PROJECT

NAME

CUSTOMER

DOC.NAME

TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

TECHNICAL SPECIFICATION
FOR
L.T. POWER CABLES,
CONTROL CABLES & ACCESSORIES

CONCEPT ENGINEERING
PROJECTS PVT. LTD.
DOCUMENT NO. : CEPL/SPEC/EL/DOC15
REV.
NO.

DESCRIPTION

CEPL/SPEC/EL/DOC15

TOTAL SHEETS : 24

REV. 0

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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

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CONTENTS

1.0

2.0

SCOPE..3

SERVICE CONDITION....3

3.0
STANDARDS...4

4.0
GENERAL CONSTRUCTION...6

5.0
DESIGN CRITERIA...6

6.0
TECHNICAL REQUIREMENT.8

7.0
CABLE SELECTION & SIZING..12

8.0
CABLE ACCESSORIES13

9.0
INSPECTION,TESTING AND ACCEPANCE..............14

10.0 PACKING & MARKING ,DESPATCH..20

11.0 ANNEXUREI.23

1.0

SCOPE

CEPL/SPEC/EL/DOC15

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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

2.0

3.0

This specification along with data sheets covers requirements for design,
manufacture, testing at work and supply of Crosslinked Polyethylene (XLPE)
insulated Flame retardant low smoke (FRLS) Aluminium Low Voltage Power
and Control cables and Cable Jointing/Termination Accessories for Low
Voltage System.


Abbreviations:

ASTM
:
American Society for Testing and Materials
BIS
:
Bureau Of Indian Standards.
BS

:
British Standard
IS

:
Indian Standard
IEC
:
International Electro technical Commission
NEMA
:
National Electrical Manufacturers Association

EPR
:
Ethylene Propylene Rubber
FR

:
Flame Retardant
HR PVC
:
Heat Resistance Polyvinyl Chloride
PVC
:
Polyvinyl Chloride
UV

:
Ultra Violet
XLPE
:
Crosslinked Polyethylene


SERVICE CONDITION
The Equipment to be supplied against this specification shall be suitable for
satisfactory continuous operation under the following tropical conditions.

i) Ambient Temp.
50 C






ii) Humidity

95%






iii) Max. Wind Pressure 150KMPH

iv) Rain fall

50mm/hr

v) Temperature
33C


CODES & STANDARDS
All standards, specifications and codes of practice referred to herein shall be
the latest editions including all applicable official amendments and revisions
as on date of opening of bid. All the cables and cables jointing & termination
accessories shall conform to the requirements of the following standards and
codes :

CEPL/SPEC/EL/DOC15

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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

IS:7098 (Part I) Specification for Crosslinked polyethylene insulated PVC

sheathed cables. PartII: For working 1KV voltages.


IS :1554 (Part1)

PVC insulated (heavy duty) electric cables for working

voltages up to and including 1100V.

IS : 3975

Low Carbon Galvanized steel wires, formed wires and tapes for
armouring of cables.

IS : 4905

Methods for random sampling.

IS : 5831

PVC insulation and sheath of electrical cables.

IS : 8130

Conductors for insulated electrical cables and flexible cords.

IS : 10418

Specification for drums for electric cables.

IS : 10810

Methods of tests for cables.

IS:3961(PartI)

Recommended current ratings for cables:part2 PVC

Insulated and PVC sheathed heavyduty cables.

IS : 6380 Specification for Elastomeric Insulation and sheath of E


Electric cables.
IS:10462(Part1) Fictitious calculation method for determination of
dimension of protective coverings of cables: Part1
Electrometric and thermoplastic insulation cables.
IS : 209
Specification for Zinc.

IS : 13573
Joints and termination for polymeric cables for working
Voltages from 6.6KV up to and including 33KV.
IEC: 227
PVC insulated electric cables
IEC: 183

Guide for selection of HV cables

IEC: 885

Electric test methods for electric cables

IEC: 12381 Power cables

IEC: 6033121 Test for electric cable under fire conditions circuit integrity
Procedures and requirements Cables of rated voltage up
and including 0.3/1.0KV.

IEC: 603323 Test on electric cables under fire conditions.
IEC754 (PartI) Tests on gases evolved during combustion of electric cables.
IEC332
CEPL/SPEC/EL/DOC15

Tests on electric cables under fire conditions. Part3: Tests on

bunched wires or cables (CategoryB).
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NEMAWC70 Standard for Non Shielded Power cables rated 2000V or

less for the distribution of Electrical energy.

NEMAWC53
Standard test, methods for Extruded dielectric Power,
Control, Instrumentation and portable cables for test.

DIN53387
Artificial weathering and ageing of plastics and elastomers
by exposure to filtered xenon are radiation.

BS: 7846
Electric cable600/100V armoured fire resistance cables
having thermosetting insulation and low emission of
smoke and corrosive gases when affected by fire.

ASTMD 2843 Standard test method for density of smoke from the burning
or decomposition of plastics.

The cables and accessories shall also confirm to the provisions of Indian
Electric Rule and other statutory regulations, as applicable.

In case of any contradiction between various referred standard /specification

/data sheet and statutory regulations, the following order of priority shall
govern:

Statutory regulations
Data Sheets
Job Specifications
This Specification
Code and Standards.

