Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist.

Thane

VOLUME 2:
220 kV XLPE INSULATED POWER CABLE
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

TECHNICAL SPECIFICATIONS°
FOR
220 kV XLPE INSULATED POWER CABLE

SECTION – IA
DETAILED SPECIFICATIONS OF 220 kV XLPE INSULATED POWER CABLE
GENERAL TECHNICAL REQUIREMENTS

1 SCOPE

1.1 The scope under this section covers design, manufacturer, testing, packing, supply,
delivery and laying of 220 kV XLPE Cable, insulated power cable including integrated
testing and commissioning, technical support, supervision of maintenance, training of
Employers staff and documentation for a complete System necessary to deliver the
requirements of this Specification.

1.2 STANDARDS:

Unless otherwise specified, the cables shall conform, in all respects, to IEC 62067 and
IS:7098 (Part- III)/1993 with latest amendment or latest edition for cross linked
polyethylene insulated, metallic sheathed & PVC or Polythylene sheathed cable for
working voltage of 220 kV.

The following standard specifications of latest version updated to as on date of

opening of this bid document will govern supply, laying testing and commissioning of
cables and their accessories that are being used in this Contract. In case of conflict
between such codes and/ or standards and the specification, the specifications shall
govern.

Sr No Title of Specification Specification No.

1 Cross linked polyethylene insulated Thermoplastic IEC: 60502–2
sheathed cables IEC: 60840,
IEC: 62067
2 Conductors for insulated cables. IEC : 60228
3 Test on cable over Sheath which have a special IEC 60229
protective function and are applied by extrusion
4 HDPE pipes BIS 4984
5 Power cables with extruded insulation and their IEC 60840
accessories for rated voltage above 150 kV- Test
Methods & requirements
6 Power Cables with extruded insulation and their IEC: 62067
accessories for rated voltages above 150kV.
7 Impulse test on cables & their accessories. IEC 60230
8 Cyclic and emergency rating of cable IEC 60852-2
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

9 Common test methods for insulating and sheathing IEC 60811

material of electrical cables.
10 Electric test methods for Electric cables – Test IEC 60885
methods for Partial Discharge measurements on
lengths of extruded power cables.

1.3 PRINCIPAL PARAMETERS:

1.3.1 220 kV (E) grade XLPE single core power cable conductor electrolytic grade copper of
single length, with formation of stranded compacted circular water blocked
conductor for size up to 1000 mm.sq and segmental type for size above 800mm2 as
per, as per IEC-60228, tapped with high penetration semi conducting water blocking
tape, shielded with extruded semi- conducting layer, insulated with dry cured cross
linked polyethylene (XLPE) insulation, insulation screened with extruded semi-
conducting layer, insulated core lapped with a combination of semi- conducting
water swell able and Corrugated Aluminium sheath (acting as a screen and also as a
mechanical protector) and black HDPE ST7 (as per IEC 62067 – 2011) with graphite
coating or extruded conductive layer overall cable confirming to IS:7098 (Part-
III)/1993 or any latest amendments thereof. Cable shall be preferred of FIPC type.
Alternatively, 48 F OFC shall be quoted (Optional).

1.3.2 Outer sheathing should be designed to afford high degree of mechanical protection
and should also be heat, oil chemicals and weather resistant.

1.3.3 The cable should be suitable for laying in covered trenches and/or underground for
outdoor. The sheath/screen bonding system shall provide a continuous current path
through the cable sheath and jointing kits and shall be bonded. The bonding ends
shall be suitably earthed with/without SVL as per approved configuration/design.
The sheath voltage under full load condition shall not exceed the voltage
specified/allowed in relevant standard for safety of personal as well as satisfactory
working of cable i.e 65 V. Sheath shall be solidly grounded at suitable location with
or without SVL.

Bidder must indicate details of configuration proposed along with sufficiency

calculation with the bid so as to limit induced voltage of sheath within 65V. Detailed
calculation supporting selection of SVL and bonding cable size and rating with margin
of protection to be submitted with bid.

NOTE: Method of LILO of integrated fiber at each joint for sensing purpose, jointing
methodology, Power cable termination to FMS connection method to be submitted
for a FIPC cable
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.3.4 CABLE PARAMETERS

Sr. No. System Particulars 220 kV
1 Voltage Grade (Uo/U) 400/220 kV
2 No. of Cores Single
3 Size (mm.sq) 630 mm.sq
800 mm.sq
1000 mm.sq
1200 mm.sq
4 Nominal system voltage 220 kV
5 Highest system voltage 245 kV
6 System Frequency 50 Hz
7 Variation in Frequency + 3%
8 Fault level individually for
Conductor 50 kA for 1 sec
Corrugated Aluminium sheath 50 kA for 1 sec
9 Maximum allowable temperature
a) Design continuous operation at rated full load current, 90 °C
the max, temp. of conductor shall not exceed.
b) The conductor temperature after a short circuit for 250 °C
1.0 sec shall not exceed.
10 Basic insulation level (1.2/50 Micro Second Wave) 1050 kVp
11 System earthing Effectively
Earthed

