Specification No. CSC-111/R-1/DH/UH/P&D/2016-2017 TECHNICAL SPECIFICATION OF ~ 6.5/11 kV TR-XLPE Power cables (Armoured) for sizes 1CX35, 50, 95, 120, 150, 185, 300, .400'and 500 mm2 ” and 3CX35, 50, 95, 120,150, 185, 300, 400-and 500 mm2 we BRE , Towser, Bors, 3er /FO TY Issue Month:June-2016 Common Specification Committee 2: (CSC Amendment date 14.06.2016 UBBYN.& DHBVN: Page 1 of 15The specification covers design, manufacturing, testing, packing, supply & delivery on FOR destination basis of 11 KV, single and three core, Water Tree Retardant (TR)- Cross linked Polyethylene (XLPE)insulated dry (gas) cured, PVC sheathed, Armoured power cables for effectively earthed systems, 2. Standards: ‘Unless otherwise specified, the cable shall conform: in all respects to IS 7098-Part-2 (2011), 48 8130-1984 and IEC::80502 IS. 5831-1984,1S 10810-1984,IS 3975-1999 and 18 10418-1982 standards with lutest amendments thereof, 3. Climatic conditions: Location Haryana 2” | Maximum ambient air 50 degC temperature [3 | Minimum ambient air (5 deg C temperature 4 TAverage daily maximum 40-deg C ambient temperature 5 [Max yearly weighted average | 32 degC ambient temperature 6 | Msoceraunic level 45 days/year 7 | Maximum altitude above 1000 meters “| mean sea level imum relative humidity | 26% 3 | Max. relative humidity 100% 10 | Average no of rainy days/ ‘20 year 1i__| Basic Wind Speed a7m/s [427 Tavg. Annual rainfall ‘300 mm 13 | Pollution ‘Moderate 14__| Maximum wind pressure. 195 ke/ m sq 15 | Sesimic Zone Zone-V, tH Note: Moderately hot & humid tropical climate is conducive to rust & fungus growth. ‘The climatic conditions are also prone to wide variations in ambient conditions. Smoke is also present in the atmosphere. Heavy lightning also occurs during June to October. 4. Principal Parameters: 1 Voltage grade (Uo/ U} [6.35/12 kW 2. Cores [3 Nos Page 2 of 153. 4. Highest Systern voltage 3. System Frequency LS Variation in:fraguency. My ‘a. Maximum allowable temperature under continuous cureent condition b, Maximum alowable temperature under 250 DegC ~ short circuit coadition & System earthing =: = Effectively earthed: 5. Conductor: ~ - ‘The conductor of the cable shall be made from high conductivity, Electrolytic, H4 Grade, ‘esistance* stranded:dluminiam to form compacted arid circular shaped: within: limits ee given in-Appendix-1) ‘as: specified in IS °B130/ 1984 with latest ameridanehts. The aluminum conductor shall be of class-2 as per IS 8330. 6-- Conductor sereen/ shicid: The condor sre hed hall ean extruded ayer of senting compound 0 confine the electrical ficld to the conductor. The allowable éperating ‘temiperatires of the conductor shield shall be equal-to or greater than those of the insulation, The conductor sereen shall be extruded in the same operation in Which the insulation is extruded. The cable rating. ‘The interface between the €xiruded conductor screen.and i free of any voids. The volume resistivity of the screen material shall tot exceed meter at 90-degC:Nute:Tapes are-notaedeptable, 7° Insulation: ‘The insulation shall be suitable for LLKV system vollage and the insillating miateril shall be cross: linked Poly Ethylene (XLPE), cured by Dry curing process: ad applied: by ‘extrusion ‘process as per 1S~7098-end its tatest'amendments. The insulation shall be an > extrusion“of dry cured thermosetting cress linked poly ethylene; water ‘tree. retardant material rated for 90°C continuiens uperation. “The bidder shall ‘submit the description of dry/ gas curing process with the clear inclusion of equipmients/ parameters involved. The insulating material shall-have excellent electrical properties with regard to resistivity, dielectric constant aiid loss factor and shall have | tensile strength and resistance 10 abrasion. This shall not deteriorate at elevated tempetatires or ‘immersed in water, The-insulation shall-be*preferably fire resistant: and resistant to. chemicals like acids, alkalis, oils and ozone, The insulation properties shall be stable under thermal. conditions ‘atising out of continuous operation at coriductor temperature of 90°C rising momentarily to, 250°C under short circuit’ conditions.