4.0 GENERAL CONSTRUCTION

4.01 The cables shall be brand new and in good condition. These shall be suitable
for laying in trays, trenches, ducts, conduits and underground buried
installation with uncontrolled backfill and possibility of flooding by water
and chemical. Extra PVC / Rubber end caps for each XLPE Cable size shall be
supplied.

4.02 Sequence marking of the length of the cable in meter shall be provided on the
outer sheath at every one meter.

The embossing/engraving shall be legible and indelible.

Cable identification: Cable identification shall be provided by embossing on
every meter on the outer sheath the following:

a) Manufacturers name or trademark
b) Voltage grade
c) Year of manufacture
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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

d) Type of insulation and outer sheath e.g. PVC/XLPE/FRLS as applicable.

e) No. of core and size of cables.
f) ISI Mark
g)
Word FRLS at every 5 meter (If applicable)

4.03 The overall diameter of the cables shall be strictly as per the values declared
by the manufacturer in the technical information subject to a maximum
tolerance of 2mm up to overall diameter of 60mm and 3mm for beyond
60mm.

4.04 PVC/Rubber end caps shall be supplied free of cost for each drum with a
minimum of eight per thousand meter length. In addition, ends of the cables
shall be properly sealed with caps to avoid ingress of water during
transportation and storage.

4.05 The cable meant to be used in mining area under the Jurisdiction of DGMS
shall comply with the requirements as specified in the job specification
/Datasheet.

5.00 DESIGN CRITERIA

5.01.1 The cables will be used for connection of power circuits of the system. All the
power cabling as required and specified in Scope of cables shall be carried
out by the contractor. Actual cable sizes will be selected by the Contractor.
Number of different sizes selected will be kept to a minimum for
optimization.

5.01.2 Cables shall be generally laid on ladder type cable trays or drawn through
rigid steel conduits.

5.01.3 For continuous operation at specified rating, maximum conductor
temperature shall be limited to the permissible value as per relevant
standard and/or this specification.

5.01.4 The insulation and sheath materials shall be resistant to oil, acid and alkali
and shall be tough enough to withstand mechanical stresses during handling.

5.01.5 Armouring shall be single round wire / strip of galvanized steel for multi core
cables and aluminum for single core cable as per the relevant standards.

5.01.6 The outer sheath shall have fire resistant low smoke (FRLS) characteristics
and shall meet the requirements of additional tests specified for the purpose.

5.01.7 Core identification for multi core cable shall be provided by color coding.
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5.01.8 Cables shall be so designed and manufactured that no damage occurs during
handling, transit, storage, installation under any operative conditions which
they may be subjected to.

5.01.9 LT XLPE FRLS power cables shall be manufactured by triple extrusion dry
cure (CCV) process using nitrogen.

5.01.10 Minimum value of volume resistivity for XLPE insulation shall be 1.0 x 1014
ohmscm at 27 C and 1.0x1012 ohmscm at 90 C.

5.01.11 Maximum continuous operating temperature shall be 90 C under normal
operation and 250 C under short circuit condition.

5.01.12 The fire survival cable shall meet the following additional requirements:

i)
The insulation shall be of EPR or equivalent material with glass mica
tape below or above insulation.
ii)
Unless otherwise specified the cable shall meet requirement of circuit
integrity test for a minimum period of 3 hours at max. Temperature of
950 C.
5.01.13 All cables shall meet the fire resistance requirement as per categoryB of
IEC 332 (Part3).
5.01.14 The eccentricity of the core shall not exceed 10% and ovality not to exceed
2%.
The eccentricity shall be calculated as:
tmax tmin
x 100
t max
and the ovality shall be calculated as
dmax dmin
x 100
d max
Where tmax/tmin is the maximum/minimum thickness of insulation and d
max/dmin is the maximum / minimum diameter of the core.
************************************************************************************
***

6.00 TECHNICAL REQUIREMENT

6.00.1 All power/Control cables for use on Low voltage system shall be heavyduty
type, 650/1100V grade and with stranded Aluminium conductor, Conductor
Screened with Extruded semiconducting compound, XLPE Insulated,
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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

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Insulation Screened with extruded semiconducting compound with copper

tape (0.3KA for
One sec.), cores laid up, inner sheath of PVC tape, galvanized steel flat strip
armoured and Flame retardant low smoke (FRLS) overall PVC sheathed cable
designed to with stand all mechanical, electrical and thermal stresses develop
under steady state and transient operating conditions. Cable conforming to
IS: 7098/II/85 with latest amendments unless specified otherwise in data
sheet.
6.00.2 KV Grade Control Cables shall have stranded copper conductor, multicore,
PVC insulated, PVC innersheathed, armoured, FRLS PVC outersheathed
conforming to IS:1554. (PartI).
6.00.3 1.1KV grade trailing cables shall have tinned copper (class5) conductor,
insulated with heat resistant elastomeric compound based on Ethylene
Propyline Rubber (EPR) suitable for withstanding 90 deg C continuous
conductor temperature and 250 deg C during short Circuit. Inner sheathed
with heat resistant, oil resistant and flame retardant heavy duty elastomeric
compound conforming to IS 9968. Minimum conductor size shall be
2.5sqmm.
6.01 Conductor

6.01.1 The conductor shall be solid for conductor of nominal area up to and
including 6mm2 and stranded beyond 6mm2 .Conductors of nominal area less
than 16mm2 shall be circular only Conductors of nominal area 16mm2 &
above my be circular or shaped as per IS:8130. Cables with reduced neutral
conductor shall have sizes as per Mfg. Catalogue for PVC insulated Cable size
as per Table1 of IS : 7098(Part2).

