3.

CABLES
a. SCOPE:-
This specification covers design, manufacturing, testing and delivery of ISI
marked 1100Volt grade, weather proof solid Aluminium conductor, PVC
insulated, PVC sheathed, heavy duty galvanized single flat steel armoured Cable
of 4 core 10 sq. mm suitable for overhead service lines.
b. APPLICABLE STANDARDS:-

All the Cables shall conform to the requirements of following standards with
latest amendments, if any:(i) IS:1554-(PART-I)1988with latest
ammendments.
for working voltage up to and including 1100 Volts)
(ii) IS:694:1990 PVC insulated Electric Cables for working
voltage up to and including 1100 Volts
(ii) IS:8130-1984 Specification for conductors for insulated
electric
cables
(iii) IS:5831-1984 Specification for PVC insulation
and
sheath of electric cables.
(iv) IS:3975-1979 Specifications for mild steel wires, strips
and taps for armouring cables
(v) IS:10810-1984 Methods for test for cables
(vi) IS:3961-(PART-II) Recommended current ratings for PVC
1967 insulated and PVC sheathed heavy duty
cables
(vii) IS:4905-1968 Methods for random sampling
(viii) IS:10418-1972 Wooden drum for electric cables

c. GENERAL TECHNICAL REQUIREMENT:-

i. CONDUCTOR: -
Aluminium conductor used in power cables shall comply to the requirement of
IS:8130-1984 with latest amendments and shall be in accordance with clause
8.1 & 8.2 of IS:694-1990 with latest amendments.

ii. PVC INSULATION, FILLER & INNER SHEATH: -

1. PVC insulation used shall comply to requirement of IS:5831-1984 with latest
amendments.

2. PVC insulation shall be suitable for continuous conductor temperature of 70ºC

under normal operation and 160º C under short circuit conditions. Insulation
The insulation shall be applied by
extrusion so that it fits closely on the conductor and it shall be possible to remove it
without damage. The average thickness of insulation shall not be less than nominal
value (ti) specified in Table 2 of IS: 694-1990.

3. The laid up cores shall be provided with inner sheath applied either by extrusion
or wrapping. It shall be ensured that the shape is as circular as possible. The
inner sheath shall be so applied that it fits closely on the laid up cores and it
shall be possible to remove it without damage to the insulation. The thickness
 of inner sheath shall be as in Table-5 of IS-694-1990.

iii. ARMOURING:-
The galvanized steel wires/ strips shall comply with the requirement of IS:3975-1979
with latest amendments. Armouring shall be applied over the inner sheath. The armour
wire/ strips shall be applied as closely as practicable. A binder tape should be provided
on the armour. Type of armour and its dimension and procedure for its lying and joints
shall comply to the requirement of clause 13.2, 13.3, 13.1.3 & 13.4 respectively of
IS:1554(Part- I)1988 as amended up to date. The D.C. resistance of galvanized steel
wire/ strips armour shall be measured and the result when corrected at 200 C shall
comply with approximate value given in Table-6 of IS:1554(Part-I)1988 as amended
up to date
iv. OUTER SHEATH: -
The material of the sheath shall be of Type ST-1 PVC compound confirming to the
requirements of IS:5831-1984. The outer sheath shall be applied by extrusion over the
armouring and shall be so applied that it fits closely over armouring. It shall be possible
to remove it without damage to inner sheath. The colour of outer sheath shall be black.
The minimum thickness of PVC outer sheath shall not fall below the nominal value
(ts) specified in IS:694-1990 by more than 0.2 mm + 0.2.
v.OVERALL DIMENSIONS :-
The mean overall dimensions of the cables shall be as specified in table-5 of IS:694.
The 2 core cables shall be flat. The difference between maximum and minimum
measured value of overall diameter of sheathed circular cables shall not exceed 15% of
the maximum measured value.
vi. CORE IDENTIFICATION:-
Core shall be identified by Red and Black in case of 2 core cable in
accordance with table-7 of IS:694-1990.
3.1 IDENTIFICATION, PACKING & MARKING:-
3.2 Identification:-
-1990
following marking shall also be embossed over outer sheath at every meter.
3.2.1.1Cable size and Voltage Grade.
3.2.1.2Name of Manufacturer
(b) Word CSPDCL- Developed under RDSS
The embossing shall be increasive, automatic in line throughout the length of the Cable
and shall be legible and indelible.
3.2.2 Packing & Marking :-
3.2.3 a) The cable shall be wound on a drum (ref. IS 10418-1972) of suitable size
and packed. The packing shall be robust for rough handling that is occasioned
during transportation by rail/road. The ends of the cable shall be sealed by means
of non-hygroscopic sealing material.

b) Te cable should carry the following information stenciled on the drum :-

i) Reference to Indian Standard
ii) mark
iii) Type of cable and voltage grade
iv) Number of cores
v) Nominal cross-sectional area of the conductor
vi) Cable code
vii) Colour of cores
viii) Length of cable on the drum
ix) Number of lengths on drum (if more than one)
x) Direction of rotation of drum by means of an arrow
xi) Approximate gross weight
xii) Running end of cable
xiii) Country of Manufacturer &
xiv) Year of manufacture

3.2.4 Mark:-
The Cable (Drum) must bear
photo-

documents, the cable shall not be accepted.

