Spec 22472

SPECIFICATION: PC-E-236/REV.NO.
1
NUCLEAR POWER CORPORATION OF INDIA LTD
TECHNICAL SPECIFICATION ON PAGE : 3 of 24
EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES REV. No. : 1
1.0 SCOPE
Manufacture, Testing, packing, delivery and Guarantee of various types and sizes
of annealed tinned copper conductor EPR insulated and LHLS Sheathed
unarmoured control cables generally conforming to IS-9968 (Part-1) and IS-6380
for two reactor units of 700 MWe PHWR project.
2.0 CONTENTS
Requirements of this specification are presented under the following section

headings:
Description Section
Applicable standards 3
Materials & workmanship 4
General Function and Description 5
Design requirements 6
Inspection, Test and Reports 7
Shop Tests 8
Packing and Shipment 9
Information required with the bid 10
Colour codes for cores & sheaths Annexure-A
Technical details require Annexure-B
Quality assurance Plan (Sample) Annexure-C
3.0 APPLICABLE STANDARDS
3.1 IS-9968 (Part I): Specification for elastomer insulated cables for working
voltage upto and including 1100 volts.
3.2 IS: 6380: Specification for elastomeric insulation and sheath of electric cables.
3.3 ASTM-D-2843: Standard test method for density of smoke from the burning or
decomposition of plastics.
60110/PC-E-236 JUN 2010

SPECIFICATION: PC-E-236/REV.NO.1
OR
3.4 IS-10810-63: Measurement of smoke density of electric cables under fire

conditions (supplier to indicate the acceptance criteria which is equivalent to
ASTM- D-2843 vide section no.6.4 of the Spec.)
3.5 ASTM-D-2863: Standard method for measuring the minimum oxygen

concentration to support candle like combustion of plastic (Oxygen index and
Temperature index.)
OR
3.6 IS-10810-58: Oxygen Index tests.
3.7 IEC-754-1: Determination of the amount halogen acid gas evolved during the
combustion of polymeric materials taken from cables.
OR
3.8 IS-10810-59: Determination of the amount of halogen acid gas evolved during the
combustion of polymeric materials taken from cables.
3.9 Swedish Svensk Standard-424-14-75 (Class F-3): Swedish Chimney Flame Test
OR
3.10 IS-10810-61: Flame Retardant Test.
3.11 BS-6360 (or IS-8130): Specification for conductors for insulated electric cables and
flexible cords.
3.12 IS-10810: Methods of tests for cables.
3.13 VG 95218-Part 66: Mutual capacitance for elastomeric compounds
3.14 NES 713: Determination of the toxicity index of the products of combustion from
small specimens of materials.
4.0 MATERIALS AND WORKMANSHIP
4.1 The materials and processes for the components of cables and their assembly shall
be chosen as specified here-in. Material shall be thermoset. Use of any substitute
shall be suitably qualified in terms of its electrical, mechanical and physical
properties and the details shall be submitted by supplier for purchaser’s approval.
All the materials and processes which are not specified herein shall be chosen so
as to enable the purchased product to meet the performance requirements of this
60110/PC-E-236 JUN 2010

specification. The construction of cable shall in general conform to IS-9968 (Part-

1) and IS-6380. Vendor shall have proper machinery for steam vulcanization / e-
beam facility.
4.2 Workmanship
Workmanship shall be of high industrial quality to ensure the product to be

uniform in quality and free from all defects and deformities so as to perform its
required function in the specified environment as mentioned in this specification
over an expected plant life of 40 years.
5.0 GENERAL FUNCTIONS AND SPECIFICATION
5.1 The cables shall be suitable for continuous and reliable operation at maximum
conductor temperature of 90 C and voltage upto and including 650V for core to
earth and 1100 V for core to core.
5.2 Environment conditions
Normal operating conditions