6.01.2 For LT power cable Aluminium conductor used in power cables shall have
tensile strength of more than 100N/mm2. Conductor shall be multi stranded.

6.01.3 For Control cable Conductor of control cables shall be made of multi
stranded, plain annealed copper.

6.02 Conductor Screening


Cross linked semiconducting compound extruded in the same operation as
the insulation.

6.03 Insulation

6.03.1 The core shall be with Cross linked polyethylene (XLPE) compound applied
over the conductor by extrusion over screed conductor and shall confirm to
the requirements of type A compound as per IS: 7098 Part2 (1985). The
Thickness of insulation and the tolerance on thickness of insulation shall be
as per Table 2 of IS: 7098(Part2). Control cables having 6 Cores and shall be
identified with prominent and indelible Arabic numerals on the outer surface
CEPL/SPEC/EL/DOC15
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of the insulation. Color of the numbers shall contrast with the colour of
insulation with a spacing of maximum 50mm between two consecutive
numbers. Colour coding for cables up to 5 Cores shall be as Indian standard.

6.03.2 For LT Power cable Cross linked polyethylene (XLPE) insulation shall be
suitable for a continuous conductor temperature of 90 deg. C and short
circuit conductor temperature of 250deg.C. PVC insulation shall be suitable
for continuous conductor temperature of 70 deg C and short circuit
conductor temperature of 160 deg. C. overload conductor temperature of 130
Deg. C.
6.03.3 For Control cable PVC insulation shall be suitable for continuous conductor
temperature of 70 deg C and short circuit conductor temperature of 160 deg.
C.
6.04 Insulation Screening

All cables shall be provided with insulation screening. The insulation
screening shall consist of extruded cross linked semiconducting compound
in combination with a layer of lapped copper tape of thickness not less than
0.1 mm.

6.05 Core Identification

6.05.1 Three (3) core cables, core identification shall be done with different
colouring of XLPE insulation, but with natural colour with black coloured
strips applied on the cores or by numerals printing on the cores.

6.05.2 Cores of the cables of upto 5 cores shall be identified by colouring of
insulation. Following colour scheme shall be adopted.
1 core Red, Black, Yellow or Blue
2 core Red & Black
3 core Red, Yellow & Blue
4 core Red, Yellow, Blue and Black
5 core Red, Yellow, Blue, Black and Grey
6.05.3 For cables having more than 5 cores, core identification shall be done by
numbering the insulation of cores sequentially, starting by number 1 in the
inner layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10).
The number shall be printed in HinduArabic numerals on the outer surfaces
of the cores. All the numbers shall be of the same colour, which shall contrast
with the colour of insulation. The colour of insulation for all the cores shall be
grey only. The numerals shall be legible and indelible. The numbers shall be
repeated at regular intervals along the core, consecutive numbers being
inverted in relation to each other. When the number is a single numeral, a
dash shall be placed underneath it. If the number consists of two numerals,
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these shall be disposed one below the other and a dash placed below the
lower numeral. The spacing between consecutive numbers shall not exceed
50 mm.

6.06 Laying up of cores:

Cores shall be laid up together as per IS 7098 Part 2 (1985).

6.07 Inner Sheath

6.07.1 The inner sheath shall be applied over the laidup cores by extrusion and
shall be HRPVC compound inner sheath confirming to type ST2 of IS:
5831/1984. Such inner sheath shall be provided by pressure extrusion
process with filler.
The minimum thickness of inner sheath shall be as per IS 7098 Part2 (1985)
Single core shall have no inner sheath.
Distinct extruded PVC inner sheath of black colour as per IS 5831 shall be
provided for all cables.

6.07.2 The cable cores shall be laid up with fillers between the cores wherever
necessary. It shall not stick to insulation and inner sheath. All the cables,
other than single core unarmoured cables, shall have distinct extruded PVC
inner sheath of black colour as per IS: 5831.
6.08 Armour

6.08.1 Unless otherwise specified all cables shall be provided with armour. for
multicore cables, the armour shall be by single round galvanised steel wires
the calculated diameter below armouring does not exceed 13mm and by
galvanised steel strips where this dimension is greater than 13 mm.
Requirement and methods of tests for armour material and uniformity of
galvanization shall be as
Per IS3975 and IS10810(Part 41).The dimension of armour shall be as per
method (b) of IS 7098 (Part2).

6.08.2 For three (3) core cables: Single galvanized steel strip armor conforming to
IS: 3975 / 1988.

6.08.3 For Single Core Cables:
Armour shall be of Non magnetic material consisting of single hard drawn
aluminum round wires conforming to H4 grade of IS: 8130 / 1984.

6.08.4 For single line core armoured cables, armouring shall be of aluminium wires.
For multicore armoured cables armouring shall be of galvanised steel as
follows.