1.4 OPERATION CHARACTERISTICS:

a. One/more Three-phase feeders, each consisting of 1 runs of 3/4 Single core

cables, feed power at 220 kV.
b. In normal situation, each cable will have to be designed to carry a continuous
current, to deliver a rated power of Transformers and its designed overload.
c. The cable should be designed for a suitable current carrying capacity under
normal situation, and which will cater for the above overload capabilities
also, will be required.

1.5 GENERAL TECHNICAL REQUIREMENTS:

Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.5.1 CONDUCTOR:

The cable conductor shall be made from electrolytic grade copper with formation as
stranded compacted circular conductor for size upto 1000 mm.sq and segmental
type as per IEC-60228 for the size above 1000 mm.sq.The conductor shall confirm to
IS:8130/2013. Conductor should be water blocked. Water blocking to be achieved by
combination of water blocking yarn and non-conducting water blocking tapes in
intermediate layers of conductor.

1.5.2 CONDUCOTR SCREEN:

A Conductor screen made of semiconducting compound shall be provided over the

conductor, by extrusion. The extruded coat shall be continuous, with a constant
mean depth, without bump, perfectly adhering to the insulation envelope. A high
penetration resistant semiconducting water blocking tape(s) shall be provided below
the extruded semi-conducting conductor screen to prevent penetration of the
compound into the underlying conductor with min 50 % overlap. The conductor
having a semi-conducting screen shall ensure perfectly smooth profile and avoid
stress concentration. The conductor screen shall be extruded in the same operation
as the insulation; the semi- conducting polymer shall be cross-linked. Minimum
thickness of the conductor screen shall be nominal 0.80 mm (minimum). The electric
resistivity of the conductor screen shall as per IS 7098 (part 3).

1.5.3 INSULATION:

The Insulation envelope shall be of cross-linked polyethylene (XLPE) insulation

applied by extrusion should be suitable for 220 kV system voltages. The nominal
thickness of insulation shall not be less than 27 mm (minimum subject to only
positive tolerances (no negative tolerance is accepted) as per IEC 60840. The
manufacturing process shall ensure that the Insulation shall be applied by extrusion
and vulcanized using dry curing process to form a compact homogenous body free
from micro voids and contaminants. The insulation compound shall be of high
quality, heat, moisture, ozone and corona resistant. The insulation shall withstand
mechanical and thermal stressed under steady state and transient operating
conditions. The extrusion method should give very smooth interface between semi-
conducting screen and insulation.
a. The nominal thickness of insulation shall not be less than 27 mm (minimum)
(IS 7098 (part 3).
b. The mechanical characteristics shall be as per IS 7098 (Part 3):
c. The isolating envelope shall be as per IS 7098 (Part 3):
d. Test for surface irregularities shall be carried out as below
Item (For XLPE/TR XLPE insulation) Clause of AEIC CS8 Unit Requirement
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

Protrusions into insulation from 3.2 mm ≤ 0.076

conductor screen
Protrusions into conductor screen 3.2 mm ≤ 0.18
Strand Convolutions 3.3 mm ≤ 0.18
Protrusions into insulation from 5.2 mm ≤ 0.13
insulation screen
Protrusions into insulation screen 5.2 mm ≤ 0.18

Procedure to Measure Protrusions & Indentations

Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

Procedure to Measure Convolutions

Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.5.4 INSULATION SCREEN:

To confine electrical field to the insulation, non-magnetic semi- conducting shield

shall be put over the insulation. The insulation shield shall be extruded in the same
operation as the conductor shield and the insulation by suitable extrusion process
(triple extrusion). The insulation shield shall be extruded in the same operation as
the conductor shield and the insulation by suitable extrusion process (triple
extrusion). The XLPE insulation shield should be bonded type. It shall be lapped by
Foam type semiconducting tape with min thickness of 1 mm. Metallic screening shall
be provided by Aluminium Sheath.

1.5.5 Metallic sheath:

The metallic screen shall be of Seam Welded/ Extruded Corrugated Aluminum having
fault current capacity 40 kA for 1-sec with initial temperature of screen as 80 and
final temperature as 250 °C calculated by adiabatic method. Supporting calculations
shall be submitted with bid

1.5.5.1 ANTICORROSIVE LAYER.

An anticorrosive layer of Bitumen compound followed by tape shall form the anti-
corrosive layer

1.5.6 OUTER SHEATH:

The outer extruded semiconducting layer sheath shall be embossed/printed

red/yellow/blue colour or similar (as per phase). Suitable semi conducting layer
coated on black HDPE ST7 with baked on graphite coating or extruded conductive
layer confirming to IEC: 60840, shall be applied over corrugation with suitable
additives to prevent attach by rodents and termites. The outer sheath should have
embossing/ indelible Printing at every one meter for Supplier Name, buyer’s name,
PO No, Voltage grade, size, type etc.