-%t shall be free from any foreign material or ‘porosity {it withotit' damaging the conductor. Page 3 of 18 jon shall be so applied that it fits closely on thess ‘The extruded water tree xetardant (TR) XLPE insolation’ shat be of very high degree of Purity. The manufacturer should provide the certification that the TR-XLPE compound used has proven track record;-Manufacturer.shall also submit Accélerated Water Tree ‘Test(AWTD@Accelerated Cable: Life Test(ACLT) céttificate also. The manufacturer shall maintain record of TR XLPE compound which may be verified by émiployer at any time doting production. The ttee retardant cross linked polyethylene insulation should be insulation should be good and insulation should climatic conditions. The average thickness of insulation shall not be'iess than the nominal valve as specified in IS: 7098 (Part 11) with-latest amendments, No tolerance on the negitive side shall be transient operating conditions, : 5 Eccentricity of insulation shall not exceed. 15. ‘percent us per-annex-A, ofS: 7098(Part i): 8 Insulation sereen/éhleld:~ : os ‘The insulation sere to be pivided over the instlaton Shall be of Non-metallic, Semi Conducting polymer to. confine the: field-.to: the insulatién.Over' ‘the © semicorkcting screen a metallic sereening-of copper tape: sball’be provided which shall ‘eOpper be generally.ax per IS: 7098 (Pax-Il) with latest amendments, The seini-canducting Compound shall be suitable for the operiting temperature of the cable-and: compatible with the insulating material. : 2 ‘The insulation screen shall be an-extruded. layei® ‘of’ semi-conducting compound and. Continuously covers the. whole area of the insulation: The insulation screen shall:-be- extruded in the same operation as the conductor sétegit and the itisalation, called triple head extrusion. The semiconducting screens should ‘effectively cross linked to achieve 90°C cable rating. ‘The contact surface between insulation and insulation. sereen shall:be smooth, and free from protrusion and irregularities. The interface: between. the insulation: and insulation screen shall be free of any voids, insulation screen shall be'strippable:type.:” ‘The metallic screen shall consist. of a layer of copper tape applied:in helical form to be applied over the insulation screen, &. 9.. Water swellable tape: 3... ee Under the copper tape, water swellable tape of semiconducting material shall be provided on'each core. The weight of the tape shall be 118 gms. Sq m, The swell height shall.be >= 12 mm in 1 minute, The ‘water swellable tape should be compatible to strippable/‘non- strippable semi-conducting insulation screen over Whick itis applied, 10, Core identification Yor three core cabsies only): Individual core of multi-core-eables' shall be colour coded and/or numbered for’ proper identification in accordance with clause 14,1 of 1S: 7098 (Part ~ I1)-2011. Page 4 of 15"11 apap rs tea 2 In three. core ‘cables, the cores shall bé laid together with a suitable right-hand lay. The interstices shall be filled with non-hygroscopic material, Polypropylene, PVC fillers arg’ not acceptable, Further, the compounds used with fillers shall be such as to have no- deleietigiis effect on other components of the cable andto be stable at cable temperatures. ‘Inner sheath {common covating): a ‘The laid up cores shail. be provided with inner sheath applied by extrusion process. It shall be ensured that the shape is as circular as possible. It shall be applied to fit closely onto the laid up coves ard shall be possible to remove easily without causing any damage to the underlying insulated cores and sereeris. ~ ‘The thickness of the inner sheath shall be as given in (Table 3, Clanisé 16.3), as per IS: 7098 (Part - II}. No tolerance: ‘pensgatve side shall be sesepable- 13. Armorings - “Tie anor ‘cables shall consist of either galvanized round steel wires oF galvanized formed wires is Be¥ clause 17:2 of IS: 7098 (Part fl) The armouting shall be applied such that the minimum area of coverage shall be 90% and the gap between any two armoitr strips’ wire shall not be more than the width’ of strip’ diameter of armour wire. The galvanized stee! strips shall comply with the requirements of 1S;,3975-1988 with latest amendments. In case of Single core cable Non-magnetic aluminium armouring’ shall be: used, exact details shall be finalized during detail ceagineeting. The dimensions of the. galvanized steel strip shall be-as per 1S: 7098 Part-II... (Table 6, Clause 17.3Method (ii), Method (i) is not acceptable) 2011 with latest amendments, No