Calculated nominal dia of cable
under armour
CEPL/SPEC/EL/DOC15

Size and Type of armour

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i)

Upto 13 mm

1.4mm dia GS wire

ii)

Above 13 & upto 25mm

0.8 mm thick GS formed wire/1.6 mm

dia GS wire

iii)

Above 25 & upto 40 mm

0.8mm thick GS formed wire/2.0mm

dia GS wire

iv)

Above 40 & upto 55mm

1.4 mm thick GS formed wire/2.5mm

dia GS wire

v)

Above 55 & upto 70mm

1.4 mm thick GS formed

wire/3.15mm dia GS wire

vi)

Above 70mm

1.4 mm thick GS formed wire/4.0 mm

dia GS wire

6.08.5 The aluminium used for armouring shall be of H4 grade as per IS: 8130 with
maximum resistivity of 0.028264 ohmsq.mm/mtrs. at 20 deg.C. The types
and sizes of aluminium armouring shall be same as mentioned for galvanised
steel above.
6.08.6 The gap between armour wires / formed wires shall not exceed one armour
wire / formed wire space and there shall be no cross over / overriding of
armour wires / formed wires. The minimum area of coverage of armouring
shall be 90%.

The breaking load of armour joint shall not be less than 95% of that of
armour wire / formed wire. Zinc rich paint shall be applied on armour joint
surface of GS wires/formed wires.
6.08.7 For mining cables, the size and type of armour shall be such that the
combined conductance of armour shall equivalent to 75 % of the conductance
of largest conductor of the cable.

6.09 Outer Sheath


6.09.1 All cables covered in this specification shall be flame retardant (FR) unless
specified otherwise in the data sheet. The outer sheath of cables shall possess
flame propagation properties meeting requirements as per IS 10810 (Part
62) category AF.

6.09.1 The outer sheath for the cables shall be applied by extrusion and shall be of
HRPVC FRLS compound conforming to the requirements of type ST2
compound as per IS: 5831/1984 shall be provided over armor.

6.09.2 The color of outer sheath shall be black.

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6.09.3 Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to
meeting all the requirements of Indian standards referred to, outer sheath of
all the cables shall have the following FRLS properties.
(a.) Oxygen index of min. 29 (Test method as per IS 10810 Part58)
(b.) Acid gas emission of max. 20% as per IEC754 (PartI)
(c.) Smoke density rating shall not be more than 60% during Smoke Density
Test as per ASTMD2843.

6.10 Discharge free construction:

Inner conductor shielding/screening, XLPE insulation and outer core
shielding/screening shall be extruded in one operation by special process (i.e.
triple extrusion dry cure process) to ensure that the insulation is free from
contamination and voids and perfect bonding of inner and outer shielding
with insulation is achieved. The bidders are requested to elaborate the
manufacturing technique adopted by their manufacturers to achieve this
motive.

*******************************************************************************

7.0 CABLE SELECTION & SIZING

7.00.1 LT Power cables shall be sized based on the following considerations:

a)
Rated current of the equipment
b)
The voltage drop in the cable, during motor starting condition shall be
limited to 10% and during full load running condition it shall be
limited to 3% of the rated voltage. And for welding and hoisting cable
voltage drop shall be 15% during running and starting shall be 5%.

c)
Short circuit withstand capability

Derating Factors

Derating factors for various conditions of installations including the following
shall be considered while selecting the cable sizes:

a)
Variation in ambient temperature for cables laid in air
b)
Grouping of cables
c)
Variation in ground temperature and soil resistivity for buried cables.

Cable lengths shall be considered in such a way that straight through cable
joints is avoided.

7.00.2 Control cables shall be sized based on the following considerations:

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(a) The minimum conductor crosssection shall be 1.5 sq.mm.

(b) The minimum number of spare cores in control cables shall be as
follows:
No. of cores in cable Min. No. of spare cores
2C, 3C NIL
5C 1
7C12C 2
14C & above 3
8.00 CABLE ACCESSORIES

8.00.1 The termination and straight through jointing kits for use on the systems
shall be suitable for the type of cables offered as per this specification and
shall meet requirements of IS 13573.

8.00.2 The accessories shall be supplied in kit form. Each component of the kit shall
carry the manufacturers mark of origin.

8.00.3 The kit shall include all stress grading insulating and sealing materials apart
from conductor fittings and consumable items. An Installation instruction
sheet shall also be included in each Kit.

8.00.4 The contents of the accessories kit including all consumable shall be suitable
for storage without deterioration at a temperature of 45 C ,with shelf life
extending to more than 5 years.

8.01 TERMINATING KITS

The terminating kits shall be suitable for termination of the cables to an
indoor switchgear or to a weatherproof cable box of an outdoor mounted
transformer/motor. For outdoor terminations, weather shields/sealing ends
and any other accessories required shall also form part of the kit. The
terminating kits shall be from one of the makes/types mentioned in the data
sheet.

8.02 JOINTING KITS

The straight through joining kits shall be suitable for installation on overhead
trays, concrete lined trenches, and ducts and for underground burial with
uncontrolled backfill and possibility of flooding by water and chemicals.
These shall have protected against rodent and termite attack. The inner
sheath similar to that provided for cables shall be provided as part of straight
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through joint..The jointing kits shall be from one of the makes/types

mentioned in the data sheet.