Ambient temperature from 8ºC to 45ºC and relative humidity up to 90 %
Occasional/Storage conditions
Ambient temperature from 5ºC to 55ºC and relative humidity up to 95 %
6.0 DESIGN REQUIREMENTS
All materials used should be first class and of standard conforming to the
requirements of this specification.
6.1 Conductor
Conductors shall be made of annealed tinned solid or stranded as the case may be,
Copper conductor in accordance with BS-6380 or IS-8130. No joints of any kind
in the conductor are allowed.
6.2 Insulation
The insulation shall be 90 C EPR type IE 2 of IS-6380 and shall be meeting all
physical and electrical properties requirement of this standard. No. joints of any
kind in the insulation are permitted. Insulation shall be applied by pressure
extrusion process and curing by steam vulcanization / e-beam method. The colour
of insulation shall be as per Annexure-A of this specification for each type of
cable.
60110/PC-E-236 JUN 2010

6.3 Core Identification
Colour code to identify the cores of all the types of cable shall be as per
Annexure-A of this specification. Shades of colour shall match with BS-6746C.
6.4 Sheath
Sheath material shall be LHLS type SE 3 meeting all physical requirements as

specified in IS-6380 respectively with anti termite compound. The oxygen index
shall not be less than 29 as per ASTM-D-2683 or IS-10810-58 and smoke density
shall not be more than 20% when tested as per ASTM-2843. Smoke density test
may be conducted as per IS-10810-63. Supplier to indicate the acceptance criteria
which is equivalent to 20% smoke density rating as per ASTM-D-2843 of test if
done as per IS-10810-63. Test shall be conducted for 12 minutes instead of 4
minutes as specified by the standard (4 minutes testing as mentioned in ASTM
standard is for PVC plastics. Since elastomeric compound specified here, do not
conform exactly to the standard, test shall be conducted for 12 minutes). HCL
emission shall not exceed 2% when tested as per IEC-754-1 or IS-10810-59.
Toxicity Index shall not exceed 5 when tested as per NES 713. It should be
possible to strip the sheath without damaging the insulation. Sheath shall be of
black colour. Sheath shall be applied by extrusion process using steam
vulcanization method.
6.5 Construction detail of cables
6.5.1 2.5 sq.mm 2 core unshielded cable
Each conductor shall be 2.5 sq.mm annealed tinned solid copper conductor
insulated with EPR of 1.0 mm (nominal) + 10% wall thickness by pressure
extrusion process and curing by steam vulcanization / e-beam method. Such 2
cores shall be laid up. Over the laid up cores shall be applied 25 micron thick
mylar tape helically and then sheathed with 1.10 mm nominal + 20% thick wall of
LHLS by pressure extrusion process and curing by steam vulcanization / e-beam
method. A rip cord shall be provided below the sheath for easy stripping of
sheath. The overall diameter shall not exceed 11.20 mm.
6.5.2 0.75 sq.mm 1 Core unshielded wire
The conductor shall be 0.75 sq.mm annealed, tinned, solid copper conductor
insulated with LHLS of 0.65 mm (nominal) + 10% wall thickness by pressure
extrusion process and curing by steam vulcanization / e-beam method. The overall
diameter shall not exceed 2.5 mm.
60110/PC-E-236 JUN 2010

6.5.3 4 sq.mm 2 core unshielded cable
Same as 6.5.1 but stranded conductor size of 4.0 sq mm (7 x 0.85) and sheath
thickness of 1.20 mm nominal + 20%. The overall diameter of cable shall not
exceed 12.5 mm.
Same as 6.5.1 but 3 core and stranded conductor size of 6 sq.mm (7 x 1.04),
Sheath thickness of 1.2 mm (nominal) + 20%. Overall diameter shall not exceed
14.5 mm.
1 core and stranded conductor size of 10 sq.mm (7 x 1.35) , insulation with 1.20
mm nominal + 20% thick wall of LHLS material by pressure extrusion process
and curing by steam vulcanization / e-beam method. Overall diameter shall not
exceed 11 mm.
1 core and stranded conductor size of 16 sq.mm (7 x 1.7), insulation with 1.20
mm nominal + 20% thick wall of LHLS material by pressure extrusion process
and curing by steam vulcanization / e-beam method. Overall diameter shall not
exceed 12 mm.
6.6 Cable identification
The following particulars shall be embossed on the cable outer sheath through out
the length of all the cables at a span of 1 meter.
a) Name of the manufacturer
b) Year of manufacture
c) LHLS cable
d) Voltage grade: 650/1100 volts r.m.s.
e) Size of cable
It may be noted than embossing on the cable outer sheath is preferred to printing.
60110/PC-E-236 JUN 2010