tolerance on the negative side shall be acceptable, _ 214. Binder Tope: Rubberised cotton tape shouldbe provided over thesis em 15, Outer sheath: ‘The iiiér shetth shall consist of extruded tough outer of PVC compound insulation over the armouring. The PVC compound for she outes.sheath shall conform to type'ST-2 of IS: 5831 - 1984 (amended. up to date) with suitable additives (to prevent attacks by rodents and termites) shall be provided. ‘The color of the outer sheath shalf be black. The cable must meet all the requirements of the #8: 7098 (Part 2) - 2011 amended up to date and shall bear ISI mark. “46. Discharge free construction; “Ws inéeeoudctoe sed: TR-XLPE: inl, and ide aula shield shall be extruded With'a true triple extruder head ising # dry‘ curé ‘process. The coriductor sereeti, Insulation and Insulation screen shalt all be exiruded in single point at ane time process to ensure-homogeneity and Féduction of voids, in the insulation and the screening system of tho-eable; “The-bidders shall submit thie manufacturing technique adopted by their manufacturers to achieve this motive. " # Page Sof 1SThe Nigam may will order the verification of true triple extrusion dry cure process at ‘iamufscturer's works as 4 jte qualification, Dura verification if ts found thatthe firm ‘not manufacturing the cable with true triple extrusion dry-eure process the offer shall be rejected, 17-General: = a Alll materials used in manufacturing of cable shall-be:new, unused and of finest quality. Ab! materials should comply with the requitemmenits / tests as per applicable 1S. /1EC specification, Indian Electricity Roles and any. other: statutory regulations. “ ana : ‘The purehaser reserves the tight to ask for documentary evidence of thé’ pufchase of various materials. (to be useil for the; manufacture of cable).as'a part of quality control. Quality Assurance plan shall be submitted. Each of cable. type. and ize ‘shall be ISI certified. The manufacturer shall. submit self certified Xerox.copy: of valid ISI license with the offer. sos aTy 20. Operation: “ )) Cable shail be suitable for operation. under frequency variation of 13% and voltage varlation of. +10%:'to’ 45% and-combined frequeticy ~ ‘Voltage Variation of 10% (absolute sum). 2 ii) Cable shall be suitable for laying in air, in duict or buried underground directly or through trenchless boring. - iii) Cable shall havé'Hieat & moisture resistance’ ‘& design with proven record _ BAyTests: All the cable types (1C or 3C).and sizes ic. items offered should have been fully type tested as per IS 7098 (Part-2)-2011 with amendments upto date at-any, NABL accredited Laboratory’ Test house. if the manufacturer's lab is accredited by NABL then it shall be acceptable for type testing. bidder shall fumish one set.of authenticated copy of type test zeporis along. with the'offer. These type tests must have been conducted within iast 8 prior to date of Bid opening..For any change between. design/type of already. und the design /-type offered against this specification. the purchaser reserves demand repetition of type tests without any extra cast, For-each type and size the type test shall be got cartied out independently. - The. purchaser also reserves the right to have tests carried. out at his owni cost from an independent ugency, whenever there is a dispute regetding the quality of supply. The type test certificates for type tests shall be furnished as Per 1S 7098 (part-2}-2011 invariably with tho offer Page 6 of 1SThe first lot offered shall not be less than 10% of ordered quantity of each size of 11 KV: XLPE ARMORED CABLE. One sample froin the Ast Lat of 11 KV XLPE ARMORED Cable of each size as received tn purchaser's store shal be selected and sealed by the inspecting officer nominated by purchaser's for getting it type tested at. any NABL accredited testing laboratory. The charges incurred towards type test of the material received in ur stores shale borne by Supplier: Incase sample from first lot fails then: 2 Supplicr shall have to replace the full quantity of the respective iispected lot supplied to various stores and lying unused at stores. 