*******************************************************************************
***

9.00 INSPECTION, TESTING AND ACCEPTANCE

9.00.1 The cables shall be tested and inspected at the manufacturers works. All the
materials employed in the manufactures of the cable shall be subjected, both
before and after manufacture, to examination, testing and approval by
customer/Owner. Manufacture shall furnish all necessary information
concerning the supply to customer /Owner inspectors. The inspector shall
have free access to the manufacturers work for the purpose of inspecting the
process of manufacture in all its stages and he will have the power to reject
any materials, which appears to him to be of unsuitable description or of
unsatisfactory quality. The vendor shall give at least 2 week advance notice to
the purchaser, regarding the date of testing to enable him or his
representative to witness the test.

9.00.2 Type and acceptance tests shall be carried out on 1 drum selected on random
basis, out of every 10 or less number of drums of each type and size of cable
of each lot. Size shall mean area of cross section in sq.mm read in conjunction
with the number of cores. Type shall mean type of insulation, outer sheath,
volt grade FRLS/FS etc.

9.00.3 All tests shall be witnessed by owners representative. All the standard Type,
Routine & acceptance tests as per IS or other relevant standards shall be
witnessed by owners representative.


9.01 TYPE , ROUTINE & ACCEPTANCE TESTS ON CABLES:

After completion of manufacture of cables, type, routine and acceptance tests
shall be performed strictly as per relevant IS & other applicable standards
amended upto date.

9.01.1 ROUTINE TESTS:

The following tests shall be carried out as Routine tests on each and every
drum length of cable, as per IS 7098 (Part 2) / 1985.

a) High Voltage Test
b) Conductor Resistance Test
c) Partial discharge test (for screened cables) on full drum length.

9.01.2 ACCEPTANCE TEST:

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The following test shall be carried out as Acceptance Test in the presence of
MSPGCL Inspecting Engineer on samples taken from the delivery lot. One
drum out of every 10 number of drums or less shall be selected at random
sampling basis in each lot for the Acceptance Tests which shall be carried
out at manufacturers /suppliers cost.
a) High Voltage Test
b) Conductor Resistance Test
c) Tensile / wrapping test.
d) Partial discharge test (In screened cables).
e) Insulation Resistance/Volume resistivity test
f) Measurement of thickness of insulation and sheath and other
dimensions
g) Tensile strength & elongation at break for insulation & sheath.
h) Hot set test on XLPE insulation
i) Flammability test as per Swedish standard SS: 4241575 ClassF3
(Swedish Chimney test)
j) Acid gas generation test as per IEC7541.
k) Smoke density test as per ASTMD2843/1977
l) Oxygen index test as per ASTMD 2863/1977
m) Temp. Index test as per ASTM2863/77

9.02 TYPE TESTS:

9.02.1 The type test as per applicable standards as given below shall be conducted
on one drum selected on random basis out of every 10 drums or less of each
type and size of cable (In presence of MSPGCL representative). In case,
facilities of any of the type tests are not available at the works of the supplier,
then such type tests shall be carried out by the supplier at independent
recognized Govt. approved laboratory at the cost of supplier.

9.02.2 Tensile test (for aluminium) as per IS: 8130

9.02.3 Wrapping test (for aluminium) as per IS: 8130
Note: In the case of compacted circular & shaped conductors these tests
shall be carried out before compacting/shaping for ensuring use of H2
grade aluminium.

9.02.4 Conductor Resistance test as per IS: 8130.

9.2.5 Test for armour wire/strip as per IS: 3975

9.02.6 Test for thickness of XLPE Insulation and HRPVC, FRLS sheath:
Requirements and methods of tests for the thickness of insulation,
outer sheath shall be as per IS: 7098 (Part2).

9.02.7 Tensile strength and elongation test for insulation & sheath:
This test shall be carried out as per IS: 7098 Part2 for XLPE cable.
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9.02.8 Ageing test for insulation and sheath:
The method of test shall be as per the relevant IS standard. The period of
test shall be 168 hours (7 days). At the end of the ageing period, the tensile
strength and elongation test shall be carried out as per Sr. No.(6) above.
The value obtained must not differ from the corresponding values obtained
before ageing by more than + or 25% in case of XLPE compound.

9.02.9 Loss of mass test for HRPVC, FRLS sheath:
This test shall be carried out as per IS 583/1984 012 IEC 540 & IEC 502, on
cables of all voltage grades. The maximum permissible loss of mass is 2
mg/sq.cm for PVC.

9.02.10 Shrinkage test for XLPE insulation & HRPVC FRLS sheath:
This shall be carried out as per IS: 5831 1984 for sheathed and as per IS
7098 (Part 2) 1985 for XLPE insulation.

9.02.11 Hot deformation test for HRPVC, FRLS sheath:
This shall be carried out as per IS: 5831 / 1984.
9.02.12 Cold Impact test for HRPVC, FRLS sheath:
This shall be carried out as per IS: 5831.