TECHNICAL SPECIFICATION ON PAGE: 8 of 24
6.7 Coil Lengths
The cables shall be supplied in coil lengths of 500 meters 10%. Coil lengths of
100m to 449m are considered non-standard lengths and such lengths of only 10%
of ordered quantity are acceptable. Lengths less than 100m are not acceptable.
7.0 INSPECTION TESTS & REPORTS
The Supplier shall be responsible for all the tests and inspection as mentioned in
this specification and any other tests which may be necessary to assess the
required performance of the cable. The characteristic and performance of the
cable shall conform to this specification on completion of tests.
The purchaser or his representative shall have right to access to manufacture’s

premises at all reasonable times for following up the manufacturing activities and
validation of testing procedures to ensure that quality of performance meets this
specification.
The purchaser shall have right to conduct at his own expenses any additional
inspection and testing deemed necessary by him.
Quality surveillance relating to all aspects of manufacture shall be carried out by

the purchaser. The supplier shall provide all the testing and inspection services
and facilities satisfactorily as required. Inspection shall be carried out in
satisfactory manner and shall be subjected to approval by the purchaser. A sample
Quality Assurance Plan (QAP) has been enclosed with the specification. The
supplier shall prepare an inspection plan based on enclosed sample QAP and
submit to purchaser for approval.
Three copies of test reports and certificates of compliance stating the material is
in accordance with the requirement specified in the specification shall be
furnished by the supplier.
8.0 SHOP TESTS
The following tests shall be carried out.
8.1 Type Tests
Applicable Standard
8.1.1 Annealing test for copper BS-6360/IS-8130
8.1.2 Conductor Resistance Test BS-6360/IS-8130
8.1.3 Measurement of diameter of conductor BS-6360/IS-8130
60110/PC-E-236 JUN 2010

8.1.4 Persulphate Test for copper (Conductor) IS-8130
8.1.5 Measurement of thickness of insulation and sheath IS-9968 Part I but

minimum values of
thickness of
insulation & sheath
tolerance shall be as
per section no. 6.5 of
this spec.
8.1.6 Tensile test on insulation and sheath IS-6380
8.1.7 Elongation test on a) Insulation IS-6380

b) Sheath BS 6899
8.1.8 Hot set test on insulation and sheath IS-6380
8.1.9 Accelerated ageing test on insulation and sheath IS-6380
8.1.10 Swedish Chimney Flame Test SS-424-14-75 (F-3)/

(Swedish Svensk Standard) IS-10810-61
8.1.11 High Voltage test At 1.5 KV as per

IS-9968 Part-1
8.1.12 Insulation Resistance Test IS-6380
8.1.13 Measurement of overall diameter --
8.1.14 Oxygen Index & Temperature Index tests on sheath ASTM-D-2863/

IS-10810-58
8.1.15 HCL Emission Test on sheath IEC-754-1/

IS-10810-59
8.1.16 Smoke density rating test on sheath ASTM-D-2843/

IS-10810-63 with
test duration as per section
no. 6.4 of
the specification.
60110/PC-E-236 JUN 2010

(Supplier to indicate the

acceptance criteria which
is equivalent to ASTM-D-
2843 vide section no.6.4
of spec. if test is done as
per IS-10810-63)
8.1.17 Measurement of mutual capacitance between core and VG 95218-Part 66

capacitance between any core and sheath
8.1.18 Toxicity Index Test on sheath NES 713 (Applicable for

same lot. If lot changes
than test is to be repeated)
8.1.19 Termite Proof Test on sheath As per supplier’s

specification. A test
procedure with acceptance
criteria shall be submitted
for purchaser’s approval. A
test certificate shall be
issued.
8.2 Acceptance tests
The following acceptance tests shall be carried out on samples taken from the lot
of each type of cable. The total number of drums of each type of cable offered at
a time shall be treated as lot size. The sample size for the acceptance test shall be
as per Appendix-B of IS-694.
8.2.1 Elongation test for copper BS-6360/IS-8130
8.2.2 Conductor Resistance Test BS-6360/IS-8130
8.2.3 Measurement of thickness of insulation and sheath IS-9968 part-1 but

minimum value of
thickness of insulation
& sheath and tolerance
shall be as per section
no. 6.5 of this spec.
8.2.4 Measurement of overall diameter --
8.2.5 Insulation resistance test IS-6380
8.2.6 High Voltage Test At 1.5 KV as per

