CONTENTS

1. SCOPE. .................................................................................................................. 3

2. APPLICABLE DOCUMENTS .............................................................................. 3

3. DESIGN REQUIREMENTS ................................................................................. 5

3.1. CLASSIFICATION IN TERMS OF SAFETY ............................................................... 5

3.2. GENERAL TECHNICAL REQUIREMENTS ............................................................... 5
3.3. SPECIFIC TECHNICAL REQUIREMENTS ................................................................ 7
3.4. MARKING REQUIREMENTS ................................................................................. 8
3.5. OPERATIONAL REQUIREMENTS ........................................................................ 11
3.6. PACKING, TRANSPORTATION AND STORAGE REQUIREMENTS ........................... 11

4. MANUFACTURER'S WARRANTY.................................................................. 12

5. CABLE MANUFACTURING OBLIGATIONS OF THE

MANUFACTURER - QUALITY ASSURANCE. .............................................. 12

6. TESTS .................................................................................................................. 13

7. DOCUMENTATION TO BE SUPPLIED BY CABLE MANUFACTURER .... 16

APPENDIX . ........................................................................................................ 17

TABLE .1 250 V TELEPHONE CABLES WITH POLYETHYLENE INSULATION AND

POLYVINYLCHLORIDE SHEATH FOR KUDANKULAM NPP UNITS 1

AND 2. DELIVERY QUANTITY ............................................................ 17

LIST OF ABBREVIATIONS .................................................................................. 18

Page 2 of 18
1. SCOPE
This document defines technical requirements for communication and signal
cables intended for operation outside the Reactor building containment of Kudan-
kulam NPP units 1 and 2 and establishes the requirements for cable manufactur-
ing, quality assurance, manufacturer's warranty, content of the documentation to
be submitted by the manufacturer and delivery quantity.
The quantity of cables to be delivered shall be as per Appendix A to this doc-
ument.

2. APPLICABLE DOCUMENTS
The communication and signal cables shall meet requirements of the present
document and the following standards:
IEC 60344 Guide to the calculation of resistance of plain and coated cop-
per conductors of low-frequency cables and wires;
IEC 60227-1 Polyvinylchloride insulated cables of rated voltages up to and
including 450/750 V. Part 1. General requirements;
IEC 60189-1 Low-frequency cables and wires with PVC insulation and
PVC sheath. Part 1: General test and measuring methods;
IEC 60708 Low-frequency cables with polyolefin insulation and moisture
barrier polyolefin sheath;
IEC 60502-1 Power cables with extruded insulation and their accessories
for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV).
Part 1. Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um =
3,6 kV);
IEC 60332-3-22 Group safety publication. Test for vertical flame spread of
vertically-mounted bunched wires or cables Category ;
IEC 60754-1 Tests on gases emission during combustion of electric cables.
Part 1. Determination of the amount of halogen acid gas;
IEC 60754-2 Test on gases emission during combustion of electric cables.
Part 2. Determination of degree of acidity of gases evolved during the

Page 3 of 18
 combustion of materials taken from electric cables by measuring pH and
conductivity;
IEC 61034-1 Measuring of smoke density of electric cables burning under
defined conditions. Part 1. Test apparatus;
IEC 61034-2 Measuring of smoke density of electric cables burning under
defined conditions. Part 2. Test procedure and requirements;
IEC 60331-23 Tests for electric cables under fire conditions - Circuit inte-
grity - Part 23: Procedures and requirements - Electric data cables;
IEC 60811-1-1 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section
One: Measurement of thickness and overall dimensions. Tests for deter-
mining of mechanical properties;
IEC 60811-1-2 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section
Two: Thermal ageing methods;
IEC 60811-1-3 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section 3:
Methods for determining the density. Water absorption tests. Shrinkage
test;
IEC 60811-1-4 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section 4:
Test at low temperature;
IEC 60811-3-1 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 3. Methods specific to PVC compounds. Sec-
tion One: Pressure test at high temperature. Tests for resistance to crack-
ing;
IEC 60811-3-2 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 3. Methods specific to PVC compounds. Sec-
tion Two: Loss of mass test. Thermal stability test;

