Ab Cable GTP
Ab Cable GTP
Ab Cable GTP
This specification covers the design, manufacturing, testing, supply, delivery and
performance requirements of LV overhead ISI marked Aerial Bunched Cable (ABC) of
different sizes indicated in our Schedule of Requirements for use in the LV network of
NESCO.
The materials offered shall have been successfully type tested and the design shall
have been in satisfactory operation for a period of not less than two years on the date
of bid opening. Compliance shall be demonstrated by submitting with the bid (i)
authenticated copies of the type test reports and (ii) performance certificates from the
users.
However where the bidder offers similar but not identical material but higher size to
that which has been type tested, the difference shall be stated in Test Certificate
Schedule. The purchaser shall adjudge whether to accept or reject the offered material
and type test data presented.
The scope of supply includes the provision of type tests. Rates for type tests shall be
given in the appropriate price schedule of the bidding document and shall be
considered for evaluation. The purchaser reserves the right to waive type tests as
indicated in the section on Quality Assurance, Inspection and Testing in this
specification.
The Aerial Bunched Cable shall conform in all respects to highest standards of
engineering, design, workmanship, this specification and the latest revisions of
relevant standards at the time of offer and the Purchaser shall have the power to reject
any work or material, which, in his judgment is not in full accordance therewith.
2. STANDARDS:
Except where modified by this specification, the Aerial Bunched Cable shall be
designed, manufactured and tested in accordance with the latest editions of the
following standards.
The Bidder shall furnish a copy of the alternative standard proposed along with his
bid. If the alternative standard is in a language other than English, an English
translation shall be submitted with the standard.
In case of conflict the order of the precedence shall be (1) IEC or ISO standards, (2)
Indian Standards, (3) Other alternative standards. This list is not to be considered
exhaustive and reference to a particular standard or recommendation in this
specification does not relieve the Contractor or the necessity of providing the goods
complying with other relevant standards or recommendation.
Environmentally, the region where the work will take place includes coastal areas,
subject to high relative humidity, which can give rise to condensation. Onshore winds
will frequently be salt laden. On occasions, the combination of salt and condensation
may create pollution conditions for outdoor insulators.
Therefore, outdoor material shall be designed and protected for use in exposed, heavily
polluted salty corrosive and humid coastal atmosphere.
4. SYSTEM CONDITIONS:
The materials shall be suitable for installation in supply systems of the following
characteristics.
Frequency 50Hz
3x35mm2 + 1x25mm2
1x35mm2 + 1x25mm2
The type of Bunched Cables shall be three phase and street lighting insulated
bundled. All Aluminum Conductors combined with a neutral and catenaries (bare)
which shall be of heat treated aluminum magnesium silicon alloy wires containing
approximately 0.5% each of magnesium and silicon respectively. The catenaries must
have an ultimate tensile stress of not less than that specified in the table of technical
requirements.
The Bidder shall specify the standard to which this bundle shall be manufactured.
The conductor bundle offered shall be designed to meet the requirements set out in
this specification taking note of safety factors pertaining to conductor or catenary
tensioning and NESC specification: General Technical Requirements for LV overhead
lines.
6.0 CONDUCTORS:
(a) The phase & street light conductors shall be of multi-stranded aluminum of compacted
circular cross section. The aluminum shall comply with IS 8130:1984. The messenger
6.0 (b) The bidder must take required precaution to ensure that the average diameter of each
strand of conductor shall be ascertained through physical measurement of dimensions
of finished cables at ambient temperature during pre-dispatch inspection or / and
verification at NESCO, WESCO & SOUTHCO Store by consignee and the value so
obtained shall have a tolerance limit with reference to the nominal diameter of each
strand of conductor as stated in the tables above.
7.0 TOLERANCES:
The measurement of strand diameter of the finished AB Cable shall not be less
0.03mm for strands up to and including 3.00mm diameter. For strands above that
size, measurement of strand diameter shall not be less than 1% of the nominal strand
diameter.
For the purpose of checking compliance with the above requirement, the diameter
shall be determined by two measurements at right angles taken at the same cross
section. The physical measurement of strands shall be conducted after opening the
strands of a finished AB Cable offered for inspection.
8.0 SPLICES IN WIRES:
Splices in Wires shall generally comply with requirements of IEC 1089.
The aluminum alloy rods may be spliced by cold pressure but welding before drawing
provided the manufacturer can guarantee that the splice can develop 90% of the
tensile strength of the un sliced rod. Wires which break during stranding may be
sliced by cold pressure butt-welding provided that:
No two splices in the completed conductor occur within 15m of each other and no two
splices in any individual wire are less than 150m apart.
The splice shall be done with high skilled workmanship. The finished splice shall be
smooth and at no point shall the cross sectional area be less than that of the un sliced
wire.
Splicing of the alloy wires on the stranding machine in order to utilize lengths of wires
on reels shall not be permitted.
The conductor cores shall be stranded and the direction of lay must be as defined in
IEC: 1089.
10.0 INSULATION:
The Aerial Bunched Cables shall be insulated for a voltage class of 0.65/1.1 KV and
shall be capable of operating permanently at 1.2KV.
