LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277------

Rev.

Modification

Date

Check

Date

STANDARD DOCUMENT
(LH PROJECTS)

Drawn:

06.11.2009

JSC

Checked:

06.11.2009

AP

Approved:

06.11.2009

ABS

Appd

LV AC/DC POWER CABLE SPECIFICATION

Internal Drawing Number:

Rev.

XXXXXX

Page 1 of 10
THIS DOCUMENT IS THE PROPERTY OF ANDRITZ HYDRO Pvt. Ltd. AND MUST NEITHER BE COPEID NOR USED IN ANY OTHER WAY WIHTOUT
THE WRITTEN CONSENT OF ANDRITZ HYDRO Pvt. Ltd. NEITHER IT IS TO BE HANDED OVER, NOR IN OTHER WAY COMMUNICATED TO A THIRD
PARTY. INFRINGMENT WILL LEAD TO PROSECUTION.OBSERVE THE PROTECTION ISSUE ISO 16016.

LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277------

STANDARD DOCUMENT
(LH PROJECTS)

INDEX

1.

Scope................................................................................................................................................ 3

2.

Code and Standards........................................................................................................................ 3

3.

General Requirement....................................................................................................................... 3

4.

1100 V Single/Multi Core LV Power Cables....................................................................................3

5.

1100 V Two Core DC Power Cables................................................................................................ 4

6.

Cable Identification.......................................................................................................................... 5

7.

Construction..................................................................................................................................... 5

8.

Drum Length & Tolerance............................................................................................................... 6

9.

Warranty........................................................................................................................................... 6

10.

Tests.................................................................................................................................................. 7

11.

Technical Particular......................................................................................................................... 7

12.

Standard Power Cable Used:.......................................................................................................... 7

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LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277------

STANDARD DOCUMENT
(LH PROJECTS)

LV AC/DC POWER CABLE SPECIFICATION

1.

Scope
This document covers the specification of design, manufacture, testing and supply of power cable
for operation & control of the power plant.

2.

Code and Standards

Following standards shall be referred in general

i)

IS: 7098 (Part I)

XLPE insulated (heavy duty) electric cables for

working voltage upto & including 1100 V

ii)

IS: 8130 1984

Conductors for insulated electric cables and flexible cords

iii)

IS: 5831 - 1984

PVC insulation and sheath of electric cables

iv)

IS: 10810 - 1984

Methods of tests for cables

v)

IS: 3975 1988

Specification for mild steel wires, formed wires and tapes

for armouring of cables

vi)

IS: 10462 (Part I)-1983

Fictitious calculation method for determination of

dimensions of protective coverings of cables

vii)

IS: 10418 - 1982

Specification for drums for electric cables

viii)

ASTMD 2863

Standard method for measuring the minimum oxygen

concentration to support candle like combustion of
plastics

3.

General Requirement
Cables shall be generally laid on ladder/perforated type trays/covered trenches. For interplant
connection cables may be directly buried in ground or through pipes. Hence cable shall be suitable
for directly laying in buried trenches with uncontrolled backfill having chances of flooding by water
and susceptible to rodent and termite attack at times.
For continuous operation at specified rating, maximum conductor temperature shall be limited to
the permissible value as per relevant standards.
The insulation and sheath materials shall be resistant to oil, acid, alkalli and shall be tough enough
to withstand mechanical stresses during handling.
Armouring shall be single round/strip wire of galvanized steel for all cables.

4.

1100 V Single/Multi Core LV Power Cables

LV Power Cable will be 1100 V grade, single / multicore, stranded aluminium conductor, XLPE
insulated, extruded PVC inner sheathed of type ST-2, galvanized single round/strip armoured and
with outer sheath made of FRLS PVC compound of type ST-2. Inner sheath is not applicable for
single core cables. Minimum conductor cross section of power cables will be 2.5 sq.mm copper and
10sq mm Aluminium.

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LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277-----5.

STANDARD DOCUMENT
(LH PROJECTS)

1100 V Two Core DC Power Cables

DC Power Cable will be 1100 V grade, two core, copper conductor, XLPE insulated, extruded PVC
inner sheathed of type ST-2, galvanized round/flat armoured and with outer sheath made of FRLS
PVC compound of type ST-2. The cables used for DC system will be of two core copper type.
XLPE insulated cables shall conform to the requirements of IS 7098, Part 1 for LV Power cables.