1.5.6.1 The Mechanical Characteristics shall be as follow:

a. - In delivery condition
1. - minimal traction resistance: 12.5 MPa
2. - minimal elongation before breaking: 200%
b. - After ageing of 240 h at 135°C:
1. - traction resistance:
2. - minimum value: 12.5 MPa
3. - maximum variation: □ 25%
4. - elongation before breaking:
5. - minimum value: 200%
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

6. - maximum variation: 25%

1.5.6.2 The variation is the difference between the medium value obtained after
ageing and the medium value without ageing, expressed in percentage of the
last.

1.5.6.3 Fiber specification for integration in Power cable

Fiber used in the power cable or supplied separately in the OFC shall be as per below
specification.
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.5.7 CONSTRUCTION:

1.5.7.1 All materials used in the manufacture of cable shall be new unused and of
finest quality. All materials should comply with the applicable provision of the
tests of the specification and any other applicable statutory provisions rules
and regulations (IS, IEC, Indian Electricity Rules, Indian Electricity Act).

1.5.8 CURRENT RATING:

The cable will have current ratings and de-rating factors as per relevant standard
IEC.

1.5.8.1 The one-second short circuit rating values each for conductor, Metal sheath
shall be furnished and shall be subject to the purchaser's approval.

1.5.8.2 The current ratings shall be based on maximum conductor temperature of 90

deg. C with ambient site condition specified for continuous operation at the
rated current.

1.5.8.3 SIZE:

The different sizes of cable shall be 220 kV Single Core

i. 630 mm.sq
ii. 800 mm.sq
iii. 1000 mm.sq
iv. 1200 mm.sq

1.5.9 OPERATION:
1.5.9.1 Cables shall be capable of satisfactory operation under a power supply system
frequency variation of plus minus 3% voltage variation of plus, minus 10% and
combined frequency voltage variation of 10% (absolute sum).

1.5.9.2 Cable shall be suitable for laying in ducts or buried under ground.

1.5.9.3 Cable shall have heat and moisture resistance properties. These shall be of type
and design with proven record on transmission network service.

1.5.10 LENGHTS
The cable shall be supplied in standard drum lengths as below:
Sr. No Size of cable Standard Drum Length
a Single Core, 1000 sq.mm 500 meters + 2% tolerance
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.5.11 INDENTIFICATION MARKING:

Identification of cables shall be provided externally at three meters' intervals to
identify as under: -
i. Name of Manufacture
ii. Year of manufacture
iii. Voltage grade' to be printed/embossed at the interval of 1 meter-length.
The identification, by printing or embossing shall be done only on the
outer sheath.
iv. Name of purchaser shall also be embossed.

1.6 TESTS

1.6.1 Type Tests

The equipment offered should be type tested as a cable system with
terminations and both type of joints. Type test report should not be more than
Five years old, reckoned from the date of bid opening, in respect of the following
tests, carried out in accordance with IEC 62067, from Govt./Govt. approved test
house, shall be submitted along with bid:
i. Physical tests for insulation and outer sheath.
ii. Bending test.
iii. Di-electrical power factor test.
iv. Heating cycle test followed by di-electrical power factor as a function of
voltage and partial discharge test.
v. Impulse withstand test.

The remaining type test report as per IEC 62067 shall be submitted by the
successful bidder. These type test reports shall be from Govt. /Govt. approved
test house and shall not be more than five years old, reckoned from the date of
bid opening. The failure to do so will be considered as a non-responsive.

1.6.2 ROUTINE TESTS AND ACCEPTANCE TESTS

All routine and acceptance tests shall be carried as per relevant ISS in the
presence of Employer's representative.
Following additional tests shall be carried out in routine tests (Optional)
a. Fiber continuity (for FIPC)
b. Optical loss measurement (for FIPC: 1 sample)

1.7 INSPECTION
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

The material shall be inspected and tested before dispatch by an authorised

representative of the Owner in respect of quality. The inspecting officer shall
also satisfy himself about the correctness of length of cables. In case the supplier
is not in a position to get these tests carried out at his works, such tests may be
got carried out by him at any Govt. recognized test agency at his own expense.
In addition to acceptance tests stipulated by relevant IS/IEC, following additional
tests need to be carried out
Measurement of gap below Corrugation
a. Measurement of thickness of Foam type semiconducting water swellable
tape
b. Measurement of protrusions and convolutions
c. Sheath integrity test
d. Wafer boil test
e. 4 hours voltage test on 3.5 m sample (once in PO)
f. Volume resistivity (once in PO)
g. Fiber continuity

1.8 TEST CERTIFICATES

To be submitted.