Page 4 of 18
 IEC 60811-4-2 Insulating and sheathing materials of electric and optical
cables Common test methods Part 4-2: Methods specific to polyethy-
lene and polypropylene compounds Tensile strength and elongation at
break after conditioning at elevated temperature Wrapping test after con-
ditioning at elevated temperature Wrapping test after thermal ageing in
air Measurement of mass increase Long-term stability test Test me-
thod for copper-catalysed oxidative degradation;
IEC 60216 Electrical insulating materials. Properties of thermal endurance;
IEC 60068-2-10 Basic environmental testing procedures. Part 2. Tests
Test J. And guidance: Mouldgrowth;
50 /SG-Q (IAEA) Code and Safety Guides. Quality Assurance for Safety
in Nuclear Power Plants and Other Nuclear Installations;
ISO 9001-2000 Quality management system. Requirements;

3. DESIGN REQUIREMENTS

3.1. Classification in terms of safety

The cables are designed for operation as a part of the NPP system equipment,
under safety classes 2, 3 and 4 as per PB 88/97 NP-001-97 (PNAEG-01-011-
97).

3.2. General technical requirements

3.2.1 All climatic for macroclimatic regions on land and sea, except macroclimat-
ic regions with a very cold climate; for indoor operation (inside enclosed
spaces) with elevated humidity (for example, in unventilated underground
spaces, including operation in basements, in soil, in shipboard and other
spaces with long-lasting exposure to water or partial moisture condensation
on walls and ceilings).
3.2.2. The cables are rated for voltages up to 315 V, frequency up to 200 kHz.
3.2.3. The cable construction shall meet requirements of this document.
The following types of cables are envisaged:

Page 5 of 18
 - cables with polyethylene insulation and polyvinylchloride sheath (type
TPVng-LS);
3.2.4. The cables shall have solid copper conductors. The conductors shall meet
the requirements of IEC 60344.
3.2.5. The conductor insulation shall be of extruded low density polyethylene as
per IEC 60708
The nominal cable insulation thickness shall comply with IEC 60708 re-
quirement. However, the manufacturer shall mention the thicknesses pro-
posed, in the data sheet, for review and approval of NPCIL.
3.2.6. The insulated conductors shall be twisted into pairs with the pitch of twist-
ing no more than 50 mm. The insulated conductor in each pair shall be of a
different colour.
3.2.7. The pairs may be stranded into sub-units of ten pairs.
3.2.8. The pairs or sub-units shall be stranded into a core.
3.2.9. A separator in the form of a polymer film tape wrapping shall be provided
over the cable core with an overlap no less than 30 %.
3.2.10. A screen of a aluminium foil with a nominal thickness no more than 0,2
mm or of a foil-plated flexible composite material with a nominal thickness
of the metal layer no less than 0,05 mm shall be provided over the separator
with an overlap. A tinned copper wire of 0,4 mm diameter shall be provided
longitudinally under the screen a drain wire.
3.2.11. Outer sheath shall be of polyvinylchloride compound of PVC-ST9 type as
per IEC 60227-11 with low hydrogen chloride emission.
The maximum hydrogen chloride emission in testing according to
IEC 60754-1 shall not exceed 14 %.
3.2.12. The nominal outer sheath thickness shall comply with IEC 60227-7 re-
quirement.
3.2.13. The physical and mechanical characteristics of the polyethylene insulation
before and after thermal ageing shall meet the requirements of IEC 60708.
3.2.14. The non-electrical characteristics of the polyethylene insulation shall meet
the requirements of IEC 60708.

Page 6 of 18
3.2.15. The physical and mechanical characteristics of the polyvinylchloride
sheath before and after thermal ageing shall meet the requirements of
IEC 60227-1.
3.2.16. The non-electrical characteristics of the polyvinylchloride sheath shall
meet the requirements of IEC 60227-1.
3.2.17. The d.c. conductor resistance/ 1 km length at temperature of 20 C shall
meet the requirements of IEC 60344.
3.2.18. The conductor resistance unbalance in a pair shall meet the requirements
of IEC 60708.
3.2.19. The cables shall withstand a 1 min test with d.c. voltage in accordance
with IEC 60708.
3.2.20. The insulation resistance shall be, MOhmkm, no less than:
- at 20 :
- for polyethylene insulation 5000;
- for halogen-free polymer insulation 100;
- at 70 :
- for polyethylene insulation 5;
- for halogen-free polymer insulation 0,1.
3.2.21. The capacitance calculated/ 1 km length, at a frequency of 1000 Hz for po-
lyethylene-insulated cables shall meet the requirements of IEC 60708.

3.3. Specific technical requirements

3.3.1. The cables shall be flame-retardant as specified in IEC 60332-3-22, catego-
ry .
3.3.2. The cables shall meet the requirements of IEC 61034-1 61034-2 for smoke
emission during burning and smouldering.
3.3.3. The cables shall be resistant to mould growth. The degree of bio-mould
growth shall not be more than 2 points when tested as per IEC 60068-2-10/
equivalent standard/procedures.
3.3.4. The cable service life shall not be shorter than 40 years.

