GENERAL SPECIFICATION FOR POWER CONTROL AND EARTHING CABLES

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INDEX

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

INTRODUCTION .................................................................................................................... 3 CODES & STANDARDS .......................................................................................................... 3 SERVICE CONDITIONS .......................................................................................................... 4 SITE CONDITIONS ................................................................................................................. 4 TYPES OF CABLES ................................................................................................................. 6 TECHNICAL REQUIREMENTS ................................................................................................ 6 COLOUR IDENTIFICATION .................................................................................................. 13 CABLE SUPPLY AND STORAGE ............................................................................................ 13 QUALITY ASSURANCE ......................................................................................................... 14

10.0 QUALITY PLAN REQUIREMENTS ......................................................................................... 15 11.0 NAMEPLATES AND LABELS ................................................................................................. 15 12.0 TESTING AND INSPECTION ................................................................................................. 16 13.0 VENDOR DOCUMENTS REQUIRED ..................................................................................... 16

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1.0

INTRODUCTION
This Specification covers requirements for the design, supply, manufacture, testing & inspection of the power control and earthing cables.

2.0

CODES & STANDARDS

Unless otherwise specified in this specification, all components and equipment shall be based on the following standard: IEC IEC-60227 International Electro technical Commission Standards Polyvinyl chloride insulated cables of rated voltages up to and including 450V/750V IEC-60183 IEC-60228 IEC-60331 IEC-60332 IEC-60446 IEC-60502 Guide to selection of high voltage cables Conductors of insulated cables Fire resisting characteristics of electric cables Tests of electric cables under fire conditions Identification of conductors by colors or numerals Part 1 - Power Cables with Extruded insulation and their accessories for rated voltages from 1KV and 3KV Part 2 - Power Cables with Extruded insulation and their accessories for rated voltages from 6KV up to 30KV Part 4 - Test requirements on accessories for cables with rated voltages from 6KV up to 30KV IEC-60754 IE60811 Test on gases evolved during combination of electric cables Common test methods for insulating and sheathing materials of electric and optical cables Measurement of smoke density of electric cables burning under defined conditions Electrical test methods for electrical cables

IEC-61034

IEC-60885

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BS-6234 BS-6360 BS-6387

Specification for polyethylene insulation and sheath of electric cables Specification for conductors in insulated cables and cords Specification for performance requirements for cables required to maintain circuit integrity under fire conditions Methods of test for insulation and sheaths of electric cables Specification for cables with extruded cross-linked polyethylene of ethylene propylene rubber insulation for rated voltages from 3800/6600V up to 19000/33000V

BS-6469 BS-6622

1)

Certificate issued by an internationally recognized testing authority may be acceptable at the owner's decision. In case of different standards regarding equipment and materials, the Standard in the country where the equipment and materials are manufactured shall apply, provided they are compatible with the above standards and safety requirements.

2)

Supply of all other items, not specified here but, necessary for safe, satisfactory and Supply of any other items required to make the system completes as per this technical specification to the clients satisfaction

3.0

SERVICE CONDITIONS
To determine the appropriate design of cables for a particular project the following information with regards to service conditions is required. Reference should made to the relevant IEC/IS/BS standards Operating conditions Installation data

4.0

SITE CONDITIONS
Site conditions may vary according to the project requirements. The equipment and materials to be supplied and installed by the vendor shall be suitable for continuous and trouble free operation at 40C. General

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Elevation of the site Climatic Data Wind load condition data Wind direction and % prevailing Wind direction Rainfall (highest annual) Earthquake design criteria Environment Air Temp (winter/summer) Relative humidity of air Prominent wind speed

: :

: :

: : :

4.1

OPERATING TEMPARATURES Table: Maximum conductor temperatures for different types of insulating compound

The temperatures in above table are based on the intrinsic properties of the insulating materials. It is important to take into account other factors when using these values for the calculation of current ratings.
Table: Maximum conductor temperatures for different types of sheathing compound

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5.0

TYPES OF CABLES
XLPE power cables (Armoured / Unarmoured) with XLPE/PVC/SWA insulation, PVC sheathed. PVC Power cables (Armoured / Unarmoured) with XLPE/PVC/SWA insulation, PVC sheathed. Control cables (Armoured / Unarmoured) with XLPE/PVC/SWA insulation, PVC sheathed. Earthing cables of PVC insulation, PVC sheathed.