The insulation wall thickness shall be determined in accordance with Table-4 (Clause-
7.2 and Clause 7.3) of IS: 14255/1995.
The insulating material shall be black and suitable to resist ultra violet radiation, salt
laden sprays, chemical pollution, ageing effects, abrasion and mechanical shocks and
The carbon black content in the XLPE insulation shall be 2.5% ± 0.5%
The distance between the tips of two adjacent projections, where there is more
than one, shall be between 1.0 and 1.5.
The width of the projection at the base shall be 1.0mm; and
The height of the projections shall be 0.5mm.
Each individual conductor comprising a bundle shall have the range of non-erasable
distinct markings listed below legibly printed on the insulation surface at one meter
intervals. The embossing should be very clear & easily visible to naked eye.
ISI Mark, IS 14255-95, Manufacturer‟s B.I.S License No. legibly embossed on
the insulation.
Name of the Purchaser.
P.O No. & Date
Manufacturer‟s trademark identification for example “UCXLPE50”
Year of manufacture: last two digits are sufficient:
Designation of conductor type
Size: for example “3x50”
Shape of conductor.
Rated voltage class: 0.65/1.1KV
Back up conductor identification: conductors with one, two and three
projections shall be marked R, Y and B respectively. The conductor with no
projection shall be marked N and
The height of the printed lettering shall be not less than 20% of the overall
diameter of the conductor
The markings shall be made in the sequence indicated above.
Thus if the manufacturer were XY, the aerial bunched cable had been manufactured
in 1994, size 3x50mm2 + 1x35mm2 + 1x16mm2 with conductors of circular cross
section and with a bundle of the self supporting type, manufactured to a recognized
international standard then the core with two projections would be marked as follows:
XY-04-NFA4X50+1X16-r-m-0.65/1.1KV-Y
13.0 TWIST:
The direction of lay of the conductors comprising the bundle shall be left-handed and
the lay ration shall comply with IEC: 1089.
With a bare catenaries configuration the insulated phase cables together with the
street lighting cores shall be twisted round the neutral catenaries to form the ABC.
This cable bundle is then strung directly onto the distribution poles supported by the
catenaries with standard approved hardware.
The cable shall be supplied in 500m . Drum Lengths as the case may be for different
sizes of LT XLPE AB Cable.
15.0 TESTS:
15.1 General
Where not specified, all tests and test results shall conform to the requirements of IEC
502/1994 or IS 7098 (Part-I) 1998, IS 10810/1984, IS: 398(Part-IV) and IS:
14255/1955.
Unless expressly stated otherwise, the ambient temperature for routine tests as well as
voltage tests shall be 20 + 150C and for all other tests be 20 + 150C.
The frequency of the alternating test voltage shall be 49 Hz to 51Hz. The voltage wave
form should be sinusoidal.
The test sample shall be 10m to 15m in length. All cores of the bundles shall be
tested.
The insulation resistance test at ambient temperature shall be carried out in a water
bath at ambient temperature.
The longitudinal projections used for phase identification shall be ignored. The results
of this test shall be used to calculate the volume receptivity and the results conform to
the requirements of IEC:502/1994 or IS 10810 (Part-43).
The AC voltage test shall be carried out by applying 1.95KV (3U 0) for four hours to the
sample, which shall be submerged in a water bath at ambient temperature, having
been steeped for a period not less than one hour. The test shall only be deemed to
have been passed if no breakdown occurs.
Furthermore, the following non-electrical type tests shall also be carried out:
The following measurement or tests shall be carried out on all drums and coils of
Bunched cable:
Conductor resistance
Voltage test.
The conductor to be tested for conductor resistance shall be stored for at least 12
hours in a room at particular constant temperature. If it cannot be established that
the conductors have reached the room temperature, the test should be postponed for a
period of further 12 hours. Alternatively, the test can be carried out on short sample
after remaining one hour in a temperature controlled water bath. The test shall be
carried out and the conversion factors used to convert the resistance value to a base of
2000C and one Km. The DC resistance of each conductor shall not exceed the
appropriate maximum values specified in IEC:228/IS:6474.
The voltage test shall be conducted by applying to each core 3.5KV AC (2.5 U 0 plus 2
KV) or 8.4 KV DC for 5 minutes with the specimen lying in a water bath at ambient
temperature. The conductor shall pass the test if no electrical breakdown occurs.
The following sample check, measurements and test shall be carried out in addition to
the Acceptance Tests as per IS 14255 – 1955, IS : 398 ( Part – IV ) 1994, IS 8130 / 1984
Measurement of insulation wall thickness;
Measurement of diameter of each strand, overall outside dia & Cross Sectional
Area of the conducting Part out of the finished product during pre-dispatch
inspection.
Thermal expansion test;
Check of physical characteristics
Tensile strength of individual wires of conductor.
High Voltage Test on drums immersed in water(apply voltage 3.5 KV AC for 5
min)
These tests should be carried out on one length form each production batch of the
same sample.
The thickness of the insulation wall shall be measured on a piece removed from each
end of the sample length. If either means or minimum values are not met, two further
samples shall be removed at 0.5m form the end corresponding to the failed specimen.
