PPC esr Was 984) | ‘hysical Property:~ \ Z xe-vtin Tense strength 12.50 N/ mm? of 1.27 Ke/mm? ' 1" Ms= Min Blongation at break 150% | | Ageing Condition: | Treatment temperature: - 802°C ‘ Duration of treatment 4168 hours \ a) TiS after ageing: - 80% (Min) & 120% (Max) | 'b) Elongation after ageing: - 80% (Min) & 120%(Max) | \ 4 (at break after ageing) ‘Loss of Mass Test (PVC) : i @ (DD-S-8-1984) 6 IEC:-540-1982 (Clause- 7) : : Loss Of Mass= WL.Difference / Evaporating Area x 1000 40 mg/m? i | va, Area of tube n(DO=T)X(LxT)/ 100 (em) | ya, Area of Strip =A 2(LxW+WxT+TxLb)/ 100 (cm?) . Eva, Area of Dumb-bell = 1256+ (1806) / 100 (em.sq) ) | | Sample length either tube or strip = L= 100 mm (max) Sarre for sheath dumb-bell test piece = 75 mim (length), 4 mm (width of marker i “Thickness of Specimen not less than 0.80 ram i NO ‘Weight | of specimen = After Keeping the sample in desiccators oy 2 hours’ > Wetaht 2 of specimen = After Keeping the sample in alr oven at 89 € £20) for 168 hows rand thatt again placed in desiceators for 20 hours Water Absorption Test pvc) | (DD-S-8-1984) ‘Water Absorption = Difference in weight (gm) / Surface Area (em?) x 1000 1.5 mg/em? (max) Siirface Area Tube=7DL/ 100. (om?) 7 Surface Area Strip = 2 (LxW + WxT + TxL)/ 100 (cm?) Length of Specimen (Tube with conductor) = 275 mv } Length ofSpecimen (Strip)- .. g, = 00m nw! yo Width of strip 4 =2 mmThickness ot stripy = Not less than 0.80 mm Strip Wt not less than 100-gm ww “fier Keeping te sample in air oven at 70 € for 48 hours Weight A _ Weight B fter keeping the sample in air oven at 70 € for 168 | 360 Vertically hanged in glass bicker which is filled with Distilled water. » | Weight C = Affer drying the sample in vacuum ( Placed on 5 mm CaCh or metcury at 70 C for 48 hours) \ i If Cis less than A =B IfC is greater than 3 Jusulation Resistance Measurement at room Temperature = (DD-S-8-1984) | “This test performed on the test sample 10 meter before any electrical test ‘After the removal of all covering, ‘sample immersed in the water ‘at room temperature for 1 hour tre etance shal be catculated from the resistance meter, applying 300V (0 500 and to reach The steady measurement; which eannot less the T minute, oan ‘Scanned with CamScannerII be calculated he given below formu rs / f= 2x xx LRiLog ex Did f / Where: / = Volume Resistivity in ohm (cm) . / R= Insulation resistance. measured in (ohm) . / Length of the sample in (cm) 7, Outer diameter of the insulation (mm) inner diameter of insulation (mm 2 eLRILog e Did 2x3.1416x10xRY log e x 6.05/4.05 =2°3.1416x1000xR / log ¢ (1.49) =6283.2xR / 0.4013 =15657.114 xR R= 107 15657.114 = 6.38 x 10°. 9 138 x 10 M 2/10 meter Insulation Resistance Constant Ki. calculated by the given below formula: Insulation Resistance Constant Ki at 20°C = 36.70 M2.Km Rx 10 /Log 10 Did = 10"' x 0.367 f MOKm 5 Cold Bend Test (Insulation) (DD-S-8-1984) & IEC-540 - ‘Test condition: Q Temperature Req, 2 1542€ Results to be obtained. = No cracks Apparatus : Mandrel Procedure: : Mandrel Diameter between 4 & 5 times of the diameter of test piece. ° ‘The number of turns shall be specified in the following tab Overall diameter of test piece Number of turns (mm) Upto and including 2.5 mim 10 : 2.5mm_to 45mm 6 4.5 mm_to_6.5 mm 4 65mm to 8.5mm 3 ‘Over 8.5 mm 2 At Specified Temperature Testing time period : 16 hours, 5 ‘The mandrel shall be uniformly rotated at a rate of one revolution in about § sewohd. * ” .