3.2.5 Standard Length:-
The standard length of cable shall be 250 mtrs/500 mtrs. with plus minus 5%
tolerance.
3.3 TESTS:-
Following type tests, acceptance tests and routine tests are to be carried out in
accordance with clause-15 of IS/1554 (Part-I) 1988 with its latest amendments as
indicated below :-
3.3.1 Type Tests: The following shall constitute type tests:-
Sl Tests For requirement For test method
. Ref. to Ref. to part No.
of IS:10810
A TEST ON
CONDUCTOR
i Tensile Test IS:8130-1984 2
ii Wrapping Test IS:8130-1984 3
iii Conductor Resistance IS:8130-1984 5
Test
B TEST ON ARMOURING
WIRES/STRIP
Sl Tests For requirement For test method
. Ref. to Ref. to part No.
of IS:10810
i Measurement of Table-5 of IS:694 - 36
Dimension 1990
ii Tensile Test IS:3975-1979 37
iii Elongation Test -do- 37
iv Torsion Test (For round -do- 38
wires only)
v Winding Test (for strips -do- 39
only)
vi Uniformity of zinc -do- 40
coating test
vii Mass of zinc coating test -do- 41
vii i Resistance Test -do- 42

C TEST FOR THICKNESS IS:694 - 1990 6

OF INSULATION AND
SHEATH
D PHYSICAL TEST FOR
INSULATION AND
OUTER SHEATH
i Tensile Strength & IS:5831-1984 7
elongation at break
ii Aging in Air oven -do- 11
iii Shrinkage Test -do- 12
iv Hot deformation -do- 15
v Loss of mass in air oven -do- 10
vi Heat shock test -do- 14
vii Thermal stability -do- Test method as
per IS:5831-
1984 shall be
followed
E ISULATION IS-5831/1984 43
RESISTANCE TEST
F High Voltage Test Clause 16.2 of 45
(Water immersion test) IS:694 - 1990
G High Voltage Test Clause 16.2 of 45
(at room temperature) IS:694 - 1990
H Flammability Test Clause 16.4 of 53
IS:1554
(Part-I)

3.3.2 Acceptance Tests:

The following shall constitute acceptance tests:-
Tensile Test (for aluminium)
b) Wrapping Test (for aluminium)
c) Conductor resistance test
 d) Test for thickness of insulations and sheath
e) Tensile strength and elongation at break of insulation and sheath.
f) Insulation resistance test
g) High voltage test at Room temperature

relevant ISS at the time of material inspection for the purpose of clearing the lot offered
by the bidder. Acceptance test shall be carried out in each type and size of cable, on
cable drum selected at random as per following sampling plan :-
No. of No. of drums/reels to Permissible
drums/reels in be taken as sample no. of
the lot defectives
Up to 50 2 0
51 to 100 5 0
101 to 300 13 0
301 to 500 20 1
501 & above 32 2

3.3.3 Routine Tests: - The following shall constitute routine tests:-

Conductor Resistance test
High voltage test at room temperature
The above routine tests shall be conducted by the bidder in accordance with relevant
ISS and test certificate, as proof of it, shall be submitted to the Employer along with
each inspection offer. In absence of routine test certificate, the inspection offer shall not
be considered valid and any or all complication arising out of it Employer shall not be
responsible.
3.4 OTHER IMPORTANT TECHNICAL REQUIREMENT OF TENDER:-
Cables shall be designed to withstand mechanical electrical and thermal stress
developed under steady state and transient operating conditions.
3.5 TYPE TEST CERTIFICATE:-
The bidders are advised to submit certified photo copy of type test certificates in respect
of each size of cables for type tests given in Table-8 of IS:694/1990 from the Govt.
National Test House, ERDA, CPRI or any other NABL accredited laboratory. The
above type test certificate should not be more than five years old on the date of opening
of the tender. The tenderer shall confirm that they will supply the material exactly for
the design for which type tests have been conducted. In absence of requisite type test
certificate, the offer is liable for rejection.

