with more than five cores and a standardised system of coded designations
of cables. In some fields IECstandards are adopted verbatim as Harmonisation
Documents or European Standards. In the cable field this applies to the Harmoni-
sation Documents for conductors and test methods mentioned above, which consti-
tute endorsements of IEC228 and IEC811 respectively, but the Harmonisation
Documents for the cables themselves, while conforming in most respects with the
corresponding IEC standards, include some differences and additions agreed between
the CENELEC countries.
One effect of the CENELEC procedure can be a delay in the up-dating of national
standards. This arises because when work is announced on a new subject a stand-still
arrangement is imposed and no changes may be made in national standards until after
harmonisation has been agreed, unless special permission has been obtained from
CENELEC.
Cable Standards and Quality Assurance 117
Harmonised types of cable may be marketed without restriction in any of the EU and
EFTA countries and attempts are made to keep the number of types to a reasonable
minimum. Provided that agreement has been obtained within CENELEC it is still
possible to retain non-harmonised designs as recognised national types if they are not of
interest to members of other CENELEC countries. These tend to be for a wider range
of conductor sizes or for particular wiring practices which are specific to national
standards. Permission would not be given to types which would inhibit the use of
harmonised designs.
Individual customers may still obtain cables manufactured to their own specification
but it is one of the aims to keep these to a minimum and to regard them as specials for
small-scale local use.
QUALITY ASSURANCE
In general the importance of quality has always been fully recognised in the cable
industry and quality assurance, which, as the term implies, comprises the planned and
systematic actions designed to give confidence that a product or service will satisfy the
requirements for quality, is an intrinsic feature of a cablemaker's activities, as it is of
reputable suppliers of most other products or services. However, quality has been the
subject of increasing publicity, with governmental bodies lending their support to, and
taking initiatives in, promoting its importance. There has been a growing emphasis on
the formalising and documentation of quality assurance procedures, not only to enable
suppliers to satisfy themselves that their system of quality assurance is effective, but also
to enable them to demonstrate this to their customers and others.
Certification
A means of providing evidence that a manufacturer's quality management system and/or
their product conforms to recognised standards is through certification to that effect by a
body recognised to be competent to apply examinations and tests to verify it. Similarly,
for a product for which no recognised standard exists, evidence of its suitability for the
function claimed for it and for its safety may be provided by an approval certificate from
a body recognised to be competent to make a judgement to that effect.
There are, then, three main categories of certification related to quality.
(a) Certification of the quality management system: this is a verification that the
supplier's organisation, planning and system of quality control and its operation
provide confidence that the supplier will satisfy requirements for quality.
(b) Certification of product conformity: this is a verification that, in so far as is
reasonably ascertainable, the supplier's product conforms with the standard with
which it is intended to comply, and is based upon the examination and testing of
actual samples of the product taken from the supplier's production or purchased in
the market.
(c) Product approval certification: for products outside the scope of existing standards,
this is a certification that a product can confidently be expected to perform safely
and reliably as required of it. To provide certification in this category the approvals
118 Electric Cables Handbook
organisation needs to go beyond satisfying itself that the product meets criteria
embodied in a standard: it needs to determine the criteria to be used to assess the
likely operational performance and satisfy itself that these are met.
BS EN ISO 9000-1 gives guidance on the selection and use of the other standards in the
series. Of these, the most appropriate for cable manufacture and supply are
BSENISO9001 and 9002. ISO9001 is the most demanding in that it requires total
quality assurance in design, development, production, installation and servicing, where
appropriate. ISO 9002 does not include the requirements for design and development. It
is therefore used where products are manufactured to a recognised standard and it is
assumed that compliance with the standard gives an assurance that the design of the
product is suitable for the intended use.
Certification of a manufacturer's quality management system by BASEC will
normally be to the effect that it conforms to BSENISO9001 or 9002 as the case may
be. The first such BASEC certificates, denoting at that time conformity with BS 5750:
Part 1 or Part 2, were issued to a number of cablemakers in 1986.
Product conformity certification has been provided by BASEC for cables to several
British Standards over a period from 1973, mainly for cables of rated voltages up to
1000 V. The schemes for appraisal include type approval and regular surveillances; they
began with flexibles and wiring cables and have extended to PVC and XLPE insulated
600/1000 V mains cables.
In the field of product approval BASEC is nominated in the lEE Wiring Regulations
as the body to assess whether a new type of cable, not included in a British Standard,
can be regarded as providing equivalent safety to types covered by the regulations,
which are all required to be to British Standards. At one time this provision in the lEE
Wiring Regulations, to allow for the use of newly developed equipment not strictly in
accordance with the regulations, was through the Assessment of New Techniques
(ANT) scheme, but this has been abandoned and, where cables are concerned, BASEC
provides the equivalent. In carrying out this function BASEC may recruit experts from
outside its regular staff.
Accreditation
One facet of government interest in quality assurance and certification was the setting
up of a body to accredit certification bodies. This body, which has merged the activities
of the NACCB and NAMAS, is now known as the UK Accreditation Service (UKAS).
A body which itself issues certificates to suppliers is able to apply for a certificate of its
own to signify that it is accredited by the UKAS. It is appraised in a way not unlike its
own appraisal of its clients, the basic criteria being impartiality and competence, and is
certified as accredited, if appropriate. It may be accredited to operate in one or more of
the areas of certification of quality management systems, certification of product
conformity and certification of product approval, but accreditation for product
conformity or product approval certification is generally not given unless the
certification body requires of its clients that their quality management systems be
approved by an accredited certification body. BASEC was accredited for certification of
quality management systems of suppliers of electric cables in 1986.
A certification body may operate without accreditation, relying on its established
prestige within the part of industry where it operates, but obviously accreditation by an
official body is seen as conferring greater status.
Governmental papers on the subject of accreditation and certification envisage the
possibility of more than one certification body being accredited for operation in a given
product area. Indeed there is implied encouragement of this in the interests of
120 Electric Cables Handbook