Page 7 of 18
 3.4. Marking requirements
3.4.1. Colour code for conductor insulation in pairs of layer-stranded cables shall
be in accordance with Table 1.
Table 1. Colour code for conductor insulation in pairs of layer-stranded signal
and communication cables
Conductor colour code
Colour of conductor insulation
Number of pair Conductor ""
Conductor ""
main colour / colour of stripe
1 blue (BU)
2 orange (OG)
white (WT)/
3 green (GN)
4 brown (BN)
5 grey (GY)
6 blue (BU)
7 orange (OG)
red (RD)/
8 green (GN)
9 brown (BN)
10 grey (GY)
11 blue (BU)
12 orange (OG)
black (BK)/
13 green (GN)
14 brown (BN)
15 grey (GY)
16 blue (BU)
17 orange (OG)
yellow (YE)/
18 green (GN)
19 brown (BN)
20 grey (GY)
21 blue (BU)
22 orange (OG)
white (WT)/
23 green (GN)
blue (BU)
24 brown (BN)
25 grey (GY)
26 blue (BU)
27 orange (OG)
red (RD)/
28 green (GN)
blue (BU)
29 brown (BN)
30 grey (GY)

Page 8 of 18
31 blue (BU)
32 orange (OG)
black (BK)/
33 green (GN)
blue (BU)
34 brown (BN)
35 grey (GY)
36 blue (BU)
37 orange (OG)
yellow (YE)/
38 green (GN)
blue (BU)
39 brown (BN)
40 grey (GY)
41 blue (BU)
42 orange (OG)
white (WT)
43 green (GN)
orange (OG)
44 brown (BN)
45 grey (GY)
46 blue (BU)
47 orange (OG)
red (RD)/
48 green (GN)
orange (OG)
49 brown (BN)
50 grey (GY)
51 blue (BU)
52 orange (OG)
black (BK)/
53 green (GN)
orange (OG)
54 brown (BN)
55 grey (GY)
56 blue (BU)
57 orange (OG)
yellow (YE)/
58 green (GN)
orange (OG)
59 brown (BN)
60 grey (GY)
61 blue (BU)
62 orange (OG)
white (WT)/
63 green (GN)
green (GN)
64 brown (BN)
65 grey (GY)
66 blue (BU)
67 orange (OG)
red (RD)/
68 green (GN)
green (GN)
69 brown (BN)
70 grey (GY)
71 blue (BU)
72 black (BK)/ orange (OG)
73 green (GN) green (GN)
74 brown (BN)

Page 9 of 18
 75 grey (GY)
76 blue (BU)
77 orange (OG)
yellow (YE)/
78 green (GN)
green (GN)
79 brown (BN)
80 grey (GY)
81 blue (BU)
82 orange (OG)
white (WT)/
83 green (GN)
brown (BN)
84 brown (BN)
85 grey (GY)
86 blue (BU)
87 orange (OG)
red (RD)
88 green (GN)
brown (BN)
89 brown (BN)
90 grey (GY)
91 blue (BU)
92 orange (OG)
black (BK)/
93 green (GN)
brown (BN)
94 brown (BN)
95 grey (GY)
96 blue (BU)
97 orange (OG)
yellow (YE)/
98 green (GN)
brown (BN)
99 brown (BN)
100 grey (GY)

3.4.2. The identification marking of the cable, year of manufacture and trademark
or manufacturer's name shall be provided on the cable sheath at an interval
not exceeding 500 mmCompliance with low smoke emission and flame re-
tardance requirements shall also be reflected in the cable designation.
Designation example for a 250 V screened cable with a polyethylene insula-
tion and a polyvinylchloride sheath with ten pairs of copper conductors of 0.4
mm diameter:
Cable TPVng-LS 1020.4 mm - 250 V, 2012, manufacturer.

Page 10 of 18
3.5. Operational requirements
3.5.1. The cables are intended for operation at an elevated ambient temperature up
to 50 C, as well as at relative air humidity up to 98 % at a temperature up
to 35 C.
3.5.2. The minimal permissible radius of cable bending during installation shall
not be lesser than 10 D, where D is the nominal outer cable diameter.
3.5.3. The permissible cable conductor heating temperature under normal opera-
tion conditions: plus 70 .

