_______________________________________________________________________

Specification No. CSC- 55/DH/UH/P&D/2010-2011

TEHNCIAL SPECIFICATION FOR HT AERIAL BUNCHED CABLE WITH XLPE INSULATION

Issue Month: Sep. 2010

Common Specifications Committee UHBVN &DHBVN

Page 1 of 10

_______________________________________________________________________

TECHNICAL SPECIFICATIONS FOR X-LINKED POLYPTHYLENE INSULATED AND PVC SHEATHED H.T. AERIAL BUNCHED CABLES.

1.

SCOPE: This specification covers manufacture, testing before dispatch, supply and delivery of ISI marked, 11 KV grade XLPE insulated screened all Aluminium conductor and PVC sheathed power cables conforming to IS-7098 (PartIi)/1985 with up to date amendments, suitable for solidly earthed system manufactured with dry cure technology (Nitrogen gas i.e with inert gas curing during using CCV system or with STOPLAS).

2.

APPLICABLE STANDARDS The cable covered under this specification shall conform in all respect with the latest editions of IS-14255: 1995, IS:7098 (Part-II)/1985, IS-398 (part-4) 1979, IS:10810(series)& IS: 8130-1984 or IEC equivalent thereof. The aluminium conductor complying to IS: 8130-1984 shall be used.

3.

CLIMATIC CONDITIONS: The material to be supplied against this specification shall be suitable for satisfactory operation under the following climatic Conditions i) Location At various locations in the state of Haryana 60 -5 40

Maximum ambient temperature (oC) Minimum ambient air temperature (oC) Maximum average daily ambient temperature (oC) v) Maximum yearly weighed average ambient 32 o temperature ( C) vi) Maximum altitude above mean sea level (m) 1000 vii) Minimum Relative Humidity (%) 26 viii) Maximum Relative Humidity (%) 95 ix) Average no of Rainy days/ year 120 x) Average annual rainfall 900 mm xi) Maximum wind pressure 195 kg/m sq. The material shall be for use in moderately hot and humid tropical ii) iii) iv) climate, conducive to rust and fungus growth 4. CONDUCTORS: The Aluminium conductors shall comply with the requirements as specified in IS-8130-1984 with up to date amendments. The stranded conductor

shall be clean and reasonably uniform in size and shape and its surface shall be free from sharp edges. Not more than two joints shall be allowed in any of the wires form and every complete length of conductor and no joint shall be within 300 mm of any other joint in the same layer. Joints shall be brazed, silver soldered or electric or gas welded. No joint shall be made in the conductor once, it has been stranded.

Page 2 of 10

_______________________________________________________________________

5.

INSULATION: The insulation shall be chemically cross linked polyethylene conforming to the physical, electrical and ageing properties as required in the specification, cross-linking may be done by exposure to organize peroxide with nitrogen curing CCV line, method with the intention to ensure lowest free formation. Only natural unfilled compound shall be used for insulation of cables. The average thickness of insulation when measured in

accordance with relevant clause of the specification shall not be less than the standard thickness value specified. The smallest of the measured

values of thickness shall not fall below the standard thickness values as specified in IS:7098 (Part-II) / 1985 by more than 0.1+0.1 standard thickness in mm. 6. SCREENING: The screening of insulated cables shall consist of conductor screening and insulation screening. i) Screening materials: Two types of materials may be used for screening of cables non-metallic and metallic. ii) Conductor screening: Conductor screening shall be non-metallic and shall consist of either semiconducting compound or a layer of extruded-semi-conducting linked ploythine compound of thickness not less than 0.5mm. iii) Insulation screening: The insulation screening shall consist of non-metallic semi-conducting part in combination with a metallic part. Non-metallic part shall be applied either directly over the insulation of each core and shall consist of either a semiconducing tape or a layer of extruded semi-conducting compound or a combination of these materials. iv) Metallic Screening The metallic part shall be applied over the individual core. Metallic

screening shall consist of copper tape sheath and shall be non-magnetic when applied to either in single core or multi-core cables. For single core cables, armouring shall constitute the metallic part of the screening. 7. OUTER SHEATH: Over the armouring the cable shall be provided with extruded PVC outer sheath. The composition of the PVC compound for outer sheath shall be Pre-Type ST2 of IS-5831-1984. The colour of the outer sheath shall be black. The average thickness of the sheath shall not be less than the

standard values specified in the IS when measured as laid in IS-7098 (PartII) / 1985. The smallest thickness of the measured values of sheath shall

Page 3 of 10

_______________________________________________________________________

not fall below the standard value, (s) specified, by more than 0.2+0.2 (ts) mm. 8. CORE IDENTIFICATION: The core identification shall be done by providing coloured strip under Copper Tape. 9. MESSENGER WIRE: Messenger wire, shall consist of Aluminium alloy wires. Aluminium alloy wires, shall be as per IS:398 (Part-IV) / 1978 and wing shall be tested as per relevant IS. 10. LAYING UP: Three Power Cores shall be twisted over bare messenger wire with right hand direction of lay. This will form the Aerial Bunched Cable. 11. 11.1 TESTS: Copies of the type test certificates in respect of all the type-tests as per IS:7098 (Part-2) / 1985 for similar type of XLPE cables, from any Government recognized testing labs shall be submitted along with the tender. 11.1.2 LIST OF TYPE TESTS: a) TESTS ON CONDUCTOR: i) ii) iii) b) c) Tensile test (for Aluminium) Wrapping test (for Aluminium) Resistance test