-* ‘The apparatus shall be held In reftigerator before and after the test = Cold Bend Test (Pve Sheath ) ‘This test for the cable with an overall diameter up to and including 12.50mm and for flat cables, ‘A width up to and including 20 mm The specified thickness should not exceed 2,0 mm. ‘Scanned with CemScanner_ter.cutting the thickness shall be not less than 0.0mm. crete the sheath of larger cable diameter shall be subjected tothe elongation testdescribed | In sub-clause 9.4(IEC-540) . | Neral covering has been removed the Pve sheath shall be eut inthe ditection ofthe axis, | ‘On Pve sheath the cold bend test is the same process as according to the Pvc insulation. \ 3 | ‘Test for Resistance of P. Insulation to cracking Heat Shock Test) IEC:-540 ‘Asaitable length taken from two places separated by atleast | meter | : ‘Test Condition: ae 5 \ ‘Treatment temperature: 150 +2°C eet Duration of treatment: 1 Hour : “The test sample shown no crack | Examined with normal or corrected Vision without magnification. Py Preparation of Sample ‘The sample shall be prepared in one of the three following ways 1: Cores overall diameter < 12.50mm | i 11s Cores overall diameter> 12.50mm having insulation thickness 12.50mm , Insulation > 5.0mm Having strip cut in accordance I. { Winding of sample on mandrels i ihe sample shall be tautly wound and fixed on a mandrel to actose helix. | Diameter of mandrel and no of turns are given: | External diameter of sample Mandiel Diameier Number of tum ! (mm) (mm), | Upto including €O 2 T 6 | \ 1.0 to 2.00 4 l 6 | \ 2.00 to 3.00, 6 i” 6 | 4 e 3,00 10 4.00) 8 6 | \ 4.00 10 5.00) 10 6 1 | ————— \ Upto and including 2.50 5 6 \ 750-45 9 6 \ 4,50 - 6.50 13 6 1 650-950 19 4 \ | | 1 . . Test for Resistance of P.V.C Sheath to eracking (Heat Shock Test): Preparation of Sample 7 ‘The sample shall be prepared in one of the three following ways \ ‘Scanned with CamScannerFor sheath overall diameter <12.50mm ' + For sheath overall diameter> 12.50mm having thickness | 5.0mm consist of strip , having width shall be at least 1.5 time its thickness but 4.0mm cut in to the axis of the cable. | “4 | Il: For sheath overall diameter > 12.50mm having thickness \ '5.0mm consist of strip , (thickness 4.00mm to 5.00 mm) Width shall be at least 1.5 times the thickness. 1 1V : For flat cable widths 12.50, sample consist of complete Cable . Ifwidth > 12.50mm sample shall consist of strip (Mentioned in item Test sample taken from length of 250mm to 500 mm . The sample-length shall be 50 mm to 100 mm. Sample preparation From each core of cable, If any covering including samiconducting layer removed either the type of cable circular or sector-shaped. Apparatus for treatment: It consist of a rectangular blade with an edge 0.70 0.0Lmm wide which can be pressed against the test sample, Flat cords without sheath shall be laid on | their flat side, The sample of sector-shaped cores shall be placed on a suppgrt witha fitting sector-shaped. The forced shall be applied in a direction of perpenslicular to axis of the core. The'blade shall be also perpendicular to the axis of the core =. e Calculation of compressing force:- | ‘The force F, in Newton, shall be exerted by the blade upon the test ‘Sample is given by the formula: \ F=kV2D0-5" \ ! Where: i k= isa coefficient according to relevant cable standard , if no value specified | according to standard, shall be: \ + 0.60 for flexible cords and cores of flexible cables. : | k —+ 0.60 for cores , with outer diameter of test sample = 10 mm. Kk 0.80 for cores with outer diameter of test sample > 10 mm 5 mean value of thickness ofthe insulation of test sample (mm) D— mean value of the outer diameter of test sample (mm)" ‘The force applied on the test piece of flat cord without sheath shall be twice the value given by the above formula. The calculated force may be rouided off downwards by not more than 3 %. The time period of keeping the sample in the testing position according to the cable standard, or if the time not specified than the given criteria shall be applied: ‘Scanned with CamScanner rf4 hour= The cores having rated VoIuKE Wor veewnnne ooo ; and cable size not exceeding 35mm7— = The cores of cable exceeding the above limited and of all cables having a rated voltage exceeding 1.8/3 Kv 6 hour s . i Pressure test at high temperature