IS-9968 Part-1
60110/PC-E-236 JUN 2010

8.2.7 Oxygen Index & Temperature Index test on sheath ASTM-D-2863/

IS-10810-58
8.2.8 Smoke density rating test on sheath ASTM-D-2843/

IS-10810-63 with
test duration as per
section no. 6.4 of
the specification.
(Supplier to indicate the acceptance criteria
which is equivalent to ASTM-D-2843 vide
section no.6.4 of spec. if test is done as per
IS-10810-63)
8.2.9 HCL Emission Test on sheath IEC-754-1/IS-10810-59
8.2.10 Measurement of mutual capacitance between cores VG 95218-Part 66

and capacitance between any core and sheath
8.2.11 Termite Proof Test on sheath Supplier’s specification
8.3 Routine Tests
8.3.1 Conductor resistance test IS-8130
8.3.2 Insulation resistance test IS-6380
8.3.3 High voltage test at 1.5 KV as per

IS-9968-Part-1
9.0 PACKING AND SHIPMENT
The cables shall be so packed as not to suffer deterioration, damage or breakage

during shipment. The ends of the cable should be sealed to prevent ingress of
moisture. Packing should be such that the ingress of moisture, dirt and other
foreign material can be avoided. Packing method shall be adequate to withstand a
period in transit for more than two months and storage at site under a tropical
climate for minimum period of one year without suffering any damage or
deterioration. Each package shall be properly labelled to indicate the type and
quantity of material it contains, purchase order number, dimensions, weight, and
any other necessary data to identify the cable and relate it to the contract.
Supplier shall not ship the material without the prior approval of the purchaser or
his authorised representative and subsequent instruction to do so.
Complete instructions relating to shipping and documentation will be furnished

with the purchase order.
60110/PC-E-236 JUN 2010

10.0 INFORMATION REQUIRED WITH THE BID

The supplier should give the technical details of the cables as per the format given
in Annexure-B.
60110/PC-E-236 JUN 2010

ANNEXURE-A
1.0 COLOUR CODE FOR CORES AND SHEATHS
1.1 1 CORE, 0.75 SQ.MM WIRE
Black
1.2 2 CORE CABLE
Black
Blue
1.3 3 CORE CABLE
Black
Blue
Orange
1.4 1 CORE, 10 SQ.MM & 16 SQ.MM CABLE
Green
2.0 COLOUR FOR SHEATH
For all multicore cables the sheath colour shall be `Black’.
60110/PC-E-236 JUN 2010

ANNEXURE-B
TECHNICAL DETAILS REQUIRE
1.0 Cable General
1.1 Make
1.2 Type reference
1.3 Minimum bending Radius
1.4 Weight of Cable (Kg/Km)
1.5 Voltage Grade
1.6 Continuous working temperature
1.7 Max. overall diameter of cable (mm)
1.8 Coil lengths offered
1.9 Construction details of the cable
1.10 Confirm whether Cable can pass fire retardant test as per Swedish chimney test
2.0 Conductor Material
2.1 Nominal Conductor resistance per Km at 20 degree C/ 27 degree C
2.2 Conductor diameter
2.3 Conductor material
2.4 Conductor material tinned copper as per IS-8130?
3.0 Insulation
3.1 Insulation resistance at 27 degree C
3.2 Insulation material type
3.3 Insulation wall thickness mm
60110/PC-E-236 JUN 2010