Test for thickness of insulation and sheath. Physical tests for insulation. i) ii) iii) iv) v) Tensile strength and elongation at break. Ageing in air oven. Hot test. Shrinkage test. Water absorption (Gravimetric)

d)

Physical tests for outer sheath:i) ii) iii) iv) Tensile strength and elongation at break. Ageing in air oven. Shrinkage test. Hot deformation.

e) f) g) h)

Bleeding and blooming test (for outer sheath). Partial discharge test. Bending test. Dielectric power factor test: i) ii) As a function of voltage As a function of temperature

Page 4 of 10

_______________________________________________________________________

i) j) k) l) m) 11.2

Insulation resistance (Volume resistivity) test. Heating cycle test. Impulse withstand test. High voltage test. Flammability test List of type test for messenger wire: a) Breaking load test on individual Aluminium Alloy wire. b) c) Resistance test. Elongation test.

12.2. ACCEPTANCE TESTS: The following shall be carried out as acceptance tests: a) b) c) d) e) f) g) h) i) 13. Tensile test (for Aluminium) Wrapping test (for Aluminium) Conductor resistance test. Test for thickness of insulation and sheath. Partial discharge test (for screened cables only) High voltage test. Hot set test for insulator. Tensile strength and elongation at break test for insulation and sheath. Insulation resistance (Volume resistively) test ROUTINE TESTS: The following shall be carried out as routine tests: a) b) c) Conductor resistance test (for Aluminium and copper) Partial discharge test (for screened cables only) High voltage test. Type test / acceptance test / routine tests and or other test required as per relevant Indian Standard shall be got conducted. 14. INSPECTION: An authorized representative of the Nigam shall inspect, examine and test the equipment/material in respect of quality, size and ratings as per relevant ISS/IEC with latest amendments at the manufacturers works during or after the manufacture of goods prior to dispatch on receipt of a clear notice of minimum two weeks in advance to be reckoned from the date of receipt of the same by the purchaser. No material will be allowed to be dispatched without prior inspection and approval. The inspecting officer of the

purchaser may also inspect the material during the course of manufacture. In case, inspection of any consignment is waived off by the purchaser, the supplier will be required to furnish the requisite test certificates (for acceptance as well as routine tests) for approval. It will be the responsibility of the supplier to make adequate arrangements for testing of material at

Page 5 of 10

_______________________________________________________________________

their works without any additional charge to the purchaser.

All testing

instruments and appliances will be made available and material destroyed/consumed during testing will be to the account of the supplier. The purchase reserves the right to carry out Type Test as per Indian Standard Specifications with latest version thereof. These tests will be

carried out at an Independent & recognized test house/agency/laboratory. All expenses whatsoever for carrying out these tests shall be to the suppliers account. The purchaser has the right to have the tests carried out at any Govt./Recognized Test agency in case of dispute in quality, size and ratings as per relevant ISS. 15 FAKE INSPECTION CALLS In case the supplier makes a fake inspection call i.e., the material is not found ready by the Inspecting Officer deputed by the Nigam for inspection, the supplier shall be liable to pay the expenses incurred by the Nigam on this account subject to minimum of a fixed penalty of Rs. 20,000/- for each such fake call made by him. 16. GUARANTEE / WARRANTEE The supplier shall be responsible to replace, free of cost, with no transportation or insurance cost to the Purchaser, up to destination, the whole or any part of the material which in normal and proper use proves the defective in quality or workmanship, subject to the condition that the defect is noticed within 78 months from the date of receipt of material in stores or 72 months from the date of commissioning whichever period may expire earlier. The consignee or any other officer of Nigam actually using the material will give prompt notice of each such defect to the supplier. The replacement shall 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 within a reasonable period, but not exceeding 45 days from the date of issue of notice in respect thereof, failing which, the 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 supplier. Any sale proceeds of the defective material after meeting the expenses incurred on its custody, disposal handling etc., shall however be credited to the suppliers account and set off against any outstanding dues of the purchaser against the supplier. The warranty for 72/78 months shall be one time. 17. SEQUENTIAL MARKING: Supplier shall provide non erasable sequential marking on one core of AB Cable at every one metre distance before assembly of different cores to