If these samples do not satisfy the mean and minimum thickness requirements, the
test shall be deemed to have been failed.
In relation to the tensile test, the tensile strength of the aluminum wires before
stranding and that of the finished conductor shall comply with IEC:1089.
Breaking load, elongation and resistance tests shall be completed on the aluminum
alloy catenaries conductor in accordance with the requirements of IS:398 (Part-
IV)/1994 or IEC:1089.
This test shall be performed on a sample of completed cable. The sample shall be bent
around a test mandrel at room temperature for at least on turn. It shall then be
unwound and the process shall be repeated after turning the cable sample around its
axis by 1800. This process shall be repeated twice more. There shall be no signs of
breaking or cracking of the cable insulation during this test.
The diameter of the mandrel shall be:
10 (D+d)
Where D = Actual diameter of the cable (mm)
d = Actual diameter of the conductor (mm)
Should any one of the test pieces first selected fail to pass the tests, two further
samples from the same batch shall be selected for testing, one of which shall be from
the length from which the original test sample was taken unless the length has been
withdrawn by the supplier.
Should the test pieces from both of these additional samples satisfy the requirements
of the tests, the batch represented by these samples shall be deemed to comply with
the standard. Should the test pieces from either of the two additional samples fail, the
batch represented shall be deemed to have failed.
16.0 COMPLIANCE WITH SPECIFICATION:
The Aerial Bunched Cable shall comply in all respects with the requirements of this
specification. However, any minor departure from the provisions of the specification
shall be disclosed at the time of bidding in the Non-compliance Schedule of this
document.
The Purchaser or his authorized representative has free entry at all times, while work
on the contract is being performed, to all parts of the manufacturer‟s works which
concerns the processing of the cables ordered. The manufacturer shall afford the the
purchaser or his authorized representatives without charge, all reasonable facilities to
ensure that the cable being furnished is in accordance with these specifications.
The cables shall successfully pass all the type tests, routine tests & acceptance Tests
referred to in the section on tests and those listed in the most recent edition of the
standards given in the specification.
The Purchaser reserves the right to reject any of the cables if the test results do not
comply with the values specified or with the date given in the Technical data schedule.
Type Test Certificates for the tests conducted earlier shall be submitted with the bid
for evaluation. The requirements of additional type tests will be at the discretion of the
Purchaser
The Purchaser may witness routine and type tests. In order to facilitate this, the
contractor shall give the purchaser of 15days notice that the material is ready for
inspection & testing. The supplier shall extend all assistance to the representative of
the Purchaser during his inspection & testing of samples at his works. The materials
shall be dispatched only after approval of such Test Reports and issue of Despatch
clearance by the Purchaser. However the Purchaser reserves the right to retest the
materials after delivery at any NABL Accredited Testing Laboratory in case of any
disputes regarding size & quality of supplied materials at a later date during
guarantee period. The cost of such retesting shall be borne by the supplier.
All costs in connection with the testing, including any necessary retesting shall be
borne by the Contractor, who shall provide the Purchaser with all the test shall have
the right to select the samples for test and shall also have the right to ensure that the
testing apparatus is correct. Measuring apparatus for routine tests shall be calibrated
at the expense of the contractor at an approved laboratory and shall be approved by
the purchaser before testing.
The Contractor shall be responsible for the proper testing of the materials supplied by
sub- Contractor to the same extent as if the materials were completed or supplied by
the contractor.
Any cost incurred by the Purchaser in connection with inspection or retesting as a
result of failure of the equipment under test or damaged during transport or off
loading shall be to the account of the Contractor.
The Contractor shall submit to the Purchaser three signed copies of the test
Certificates, giving the results of the tests as required. No materials shall be
dispatched until the Purchaser has received the test certificate and the contractor has
been informed that they are acceptable.
The test certificate must show the actual values obtained from the tests, in the units
used in this specification, and most merely confirm that the requirements have been
met.
In the case of components for which specific type tests or routine tests are not given in
this specification, the Contractor shall include a list of the tests normally required for
these components. All materials used in the Contract shall withstand and shall be
certified to have satisfactorily passed such tests.
No inspection or lack of inspection or passing by the Purchaser‟s representative of
equipment or materials whether supplied by the Contractor or sub- Contractor, shall
relieve the contractor from his liability to complete the contract works in accordance
with contract or exonerate him from any of his guarantees.
20.0 GUARANTEE:
The contractor shall guarantee the following:
Quality and strength of materials used.
Satisfactory operation during the guarantee period of 24 months from the date of
commissioning or 30 months from the date of receipt of the cables at
NESCO,whichever is earlier.
Performance figures as supplied by the bidder in the technical data sheet.
The cable shall be wound on strong drums or reels capable of withstanding all normal
transportation and handing.
22.0 PERMANENT EMBOSSING:
N.B : 1) For values not available in relevant ISS, values indicated in our
GTP/ Tender Specification shall be valid.
2) In case of discrepancies between values of ISS & GTP, better will prevail.
3) Average diameters of strands of each cable shall be ascertained by physical measurement
after opening the strands of each phase of a finished AB Cable offered for inspection.