1.9 PACKING

The cable shall be supplied in returnable Steel drum as per so constructed, as to

enable the cable to be transported on each drum. The cable wound on such
drum shall be one continuous length. The ends of cables shall be sealed by
means of non-hygroscopic sealing material. The Top end shall be provided with
Suitable Pulling eye.

1.10 MARKING

The marking on the drum shall have the following information: -

a. Reference to Indian Standard & cable code.
b. Name of the manufacturer & trade name.
c. Nominal cross section area of conductor for the cables.
d. Number of core.
e. Sequential No. at each meter.
f. Type of the cable & voltage for which it is suitable.
g. Length of cable on the drum.
h. Approximate gross weight.
i. Net weight of the cable.
j. Drum identification number.
k. P.O. No. and date.
l. Consignee's name with designation.
m. Year of manufacture.
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.11 DRAWINGS & INSTRUCTION MANUAL

The tenderer shall supply the following drawings with the tender: -
i. Detailed drawing of the cable showing conductor, screening insulation,
Armouring, outer sheath etc.
ii. Detailed drawing showing jointing of cable and sealing of end boxes.

Copies of instruction manuals for testing, installation jointing operation and

maintenance of cables shall also be submitted with the offer for reference of the
purchaser.

1.12 TECHNICAL & GUARANTEED PARTICULARS:

The tenderer shall furnish guaranteed technical particulars as per the tender
specification. Particulars, which are subject to guarantee, shall be clearly
marked. Offer not containing this information will not be considered.

1.13 TERMINATION KITS AND STRAIGHT THROUGH JOINTS

The entire necessary Straight through joints and Sealing Ends for 220 kV shall be
supplied and erected. The Straight through joints and Sealing Ends wherever
required shall be Heat Shrink Type or equivalent, of reputed make with shear
head type mechanical connectors or cold shrink type of proven technology &
make.

1.14 ISO Accreditation

The cable shall be manufactured by a company having ISO accreditation for

quality. The manufacturing process of XLPE cable shall consist of conductor
screen, insulation & insulation screen shall be extruded in a single process (Triple
extrusion) and cross linked by a suitable proven & latest Process having dry
curing technology to ensure homogeneity and absence of micro voids. The
cables shall be manufactured by “Dry Curing” Process. It is mandatory that
bidder should submit Plant Installation Certificate for process Line and for
Metallic sheath machineries indicating the year of installation and other details
along with bid. The Employer may decide to visit the works of cable
manufacturer to confirm the manufacturing process mentioned & decision of
accepting the process is the sole discretion of MSETCL.
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

SECTION – IB
DETAILED SPECIFICATIONS FOR LAYING, TESTING AND COMMISSIONING
OF 220 kV XLPE UNDERGROUND POWER CABLE
GENERAL TECHNICAL REQUIREMENTS

1 GENERAL

1.1 The Cable Laying works shall be executed according to the rules of the Art
pertaining to professional grade and generally incompliance with International
Standards and Indian Standards.

1.2 The EHV Cables between the Power Supply Authorities Substation and the DMRC
RSS shall be laid in ground depending upon the site conditions of the selected
route, any of the following paying conditions, may be adopted.

1.3 Cable Laying Cases

Case 1 – Direct buried, with all cables laid in flat formation.
Case 2 – Direct buried, with the cables (3) of each circuit laid in trefoil
formation and side by side in one trench.
Case 3 – Laid in underground duct.

Case 4 – Laid in Trench less piping.

Case 5 – Laid in abutment crossing

Case 6 – Laid in Rail Track crossing

Case 7 – Laid in Air, supported on piers/walls, for nallah-crossing

1.4 Details of Case 2:

The trench for carrying the cables shall be at least 1.8m deep and 1.1m wide,
which may vary as per site conditions with the approval of employer. Each of the 2
feeders shall consist of 3 single-core cables, and laid in trefoil formation. Cables
shall be laid at a depth of 1.7m below the ground level and over a 100 mm bed of
coarse sand. Trench is to be filled with sand upto a depth of 1100mm below the
ground level. Warning concrete slabs of at least 50mm thickness shall then be laid
above the sand. Trench shall then be filled with earth upto a depth of 300 mm
below the ground level. A warning net shall then be laid above the earth filling (at
300 mm depth below the ground level). A warning tape shall also be laid
appropriately with Purchaser’s Name marked on it. The top space of 300 mm shall
be suitably filled with compacted Boulder and Bitumen/Jelly and given a final
finish matching the surroundings. The cables shall be tied through locking belts
after 2 meters each for keeping the cables intact in case of trefoil formation. At
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

locations, where there is change of level of laying, the cables shall be tied through
locking belts after 1 meter each.