9.02.13 Heat shock test for HRPVC,FRLS sheath :
This test shall be carried out as per IS 5831 / 1984 and IEC 540 and
IEC 502 & sheath shall pass the requirements of this test.

9.02.14 Thermal stability test for HRPVC, FRLS sheath:
This test shall be carried out on cables as per IS 5831 / 1984 and IEC
540 and cables shall pass the minimum requirements of 80 minutes for
sheath.

9.02.15 Hot set test for XLPE Insulation:
This test shall be carried out as per IS: 7098 Part1 and Part2 and cable
shall pass the requirements given therein.

9.02.16 Test for bleeding and blooming of Pigments for HRPVC, FRLS Sheath :

This shall be carried out as per IS: 5831 / 1984.

9.02.17 Fire Resistance Test
This test is compulsory and shall comply with the relevant clause of
applicable IS.

9.02.18 Partial Discharge Test for XLPE Cables :
The partial discharge test for XLPE insulation shall be carried out as
per IS:7098 (PartII).

9.02.19 Bending Test for XLPE Cables:
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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

The test method and test requirement shall be as per IS: 7098 (PartII).
On completion of this test, the sample shall be subjected to partial
discharge measurement and comply with the requirements given in
above subclause 17.

9.02.20 Insulation Resistance / Volume resistivity
As per IS 7098 Part2/1985.

9.02.21 Dielectric Power Factor Test
As per IS 7098 Part2/1985.

9.02.22 Heating cycle test for XLPE Cables:
This test shall be as per IS: 7098 (PartII)

9.02.23 High Voltage Test
This test shall be performed as per the relevant Indian Standard 7098
Part 2/1985.
9.02.24 Test for Rodent & Termite Repulsion Property of Sheath:
Test for Rodent and termite repulsion properties Test shall be conducted to
note the presence of rodent and termite repelling chemical in PVC compound.
Normal procedure is that a few chippings of PVC compound are slowly
ignited in a porcelain dish in a muffle furnace at about 600 C The resulting
ignited ash is boiled with a little ammonium acetate solution (10%). A drop of
aqueous sodium sulphide solution is placed on a thick filter paper and it is
allowed to soak. The spot is touched with a drop of above extract. A black
spot indicates the presence of anti termite & rodent compound.

9.02.25 Impulse Withstand Test
As per IS 7098 (2) (amended upto date).

9.02.26 Accelerated water absorption test for insulation: As per NEMAWC70 (for
PVC insulated cables) and as per NEMAWC53(for XLPE / EPR insulated
cables). Test certificates with respect to this test (not older than one year)
from recognized testing laboratory to be furnished for review by
customer/owner before dispatch clearance of cables. In case test certificates
are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in house testing laboratory, before dispatch
clearance of cables. Sampling for this test is to be done randomly once for
each order, provided type of insulation remains same.

9.02.27 The normal sequence of the electrical tests shall be as per Clause 16.1.1 of
IEC502/1978 and / or as per IS 7098 Part 2 / 1985. All the tests listed
herein shall be applied successively to the same sample.

9.02.28 The inner sheath of the XLPE insulated cable shall be subjected to all the
tests applicable for PVC sheath as per IS 5831 / 1984.

9.03
SPECIAL TEST
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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

The following special tests to be performed on the cables as per sampling
plan. These tests are required to be witnessed by customer/Owner before
dispatch of cable.

9.03.1 Special Test on HRPVC FRLS materials
All the sizes of XLPE power cables of the FRLS HRPVC sheathed type shall
pass following special test requirements.

9.03.2 Oxygen/Temperature Index test on sheath material:
This test shall be carried out as per American National Std. ASTMD
2863/77. The minimum oxygen index shall be 29 at room temperature. For
determination of the temp. Index, the oxygen index test shall be carried out
at different temperature upto 250C. However, the test shall be carried out
by extrapolation method beyond temperature at which the material of
sheath may start deformation. The min/ temp. Index (i.e. the temperature
at which the oxygen index is minimum 21) shall be 250C generally as per
BICC Hand Book Chap6.

9.03.3 Acid gas emission test on sheath material:
This test shall be carried out as per IEC Std. 7541. The maximum acid gas
emission shall be less than 20 by weight.

9.03.4 Smoke density test on sheath material:
This test shall be carried out as per American National Standard ASTMD
2843/1977 and also as per UITP method (3M cube test on finished cable
sample). The ASTM test method is compulsory. For passing this test, the
requirement of light transmission shall be minimum 40% after the test.

9.03.5 Flammability test on finished cable sample:
Flammability tests on finished cable as per the requirements of IEEE383,
IEC3321 and Swedish standard SS 4241475 clause F3. Smoke generation
by sheaths under fire as per ASTM D 2843. The cables shall meet the
requirements of light transmission of minimum 40% after the test. The test
shall be carried out by extrapolation method beyond temperature at which
the material of sheath may start deformation as per BICC handbook
chapter6 on cable in fire. Acid gas generation by sheaths under fire as per
IEC7541 and the minimum acid gas generation shall be less than 20% by
weight. Each type of cable shall also be subject to the following additional
type test at works.

This test shall be carried out as per the following method:

Swedish Std.SS:4241475 ClassF3 This test known as Swedish

Chimney test is compulsory.