The conductor shall be composed of plain copper or aluminium wires, complying to

IS 8130.
The insulation shall be XLPE insulated, extruded, conforming to the requirements
of Table 1 of IS 7098, Part 1.
For all cables, PVC inner sheath shall be applied over laid up cores by extrusion.
The inner sheath shall be Type ST2, extruded PVC compound, conforming to the
requirements of IS 5831.
For single core armoured cables, armouring shall be of aluminium wires. For
multicore armoured cables, armouring shall be of galvanised steel single round
wire as per IS 7098, Part 1.
The outer sheath shall be Type ST2, extruded PVC compound, conforming to the
requirements of IS 5831 applied over the armouring.
XLPE insulation shall be suitable for continuous conductor temperature of 90C
and short circuit conductor temperature of 250 C. Insulation thickness should
conform to Table 3 of IS 7098, Part 1.
The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground buried installations with chances of flooding by water.
Cables shall be able to withstand all mechanical, electrical and thermal stresses
under the foreseen steady state and transient/fault operating conditions and shall
be suitable for proposed method of installation.
The cable cores shall be laid up with fillers between the cores wherever necessary.
It shall not stick to insulation and inner sheath. All the cables, other than single
core cable shall have distinct extruded PVC inner sheath of black in colour as per
IS: 5831.
Armouring shall be single round wire of galvanised steel for multicore cables and
aluminium for single core cable.
Outer sheath shall be of PVC, black in colour for LV power cables. In addition to
meeting all the requirements of Indian standards referred to, outer sheath of all the
cables shall have the FRLS properties.
The insulation and sheath materials shall be resistant to oil, acid and alkali and
shall be tough enough to withstand mechanical stresses during handling.
Cables shall be suitable for laying outdoors exposed to direct sunlight, with
resistance to ultraviolet radiation. Cables shall be suitable for operation in high
ambient, high humid tropical Indian climatic conditions.
All environmental and safety guidelines are to ensured while selecting the raw
materials for the cables to be supplied.

PVC outer sheath will have following properties

6.

Oxygen Index
Smoke Density
Acid Gas
Flame propagation

:
:
:
:

Min.29
Min 40% light transmittance
Max 20% by weight
As per IEC-60332-1, IEEE-383

Cable Identification
Core Identification for various control cable shall be as follows.
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LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277-----

STANDARD DOCUMENT
(LH PROJECTS)

1 core Black
2 core Red & Black
3 core Red, Yellow & Blue
4 core Red, Yellow, Blue & Black
For reduced neutral conductors in 3 core cables, the core shall be black.

All finished cables shall be identified by surface markings at intervals of not more than one meter containing
the following information:
i)

Name of the manufacturer

ii)

Rated voltage

iii)

Cable type (including insulation and sheath material)

iv)

Conductor size

v)

Year of manufacture

vi)

Number of cores
The above markings or indications shall remain legible for the life of the cable.

7.

Construction

i)

Insulation thickness shall be decided on the basis of electrical stresses and adequate mechanical
strength. Shall meet the relevant standard for a given voltage class.

ii)

Cable insulation resistance and break down strength (dielectric strength) shall not be affected by
moisture i.e. non-hygroscopic. Insulation shall not contain any impurities. Insulation material shall
be resistant to oil, acid and alkali and shall be tough enough to withstand mechanical stresses
during handling.

iii)

Flexible, mutlistrand, copper conductor.

iv)

Inner sheath shall be easily removable at the time of jointing. End dressing shall be of softer
consistency compared to the insulation such that while removing the inner sheath insulation shall
not get affected.

v)

Common covering of PVC sheath shall be extruded together with suitable non-hygroscopic fillers in
the interstices.

vi)

Core identification shall be as per BIS"1554/1/88.

vii)

Cable shall be capable of overload for short period without any effect on cable.

viii)

Cables shall be supplied in one Length, as per requirements.

8.
i)

Drum Length & Tolerance

Cable drum shall be non returnable and made of good quality wood, pressure impregnated against
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LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277------

STANDARD DOCUMENT
(LH PROJECTS)

fungal and insect attack.

ii)

Cables shall be supplied in wooden drums conforming to IS. Cables can be supplied in drums with
500mtr or more cable length as per requirement. Allowable tolerance on individual drum length is
+5 %. (with no negative tolerance)

iii)

The ends of each length of cable shall be sealed before dispatch.

iv)

Purchaser reserves the right to indicate the cable drum length to the bidder, while placing the order
or in course of manufacture.
The cable drum shall carry the following information either stencilled on the drum or contained in a label
attached to it:i)

Reference to applicable standard

ii)

Manufacturer's name, brand or trade mark

iii)

Type of cable and voltage grade

iv)

No. of cores

v)

Nominal cross-sectional area of conductor

vi)

Cable code

vii)

Length of cable on drum

viii)

No. of lengths on reel, drum or coil (if more than one]

ix)

Gross weight

x)

Country of manufacturer

xi)

Direction of rotation of drum (an arrow)

xii)

Year of manufacture

9.

Warranty

i)

Warranty shall remain valid for 18 months after the cables or any portion there of as the case may
be, have been delivered to the final destination and after final acceptance is given after
commissioning or for 24 months after the receipt at site, of the last consignment, whichever period
concludes earlier.

ii)

If the cable is found defective, upon receipt of such notice, the supplier shall, with all reasonable
speed, repair or replace the defective cables or parts thereof, without any costs to the purchaser.

iii)

The repaired / replaced cables shall be further warranted for a period of 12 months from the date of
repair / replacement.