1.5 Details of Case 3

In specific locations, the Employer may require the cables to be laid in

underground ducts. The underground ducts shall be laid where road construction
or formation is under construction or where water logging stretch is expected or
as per the specific site condition.

1.6 Details of Case 4 & 6

On all road/rail crossings and at other specific locations, cable laying shall be
through trenchless drilling and the cables shall be passed through High Density
Polyethylene (HDPE) Pipes or G.I. Pipes of appropriate diameter and thickness
(Case-4). One spare HDPE pipe shall be laid for each feeder of 3 cables at the
road/rail crossings.

1.7 Details of Case 5 & 7

On all abutment crossing or in air, supported on piers/walls, for Nallah crossing

and at other specific locations, cable laying shall be on the galvanized steel
structures which can withstand wind velocity of 160kmph, supported on piers and
have sufficient structural strength. The minimum average weight of zinc coating
should be 1000g/m2 (RDSO). The cables should be well protected by providing MS
sheet of thickness 8mm at least fastened with nuts and bolts & tag welded on all
sides to be protected from any pilferages. The arrangement shall render cable
absolutely safe from any natural calamity. The cable shall not be exposed or get
affected due to stray fire caused in the vicinity. Indicative arrangement is shown in
the drawing.

1.8 Spare Cables and Pipes

When cables are laid in pipes, in addition to the pipes carrying the cables, at least
one spare pipe (minimum 200 mm dia), without cable shall also be provided. In
the case cables laid in underground ducts (Case 3) and cables laid in Trenchless
piping (Case 4), spare HDPE pipes, one for each circuit, shall be provided. In
addition to pipes for power cables, 2 additional pipes, each of not less than 100
mm dia, shall be provided to carry control and monitoring cables, one operational
and one spare (As indicated in the Interfacing Requirements, other cables such as
pilot wire for pilot wire protection, if required, copper-core or optic fibre cables
for control and monitoring, tele-communication etc, supplied by other Suppliers.

1.9 Cable protection at changeover location

The cable path, when changing from buried in ground to underground duct or
trenchless piping shall be adequately protected by proper sealing in concrete or
other suitable means of sufficient mechanical strength to avoid cable from
suffering damage due to heat/fire/water ingress etc.
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.10 Pulling Chambers

Pulling chambers shall be provided, as necessary, along the route. Such pulling
chambers shall be 4m long, 3m wide and at least 2.5m deep. The masonry
structure should be of adequate strength with water proofing to avoid any
accumulation of seepage of water inside. The edges of RCC covers and masonry
shall be lined in GI angles to achieve a long service life.

1.11 Route Markers

The route shall be appropriately marked by suitable retro-reflective cable
markers, at suitable intervals and positions of straight through joints shall be
indicated by suitable boards.

2 CABLE ACCESSORIES AND BONDING

2.1 Straight Through Joints

2.1.1 The straight through Joints should be HEAT SHRINKABLE type or cold shrink type
of proven technology and make, suitable for underground buried cables. The
joint should comprise of stress control sleeves, insulating sleeves and co-
extruded dual wall Tubing comprising of an insulating and semi-conducting layer.
A mechanical connector with shear head bolts shall make the conductor
connection.

2.1.2 The product should be type tested as per IEC /IS specifications

2.1.3 GENERAL SPECIFICATIONS

a. The product offered should be proven and should be in use in India for a
minimum period of 5 years for the same voltage class. List of past
supplies in India to be furnished. Performance certificates to be
submitted along with the offer.
b. The product offered should have unlimited shelf life.
c. Offers should be supported with type test certificates from test
laboratories of repute, as per IEC /IS specifications, failing which the
offers shall be ignored.

2.1.4 General Specifications for Joints and Terminations for 220 KV XLPE Cables.
Suitable Terminations (Outdoor & Indoor Sealing ends) and Straight through
Joints having proven technology of reputed international make & of 220 kV
grade or higher for single core 220 kV cables, XLPE Insulated, Aluminium
sheathed cables to be used. The Indoor termination for use in the GIS
Substation.

2.2 Bonding
2.2.1 Suitable bonding methods viz., Single End, Both End and Cross Bonding shall be
used.
2.2.2 Link boxes with & without SVL shall be used as required.
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

3 TESTING AND INSPECTION:

AS per IS/IEC to be carried out before election.