3.4 Colour code as per Annexure A of our specification?
4.0 Binder tape (applied on the laid cores before sheathing)
4.1 Thickness of binder tape mm
4.2 Percentage of overlap %
4.3 Material of binder tape mm
5.0 Sheath
5.1 Sheath material type
5.2 Nominal Sheath wall thickness
5.3 Colour of the Sheath
5.4 Oxygen Index and Temperature Index as per ASTM-D-2863
5.5 Smoke density rating as per ASTM-D-2843
5.6 Halogen (HCL) emission as per IEC-754-1
5.7 Toxicity Index as per NES 713
5.8 Termite Proof as per Supplier’s specification
5.9 Deviations
Following deviations if any from the specification shall be clearly brought out in
the offer, otherwise it will be presumed that the offer is in compliance with
NPCIL specification requirements.
5.7.1 Deviations from Specification
5.7.2 Any deviation in test procedure from the Specification.
5.7.3 Any deviation in Cables offered.
6.0 Colour Code
Whether colour code is followed as per Annexure A and section no. 6.3 of our
Specification.
60110/PC-E-236 JUN 2010

7.0 Proof of Capability
7.1 The bidder shall submit a list of similar supplies made by him to standards and
tolerances specified in this tender document. The bidder shall also submit copies
of purchase orders of similar cables executed by them as a proof of capability.
7.2 The bidder shall submit alongwith the offer, a list of manufacturing equipment
available with him on the date of submitting the quotation and a list of inhouse
test facilities available with them for carrying out all tests specified in section no.
8.0 of this specification.
7.3 The bidder shall submit along with the offer the test reports of all the tests
specified in 8.0 carried out by him on similar type of cables.
Bidder shall submit along with the offer descriptive and illustrative literature
covering construction and materials used for the cables offered.
7.4 The vendor information form enclosed shall be filled and submitted along with the
bid.
8.0 Information required after award of Contract
Five (5) copies of History Docket in hard form and soft form shall be furnished.
History Docket shall be made as per PRD-PROC-19. A sample History Docket
shall be submitted to the purchaser for clearance. Once purchaser clears the same,
5 copies of History Docket shall be submitted in hard form and soft form.
60110/PC-E-236 JUN 2010

EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES REV. NO. : 1
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component Characteristic Class TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK CHECK DOCUMENT NORMS OF
RECORDS P W V
1.0 RAW
MATERIALS
1.1 CONDUCTOR
1.1.1 Copper Surface finish B Visual Random sample The conductor shall be The conductor T.C. 2 2 1
conductor smooth & free from shall be smooth &
scratches & burrs free from scratches
& burrs
Diameter B Physical One sample NPCIL Spec.& NPCIL Spec. & -do- 2 2 1
from lot of 10 IS-8130 IS-8130
Conductor C Electrical bobbins/Baskets “ --do-- -do- 2 2 1
Resistance at 20 /Drums or part
deg.C there of
Annealing test C Physical “ “ “ -do- 2 2 1

(Cu)
Tinning test of C Chemical “ “ “ -do- 2 2 1
Cu wire
1.2 INSULATION
EPR (TYPE Type of C Visual One sample per Should be free from IS-6380 T.C. 2 2 1
IE-2) Compound Batch of 10 MT foreign particles
or part there of IS-6380
Tensile strength C Physical IS-10810 Part 7 & IS-6380 -do- 2 2 1
& Elongation “ IS-6380
60110/PC-E-236 JUN 2010

ANNEXURE-C
RECORDS P W V
1.3 BINDER
(Mylar type) Visual check of A Visual Random Sample Shall be smooth Shall be smooth T.C. 2 2 1
Tape
Thickness C Physical -do- NPCIL Spec. NPCIL Spec. -do- 2 2 1

1.4 SHEATH
Visual Check of A Visual Each lot one Should be free from Should be free from -do- 2 2 1
LHLS(Type- material sample per batch foreign particles foreign particles IS-
SE3) Type of C Visual of 10MT or part IS-6380 6380
compound thereof
Tensile strength C Physical “ IS-6380 & BS 6899 IS-6380 & BS 6899 -do- 2 2 1
& Elongation
Oxygen index & C Physical “ ASTM-D-2863/ NPCIL Spec. -do- 2 2 1