6.0 6.1

TECHNICAL REQUIREMENTS GENERAL REQUIREMENTS

All accessories and materials used in the manufacture of cables shall comply with the latest relevant applicable standards and shall be of such quality, type and design to satisfy the following. a) The conductors shall be either of Class 1 or Class 2 of plain or metal-coated annealed copper or of plain aluminium or aluminium alloy, or of Class 5 of plain or metal-coated copper in accordance with IEC 60228. b) They shall ensure to provide adequate protection in normal use against mechanical & electrical failures. c) They shall ensure protection against electro-chemical action and exposure to the risk of injury or electric shock to the personnel. All equipments shall be suitable for use in a hot humid and tropical industrial climate in which corrosive gases/saline atmosphere and chemicals may be

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present. All external surfaces shall be suitably treated to provide protection against corrosive plant atmosphere. d) Cables shall be suitable for operation at guaranteed maximum sustained rating throughout all seasons of the year. e) The cables shall be suitable for laying in trays, trenches, ducts, pipe sleeves and conduits and for underground-buried installation with uncontrolled backfill and possibility of flooding by water and chemicals. f) The overall diameter of the cables shall be strictly as per the values declared by the manufacturer in the technical information subject to a maximum tolerance of 2 mm up to 3mm. g) After the work tests both ends of the cable shall be sealed against the ingress of moisture, dirt and insects. The end projecting from the drum shall be adequately protected against mechanical damage during handling. Brass or other approved sealing caps of the correct size shall be supply with each drum. h) Cables shall be supplied in maximum drum lengths bearing in mind the transport limitations in gaining access to the site. In order to avoid straight through joints, single length of cables shall be supplied by the Vendor, in a single drum. The drum schedule will be provided to the Vendor in event of Order. Approximate quantity of Cables required in meters is specified in Schedule of Quantities of cable. The Drum Schedule for Cables shall be given after the placement of order. Tolerance on Drum Length: +2% & No negative tolerance.

6.2
6.2.1

CABLE CONSTRUCTION
High Voltage Power Cables The rated voltages U0/U (Um) of the cables are as follows: U0/U (Um) = 3.6/6 (7.2) 6/10 (12) 8.7/15 (17.5) 12/20 (24) 18/30 (36) kV. Where U0 is the rated power frequency voltage between conductor and earth or metallic screen for which the cable is designed; U is the rated power frequency voltage between conductors for which the cable is designed

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Um is the maximum value of the "highest system voltage'' for which the equipment may be used (as per IEC 60038). Standards Conductors : : IEC 60502-2, IEC 60092, IEC 60754-1, IEC 60754-4, IEC 61034 Either Class 1 or Class 2 of Plain or metal coated annealed high conductivity copper or of aluminium or aluminium alloy wire complying in accordance with IEC 60228. Conductor screen : Extruded layer of semiconducting compound applied

concentrically over the conductor. Insulation : Insulation shall be extruded dielectric of one of the types listed in below Table

INSULATING COMPOUND
a) Thermoplastic polyvinyl chloride intended for cables with rated voltages U0/U = 3.6/6 kV b) Thermosetting ethylene propylene rubber or similar (EPM or EPDM) high modulus or hard grade ethylene propylene rubber cross-linked polyethylene Insulation screen :

ABBREVIATED DESIGNATION
PVC/B

EPR HEPR XLPE

Extruded semi-conducting compound in combination with Nonmagnetic metallic layer. For Single Core cable, copper screen along with Non magnetic Armour shall be able to carry the above current.

Core identification : Bedding Armor : :

As per color Identification 11.0 Extruded layer of black coloured PVC compound. Multi-core cables Single layer of Galvanized steel wire armor (SWA). Single core cables - H4 grade Hard drawn aluminium round wires of 2.5 mm diameter.

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Over sheath

Normally Black coloured consist of a thermoplastic compound (PVC or polyethylene) or an elastomeric compound

(polychloroprene, chlorosulfonated polyethylene or similar polymers). Temp. rise of conductor on continuous load 6.2.2 Low Voltage Power Cables The rated voltages U0/U (Um) of the cables considered are as follows: U0/U (Um) = 0.6/1 (1.2) kV - 1.8/3 (3.6) kV. Where U0 is the rated power frequency voltage between conductor and earth or metallic screen for which the cable is designed; U is the rated power frequency voltage between conductors for which the cable is designed Um is the maximum value of the "highest system voltage'' for which the equipment may be used (as per IEC 60038). Standards Conductors : : IEC 60502-2, IEC 60092, IEC 60754-1, IEC 60754-4, IEC 61034 Either Class 1 or Class 2 of Plain or metal coated annealed high conductivity copper or of aluminium or aluminium alloy, or of Class 5 of plain or metal coated copper wire complying in accordance with IEC 60228. Insulation :
The insulation shall be extruded dielectric of one of the types listed in below Table.