Page 6 of 10

_______________________________________________________________________

form the cable. However, the length of cable for acceptance shall be based on length of finished cable and not on the basis of sequential marks. 18. PACKING & MARKING: The cable shall be supplied in suitable non-returnable wooden drums of suitable size in standard lengths subject to a tolerance of +/- 5%. The cable shall be wrapped with polythene under wooden covering. Each meter

length shall be embossed with the trade name of manufacturer and the work UHBVN CABLE. The ends of the cable shall be sealed by means of non-hygroscopic sealing material. In addition to this each drum shall carry the following information either stenciled on flange or label attached to it. a) b) c) d) e) f) g) h) i) j) k) l) m) n). 19 Manufacturers name. Trade mark, if any. A reference to ISS i.e. IS-7098 (Part-II) / 1985. Length of the cable on the drum. Voltage grade and type of the cable. Colour of outer sheath. Nominal cross-sectional area of the cable conductor. Purchase order No. & Date. Name and address of consignee. Number of cores. Gross weight of packed and net weight of the power cable. Drum No. & its direction of rotation (with an arrow) Year of manufacture. ISI MARK. ISI mark cable shall be preferred. FAKE INSPECTION CALLS In case the supplier makes a fake inspection call i.e., the material is not found ready by the Inspecting Officer deputed by the Nigam for inspection, the supplier shall be liable to pay the expenses incurred by the Nigam on this account subject to minimum of a fixed penalty of Rs. 20,000/- for each such fake call made by him. 20. GUARANTEE / WARRANTEE The supplier shall be responsible to replace, free of cost, with no transportation or insurance cost to the Purchaser, up to destination, the whole or any part of the material which in normal and proper use proves the defective in quality or workmanship, subject to the condition that the defect is noticed within 78 months from the date of receipt of material in stores or 72 months from the date of commissioning whichever period may expire earlier. The consignee or any other officer of Nigam actually using the material will give prompt notice of each such defect to the supplier. The

Page 7 of 10

_______________________________________________________________________

replacement shall 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 within a reasonable period, but not exceeding 45 days from the date of issue of notice in respect thereof, failing which, the 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 supplier. Any sale proceeds of the defective material after meeting the expenses incurred on its custody, disposal handling etc., shall however be credited to the suppliers account and set off against any outstanding dues of the purchaser against the supplier. The warranty for 72/78 months shall be one time. 21. CHALLENGE CLAUSE The material offered/received after the inspection by the authorized inspecting officer may again be subjected to the test for losses or any other parameter from any Testing House/in-house technique of the Nigam & the results if found deviating un-acceptable or not complying to approved GTP's the bidder shall arrange to supply the replacement within thirty (30) days of such detection at his cost including to & fro transportation. In addition to this penalty @10% of cost of the inspected lot of material shall be imposed.

22.

SCHEDULE OF PARTICULARS:-

GUARANTEED

AND

GUIDING

TECHNICAL

The tenderers must supply the detailed guaranteed and other technical particulars as detailed in Appendix-I. For values, use of Dash Do Blank or As per ISS/IEC will not be entertained.

General Manager/P&D Cum-Member Secretary CSC UHBVN Panchkula.

Page 8 of 10

_______________________________________________________________________

APPENDIX-I

GUARANTEED TECHNICAL PARTICULARS FOR HT AERIAL BUNCHED CABLE WITH CROSS - LINKED POLYETHYLENE (XLPE) INSULATION & BARE MESSENGER WIRE (FOR NEUTRAL & EARTHING)

S.N.

Particulars

HT Aerial Bunched Cables Size-1 Size-2 Size-3 Size.. so on

1 2 3 i) ii) iii) iv) v)

vi) vii) viii) ix) 4. i) ii) iii)

iv) v) vi) vii) 5 i) ii)

iii) 6

Makers name & address Rated voltage Phase conductor details No. of phase conductors Nominal cross-sectional area of each conductor-mm No. & size of strands (mm) Minimum tensile strength of each strand-N/mm Diameter of compacted conductor along with tolerance (mm). Approximate mass (Kg/Km) Maximum DC resistance at 20o C (Ohm/Km) Insulation thickness (mm) Standard to which this material conforms Messenger (Neutral conductor) Nominal sectional area of each conductor in mm No. & size of strands (mm) Diameter of compacted conductors along with tolerance (in mm) Approx. mass (Kg/Km) Minimum Tensile strength in KN Max. DC resistance at 20o C (Ohm/Km) Standard specification to which this material conform Insulation of phase conductor Material Whether all properties as mentioned in the technical Specifications are guaranteed if not indicate deviations in properties Standard specification to which this material shall conform Finished cable (complete bunched cable) Overall diameter (approx.) in mm
Page 9 of 10

i)

_______________________________________________________________________

ii) 7. i) ii) iii) 8 9 i) ii) 10. 11 12. 13. 14 15

Total mass (approx.) in Kg/Km Drum Tare weight of drum Whether drum is wheel mounted Standard specification to which drum shall conform Standard length of each cable and its tolerance Total length of cable in a drum and its tolerance Mass of finished cable in a drum and its tolerance Whether material bears ISI certification mark Serial number of ISI license and its validity Max. Continuous current carrying capacity Max. Continuous conductor temperature due to load Embossing Any other particulars

(Suppliers Name & Address)

Page 10 of 10