Professional Documents
Culture Documents
0. Foreword
1. Scope
2. Service Conditions
3. Ratings and Characteristics
4. Design & Construction
5. Cable Material
6. Accessories
7. Tests
8. Partial Discharge Test
9. Bending Test Plus Partial Discharge Test
10. Measurement of Dielectric Power Factor as Function of the Voltage and
Capacitance Measurement.
11. Dielectric Power Factor Measurement as Function of the Temperature
12. Insulation Resistance Measurement at Maximum Rated Temperature
13. Heating Cycle Test followed by Partial Discharge Test
14. Impulse Withstand Test followed by a Voltage Test
15. High Voltage Test (4h)
16. Microscopic Test for Insulation to Determine Voids and Contaminants
17. Measurement of Insulation thickness
18. Measurement of Thickness of Non-Metallic Sheath
19. Test for Determining the Mechanical Properties of Insulation before and after
Aging
20. Test for Determining the Mechanical Properties of PVC Sheath before and
after Aging
21. Aging Test on Completed Cable
22. Measurement of Weight Loss of PVC Sheath
23. Test for Behaviour of PVC Sheath at High Temperature
24. Test for Behaviour of PVC Sheath at Low Temperature
25. Test for Resistance of PVC Sheath to Cracking (Heat Shock Test)
26. Test of Degree of Crossing Linking of the Insulation
27. Flame Retardant Test
28. Test on Corrosion Resistance Covering
29. Verification of Dimensions for Cable
30. Measurement of Electrical Resistance of Conductor
31. High Voltage Test (15 min)
32. Verification of Dimensions for Accessories
33. Packing and Marking
34. List of Drawings to be submitted alongwith Tender
35. Qualification Tests.
PRINTING HISTORY
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First approved on February, 1983.
SPECIFICATION P-168:83
0. FOREWORD
0.1 This Standard specification has been prepared by the Transmission Line
Directorate of Chief Engineer (Design) NTDC.
0.2 This specification is intended for procurement of material and does not include
provisions of the contract.
1. SCOPE
2. SERVICE CONDITIONS
2.2 Earthing
Earthing may be done at one end leaving the other end open circuited for short
runs, the open circuited end will however be connected to ground through non-
linear resistor type lightning arrestor, whereas for longer runs earthing at one end
only as well as cross bonding of the sheath or transposition may be employed.
It may be assumed that the air is not normally heavily polluted by dust, smoke
aggressive gases or vapour, However, at certain times of the year severe dust
storms may occur.
Maximum = 50ºC
Maximum mean over any 24 Hrs. = 45ºC
Mean in any year = 30ºC
Minimum = 5º
Relative humidity may range upto 100%. The maximum value of the ambient
temperature and humidity however does not occur simultaneously, during the
monsoons, high humidity may persist for many days at a time.
2.4.3 Altitude
The cable shall be suitable for direct burial and installation in ducts.
2.5.1 The ducts and soil conditions vary from dry to wet. Highly corrosive salts shall be
encountered in the soil.
2.5.2 The cable shall be laid down in flat formation at a minimum depth of 1.5M.
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Max. increment 20x10-4 between 38kV &
152kV
4.1 The cable shall be designed by the Tenderer for the rating and service conditions
mentioned in clause 2 & 3.
4.3 The cross-sectional area of the conductor shall be the sum of the areas of its
component wires at any point.
TABLE-I
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5. P.V.C. Jacket 3.5
5. CABLE MATERIAL
5.1 Conductor
5.1.1 Conductor shall consist of plain or metal coated copper or of plain aluminium.
5.1.2 The wires of stranded conductor shall all have the same nominal diameter.
5.1.3 The number of wires in each conductor shall be not less than appropriate
minimum numbers given in IEC 228.
5.1.4 The resistance of conductor at 20ºC shall not exceed the approximate maximum
value given in IEC 228.
5.2 Insulation
5.2.1 Insulation shall be pure; extruded solid dielectric insulation compound based on
chemically cross linked polyethylene using dry curing process which shall attain
the properties of being void free, more resistant to thermal, electrical and
mechanical stresses. It shall have better resistances against chemicals such as
ordinary acids, bases and oils. Insulation is to be laid over semi-conducting layer
adhering firmly to it which in turn, is to be applied with conductor.
5.2.2 The nominal insulation thickness shall not be less than as specified in Table-I.
5.3.1 Conductors screening shall be non-metallic and shall consist of either semi-
conducting tape or a layer of extruded semi-conducting compound or a
combination of the two.
5.3.2.1 The insulation screen shall consist of a non metallic semi-conducting part in
combination with a metallic part.
5.3.2.2 The non metallic part shall be applied directly upon the insulation of the core and
shall consist of a semi-conducting layer of extruded semi-conducting compound.
5.3.2.3 The metallic part shall be applied over the core and shall consist of either one or
more tapes, or braid, or a concentric layers of wires or a combination of wires
and tape.