Temp. index IS-10810-58
C Physical “ ASTM-D-2843/ NPCIL Spec. -do- 2 2 1
Smoke density IS-10810-63
C Chemical “ IEC-754-1/ NPCIL Spec. -do- 2 2 1
HCL emission IS-10810-59
C Chemical “ NES 713 NES 713 -do- 2 2 1
Toxicity Index
C Chemical “ Supplier’s spec. Supplier’s spec. -do- 2 2 1
Termite Proof
60110/PC-E-236 JUN 2010

ANNEXURE-C
Sl. Component Characteristic Class TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK OF CHECK DOCUMENT NORMS OF
RECORDS P W V
2.0 PROCESS
INSPECTION
2.1 Insulation Type of insulation B Physical Each setting & Approved Data Sheet Approved Data T.C. 2 2 1
Compound once in a shift & NPCIL spec. Sheet & NPCIL
Dimensions/Dia. B Physical -do- “ spec.
over conductor “ -do- 2 2 1
Dimensions/Dia. B Physical “ “
over core “ -do- 2 2 1
Thickness of C Physical “ “
insulation (Avg. & “ -do- 2 2 1
Min)
Spark Testing Electrical 100% IS-9968 IS-9968 -do- 2 2 1
Surface Finish Visual Each setting Smooth and free Smooth and free -do- 2 2 1
from porosity from porosity
Colour Visual -do- NPCIL Spec. NPCIL Spec. -do- 2 2 1
2.2 Laying up Direction of lay C Visual Each setting & Approved data Sheet Approved data sheet -do- 2 2 1
Diameter over B Physical twice in a shift Approved data Sheet Approved data sheet -do- 2 2 1
laidup
Lay length B Physical -do- Approved data Sheet Approved data sheet -do- 2 2 1
2.3 Binding %age overlap/ C Physical -do- NPCIL spec. NPCIL spec. -do- 2 2 1
coverage
Tape Dimensions C Physical -do- Approved data sheet Approved data sheet -do- 2 2 1
NPCIL Spec NPCIL Spec
60110/PC-E-236 JUN 2010

ANNEXURE-C
Sl. Component Characteristic Class TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK OF CHECK DOCUMENT NORMS OF
RECORDS P W V
2.4 LHLS Type of C Physical Each setting & IS-6380 IS-6380 T.C. 2 2 1
Sheath Compound at random
(Type SE3)
Thickness C Physical Each setting & NPCIL Spec. NPCIL Spec. -do- 2 2 1
Average/ twice in a shift
Minimum
Dia over outer B Physical Each setting & -do- -do- -do- 2 2 1
sheath twice in a shift
Colour B Visual During setting NPCIL Spec. Approved Data -do- 2 2 1

& running Sheet and NPC
spec.
Surface finish B Visual In each shift Surface shall be Surface shall be -do- 2 2 1
smooth & free from smooth & free from
porosity porosity
Embossing/ B -do- Each setting & Approved Data Sheet Approved Data -do- 2 2 1
Printing/ twice in a shift and NPCIL Spec. Sheet and NPCIL
Sequential Spec.
Marking
60110/PC-E-236 JUN 2010

ANNEXURE-C
RECORDS P W V
3.0 TYPE TESTS

ON FINISHED
CABLE
3.1 Annealing test for Cu C Physical Random sample IS-8130 IS-8130 TR 2 1,2 1
3.2 Conductor resistance test C Electrical -do- IS-8130 IS-8130 -do- 2 1,2 1
3.3 Dia of conductor C Physical -do- NPCIL Spec. NPCIL Spec. -do- 2 1,2 1
3.4 Thickness of insulation C Physical -do- NPCIL Spec. NPCIL Spec. -do- 2 1,2 1
and sheath
3.5 Tensile & elongation on C Physical -do- IS-6380, IS-6380, -do- 2 1,2 1
insulation & sheath BS 6899 BS 6899
3.6 Hot set test on sheaths C Physical -do- IS-6380 IS-6380 -do- 2 1,2 1
3.7 Accelerated aging test on C Physical -do- IS-6380 IS-6380 -do- 2 1,2 1
insulation and sheath
3.8 Flame Retardant test C Physical -do- SS-424-14-75/ NPCIL Spec. -do- 2 1,2 1
IS-10810-61
3.9 H. V. Test C Electrical Random sample IS-6698 part-1 IS-6698 part-1 TR 2 1,2 1
0
3.10 IR test at 27 C and at C Electrical -do- IS-6380 IS-6380 -do- 2 1,2 1
max. rated temperature
3.11 Dia. of finished cable C Physical -do- NPCIL Spec. NPCIL Spec. -do- 2 1,2 1
3.12 Tinning test for C Chemical -do- IS-8130 IS-8130 -do- 2 1,2 1
conductor & drain
wire
60110/PC-E-236 JUN 2010