'b. For the quantity already: utilized against the Order in field a deduction @ 15% (Fifteen Percent) of F.0.R. Destination prices of the material supplied shalt be made, «. Sample fom nest lotsa be selected gain for tp test. All-t hargs incited _ towards type test of the material for second time shall be bomie by the Supplicr, ti case ‘sample again fails in the type test then further supplies shall not be accepted 8. Acceptance test: The selection of sample pieces for uvceptance test shal’be as pet Annexate D of IS 7098 (Pan-I1) 2011, of each tot offered for inspectioi or-par-thereof. The minimum shall-be ‘one drum, The soceptance tests shall be carried ‘as per IS:.7098 (Part-Il) 2011 out on the selected samples. All the acceptance tests shall be carried out ‘by tthe firm, in the. presence of purchaser's representative at their works. The firm shall give atleast 15 days advance notice to the purchaser to enable him fo depute ‘the engineer for witnessing the tests. The test certificates for acceptance tests witnessed by inspecting officer! engineer shall be subinitted for approval before dispatch of material. ¢, Routine Tests: The following shall constitute the routine tests. The Inspector may: also. inspect the routine tests atthe time of inspettonas pr Clause 20°72 of 18: 7098 (Part-I) ~ 2011. 22, (Quality Assurance Plan: A detailed list of bought out items which got'into the manufactire of cables should be furnished indicating the name of the firms from whom these items are procured. The bidder shall enclose the quality assurance plan invariably along will offer followed by hhim in respect of the bought out items, iteins manufactured: by him & raw materials in process as well as final inspection, packing & marking. The Company niay’at its option ‘order the verification of these plans at manufacturer's works a3 a pre gutlificalion for technfeally accepting the bid Page 7 of 1S~ 23, identification mark: ‘The olter sheath of the cable shall bear following identification parameters embossed at intervals of length of one meter of cable, throughout the cable + 2a: iy Name of manufacturer ji) Year of manufacture ii) Voltage grade iv) Size of cable ¥) Cable code wi) ‘Name of purchaser “ DHBVN”. vil) “ISI certification mark. viii) Successive length 24.1 The cable shall be wound on non-tetumable steel/wooden drums as.per relevent IS:-and packed in drums'suitable for vertical / horizontal transport, as the case may be and shall be‘sultable to withstand rough havidling during transport and outer storage. The outer surface of the drum shall be painted with white aluminum paint. Similarly, the inside ‘surface of drum shall have ‘the protective layer of varnish / paint. . 24.2 The wooden drums shalt be réinforced with steel binds and strips for better protection. “24.3 - Length: For single and three core cablés, ‘the cable’ ‘shall be supplied:in standard drum fength of 1000 meters +/- 5% tolerance’ for ali the sizes of cable except for 300 mm2 cable and above, The cable length for sizes 300 smmm2’and above’ shall be 500 meters +/- 5%, Overall tolerance in total Quantity of ordered cables shall be +/- 2%, 24.4 The ends of the cable shall be sealed-by:means-of nion-hygroscopic heat. shrinkable type sealing material. 24.5, The following information-be stenciled on the crum with either water proof ink or oil paint: i, Reference of IS / TEC standatd, i, Manpfacturer’s name or trademark, ili, Type of cable and voltage grade. iv. No. of cores, v. Nominal cross-sectional area of conductor. Cable code, ‘the dram ix, Direction of rotation of dum (by means of an arrow) x. Position of outer end of cable xi. Nigam’s technical specification number. wii, Year of manufacture xiii Reference of Tender No. /P.O. No. date Page 8 of 1Sxiv Property of “SDHBVN”. xv, Name of consignee and the destination, ‘Xvi ISI Certification Mark. 24.6 247 ‘The firm shall be responsible for any damage to the cables during transit due to improper and iniadequate packing. Wherever ‘necessary, proper. arrangement for lifting, such as lifting hooks, shall be provided. Any cable found short inside the packing cases shail be supplied by the supplier, without any extra cost. _ Facti consignment shall be accompanied by a detailed packing ist, containing the following information: “@) Name of consignee © (b) Details of consignment (c) Destination {@} Total weight of consigiiment (@) Handling and unpacking instnuctic + (0 Bill of materials, indicaring contents of eipacage. 