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LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277-----10.

STANDARD DOCUMENT
(LH PROJECTS)

Tests
Cables shall be subject to shop tests in accordance with the relevant standards to prove the design
and general qualities of the cables as below.

i)

Routine tests on each drum

ii)

Acceptance tests on drums chosen at random

iii)

Type tests on each type of cable inclusive of measurement of armour D.C. Resistance

11.

12.

Technical Particular
1100 V grade, 90C rating, XLPE Power cable conforming to following requirement and in line with
IS:7098, IS:8130, IS:5831 and IS:3975.
Voltage grade

650/1100 V grade

Conductor

Stranded Annealed Copper

Insulation

XLPE

Outer sheath

Extruded PVC

Armouring

Galvanized steel strips round/flat wire (if

required)

Cont. conductor Temperature rating

90 C

Short circuit withstand temperature

250C

Standard Power Cable Used:

Core Number

Materia
l

Insulation

1Cx400 Sq mm

Al/Cu

XLPE

1Cx500 Sq mm

Al/Cu

XLPE

1Cx630 Sq mm

Al/Cu

XLPE

1Cx1000 Sq mm

Al/Cu

XLPE

3Cx2.5 Sq mm

Cu

XLPE

3Cx4 Sq mm

Cu

XLPE

3Cx6 Sq mm

Cu

XLPE

3Cx10 Sq mm

Al

XLPE

3Cx16 Sq mm

Al

XLPE

3Cx25 Sq mm

Al

XLPE
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LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277------

STANDARD DOCUMENT
(LH PROJECTS)

3Cx35 Sq mm

Al

XLPE

3Cx50 Sq mm

Al

XLPE

3Cx70 Sq mm

Al

XLPE

3Cx95 Sq mm

Al

XLPE

3Cx120 Sq mm

Al

XLPE

3Cx150 Sq mm

Al

XLPE

3Cx185 Sq mm

Al

XLPE

3Cx240 Sq mm

Al

XLPE

3Cx300 Sq mm

Al

XLPE

3Cx400 Sq mm

Al

XLPE

3Cx500 Sq mm

Al

XLPE

3.5Cx25 Sq mm

Al

XLPE

3.5Cx35 Sq mm

Al

XLPE

3.5Cx50 Sq mm

Al

XLPE

3.5Cx70 Sq mm

Al

XLPE

3.5Cx95 Sq mm

Al

XLPE

3.5Cx120 Sq mm

Al

XLPE

3.5Cx150 Sq mm

Al

XLPE

3.5Cx185 Sq mm

Al

XLPE

3.5Cx240 Sq mm

Al

XLPE

3.5Cx300 Sq mm

Al

XLPE

3.5Cx400 Sq mm

Al

XLPE

3.5Cx500 Sq mm

Al

XLPE

4Cx2.5 Sq mm

Cu

XLPE

4Cx4 Sq mm

Cu

XLPE

4Cx6 Sq mm

Cu

XLPE

4Cx10 Sq mm

Al

XLPE
Page 8 of 10

LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277------

STANDARD DOCUMENT
(LH PROJECTS)

4Cx16 Sq mm

Al

XLPE

4Cx25 Sq mm

Al

XLPE

4Cx35 Sq mm

Al

XLPE

4Cx50 Sq mm

Al

XLPE

4Cx70 Sq mm

Al

XLPE

4Cx95 Sq mm

Al

XLPE

4Cx120 Sq mm

Al

XLPE

4Cx150 Sq mm

Al

XLPE

4Cx185 Sq mm

Al

XLPE

4Cx240 Sq mm

Al

XLPE

4Cx300 Sq mm

Al

XLPE

4Cx400 Sq mm

Al

XLPE

4Cx500 Sq mm

Al

XLPE

2Cx2.5 Sq mm

Cu

XLPE

2Cx4 Sq mm

Cu

XLPE

2Cx6 Sq mm

Cu

XLPE

2Cx10 Sq mm

Cu

XLPE

2Cx16 Sq mm

Cu

XLPE

2Cx25 Sq mm

Cu

XLPE

2Cx35 Sq mm

Cu

XLPE

2Cx50 Sq mm

Cu

XLPE

2Cx70 Sq mm

Cu

XLPE

2Cx95 Sq mm

Cu

XLPE

2Cx120 Sq mm

Cu

XLPE

2Cx150 Sq mm

Cu

XLPE

2Cx185 Sq mm

Cu

XLPE

2Cx240 Sq mm

Cu

XLPE
Page 9 of 10

LV AC/DC POWER CABLE

SPECIFICATION
DOC. NO: 277------

2Cx300 Sq mm

Cu

STANDARD DOCUMENT
(LH PROJECTS)

XLPE

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