90 deg centigrade

INSULATING COMPOUND
a) Thermoplastic polyvinyl chloride intended for cables with rated voltages U0/U <= 1.8/3 kV b) Thermosetting

ABBREVIATED DESIGNATION
PVC/A

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ethylene propylene rubber or similar (EPM or EPDM) high modulus or hard grade ethylene propylene rubber cross-linked polyethylene Insulation screen :

EPR HEPR XLPE

Extruded semi-conducting compound in combination with Nonmagnetic metallic layer. For Single Core cable, copper screen along with Non magnetic Armour shall be able to carry the above current

Core identification : Bedding Armor Over sheath : : :

As per color Identification 11.0 Extruded layer of black coloured PVC compound. Single layer of Galvanized steel wire armor (SWA). Normally Black coloured consist of a thermoplastic compound (PVC or polyethylene) or an elastomeric compound

(polychloroprene, chlorosulfonated polyethylene or similar polymers). Temp. rise of conductor on continuous load 6.2.3 Control Cables The rated voltages U0/U (Um) of the cables considered are as follows: U0/U (Um) = 0.6/1 (1.2) kV Where U0 is the rated power frequency voltage between conductor and earth or metallic screen for which the cable is designed; U is the rated power frequency voltage between conductors for which the cable is designed Um is the maximum value of the "highest system voltage'' for which the equipment may be used (as per IEC 60038). Standards : IEC 60502-1, IEC 60092, IEC 61034, BS 6346 : 90 deg centigrade

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Conductors

Class 2 of Plain or metal coated annealed high conductivity copper wire complying in accordance with IEC 60228.

Insulation

The insulation shall be extruded dielectric of one of the types listed in below Table.

INSULATING COMPOUND
a) Thermoplastic polyvinyl chloride intended for cables with rated voltages U0/U <= 1.8/3 kV b) Thermosetting ethylene propylene rubber or similar (EPM or EPDM) high modulus or hard grade ethylene propylene rubber cross-linked polyethylene Core identification :

ABBREVIATED DESIGNATION
PVC/A

EPR HEPR XLPE

Bedding Armor Over sheath

: : :

Cores of the cables up to 4 cores shall be as per color Identification 11.0. For cables having 5 cores and above, be identified with prominent and indelible numerals on the outer surface of the insulation. Extruded layer of black coloured PVC compound. Single layer of Galvanized steel wire armor (SWA). Normally Black coloured consist of a thermoplastic compound (PVC or polyethylene) or an elastomeric compound

(polychloroprene, chlorosulfonated polyethylene or similar polymers). Temp. rise of conductor on continuous load 6.2.4 Earthing Cables The rated voltages U0/U (Um) of the cables considered are as follows: U0/U (Um) = 0.6/1 (1.2) kV : 70 deg centigrade

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Standards Conductors

: :

IEC 60502, IEC 60227 Class 2 of Plain or metal coated annealed high conductivity copper wire complying in accordance with IEC 60228.

Insulation

The insulation shall be extruded dielectric of one of the types listed in below Table.

INSULATING COMPOUND
a) Thermoplastic polyvinyl chloride intended for cables with rated voltages U0/U <= 1.8/3 kV b) Thermosetting ethylene propylene rubber or similar (EPM or EPDM) high modulus or hard grade ethylene propylene rubber cross-linked polyethylene

ABBREVIATED DESIGNATION
PVC/A

EPR HEPR XLPE

Over sheath

Normally Black coloured consist of a thermoplastic compound (PVC or polyethylene).

Cable identification : 6.2.5

Green with yellow strip.

All multi-core cables liable for mechanical damage and all HV cables (Irrespective of the situation of installation) shall be armored. Where armoring is unavoidable in single core cables, either the armour should be made of nonmagnetic material, or it should be ensured that the armouring is not shorted at terminations, thus preventing the flow of circulating currents therein.

6.2.6

For cables with circular cores, except cables with more than five cores, a lapped inner covering shall be permitted only if the interstices between the cores are substantially filled. A suitable binder is permitted before application of an extruded inner covering.

6.2.7

The materials used for inner coverings and fillers shall be suitable for the operating temperature of the cable and compatible with the insulating material.

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7.0 7.1

COLOUR IDENTIFICATION
Cable core shall be identified by color coding using red, black, yellow, and blue insulation or outer tapes along entire core length. The IEC preferred color coding for cable cores as follows: 1 Core 2 Core 2 Core + Earth 3 Core 3 Core +Earth 4 Core Earth conductor : : : : : : : Red or Black Red and Black Red, Black and Green with Yellow Stripe Red, Yellow and Blue Red, Yellow, Blue and Green with Yellow stripe Red, Yellow, Blue and Black Green with Yellow Stripe

7.2

For cables having 5 cores and above, be identified with prominent and indelible numerals on the outer surface of the insulation.