25. Inspection: 25.1° ‘The inspection may be carried out by the purchasér ‘at any stage of 25.2 25.5 28 manufacture. The successful bidder shall graiit free access to the purchaser's representative -at-Feasonable time, when the work ls in progress. Inspection ‘and acceptance, of aby cables under this specification by the purchaser, shall not relieve the supplier of his obligation of supplying cable in accordance with the specification and, shall ‘not ‘prevent subsequent rejection, if the cables are not found as per the technical specifications. ‘The supplier stall keep ‘the purchaser informed in advance ‘about the ‘programme of manufacturing of cables so that arrangement can-be made for inspection. ‘The purchasér reserves the right to insist for witnessing the acceptance / routine tests of the bought out items. ‘The manufacturer shall be responsible to pay penalty of Rs 20,000/- for each occasion at which the fake inspection call has been made or the material is rejected, during testing/inspection by the authorized agency/representative of the Nigam. This penalty would be in. addition to the expenses incurred by the Nigam in-deputing the Inspecting Officer, carrying out such inspection. ‘At least 5% of total numbers of drums subject to minimum’of 2 in each lot put up for inspection shall be selected at random to:.ascertain the Jength/workmanship of cable by the following method: At the work.of the manufacture, the cable shall be:transferred from one drum to another for checking any manufacturing defects in the cable drurr ‘selected for conducting acceptance tests, at. tthe same time measuring its Page 90f15length with the help of pulley & cyclometer ‘graduated-in presence of inspector. The difference in the measured length thus obtained from the Geclared length by the supplier in the packing list shall he ay drums if the cable is fouind short: g checking the sample fot (s). 25.7 The supplier shall present the latest Calibration Certificate(s) of testing instrumenits/equipments to be used for the testing of the material covered in the Purchase Order to the authorized inspecting officer /inspecting agency of the purchaser. The testing instruments / meters /apparatus etc. should be ‘got calibrated by the supplier from time to time from an independent testing laboratory / house having valid accreditation. from: National Accreditation Board for testing and calibrating faborataries for the testing equipment or from original manufacturers having traceability to NABL /NPL. The calibration = certificate(s) should not in any case be older than one year-at-the time of. presenting the same.to the inspecting officer / inspecting agency ofthe Purchaser, The testing instruments / equipment should be duly sealed by the Calibrating Agency and mention thereof shallbe indicated in the calibration certificate(s). . 26. Documentation: . oe 26.1" The bidder shall furnish following documents along with his offer-~ Sectional view, showing the General constructional feature with coniductor / conductor screen / insulation / armoring / inner and outer sheath etc. . 26.2 Drawing of cable drums with details of material dimension and paint ete, 26.3 All the required type test reports. 26.4 Literature, pamphlets for the supplied items. 27, Technical and guaranteed particulars: ‘The bidder shall furnish all ‘Guaranteed Techical Particulars, as called for, in Appendix - 2 of this. Specification. Particulars, which are subject to guarantec, shall be clearly identified. Offer not cotitaining these information ‘will not be considered for acceptance, 28. Challenge Causes. . ‘The material offered/reccived after the inspéetion by the authorized inspecting officer may again be subjected to“test for ‘any parsimeter from any’ testing” bouse/in-house technique‘of the Nigam & the results if found devinting/ un-acceptable or not complying to Technical specification, the bidder shall arrange: supply the replacement within thirty (30) days of such detection at his cost including to:2& fro transportation. In addition, penalty (@10% of cost of the inspected lot of material shall be imposed. Page 10 of 1529. Warranty Period: = ; ms The ‘supplier shali be responsible to replace, tree of cost, with. no. twansportation or insurance cost-to the purchaser, up to destination, the whole or any part to the materiaf which iti normal and proper use provedas defective ity quality or workmanship, subject’ the condition that the detect is noticed within from the'date of