for P.V.C Sheath (Heat distortion test): TEC:- 540-1982(Clause-8.2) Sampling: . | \ - \ For sheath 3 adjacent pieces shall be taken having length of 2500 mm to 500 mim which the covering , all the internal parts, inner covering,armoury etc,have been removed. i ‘The length of each sheath piece shall be 50 mm to 100 mm( the greater Values for the larger diameter). | Preparation of sample:- | Each sheath piece, a strip, enclosing about one-third of the circumference} shall be cut in the direction of the axis of the cable if the sheath does not - have ridges. . i Ifthe has ridges, the strip shall be cut in the same manner and these Ridges shall be removed by grinding. Ifthe sheath directly applied on a concentric conductor , an armour or a Metallic sor%en, than the sheath shall not be removed and the whole cable} Shall be used as test piece ‘The sample kept in the apparatus: . \ 1 ‘The strip shall be supported by a metal pin or tube, the pin supports the | strip an d the blade is pressed against the outer surface of the test sample. ‘The force shall be applied in the direction perpendicular to the axis of the pin ' i Calculation of compressing foree:- \ ‘The force F, in Newton, shall be exerted by the blade upon the test ‘Sample is given by the formula: \ F=kV2D8-8 Where: isa coefficient according to relevant cable standard ,ifno value specified | according to standard, shall _ k -+0.60 for flexible cords and cables. k —+ 0.60 for cables , with outer di meter of test sample < 10 mm k 0.80 for cables, with outer diameter of test sample > 10 mm_,, 5 — mean value of thickness of the (est sample of sheath (mm) ‘Scanned with CamScanner1D —+ mean value of the outer diameter of test sample of sheath (mm) i ‘The time period of keeping the sample in the testing position according to the Ne standard, or if the time not specified than the given criteria shall be applied: | “4 hour = The test piece having an outer diameter not exceeding | 12.50 mm | ‘The test piece with an outer diameter exceeding 12.50mm = 6 hour Color Fastness Test for Insulation & Sheath l= Color Fastness o Water: ret _ A piece of core about 100mm long , from which the conductor has been removed (or apiece | Of sheath about 100mm long, from wl 1 the cores have been removed) shall be cut into small; Pieces and than immersed in, about 10 time its own volume , of stlled water for 48 hours ata | “Temperature of 70 °C. AL end of this period the water shall be examined Result Obtained: — “The color of insulation and sheath shall be fast to both water and to sunlight. ~ Ms Color Fastness to Day Light: Procedure: “The length of core or sheath, as appropriate, shall be exposed to day light on the rack Exposure ease {ogether with cut of the standard color patterns for a suicien length oftime to | Cause change of color in the test piece (B.S. 1006, Determination of fastness to cay light of colored ante. Length of one end ofthe test piece shall be suitably wrapped so as to exclude daylight from ‘This position 7 : ‘The test piece shall be fixed the top aid bottom on the rack go thatthe wrapped 2° ave at he fon He eave rely exposed and he remaining inch rest onthe fower batten. No test pece shall Be placed within % in of any other tet piece, or within | in, of the end of the spaces between the | Battens , to permit free 2’¢ circulation round the test pieces and to avoid any shadowing . ' “The slandered color patterns shall be exposed on the same rack, they shall be fixed YA in. apart \ Ina special support s0 the flap covers that.S in. of each standard the next ine is freely ' Exposed and the remaining haf inch rest on the lower edge of the suppor. “The test pieces all be removed from the rack, cleaned with soap and cold water, dried and examined Indoor, and comparison with the standard pattems. The change color of the test piece and the standard Shall Lave contrast with the exposed portion