IEEE std. 3831974 This test known as the vertical tray flame
propagation test shall be conducted if insisted by purchaser.

IEC Std: 3321. The cable should meet the requirement of all the
above standards.
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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

IS10810 (Part 61&62). The acceptance criteria for tests conducted

shall be as under.
Part61 The cable meets the requirement if there is no visible
damage on the test specimen within 300mm from its upper end.
Part62 The maximum extent of the charred portion measured on
the test sample should not have reached a height exceeding 2.5 m
above the bottom edge of the burner at the front of the ladder.

9.03.6
Test for Resistance to Ultra Violet Radiation:

This test shall be carried out as per DIN 53387 or ASTMG154 on outer
sheath. The retention value of Tensile strength and ultimate elongation
after the test shall be minimum 60% of tensile strength and ultimate
elongation after the test shall be minimum 60% of Tensile strength and
ultimate elongation before the test. Test certificates with respect to this test
(not older than one year) from recognized testing laboratory to be
furnished for review by EIL before dispatch clearance of cables. In case test
certificates are not available, test is to be conducted by vendor at his own
cost in any recognized test laboratory or in house testing laboratory, before
dispatch clearance of cables. Sampling for this test is to be done randomly
once for each order, provided outer sheath remains same.

9.03.7 Accelerated water absorption test for insulation:

As per NEMAWC70 (for PVC insulated cables) and as per NEMAWC53(for
XLPE / EPR insulated cables). Test certificates with respect to this test (not
older than one year) from recognized testing laboratory to be furnished for
review by customer/owner before dispatch clearance of cables. In case test
certificates are not available, test is to be conducted by vendor at his own
cost in any recognized test laboratory or in house testing laboratory, before
dispatch clearance of cables. Sampling for this test is to be done randomly
once for each order, provided type of insulation remains same.

9.03.8 Dielectric retention Test:

The dielectric strength of the cable insulation tested in accordance with
NEMAWC70 at 75 1C shall not be less than 50% of the original
dielectric. Strength (for PVC insulation cables).Test certificates with respect
to this test (not older than one year) from recognized testing laboratory to
be furnished for review by customer/owner before dispatch clearance of
cables. In case test certificates are not available, test is to be conducted by
vendor at his own cost in any recognized test laboratory or in house testing
laboratory, before dispatch clearance of cables. Sampling for this test is to be
done randomly once for each order.

9.04 TYPE TEST ON CABLE ACCESSORIES

Type test should have been carried out to prove the general qualities and
design of a given type of termination/jointing system as per IS13573.The
type test certificates from independent testing laboratory shall be submitted
before dispatch.
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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

10.0 PACKING AND MARKING,DISPATCH

10.0.1 Cables shall be supplied in nonreturnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with waterproof cover. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection.
Wood preservative antitermite treatment shall be applied to the entire
drum. Wooden drums shall comply with IS: 10418.

10.0.2 Each drum shall carry manufacturer's name, purchasers name, address and
contract number, item number and type, size and length of cable and net
gross weight stenciled on both sides of the drum. A tag containing same
information shall be attached to the leading end of the cable. An arrow and
suitable accompanying wording shall be marked on one end of the reel
indicating the direction in which it should be rolled.
10.0.3 The standard drum length for power cables shall not be less than 500
meters. The length per drum shall be subjected to a maximum tolerance of
+/ 5% of the standard drum length. Approval from Owner shall be obtained
for supplying cable drum with shorter lengths.

10.0.4 Unless otherwise specified, cables shall be supplied in drum lengths as
follows:
MV Cables


: 1000 m
Multicore Power cables up to 6 mm2
Multicore Power cables from 10mm up to 300mm2
: 500 m
Single Core Power cable up to 630 mm2


: 1000 m
Control Cables up to 61 Cores



: 1000 m

HV Power Cable Up to 11kV (E) Grade
Three Core cable up to 400 mm2



: 500 m
2
Single Core cables up to 400 mm



: 1000 m
2
2
Single Core cables above 400 mm and up to 630mm
: 750 m

HV Power Cables above 11kV (E) Grade and up to 33kV (E) Grade
Three Core cables up to 300 mm2 grade


: 350 m
Single Core cables up to 400mm2



: 1000 m
2
2
Single Core cables above 400 mm and up to 1000mm
: 500 m

A tolerance of 3 % shall be permissible for drum. However overall tolerance on
each size of cable shall be limited to 2 % .Offers with short /nonstandard lengths
are liable for rejection. If nostandard drum lengths are specified in the data sheet,
the same shall be supplied.

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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

*******************************************************************************
***




ANNEXUREI


Following is the list of LT Power Cables required:

650/1100 V Three core Aluminium Conductor, XLPE Insulated Cables.
Three Core Aluminium Conductor, XLPE Insulated, and Unarmoured & strip
Armoured, FRLS Cables conforming to IS: 7098 Part1/1988.