3.6. Packing, transportation and storage requirements

3.6.1. The cables shall be wound on drums. The cable ends shall be hermetically
sealed with heat shrinkable caps
The drum length shall be a minimum 1000m with a tolerance of +5%.
However in case NPCIL prefer to have different drum lengths, the same
shall be mutually agreed.
3.6.2. The cable drums shall be made from wooden battens as per IS and shall be
provided with anti termite treatment.
The outer cable layer under the battening shall be wrapped with a polymer
film or water-proof paper and secured with a cord of antiseptized yarn or
synthetic material.
3.6.3. The cables shall be transported and stored on cable drums so as not to
cause the cable damage.
The drums shall always be kept in vertical position.
The cables may be transported by any mode. During transportation the
cables shall not be subjected to exposure to acid or alkali vapours and other
corrosive media that may have a detrimental effect on the package and the
cables.
3.6.4. As for the exposure to ambient climatic conditions, the cables may be
transported and stored out doors in any macroclimatic area, including tropi-
cal climatic regions, in any type of atmosphere.

Page 11 of 18
3.6.5. The cable drums may be stored in specially equipped outdoor areas, indoors
and under a shed.
The cables shall be stored as packed by the manufacturer.
The cables ends shall be protected against ingress of moisture. During sto-
rage the cables shall be protected against mechanical actions, exposure to
acid or alkali vapours and other corrosive media that may have a detrimen-
tal effect on the packages and the cables, as well as against sun rays, atmos-
pheric precipitation and dust.

4. MANUFACTURER'S WARRANTY
4.1. Standard warranty / guarantees clauses of the GCC shall be applicable /
complied.

5. CABLE MANUFACTURING-. OBLIGATIONS OF THE

MANUFACTURER. QUALITY ASSURANCE.
5.1. The cable manufacturer shall:
- fulfil all the technical requirements of this document;
- submit list of all the applied/ used materials with the indication of relevant
standards for the materials and the material quality certificates;
- conduct the required checks and tests (Section 6).
5.2. The manufacturer shall prepare a Quality Assurance Program (QAP) based
on the relevant standards for review and approval by NPCIL. A sample
QAP has been included in the tender under annexure 1, to facilitate the
same. Cables shall pass all the tests indicated in QAP...
5.3. The manufacturer shall preferably have a certified quality management sys-
tem as per ISO 9001-2000 standard.
5.4. The manufactures scope of supply covers design, manufacture, inspection,
testing, packing in drums and safe delivery at KKNPP site (Kudankulam
Nuclear Power Project, Kudankulam P. O. Radhapuram Taluk, Tirunelveli
Distt., Tamil Nadu-627106).

Page 12 of 18
 6. TESTS
The cables shall be checked and tested according to the approved plan at the
manufacturer's premises or in any NPCIL approved laboratory.
The following kinds of minimum tests are established to prove the cable com-
pliance with the requirements of this document:
- Routine tests;
- Type tests;
- Acceptance tests.

6.1 Acceptance/ Routine tests to be conducted

The tests shall be carried out within the scope specified in Table 6 and approved
QAP.
Table 2. Acceptance / Routine tests

Kind of Applicable documents

Test or check
test Requirements Test method
1. Check of construction S items 3.2.3 3.2.12 of IEC 60811-1-1,
and geometrical dimen- this technical require- item 8
sions ments
2. Measurement of con- R item 3.2.17 of this tech- IEC 60189-1,
ductor resistance nical requirements item 5.1
3. D.c. voltage test R IEC 60708, IEC 60189-1,
item 7.4 item 5.2
4. Measurement of con- R IEC 60708, item 7.3 IEC 60189-1,
ductor resistance unbal- item 5.1
ance
5. Measurement of insu- R item 3.2.20 of this tech- IEC 60189-1,
lation resistance at nical requirements item 5.3
20
Note: R tests are carried out on each manufactured length;
S tests are carried out on specimens

6.2. Type tests

The cables shall be subjected to the type tests described in Table 7 and ap-
proved QAP.