of the Lest piece and standard respectively equivalent To contrast Grade 4 on the international Geometric Grey Scale (B.S. 1006). \ Sel ‘The test is made in still air with flaming with the burner in the vertical position , the flame is adjusted so thatthe over-all height of the flame in 10 cm with an inner blue cone 5 em; The bumer is than supported so that its axis is at an angle of 45 degree to the vertical i “The sample is held in vertically , in such a position thatthe tip ofthe inner cone of the flames touches the surface of the sample at distance of approximately 10cm from the lower tend The sample is held in the flame for | minute Ifthe insulation or sheath burns it shall be ‘so slowly and the burning shall not spread appreciably, any flame shall have died out in | Jess than 30 second after removal of the burner : ‘Scanned with CemScanner rn\ + WRs t 60 +294 / 25= 71.76 or 72 Second= 1 Minutes \ & 12Second i W= wt of 600mm sample of cable in gram, & T= Constant ‘Time contain to burn the sample = Angle of burner = 45°C ‘ Overall diameter of cable greater than 50 = Use 2 bumer Overall diameter of cable Less than‘50 = Use 1burner 1 Length of blue flame = 50mm Length of yellow flame = 75 mm i Flame capacity = 0.74mm wire should burn at least shown radish within 3 to 4 minutes | Test sample length 600 mm according to the apparatus Measurement of _chuckhole From the burner flame ‘The flame length from burner to the end of flame = 250 mm (max) From the upper clump The flame length from Upper clump to the finish point of the flame =50 mm (min) 1EC-331-Part-t a i ‘Scanned with CamScanner/ZOWER CABLE TESTING : NIDC Specification P-29:2010 (15000 VOLT XLPE) ~ Insulated Stranded Circular & Compacted Aluminum/ Copper Conductor on he Cross-sectional area of conductor to be tested:- 35m’, 120mm?., 240mm? , for Single & Three Core Power Cable i 500mm’ Only for Single Core. | INSULATION i Physical Requirement:~ i |: TS , (min) 1.275 Ke/mm? ! . Il ELONGATION, (min) 200% ' Physical Properties Aer Aging:- . ‘ Aging Treatment:- 135 °C & 3 (for 168hours) in air oven \ TIS unaged value (min) £25% ' ) Elongation unaged value(min) . 25% ' Water Absor | “Afier immersion in water at 85 «2°Cfor 336 hours , the mechanical Water absorption shall not exceed 1.0 mg/cm? Hot Set Test:~ a i I Temperature At 2004 3°C. | \\:- Time under load. 15 minutes t Wk Mechanical Stress 20 N / sq.cm (20.40 Kg/sq.nm | IV Max, Elongation under load:- 175 % ! Vs- Max.permanent elongaton 15 % ! Allercooling \ Loss of Mass after ageffig, Maximum:- i 1.50 mg/ om? ' e Cold Bend Test:- i - 15°C £2 °C as per IEC 60811-1-4, Clause 8 1 High Voltage A.C. Test:- A.C. Test voltage 30.5 Kv for 5 minutes. ! Direct current voltage Test:- i Each length of cable , withstand a DC test voltage of three + times ‘The AC test voltage for 15 minutes. i CRONA LEVEL: i Bach length of cable shall be comply with the minimum Corona Level 13.05. " t SHORT CIRCUIT CURRENT TEST: ‘The test will be carried out according to the KEMA Specification (Kema: $8, 1981). ‘Scanned wih CamScanner‘CAPACITY & POWER FACTO) Samples of insulated conductor shall be immersed in water at room temperature for a least 24 hours, After which measurement shall be made at voltage corresponding t To an average stress of 1575 volts/inm based on the insulation thickness (4.50mm). The measured ‘Values shall beas follows: | Direct constant , max 38 | Power Factor, max. Percent 2.0 1 \ Polyvinyl Ciloride SHEATH: \ Physical Requirement Overall sheath | a) TIS, min.