ANNEXURE-C
RECORDS P W V
TYPE TESTS
ON FINISHED
CABLE
3.13 Oxygen index on sheath C Physical -do- ASTM-D-2863 NPCIL Spec. -do- 2 1,2 1
/IS-10810-58
3.14 Temperature index on C Physical -do- ASTM-D-2863 NPCIL Spec. -do- 2 1,2 1
sheath /IS-10810-58
3.15 HCL emission on sheath C Physical -do- IEC-754-1 NPCIL Spec. -do- 2 1,2 1
/IS-10810-59
3.16 Smoke density on sheath C Physical -do- ASTM-D-2863 NPCIL Spec. -do- 2 1,2 1
/IS-10810-63
3.17 Toxicity Index on sheath C Chemical -do- NES 713 NES 713 -do- 2 1,2 1
3.18 Termite Proof on sheath C Chemical -do- Supplier spec. Supplier spec. -do- 2 1,2 1
3.19 Measurement of Mutual C Physical -do- VG 95218-Part Approved data -do- 2 1,2 1
Capacitance between 66 sheet
cores and between core
and earth
60110/PC-E-236 JUN 2010

ANNEXURE-C
Sl. Component and Characteristic Class TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No Operations CHECK CHECK DOCUMENT NORMS OF
RECORDS P W V
4.0 ROUTINE
4.1 TESTS Conductor resistance test C Electrical 100% IS-8130 IS-8130 TR 2 1,2 1
4.2 H. V. Test C Electrical 100% IS-9968 part-1 IS-9968 part-1 TR 2 1,2 1
4.3 IR test C Electrical 100% IS-6380 IS-6380 TR 2 1,2 1
5.0 ACCEPTANCE
5.1 TESTS Annealing test on cu C Physical Samples as per IS-8130 IS-8130 TR 2 1,2 1
IS-9968 Part I
5.2 O.D. of cable C Physical -do- NPCIL Spec NPCIL Spec TR 2 1,2 1
5.3 Conductor resistance test C Electrical -do- IS-8130 IS-8130 TR 2 1,2 1
5.4 H. V. test C Electrical -do- IS-9968 part-1 IS-9968 part-1 TR 2 1,2 1
5.5 Thickness of insulation C Physical -do- NPCIL Spec NPCIL Spec TR 2 1,2 1
sheath
0
5.6 IR at 27 C C Electrical -do- IS-6380 IS-6380 TR 2 1,2 1
Oxygen index test on C Physical -do- ASTM-D- NPCIL Spec. TR 2 1,2 1

5.7 sheath 2863/
IS-10810-58
60110/PC-E-236 JUN 2010

ANNEXURE-C
Sl. Component and Characteristic Class TYPE OF QUANTUM REFERENCE ACCEPTANC FORMAT AGENCY REMARKS
No Operations CHECK OF CHECK DOCUMENT E NORMS OF
RECORDS P W V
ACCEPTANCE
TESTS
.
5.8 Temperature index C Physical Samples as per ASTM-D-2863/ NPCIL Spec. TR 2 1,2 1
on sheath IS-9968 Part I IS-10810-58
5.9 Smoke density on C Physical -do- ASTM-D-2843/ NPCIL Spec. TR 2 1,2 1

sheath IS-10810-63
5.10 HCL emission on C Chemical -do- IEC-754-1/IS-10810-59 NPCIL Spec. TR 2 1,2 1
sheath
5.11 Termite Proof on C Chemical -do- Supplier’s specification Supplier’s TR 2 1,2 1