Page 13 of 18
 Table 3. Type tests

Kind of Applicable documents

Test or check
test Requirements Test method
1. Electrical tests
1.1. Measurement of capacitance IEC 60708, IEC 60189-1,
item 7.6; item 5.4
item 3.2.21 of
this technical
requirements
1.2. Measurement of insulation resis- T item 3.2.20 of IEC 60189-1,
tance at 70 this technical item 5.3
requirements
2. Non-electrical tests
2.1. Polyethylene / PVC insulation:
2.1.1. Measurement of elongation at IEC 60708, IEC 60811-1-1,
break item 5.2 item 9;

2.1.2. Thermal oxidation resistance IEC 60708, IEC 60811-4-2,

test item 6.1.1 Appendix
2.1.3. Shrinkage test IEC 60708, IEC 60811-1-3,
item 6.1.2 section 10
2.2. Measurement of physical and IEC 60227-1, IEC 60811-1-1,
mechanical characteristics of sheath table 2, item 9;
before and after thermal ageing IEC 60502-1, IEC 60811-1-2,
table 18 items 8, 9
2.3. Pressure test of sheath at high IEC 60227-1, IEC 60811-3-1,
temperature table 2, item 8.2
IEC 60502-1,
table 21

2.4. Measurement of polyvinylchlo- IEC 60227-1, IEC 60811-3-2,

ride sheath mass loss due to thermal table 2 item 8
ageing
2.5. Heat shock test of polyvinylchlo- IEC 60227-1, IEC 60811-3-1,
ride sheath table 2 item 9.2
2.6. Test of cable for flame retardance item 3.3.1 of IEC 60332-3-22,
this technical category
requirements
2.7. Measurement of hydrogen chlo- item 3.2.11 of IEC 60754-1
ride emission during polyvinylchlo- this technical
ride sheath burning requirements

Page 14 of 18
2.8. Determination of corrosivity val- IEC 60502-1,
ues of smoke and gas emission prod- table 23
ucts during burning and smouldering
of insulation and outer sheaths mate-
rials:
- Measurement of content of halogen- IEC 60502-1, IEC 60754-1
containing acid gases in terms of table 23
HCl;
- and conductivity test IEC 60502-1, IEC 60754-2
table 23
2.9. Measurement of optical smoke item 3.3.2 of IEC 61034-1;
density during cable burning and this technical IEC 61034-2
smouldering requirements
2.10 Mould-growth test item 3.3.3 of IEC 60068-2-10
this technical
requirements

6.3 Acceptance test

Following tests and tests as per QAP shall be carried out.

6.3.1 Test on conductor
a. Annealing test
b. Conductor resistance test

6.3.2 Test on insulation

a. Thickness (Minimum & Average)
b. Tensile strength & Elongation at break before and after ageing
c. Volume resistivity at room temperature

6.3.3 Test on outer sheath

a. Thickness (Minimum & Average)
b. Tensile strength & Elongation at break before and after ageing.

6.3.4 Test on cables

a. IR test
b. HV test

6.3.5 FRLS Tests

a. Smoke density test
b. Oxygen index
c. Temperature index
d. HCL gas generation

Page 15 of 18
 e. Flammability test

7. DOCUMENTATION TO BE SUPPLIED BY CABLE MANUFACTURER

The set of documents to be supplied by the cable manufacturer to the Custom-
er shall consist of the following:
7.1. passport for each cable drum with the following information duly pre-
sented:
passport number, cable type, manufacturer;
basic technical characteristics (within the scope of acceptance tests);
approved data on acceptance tests;
manufacturer's warranty.
7.2. construction and dimension tables, including design mass and overall di-
ameters;
7.3. tables of drum dimensions and mass (net and gross values);
7.4. test reports and technical report with type test results to prove cable
compliance with these technical requirements; compliance reports
7.5. table of cable combustion - specific heat values in MJ/m.
7.6. operating instructions;
7.7. cable installation instructions.

Page 16 of 18
 APPENDIX
Table .1 250 V telephone cables with polyethylene insulation and polyvinyl-
chloride sheath for Kudankulam NPP 2. - delivery quantity

Cable
Size Quantity, meters
description
Communication cable with solid
Copper conductor, low density po-
lyethylene insulation, cores twisted 10x2x0.5 sqmm 8000
into pairs, polymer film tape,
screen of a aluminium foil over the
polymer tape, tinned Copper drain
wire longitudinally placed under
the screen, polyvinylchloride
(PVC-ST-9) compound outer
sheath, flame retardant, with low 5x2x0.5 sqmm 2500
smoke and low gas (maximum
14% HCL content in sheath) emis-
sion
TPVng-LS
Total 10500

Page 17 of 18
 LIST OF ABBREVIATIONS
NPP Nuclear Power Plant
IEC International Electrotechnical Commission
IAEA International Atomic Energy Agency
ISO International Standardization Organization
LS cable meeting the smoke emission in burning requirements
of IEC 61034-1, 2
IS Indian Standard

Page 18 of 18