Sr. Nominal Size of
Qty. Unit
No.
Conductor
1
3 x 4 Sq.mm.
0
Mtrs.
2
3 x 6 Sq.mm.
0
Mtrs.
3
3 x 10 Sq.mm.
0
Mtrs.
4
3 x 16 Sq.mm.
0
Mtrs.
5
3 x 25 Sq.mm.
0
Mtrs.
6
3 x 35 Sq.mm.
0
Mtrs.
8
3 x 50 Sq.mm.
0
Mtrs.
9
3 x 70 Sq.mm.
0
Mtrs.
10
3 x 95 Sq.mm.
0
Mtrs.
11 3 x 120 Sq.mm.
0
Mtrs.
12 3 x 150 Sq.mm.
0
Mtrs.
13 3 x 185 Sq.mm.
0
Mtrs.
14 3 x 240 Sq.mm.
0
Mtrs.
15 3 x 300 Sq.mm.
0
Mtrs.
16 3 x 400 Sq.mm.
0
Mtrs.
17 3 x 500 Sq.mm.
0
Mtrs.
18 3 x 630 Sq.mm.
0
Mtrs.


650/1100 V Three and Half core Aluminium Conductor, XLPE Insulated Cables.
Three Core Aluminium Conductor, XLPE Insulated, and Unarmoured & strip
Armoured, FRLS Cables conforming to IS: 7098 Part1/1988.

Sr.
Nominal Size of
Qty. Unit
No.
Conductor
1
3 x 25/16 Sq.mm.
0
Mtrs.
2
3 x 35/16 Sq.mm.
0
Mtrs.
3
3 x 50/25 Sq.mm.
0
Mtrs.
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4
5
6
7
8
9
10
11
12

TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

3 x 70/35 Sq.mm.
3 x 95/50 Sq.mm.
3 x 120/70 Sq.mm.
3 x 150/70 Sq.mm.
3 x 185/95 Sq.mm.
3 x 240/120 Sq.mm.
3 x 300/150 Sq.mm.
3 x 400/185 Sq.mm.
3 x 500/240 Sq.mm.

0
0
0
0
0
0
0
0
0

Mtrs.
Mtrs.
Mtrs.
Mtrs.
Mtrs.
Mtrs.
Mtrs.
Mtrs.
Mtrs.

650/1100 V Four core Aluminium Conductor, XLPE Insulated Cables.
Three Core Aluminium Conductor, XLPE Insulated, and Unarmoured & strip
Armoured, FRLS Cables conforming to IS: 7098 Part1/1988.

Sr. Nominal Size of
Qty. Unit
No.
Conductor
1
3 x 4 Sq.mm.
0
Mtrs.
2
3 x 6 Sq.mm.
0
Mtrs.
3
3 x 10 Sq.mm.
0
Mtrs.
4
3 x 16 Sq.mm.
0
Mtrs.
5
3 x 25 Sq.mm.
0
Mtrs.
6
3 x 35 Sq.mm.
0
Mtrs.
8
3 x 50 Sq.mm.
0
Mtrs.
9
3 x 70 Sq.mm.
0
Mtrs.
10
3 x 95 Sq.mm.
0
Mtrs.
11 3 x 120 Sq.mm.
0
Mtrs.
12 3 x 150 Sq.mm.
0
Mtrs.
13 3 x 185 Sq.mm.
0
Mtrs.
14 3 x 240 Sq.mm.
0
Mtrs.
15 3 x 300 Sq.mm.
0
Mtrs.
16 3 x 400 Sq.mm.
0
Mtrs.
17 3 x 500 Sq.mm.
0
Mtrs.
18 3 x 630 Sq.mm.
0
Mtrs.













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TECHNICAL SPECIFICATION FOR L.T .POWER CABLE,CONTROL CABLE &

ACCESSORIES

650/1100V Multicore Control Cable with soild copper Conductor of size 1.5
Sqmm, XLPE Insulated Cables.
Three Core copper Conductor, XLPE Insulated, and Unarmoured & strip
Armoured, FRLS Cables conforming to IS: 7098 Part1/1988.

Sr. Number of Nominal Size
Qty. Unit
of Conductor
No.
Core
1
2
1.5 Sq.mm.
0
Mtrs.
2
3
1.5 Sq.mm.
0
Mtrs.
3
4
1.5 Sq.mm.
0
Mtrs.
4
5
1.5 Sq.mm.
0
Mtrs.
5
6
1.5 Sq.mm.
0
Mtrs.
6
7
1.5 Sq.mm.
0
Mtrs.
8
8
1.5 Sq.mm.
0
Mtrs.
9
9
1.5 Sq.mm.
0
Mtrs.
10
10
1.5 Sq.mm.
0
Mtrs.
11
12
1.5 Sq.mm.
0
Mtrs.
12
14
1.5 Sq.mm.
0
Mtrs.
13
16
1.5 Sq.mm.
0
Mtrs.
14
19
1.5 Sq.mm.
0
Mtrs.
15
21
1.5 Sq.mm.
0
Mtrs.
16
24
1.5 Sq.mm.
0
Mtrs.
17
27
1.5 Sq.mm.
0
Mtrs.
18
30
1.5 Sq.mm.
0
Mtrs.
19
33
1.5 Sq.mm.
0
Mtrs.
20
37
1.5 Sq.mm.
0
Mtrs.
21
44
1.5 Sq.mm.
0
Mtrs.
22
52
1.5 Sq.mm.
0
Mtrs.
23
61
1.5 Sq.mm.
0
Mtrs.

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