sheath specification
5.12 Measurement of C Electrical -do- VG 95218-Part 66 Approved data TR 2 1,2 1
mutual capacitance sheet
between core and
between core and
earth
5.13 Flame retardant C Physical -do- SS-424-14-75/ NPCIL Spec. TR 2 1,2 1
test IS-10810-61
5.14 Embossing on the B Visual -do- NPCIL Spec. NPCIL Spec. TR 2 1,2 1
cable
LEGEND:
P : Performed by A : Minor 1 : Purchaser (NPCIL)
W : Witnessed by B : Major 2 : Prime Supplier
V : Verified by C : Critical 3 : External Laboratory
TC : Test Certificate
TR : Test Report
60110/PC-E-236 JUN 2010

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Spec 22472

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SPECIFICATION: PC-E-236/REV.NO.

Requirements of this specification are presented under the following section

Materials & workmanship 4

General Function and Description 5

Inspection, Test and Reports 7

Packing and Shipment 9

Information required with the bid 10

Colour codes for cores & sheaths Annexure-A

Technical details require Annexure-B

Quality assurance Plan (Sample) Annexure-C

3.0 APPLICABLE STANDARDS

60110/PC-E-236 JUN 2010

3.4 IS-10810-63: Measurement of smoke density of electric cables under fire

3.5 ASTM-D-2863: Standard method for measuring the minimum oxygen

3.6 IS-10810-58: Oxygen Index tests.

3.10 IS-10810-61: Flame Retardant Test.

3.12 IS-10810: Methods of tests for cables.

3.13 VG 95218-Part 66: Mutual capacitance for elastomeric compounds

4.0 MATERIALS AND WORKMANSHIP

60110/PC-E-236 JUN 2010

specification. The construction of cable shall in general conform to IS-9968 (Part-

Workmanship shall be of high industrial quality to ensure the product to be

5.0 GENERAL FUNCTIONS AND SPECIFICATION

5.2 Environment conditions

Normal operating conditions

6.0 DESIGN REQUIREMENTS

60110/PC-E-236 JUN 2010

6.3 Core Identification

Sheath material shall be LHLS type SE 3 meeting all physical requirements as

6.5 Construction detail of cables

6.5.1 2.5 sq.mm 2 core unshielded cable

6.5.2 0.75 sq.mm 1 Core unshielded wire

60110/PC-E-236 JUN 2010

6.5.3 4 sq.mm 2 core unshielded cable

6.5.4 6 sq.mm 3 core unshielded cable

6.5.5 10 sq.mm 1 core unshielded cable

6.5.6 16 sq.mm 1 core unshielded cable

6.6 Cable identification

a) Name of the manufacturer

d) Voltage grade: 650/1100 volts r.m.s.

60110/PC-E-236 JUN 2010

6.7 Coil Lengths

7.0 INSPECTION TESTS & REPORTS

The purchaser or his representative shall have right to access to manufacture’s

Quality surveillance relating to all aspects of manufacture shall be carried out by

8.0 SHOP TESTS

The following tests shall be carried out.

8.1 Type Tests

8.1.1 Annealing test for copper BS-6360/IS-8130

8.1.2 Conductor Resistance Test BS-6360/IS-8130

8.1.3 Measurement of diameter of conductor BS-6360/IS-8130

60110/PC-E-236 JUN 2010

8.1.4 Persulphate Test for copper (Conductor) IS-8130

8.1.5 Measurement of thickness of insulation and sheath IS-9968 Part I but

8.1.6 Tensile test on insulation and sheath IS-6380

8.1.7 Elongation test on a) Insulation IS-6380

8.1.8 Hot set test on insulation and sheath IS-6380

8.1.9 Accelerated ageing test on insulation and sheath IS-6380

8.1.10 Swedish Chimney Flame Test SS-424-14-75 (F-3)/

8.1.11 High Voltage test At 1.5 KV as per

8.1.12 Insulation Resistance Test IS-6380

8.1.13 Measurement of overall diameter --

8.1.14 Oxygen Index & Temperature Index tests on sheath ASTM-D-2863/