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The PVC sheath shall be made from a polyvinyl chloride compound suitable for a
minimum installation temperature of -5ºC.
6. ACCESSORIES
6.1 Splice
The cable splice shall either be a straight joint or an insulting type straight joint
depending on the type of earthing to be used. The cable splice shall be of same
electrical mechanical and corrosion resistant characteristic as the cable itself to
ensure a complete reliable cable system.
This requires that the conductor must be securely connected, the inner semi
conducting layer must have a smooth surface for a good contact with insulation,
which in turn must be free from voids and impurities. The splice insulation must
be sufficiently thick and outer semi conducting layer must adhere firmly to it.
An outdoor type porcelain sealing end be designed for the service conditions and
ratings mentioned in clause 2 &3 and shall be of same electrical, mechanical and
corrosion resistant characteristic as the cable itself to ensure a complete reliable
cable system. It must provide such stress relief that partial discharge does not
occur. Surface cracking shall also not occur and the creepage path be designed to
this end. It shall have creepage distance not less than 2400mm.
7. TESTS
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7.1.2 Non Electrical Test
This test shall be carried out according to clause 3 of IEC Publication 540, The
rated power frequency voltage between conductor and screen, Uo = 76kV.
The sample shall be bent around a test cylinder at room temperature for at least
one complete turn. It shall then be unwound and the process shall be repeated
after rotating the sample through 180º about its axis.
20 (d + D) ± 5%
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Where D = overall dia of cable, mm
d = overall dia of conductor, mm
After completion of this test, the sample shall be subjected to a partial discharge
measurement and shall comply according to clause 8.
The power factor shall not exceed 40 x 10-4 at the medium measurement voltage.
The increase of the power factor between the lower and upper measurement
voltage shall not exceed 20 x 10-4.
This test shall be performed according to IEC 502 clause 16.1.7. The measured
values shall comply with following requirements:
The prepared test cable, from which sheath, fillings screens and armouring if any
have been removed, is immersed into a water bath with a temperature of 90°C for
at least 1 h before measuring.
This is performed with a DC voltage of 300 to 500V applied between the cable
conductors and the water bath. The measuring shall not, after the voltage has been
applied, be performed until stabilized conditions almost have been obtained,
earliest though after a 1 minute.
The volume resistivity is calculated from the measured insulation resistance with
the help of the following formula:
= 2 1R
----------
Loge D
d
= Volume resistivity, cm
R = measured insulation resistance,
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l = test cable length, cm
D = diameter over the insulation, mm
d = diameter over the conductor, mm
The volume resistivity must not be less than 1012 cm at 90°C. The insulation
resistance constant Kl must not be less than 3.67M km.
The test cable is heated with current in all conductors until the conductor
temperature has been stabilized at 130ºC. This temperature shall be kept for at
least 2 h after which the load current is cut and the cable is left to cool for at least
4 h. Forced cooling shall not be used.
This test shall be made on a sample of cable at least 10m in length, at a test
temperature of the value of 95°C. The heating shall be performed at the test
temperature for at least 2 hours, then the cable shall be subjected to 10 positive
and 10 negative impulses, applied between conductor and core screen. The peak
value of the impulse test voltage shall be equal to 650kV. The calibration of
impulse generator, test procedure and wave form shall comply with IEC
Publication 230. After the impulse test, the test cable is subjected to a voltage test
described in clause 3.
This test shall be made at room temperature on a piece of cable not less than 5M,
the termination not included. A power frequency voltage shall be applied for 4 h
to the sample between conductor and the screen.
The test voltage shall be 228 kV. The voltage shall be gradually increased to the
specified value. No breakdown of the insulation shall occur.
Samples shall be prepared as follows. Two inches of the sample shall be cut
helically or in some other convenient manner to produce thin samples of the
insulation and conductor shield. Wafers (or the turns of the helix) shall be
approximately 25 mils thick (Producing approximately 80 wafers). The cutting
blade shall be sharp and shall produce a sample with uniform thickness and with
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very smooth cut surfaces. The sample shall be kept clean and shall be handled
carefully to prevent scratching the cut surfaces.
The entire area of 20 consecutive wafers (or equivalent turns of the helical
sample) shall be examined with a minimum of 15 power magnification, including
any areas which appear suspect during the above examination by transmitted
light.
The largest void, the largest contaminant and the largest translucent material shall
be marked by encircling and must be subsequently measured on a micrometer
microscope.
The number of voids, contaminants and translucents per cubic inch of insulation
shall be calculated from the tabulation. (The volume of the 20 wafers, or
equivalent turns, may be determined by any convenient methods). If the 20 wafers
constitute less than one cubic inch and if the void or contaminant count exceeds
the allowable number, then a sufficient number of wafers from the same sample
shall be examined to total one cubic inch of insulation.