8.0

CABLE SUPPLY AND STORAGE SUPPLY

8.1

Cables shall be supplied in non-returnable wooden or steel drums of heavy construction and drum shall be properly seasoned, sound and free from defects. Wood preservative shall be applied to the entire drum.

8.2

All Power Cables shall be supplied in standard drum lengths specified. Each drum shall contain one continuous length of cable. Owner shall have the option of rejecting cable drums with shorter lengths. The cable length per drum is allowed a tolerance of +2%.

8.3

A layer of water proof paper shall be applied to the surface of the drums and over the outer most cable layer.

8.4

Packing shall be sturdy and adequate to protect the cables, from any injury due to mishandling or other conditions encountered during transportation, handling and storage. Both cable ends shall be sealed with PVC/Rubber caps so as to eliminate ingress of water during transportation and erection.

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8.5

Each drum shall carry manufacturers name, purchasers name, address and contract number, item number and type, size and length of the cable, net and gross weight stenciled on both sides of drum. A tag containing the same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wordings shall be marked on one end of the reel indicating the direction in which it should be rolled.

STORAGE 8.6
The cable drums shall be stored on a well drained, hard surface, so that the drums do not sink in the ground causing rot and damage to the cable drums. Paved surface is preferred, particularly for long term storage.

8.7 8.8

The drums shall always be stored on their flanges, and not on their flat sides. Protection from rain and sun is preferable for long term storage for all types of cables. There should also ventilation between cable drums.

8.9

During storage, periodical rolling of drums once in, say, 3 months through 90 degrees shall be done, in the case of paper insulated cables. Rolling shall be done in the direction of the arrow marked on the drum.

9.0

QUALITY ASSURANCE
All materials supplied by Vendor shall be new and comply with the specifications. When material are not specified on the specifications, Vendor shall provide such material as are fit for the purposes for which they are to be used and that have been proven to be resistant to those elements, pressures and chemicals with which they are expected, in accordance with the specifications, to come into contact. The quality of the materials supplied by Vendor in accordance with the terms set forth in this article may be verified at any time by Purchaser. Vendor shall comply with the following requirements of Quality Assurance and Quality Plan. The Quality Plan shall be submitted by the vendor for review by the Client and the Purchase in accordance with the Test and Inspection Procedure.

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10.0

QUALITY PLAN REQUIREMENTS

a) Vendor shall submit a detailed Quality Plan specifically developed to the requirements of this specification within twenty one (21) days of award. b) This plan will integrate the practices and procedures contained in the vendors Quality Control System with the specifications and requirements. The Detailed Quality Plan will include, but not be limited to the following; i. A complete listing of Quality Control activities to be performed including with factory acceptance test, site acceptance test, etc. ii. iii. Acceptance criteria showing specific Code, Standard and Specification references. Listing of other major ordered items, the level of vendor source inspection and the extent of vendors receipt inspection. iv. Quality Control forms and reports to be used to document inspections and test performed, non conformance and corrective actions

v.

A quality alignment meeting with owner, the vendor may be held at the vendors manufacturing facility prior to start of fabrication. The purpose of the meeting will be to review the Quality Plan, Quality Requirements, Specification Requirements and

reference document. 11.0 NAMEPLATES AND LABELS

a) Unless otherwise specified, nameplates shall be of 316 stainless steel, and information shall be etched or embossed. b) Nameplate shall be mounted on equipment in a visible location. Consideration shall be given to mounting, so nameplate can be readily visible after installation of equipment. c) Label plates shall be engraved, 3-laminate, colored plastic. d) Non-corrosive methods shall be used to permanently and clearly identify all components. e) Nameplates shall be permanently mounted on the unit in an accessible location using stainless steel pins f) All nameplate details shall be shown on drawings and submitted for Company review and comment.

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g) Major equipment components shall have a permanently attached, engraved, or stamped nameplate reference to IEC standard with the following information: Voltage Grade Cable Type Number of Cores Size of Conductor Item tag Number Name of Manufacturer Year of Manufacture

12.0

TESTING AND INSPECTION

All cables to be tested and inspected being witness by the Purchaser or his representative. The following tests and inspections shall be conducted by VENDOR/MANUFACTURER. Test result/certificates shall be submitted for approval by the Purchaser and/or his representative. Routine tests Sample tests Type tests Common Tests Electrical tests after installation

13.0

VENDOR DOCUMENTS REQUIRED

All information listed here is to be furnished along with the offer as a minimum. Clause wise comments / deviations on specification. Duly filled up Guaranteed Technical Particulars. List of components & accessories with Makes. List of recommended spares for a minimum years of normal operation as per clients requirement with itemised rates. All test certificates.

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Technical Catalogues and brochures of Cables.

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