3.1 TECHNICAL DATA FOR 220kV SINGLE CORE 1000 SQMM XLPE INSULATED,
ARMOURED CABLE:
Sr. Name of Particular Desired Value
No
1 No. of cores 1 (Single)
2 Size (in mm.sq) 1000
3 Voltage Grade (in kV) 127/220 (245) kV
4 Type of cable 2XA2Y
5 Standard according to which cable IS: 7098- Part 3, IEC-60840
has been manufactured and tested IEC-60502-2, Testing as per IEC- 62067.
6 Permissible Voltage & Frequency
variation for satisfactory operation.
Voltage + 10%
Frequency + 5%
7 Maximum rated conductor 900C
temperature
8 Max. allowable conductor 2500C
temperature during short circuit
9 Conductor Details
(a) Normal Cross-Sectional Area 1000 mm.sq
(b) Material and Grade Annealed Plain Copper to IEC 60228
(c) Shape of Conductor Compacted stranded circular
(d) Separator over conductor Semi-conducting tapes
10 Conductor Screen
(a) Material Extruded Semi-Conducting
XLPE compound
(b) Nominal Thickness 1.5 mm (Approx.)
11 Insulation
(a) Material Cross linked Polyethylene to IEC 62067
(b) Nominal Thickness 27.0 mm
12 Insulation Screen
(a) Material Extruded Semi-Conducting XLPE (SC)
layer followed by water swellable SC
tapes
(b) Min. Thickness 1.0 mm
(c) Longitudinal Water Sealing Semiconducting water blocking tape(s)
with 50% over lap
13 Metallic Sheath
(a) Material Seam Welded/ Extruded, Corrugated
Aluminium sheath with anti-corrosion
protection
(b) Thickness 2.3mm
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

(c) Short Circuit current of metallic >40

screen for 1 sec (kA)
14 Outer Sheath
(a) Material Extruded HDPE Type ST-7 to IEC 62067
(b) Colour Black
(c) Thickness (Nom/Min) 4.0 mm
(d) Conducting layer over outer Graphite Coating
sheath
15 Nominal overall Diameter of cable 125 mm (Approx.)
16 Nominal Overall Weight of Cable 18.6 kg/m (Approx)
per Meter
17 Standard Drum Length with 500m ±5%
Tolerance
18 Minimum Bending Radius 20 x OD
allowable during installation
19 Safe Pulling force 5 kg/mm.sq of CU area.
20 Impulse Withstand Voltage 1050kVp
21 One minute Power Frequency 318kV for 30 sec
Withstand Voltage (kV)
22 Short circuit current for one second 143
(kA)
Max conductor DC resistance at 0.0176 ohm/km
200C
Approx. AC resistance at 900C 0.0234 ohm/km
Max. capacitance 0.17 microF/km
23 Continuous Current Rating for BEB SPB
cable laid in close trefoil formation
(a) In ground at 300C ground temp, 650 820
Depth of laying 1.0 m, Thermal
Resistivity of soil 150°C Cm/W
(b) In free air at 400 C Ambient Air 1100 1345
Temperature
BEB: Sheath both end bonded
SPB: Sheath single point/ Cross bonded

3.2 GTP FORMAT:

Sr. Name of Particular Desired Value
No
1 No. of cores
2 Size (in mm.sq)
3 Voltage Grade (in kV)
4 Type of cable
5 Standard according to which cable
has been manufactured and tested
6 Permissible Voltage & Frequency
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

variation for satisfactory operation.

Voltage
Frequency
7 Maximum rated conductor
temperature
8 Max. allowable conductor
temperature during short circuit
9 Conductor Details
(a) Normal Cross-Sectional Area
(b) Material and Grade
(c) Shape of Conductor
(d) Separator over conductor
10 Conductor Screen
(a) Material
(b) Nominal Thickness
11 Insulation
(a) Material
(b) Nominal Thickness
12 Insulation Screen
(a) Material
(b) Min. Thickness
(c) Longitudinal Water Sealing
13 Metallic Sheath
(a) Material
(b) Thickness
(c) Short Circuit current of metallic
screen for 1 sec (kA)
14 Outer Sheath
(a) Material
(b) Colour
(c) Thickness (Nom/Min)
(d) Conducting layer over outer
sheath
15 Nominal overall Diameter of cable
16 Nominal Overall Weight of Cable
per Meter
17 Standard Drum Length with
Tolerance
18 Minimum Bending Radius
allowable during installation
19 Safe Pulling force
20 Impulse Withstand Voltage
21 One minute Power Frequency
Withstand Voltage (kV)
22 Short circuit current for one second
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

(kA)
Max conductor DC resistance at
200C
Approx. AC resistance at 900C
Max. capacitance
23 Continuous Current Rating for BEB SPB
cable laid in close trefoil formation
(a) In ground at 300C ground temp,
Depth of laying 1.0 m, Thermal
Resistivity of soil 150°C Cm/W
(b) In free air at 400 C Ambient Air
Temperature
BEB: Sheath both end bonded
SPB: Sheath single point/ Cross bonded
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