The largest void, contaminant and translucent material marked on the sample shall
be measured with a micrometer microscope using a minimum of 40 power
magnification. The largest dimension shall be measured only. If voids,
contaminants or translucents exceed the dimensions shown in Table-II< the
sample shall be considered to have failed to meet the test requirements:
TABLE-II
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Maximum Allowable Size
Of Voids, Contaminants and Translucents
Three samples be taken from a cable at three places separated by each other by at
least 1m. The measurement shall be made according to clause 4 IEC 540.
The average, which shall be rounded off to the nearest 0.1mm, of all the measured
values on each core shall be not less than the specified nominal thickness and the
smallest measured value shall not fall below 90% of the specified thickness by
more than 0.1mm.
Three samples be taken from a cable at three places separated by each other by at
least 1m. The measurement shall be made according to clause 4 IEC 540.
The average, which shall be rounded off to the nearest 0.1mm of all the measured
values on each core shall be not less than the specified nominal thickness and the
small measured value shall not fall below 85% of the specified thickness by more
than 0.1mm.
The measurement is carried out according to IEC 540 clause 5.1. The test piece is
aged in an oven at a temperature of 135 ± 2ºC during 7 x 24 h. The aging is done
according to IEC 540 clause 6.1.
The median value after aging shall, for tensile strength and for elongation at
break, not deviate more than ± 25% from the value before aging.
The median value after aging for the tensile strength and for the elongation at
break must not deviate more than ± 25% from the value before aging.
The purpose of this test is to verify that the material of the insulation or of the
sheath does not deteriorate under the influence of other components in the cable.
The test is carried out on all cable types. The selection of test piece and aging is
made according to IEC Publication 540 clause 6.1.4. The aging is carried out at a
temperature of 100±2°C during 7x 24 h.
Test pieces, taken from the insulation of the cable before and after aging, shall be
tested according to clause 20 and thereby fulfil the indicated requirements.
Test pieces, taken from the sheath before and after aging, shall be tested
according to clause 21 and thereby fulfil the indicated requirements.
The measurement shall be carried out according to IEC Publication 540 clause 7.
The sampling and test procedures shall be in accordance with clause 8.2 of IEC
540 at a temperature 80±2°C during 6 hours. The maximum permissible depth of
Indentation is 50%.
The sampling and test procedure shall be in accordance with clause 9 of IEC 540
at a temperature of -15 ±2°C. The results of test shall comply with the
requirements according to clause mentioned, above.
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25. TEST FOR RESISTANCE OF PVC SHEATH TO CRACKING (Heat Shock
Test)
The elongation must not after 15 min. load, exceed 175%. The remaining
elongation after unloading in heat and cooling down to ambient temperature, must
not exceed 15% of the value before heating the test piece.
This test shall be carried out on pieces of completed cable only when specially
required. The method of test and requirements shall be those specified in IEC
Publication 332, Flame Retardant Characteristics of Electric Cables.
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The d.c. resistance of the conductor in the completed cable shall be measured. The
measured value of resistance shall be corrected to a temperature of 20°C and 1 km
length by using the appropriate formula and factors specified in IEC 228.
The resistance shall not exceed either the appropriate value or the declared value.
The cable shall be kept in the test room at constant temperature for atleast 12
hours before the test.
This test shall be made at ambient temperature with a power frequency a.c. test
voltage applied for 15 min. between the conductor and core screen. The value of
test voltage shall be 162kV.
The voltage shall be gradually increased to the specified value. No break down of
the insulation shall occur.
Each length of the finished cable shall be wound on a strong reel carefully lagged,
and each end of cable will be sealed hermetically before shipment. The complete
periphery of each reel shall be protected with heavy wood lagging bound with
galvanized steel straps. The reels and lagging shall be sufficiently strong to
withstand the rigors of marine shipment. The lagging and wooden reels shall be
pentachlorophenol treated for protection against vermin.
The spare parts and tools shall be treated and packed for long term strong under
the climatic condition indicated in clause 3.3.
i) Type of cable
ii) Direction of rolling and unrolling
iii) Rated voltage and conductor size
iv) Reel length
v) Cable net weight and gross weight
vi) Name of manufacturer/trade mark
vii) Year of manufacture
viii) Contract No.
Spare parts and tools shall be clearly marked so as to be used for erection purpose.
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34.1 The Tenderer shall ensure submission of the following drawings with his tender.
A tender will not be deemed to be completed unless the drawings listed are
submitted. All drawings shall be to scale and shall be fully detailed. The tenderer
shall fill in the blank spaces for identification of their drawings:
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35.1 The Tenderer is required to supply the results of qualification tests carried out on
various types of cables being manufacturered at his works. These tests are
intended to demonstrate the capability of tenderer to furnish high quality cable
with the desired performance characteristics.
The tests shall be for different designs by varying, type of material, thickness of
insulation, sheaths or overall covering. The tests described below, shall be carried
out in accordance with AEIC-C35-79:
35.2 In case Tenderer has not carried out tests according to AEIC Standard then results
of similar qualification tests carried out to assess the suitability of design over a
longer period of time based on International Standard be supplied.
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