commissioning. The consignee or any other officer of Nigam actially using the material ‘ill gi notice of each such defect to the supplier. The replacement shail be effected. by” the supplier within a reasonable time, but not, in any case, exceeding 45 days/ ‘The supplier shall, also, arrange'to remove the defective material purchaser reserve the right to dispose of-defective material-in any manner-considered fit by him (purchaser), at the sole risk and cost of the supplies: Any sale proceeds of the = defective material after meeting the expenses. incurred on its custody, disposal handling’ ete, shall however be crédited to the supplier's account and set off against’ any’ outstanding dues of the purchaser againit the: supplier. The “warranty shall be for the ~* entire duration of the warranty period. The Nigam's Quality assurance plan for the inspection. of material at ‘manufacturer's factory,” post receipt ‘inspection at Nigam’s stores/, tumkey ‘litractor's site stares , dispatch of material, supply lots, countéi checking etc is “jn force for the’ procurement and: turnkey works which shall:-be applicable, as the case may be,alongwith upto date amendments;itany. fi Page 11 of 1SNominal cross entinuous rant aig Tor Tver sectional area of | core cables (Amps), conductor (sq mm) [inground [invait 35 i a5 a5 _ ‘resistance at 20:deg¢ mm} f0hms/ km) sec) Se 35 0.8680 3.29 +. ss ‘50 0.6410 470 ~ 95 0.3200 8.93 120 0.2530 11.28 150 0.2060 14:10 185 0.1645 17.39 300) 04000 728.20 ‘400 0.0778. 37.60 ‘500 0.0605 ‘47.00 Page 12 of 18EDI GUARANTI -- (ER CAB i i Quoted ‘Standard to which cable conforms. ale [ea]z. Conductor Details = a) Material compositions class as per 18:8130 b)' Shape of stranded condiictor c): Number of strands in each care (Min) d) Diameter of each strand e), Nominal.cross section area.of each core. f) Guaranteed weight. of--2tuminum per" Core per Km (min): 5. |Conductor'Screen a) Material b) Thickness (min) 6. ~ Insulation 2) Material with ref. of ISS b) Thickness of insulation (mm) (min): 7 Thsulation Screen a) Material 1). Semi Conducting Part 2) Metallic Part b) Thickness for 1). Semi condiicting part (rin). 2) Metallic part (min) INNER SHEATH a) Material b) Thickness (min; Filler material ‘ARMOURING a) Material b) Dimension of Flat sriaurog stripfwire iW OUTER SHEATH a)’ Material b): Thickness of sheath Cento) 15 cable ss Gross weight of drum including cable (approx) Recommended depth of laying __ Page l3 of 1517__[Short circuit withstand current for 1 sea. ‘current a). When laid diréety:in ground b) When laid directly in covered treneh” ..£}_When faid directl 18 [Voltage drop per thousand m length-at rated "] 19 | Impulse voltage withstand | Derating factors under ve rious conditions oF installation 2) D.C resistance per core at 20°C {Max |b) AC impedance per-core at ) ¢)_ AC Reactance per core at 206C (Max) 4) Capacitance per core Je) Insulation resistance at 27:C (Min) Volume resistivi at 270€ (Min) 21 [Maximum partial discharge-magnitude at 5 |= Uo 22° [Maximum cable charging current at normal. operating voltage 23 [Recommended minimunt ‘bending radius? material a) Aluminium b) PVC compound ¢). XLPE compound d) Galvanized steel strip for armouring ‘e) Any other 24 | Name of manufacturers of bought out raw f 25. JA) Whether same cable has been type tested? If yes, when and where it was tested B) It is expected that-you wilkenciése:an -» -:, authenticated electrostate-copy.of type test of same design, size and type of cable, i) Please inform whether or not you have enclosed thesame. - how main sheats does it contain. % [2 whoie-drum? Tf yes, Details in iat Weer aT Teros parts shall be treated with rust preventive: finish or coating? [it-yes, detalls in brief. 28 | Whether water proof paper layer “shall ‘be “fapplied to the surface of dim and over the {outer cable layer? ‘29° [Reference of license in use OFIST end ithe certification marks, if-any SS I Page 14 of 15- [ene air een fa azo ocr Dated For M/s Place Signature (By its constituted attorney) ‘Note: The tenderes should clearly note that above guaranteed technical particulars are to be given only in the proforma given above and not in random form. Technical particulars. given in any other forma shall not be considered. Any extra information can be given separately in the form of Annexure to above technical particulars Page 15 of 15