SECTION – IC
DETAILED SPECIFICATIONS FOR TECHNICAL SPECIFICATION CABLE SEALING END KIT
FOR 220 kV
GENERAL TECHNICAL REQUIREMENTS

TECHNICAL SPECIFICATION CABLE SEALING END KIT for 220 kV

a. Specifications of 245 kV Dry type.
b. Termination, Dry type O/D Termination & St through Joints
c. Applicable IECs: IEC 60840 for technical data, IEC 62271-209 for dimensioning,
EN 50089 for routine tests on Epoxy insulators

1 TYPE & MAKE OF CABLE KITS

1.1 SF6 SWITCHGEAR TYPE SEALING END:

1.1.1 For the feeder bays having power cable connections, the suitable cable sealing
end enclosures will be supplied by the GIS bidder but 245 kV XLPE cables and
cable sealing end terminators with cable cone will not be included in the GIS
bidder’s supply. Interface between GIS and power cable will be in accordance
with IEC 62271-209 (2007-08).

1.1.2 The GIS Plug-in (Dry) type cable sealing end, confirming to IEC: 60840 for
termination of the Cables for maximum continuous voltage of 245 kV at SF6
switchgear end will be supplied by the cable manufacturer. The contractor shall
be responsible for the preparation of the cable insulation and conductors and
correct termination of each cable to these sealing ends.

1.1.3 3 Bidders are requested to quote cable sealing end with design that helps
reducing, if possible, the works on the gas compartments. The cable sealing end
shall be of plug-in type that allows easy plugging and unplugging of high voltage
power cable without the need of opening the GIS and related time consuming
gas works. The supplier of GIS Plug-in (Dry) type Termination will coordinate
closely with GIS manufacturer for mounting the epoxy insulator in the GIS cable
chamber. The cable contractor will supply only the Plug-in part and associated
components.

1.1.4 Cable manufacturer shall furnish large scale general assembly drawings of the
SF6 sealing ends, mounting flange details, size of terminal opening in the
junction box, weight of terminal including accessories, physical shape and
dimensions of all live part, recommended clearances form live parts to the inside
surface to permit the SF 6 switch gear manufacturer to design and supply
junction boxes of adequate dimensions and construction to permit the
installation and maintenance of the terminals without difficulty.
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

1.1.5 The stress cone made of EPDM rubber shall inhibit possible mechanical stress
and deformation of the cable insulation surface during operation and also shall
be capable of accommodating minor radial and longitudinal movement without
determent to the dielectric stress in the insulation shield.

1.1.6 Manufacturer shall state the connector clearances required when the assembled
cable DC proof test is undertaken for co-ordination with the SF6 switch gear
design.

1.1.7 All supporting structures for the SF6 bus-duct connections between the XLPE
cable sealing ends and the GIS shall be supplied by the outdoor GIS supplier. The
supplier may specify connecting & supporting arrangements for approval of the
purchaser.

1.2 OUTDOOR TYPE SEALING END.

1.2.1 The Dry type cable sealing end (where no oil filling is required in the
Termination), conforming to IEC-60840 will be preferred, for maximum
continuous voltage of 245 kV cables at the outdoor yard shall be supplied by the
cable manufacturer. The contractor shall be responsible for correct termination
of each cable to sealing ends, installation of the cable sealing end and providing
of terminal connectors for connecting to terminal conductor. The requisite
interconnection between line end & sealing end is required to be designed (as
per safety and statutory provision aspects) and executed (after approval of
Owner) by successful bidder.

1.2.2 The silicone rubber /composite bushing termination of rated capacity, suitable
for outdoor installation in heavily polluted atmosphere shall be used. The
minimum creepage offered should not be less than 31mm/kV. It should resistant
to UV exposure. The termination stress control shall be means of stress cone.

1.2.3 The stress cone made of EPDM rubber shall inhibit possible mechanical stress
and deformation of the cable insulation surface during operation and also shall
be capable of accommodating minor radial and longitudinal movement without
determent to the dielectric stress in the insulation shield.

1.3 STRAIGHT THROUGH JOINTS

1.3.1 The Pre-Moulded type straight through joints for XLPE cable, conforming to IEC
60840 shall be suitable for underground buried installation with incorporated
back fill and chances of flooding by water. The straight through joints should be
absolutely impervious to the entry of water. The manufacturer shall use the
proven technology and design to prevent entry of water or any other liquid
inside the straight through joints and cables.