3.6 INSPECTION:-
All the tests and inspection may be conducted at the place of manufacturer unless
otherwise specifically agreed upon by the manufacturer and purchaser at the time of
purchase. In case of inspection at works, the manufacturer shall offer all reasonable
facilities to the purchaser without charges to satisfy him that the material is being
furnished in accordance with the specification. In
 order to ensure that quality of raw materials used during manufacturing of PVC Cables
is as per requirement of IS:694/1990, the inspecting officer shall check quality of raw
material, obtain necessary invoices in proof that raw materials used are of desired
quality.

In addition to above, on receipt of Cables at consignee Area Store, the purchaser has
the right to have any or all type/acceptance test carried out through an independent
NABL accredited lab like ERDA, CPRI etc. to ascertain the quality of supply. In case
the material fails to pass the test as per specification, the entire lot shall be rejected and
the testing charges along with the other charges which may likely to be incurred for
arranging the testing through independent lab shall be recovered from the supplier. In
addition to this, action as deemed fit, may be taken against the supplier.

Guaranteed Technical Particulars for 4 core 10 sq. mm. Armoured LT Aluminium

stranded conductor PVC Sheathed and PVC insulated 1100 Volt grade Cable as per IS:
1554(Part-I)-1988
The following information should be furnished for the quoted size of cable:
SN Particulars Details to be furnished by the tenderer
1 Name of manufacturer & Address
2 Size/Type of Cable
3 Whether your product confirms to relevant ISS
(please specify the Standard applicable)
4 Whether material offered is ISI mark (Give ISI
marking license no. and its validity period).
5 Rated Voltage
6 Permissible voltage & frequency variation for
satisfactory operation.
a. Voltage
b. Frequency
7 Continuous current rating when laid in air in an
ambient temp.
a) Current in Amp.
b) Ambient Temp. in Degree C
c) Conductor Temp. in Degree C
8. Short Circuit Current carrying capacity
a. Short circuit Current in Amp. (RMS)
b. Duration of short circuit
c. Conductor temperature allowed for short
circuit duty (in Degree C)
9. Conductor
a. Grade of Aluminium (Please confirm that
conductor shall be of Class-2).
b. name)
c. Nominal cross sectional area (in sq. mm.)
d. Number and diameter of wires
e. Weight of conductor per coil of 100 mtr. In
Kg.
10 Insulation:
a. Type of insulation
 b. name)
c. Thickness of insulation in mm.
d. Tolerance on thickness of insulation
e. Colour Scheme for identification of cores.
f. Weight of PVC compound used for insulation
for 1.0 Km.
11. Inner sheath
a. Type of PVC Compound used.
b. name)
c. Extruded or wrapped
d. Thickness of inner sheath (in mm.)
e. Calculated diameter over the standard cores
f. Tolerance of thickness of inner sheath
12. Outer sheath:
a. Type of PVC Compound
b. name)
c. Thickness of the outer sheath (in mm)
d. Tolerance of thickness of outer sheath
e. Weight of PVC Compound used for outer
sheath of cable (per Km.)
f. Calculated diameter under the sheath
13. Armour:
a. Type of armour
b. name)
c. Nominal diameter of cable under the armour
d. Nominal dimension of strips or nominal
diameter of round wires
e. Minimum no. of dips (one minute) for
galvanised formed strip.
f. Minimum weight of Zinc coating (in gms/sq.
mtr.)
g. DC resistance of armour.
14 Overall diameter of cable over the outer sheath
15 Whether double extrusion processed.
16 Conductor resistance at 200 Centigrade per Km.
17 Insulation resistance constant at 270 Centigrade per
Km
18 Volume Resistivity (per Km) at
i) 270 C (Ohm-cm)
ii) 700 C (Ohm-cm)
19 High Voltage Test
i) Voltage applied (in kV)
ii) Duration for which voltage applied.
20 Standard Coil Length
21 Net weight of cable (Kg/Km)
22 TYPE TEST CERTIFICATE:
i) Whether you have submitted certified copy of
the type test certificate of any Govt. Institution/
Govt. recognised Testing laboratory for each of the
offered items for all the tests as per relevant ISS.
ii) Whether you agree to conduct test on item
selected by
your works or from your supplies already made
even though your design is tested as per
 stipulations made in the specification.
23 Quality Assurance Of Raw Material
i) Whether the material will be supplied by you by
using raw material from stock/own quota (if not,
then how do you propose)
ii) What is the quality assurance programme
regarding procurement of raw material part used in
the finished product and at different stages during
the manufacturing of the product?
iii) Indicate your quality assurance programme in
details (please enclose the method proposed to be
adopted for the same)