( Ke/mm?) 1.275 | b) Elongation , min . Percent ( %) 150 Physieal Properties After Aging:- i) Air oven Temp, (°C) 1002 Treatment time period (Hours) 168 TIS unpaged value (min) 425% . Elongation iunaged value(max) 425% =n ciaks x Meat Shoe! IEC 608T1-3-1 Clajse-9 - Air oven Temp, (°C ) 150 #3 i ‘Trealment time period (Hours) L : Result No cracks Stee! Wire Armouring:- i Tolerance in wire’ (mrr'y 5% Weight of Zinc Coating 195 g/m? (min) i Tensile Strength (Kg/mm? ) 28.12 49.21 | Gauge length:- 250mm Min, elongation 10% 1 Lay Length:- { “Armouring shall be laid up with a left or right hand lay but in opposite direction to the lay of core s. The length of lay shall not exceed 30 times , the diameter over inner PVC (separator) sheath, Shrinkage Test i ‘Treatment Temperature:- 130°C (#3) (P-29:2010) Duration under Treatment:- { Hour ‘Max Permissible Shrinkage:y 4°% Sampling:- (P-29:2010) ‘A sample about.0.2m (200mm) from the length of core shall be tested feet away : | meter from the end of the cable length. ‘Scanned with CamScannerSample preparation:- { | All covering ,shall be removed from the sample of insulated conductor . The sample at least Length of 200 + ‘5mm shall be marked on the middle part of the sample. The distance between The marks shall be by accuracy ‘of 0.50mm. The sample shall than be prepared by removing the insulation both end of sample up to 2mm to 5mm away from the marks. ! Test Procedure:- | ‘The sample shall be placed on tale{ calcium carbonate ) spread on the tray by bares ends ¢ conductor supported horizontally in an air oven. The temperature of the treatment and the ime period specified in the relevant cable standard. | Results Obtained:- ! ‘The sample shall be examined after cool the sample at room temperature. i ‘The distance between two marks measured again to nearest to 0.50mm, the difference between the distance between the marks before the heat treatment and after the heating Ahad cooling shal be recorded as a percentage ofthe distance marks before the treatment Cable Sample Lents 0.5 meter Ce 50" (Ae Msn te Tempel, Keep he sane fr 30 Mini the Oven an Mesure the Resins wi the Mutineier athe ange Conair Seren pe = Rexx (De~ Te) Te/2he Cone Seen = 1200) Conta Sen = 2000.0) Son il Se Tek 2 tc mesrig Legh lion Sen pl R= T)# TU i Instat Seen = 50 (3) i ain Seen SOD. MY) sot ae dn Sn Wn) x Soe Te) Disc easing Fgh For Example *«, ‘ . Conder geen 38.106" 3.1416 01 ~0390)x090 05, : Insulation Sereen = 7.1 x 10° x. 3.1416 (200.80) x 0.80/2x 0.50 1 Conductor Sereen = 3.8 x 10x 3.1416 (0.031 ~ 0.0009) x 0.0009 / 0.5 = 646.8647 Q.m Insulation Screen = 7.1 x 10° x 3.1416 (0.02 - 0.0008) x 0.0008 /2 x 0.50 = 342 Q.m ‘Scanned wih CemScanner[T Nominal cross-section al area of conductor imum No . of Aluminum wire. Sq.) ts 120 [240 [300 1S [30] z 5] Minimum No . of Copper wire | Complete Conductor diameter “8 18 Mi M 57 Maw Deine of CogteAU Car 20 ~gree (Olin/Km) 0.868 | 0.253 [0. 00s 5 bic nermancs af Conic Cpa Conuaora 30 aepeeTOhmRay OSE] OUE [OMT fe i 666 | | i2'30 | 17.60 rs0- [iso |a0,| drab ‘Nominal Thickness of XLPE Insulation(mm) 4s 4s 45 45 7 | Nominal Thickress oF semi-conductng compound layer over conductor (mm) —_[070__[0.70_[ 070 07 | Nominal Thickness of semi-condueting compound layer over Insulation (mm) [0.70 [0.70 | 0-70 [070 10 | DC resistance of copper screen at 20 degree (Ohm/Km) Tas] 113] 0027 | oz TI | Nominal thickness of PVC over sheath (mm) = Single Core (Un-armoured) | 160 | 140 [39, |230 1g0 | 210 | 230 | 260 = Single Core (Armoured) j = Three Core 2m” [99s | aa 72 | Nominal Thickness of PVC separation Sheath = - Single Core(Armoured) iA re ia te = Three Core i Ta }20 [20 [250 73 | Din of AL- armouring wire(mm) for single core cable bia [Din of Galvanized- anmouring wire(am) for Three core cable” 230/250) 3-13_| = 17 Power quency test voliage est for 4 Hour on Smetr sample able(kV_ rms) { 35—_1 7° aE 1a Feet Tequnty text voage est orSminoneach manufactured length of | [30.5 | 30.5 | 303 305 individual cove om a reel (KY #ms) I ; 7 Partial Discharge on each manufactared lenglh of eable for routine Tope | Tope | FOpC | Tp tes(Max,) i Te | Partial Discharge La each manufa test(Max,) tured length of cable for prototype | 5eC | 5pC | SC | Spc od ‘Scanned wih CamScanner