INSTRUMENT CABLES VARIOUS TEST METHODS Following various tests had been done at M/s. Delton Cables Ltd.

1) Acid Gas Generation Test ( Standard : IEE-754-Part-I ) :Chlorine %age should not be more than 20% . Steps : Outer sheath insulation : 0.839 gms was taken. ( As per Std : Insulation weight should be in between 0.5 ~ 1.0 gm ). Heated in a furnace up to 800 deg.C for 20 minutes. Dilute chlorine gas collected in a NOH solution. Then, by Titration method, Chlorine was analyzed to 14.75%. Test Report is available. 2) Oxygen / Temperature Index ( Standard : ASTM D - 2863 ) :Oxygen Index : 29% and Temperature Index : 250 deg.C. Cable should start burning at 29% oxygen at 250 deg.C. Various readings were taken by an Analyzer and found cable start burning and remain in burning condition at @ 37% at a 435 deg.C temperature. Test Report is available. 3) Test Method For Detection Of Rodent and Termite Repulsion Agent :Objective : To determine the presence of Lead nepthanate in PVC compound. Steps : A Few chips of PVC sheath was ignited in a furnace at a temperature 600 deg.C. The resulting ignited ash is boiled with a little ammonium acetate solution (10%). A drop of sodium sulphide solution was placed in a filter paper and was allowed to soak. This drop was converted to Black spot in a filter paper, indicated the presence of Lead the anti-termite and anti-rodent compound. 4) Smoke Density Test ( Standard : ASTM D - 2863 ) :Smoke density should not be more than 60%. Standard volume cubes of PVC sheath were burnt in Smoke density Analyzer (Photometric). Various readings at 15 second time interval were taken for 3 samples.

Average smoke density was found 44.41%. A test report is available. 5) Thermal Stability Test ( Standard : IS 5831 ) :PVC compound should not get decomposed i.e. insulation/sheath colour should not change up to 200 deg.C for , 40 minutes for Sheath colour and 80 minutes for Insulation colour. The Pieces of specified size of PVC of primary insulation ( B/W, R/B/W ) and Outer / Inner sheath ) were kept in oven with pH paper on each pieces. No colour changes were found up to 110 deg.C. Oven temperature could not be raised beyond this. A Test Report is available. 6) Persulphate Test ( Standard IS-10810 ) :It is for annealed tinning uniformity on drain wire strand. Steps :A piece of drain wire was merged in a Ammonium persulphide solution for a 10 minutes. Its colour should not change to Blue. No colour change was found. This confirmed the tinning uniformity. 7) Dip Test ( Standard IS-10810 ) :It is for Galvanization Uniformity of Armour wire. Steps :A piece of GI armour wire was merged in copper sulphate solution for minute. colour should not change to red. No colour change was found. This confirmed the galvanization uniformity. 8) Zinc Coating on Armour ( Standard IS-10810 Part-41 ) :Mass of Zinc should not be less than 95 gm/m2. A GI armour pieces- 4 nos. (125 mm length) were weighed. Readings were noted down. Same pieces were merged in HCL for 2 minutes. Again, same pieces were weighed. There was a weight difference, which indicated presence of Zinc. By entering the weight difference in a standard formula, mass was found 125, 102, 160 and 167 gm/m2 respectively.

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Sheath Tensile Strength and Elongation Test ( Standard IS-583 ) :Red/Black/White insulation and Sheath pieces (Specified size) were tested on a machine. Readings were noted down as mentioned below : Red Insulation : 1500 mm length : Elongation 75 mm : 18.2 N/mm2. Black Insulation : 1500 mm length : Elongation 80 mm : 20.42 N/mm2 White Insulation : 1500 mm length : Elongation 80 mm : 19.98 N/mm2 Inner Sheath : 1500 mm length : Elongation 70 mm : 16.36 N/mm2 Outer Sheath : 1500 mm length : Elongation 70 mm : 16.85 N/mm2

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GI Armour Tensile Strength and Elongation Test ( Standard IS-583 ) :GI Armour pieces were tested on a machine. The Readings were noted down for T.S. and Elongation ok. 1500 mm length : Elongation 10.4 % : 452 N/mm2. 1500 mm length : Elongation 16 % : 418 N/mm2. 1500 mm length : Elongation 16.8 % mm : 456 N/mm2. 1500 mm length : Elongation 16 % : 448 N/mm2. Changes in armour diameter were taken in to account.

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Heat shock Test :PVC Insulation and Sheath pieces were kept in oven up to 150 deg.C for 1 minute. No crack should develop. No crack was found.

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Heat shrinkage Test :A conductor having PVC Insulation of 200 mm were kept in oven up to 150 deg.C for 15 minute. Insulation length should not be less than 192 mm due to heat shrinkage. Insulation length was found 197 ~ 198 mm.

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Flammability Test :The Cable pieces of 2.5 mtr were burnt. Burning should stop atleast before 0.5 mtr. Only 0.75 mtr cable burning was observed.