1.3.2 The stress cone made of EPDM rubber shall inhibit possible mechanical stress
and deformation of the cable insulation surface during operation and also shall
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

be capable of accommodating minor radial and longitudinal movement without

determent to the dielectric stress in the insulation shield.

1.4 Type tests conducted for offered make cable and accessories separately will be
considered for evaluation.

Type test for cable conducted shall be as per IEC 60840 or equivalent/higher
standard for 245 kV 1000 mm.sq copper cable or above sizes offered make cable &
pre moulded joints and end terminations.

The above tests should have been conducted from any one of the reputed
International Test Laboratories mentioned below.
a) CPRI, Bangalore.
b) STRI Sweden.
c) Hydro-Quebec, Canada
d) EDF, France.
e) KEMA, Holland.
f) CESI, Italy.
g) IPH, Germany.
h) NEETRAC (USA).

However, the type tests conducted at any other international accreditation test
laboratory is also considered, subject to verification of accreditation certification
issued by international accreditation board only and for the purpose of conducting
type test.
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

SECTION – ID
DETAILED SPECIFICATIONS FOR CROSS BONDING OF EHV CABLES FOR 220 kV
GENERAL TECHNICAL REQUIREMENTS

1 Link boxes and sheath voltage limiters:

1.1 General

Link boxes are used with cable joints and terminations to provide easy access to
shield breaks for test purposes and to limit voltage build-up on the sheath.
Lightening, fault currents and switching operations can cause over voltages on
the cable sheath. The link box optimizes loss management in the cable shield on
cables grounded both sides.

1.2 Cross Bonding:

For cross bonding, the cable length is divided into 3 equal sections. Each of the
alternating magnetic fields induces a voltage with a phase shift of 120° in the
cable shields. The cross bonding takes place in the link boxes. Ideally, the
vectorial addition of the induced voltages becomes zero. In practice, the cable
length and the laying conditions will vary, resulting in a small residual voltage and
a negligible current. Since there is no current flow, there are practically no loses
in the screen. The total of the three voltages is zero, thus the ends of the three
sections can be grounded. However sections for cross bonding may vary
depending on the length of cables.

1.3 Mechanical Design

a) Made of stainless steel
b) Compact design
c) Single phase and 3-phase link boxes
d) Hermetically sealed
i. Resists water pressure up to 1 bar (20 psi)
ii. Lugs and bonding cables are heat shrink sealed inside and outside
e) Suitable for different applications
i. Single point bonding
ii. Cross bonding
iii. Direct grounding
iv. Grounding through SVL
v. Combined direct and SVL grounding
vi. Cross bonding and transposition

1.4 Electrical Design:

a) Grounding box
b) Link box
c) ZnO sheath voltage limiter
Request for proposal -220/33 KV GIS SS (Phase -1) At Mukand Plot, Bhola Nagar, Kalwa, Dist. Thane

d) 3 kV and 6kV protection levels

e) Same outer dimensions for both levels

1.5 Applications:
a) Can be installed in underground pits at a depth of 2mtr and more.
b) Use with single core or concentric bonding lead

1.6 Type Tests:

a) Tested to ANSI/IEEE Std 575-1988 IEEE-Guide for the application of sheath-
bonding methods for single conductor cables and the calculation of induced
voltages and currents in cable sheaths.
b) Any NABL accredited laboratories.

1.7 Dimensions:
a) Single Phase Link Box: L 300 x W 190 x H 165 (mm)
b) Three Phase Link Box with or Without SVL: L 310 x W 310 x H 255 (mm)

Note: This is Dimensions are indicative only which will be finalized during detailed
engineering.

1.8 Factory Type Tests:

a) Water Immersion Test (IP 68- IEC 60529)
b) Impulse Voltage Withstand Test
c) Dust Test
d) Water Jet Test

1.9 Routine Tests:

a) DC Withstand Test:
25 kV DC voltage is applied for 5 minutes to each cable lug meanwhile all other
lugs to be earthed. If exist(s), SVL(s) dismounted during test. In the DC withstand
test is no breakdown and flash over.

b) Insulation Resistance Measurement Test:

5 kV DC voltage is applied for 1 minute to each cable lug meanwhile box itself to
be earthed. If exist(s), SVL(s) dismounted during test. At the end of test duration
insulation resistance of each link box is greater than 100 MΩ.

c) Contact Resistance Measurement Test:

50 A DC current will be applied to each contact points which had been squeezed
with 40 kN torque. If exist(s), SVL(s) dismounted during test. Contact resistance
each contact point is less than 10 μΩ.

d) Water Sealing Test:

All underground type link boxes after manufacturing with cover bolted closed,
and phase glands capped, filled with water trough earthing gland will be subject
to equivalent 3 meter water pressure (0.3 bars) for 15 minutes. VISUALY
inspection of external surf. There is no leaks and water spots.