Cables Specifications VF
Cables Specifications VF
Cables Specifications VF
This section provides for manufacture, testing before dispatch, supply and delivery F.O.R. destination of Four
Core & Twin Core size 16mm2 , 10mm2 XLPE insulated and XLPE Sheathed Un-armored circular LT cables with
aluminum conductor suitable for working voltage up to & including 1100 Volts ISI Marked & Conforming to IS
7098 (Pt-I)/1988 with latest amendments.
STANDARDS
Unless otherwise stipulated in this specification the following standards with latest amendments shall be
applicable.
a) IS: 7098(Pt-I)/1988 XLPE Insulated (Heavy Duty) Electric cable for Voltages up to
and including 1100 Volts working
b) IS: 8130/1984 Conductors for insulated cables.
c) IS: 5831/1984 XLPE insulation and sheath of electric cables.
CLIMATIC CONDITIONS:
Parameters Conditions
Maximum altitude above sea level 5000m
Maximum ambient air temperature 50° C
Maximum daily average ambient air temperature 40° C
Minimum ambient air temperature -30° C
Maximum temperature attainable by an object 60 ° C
exposed to the sun
Maximum yearly weighted average ambient 32° C
temperature
Maximum relative humidity 100%
Average number of thunderstorm days per 70
annum (isokeraunic level)
Average number of rainy days per annum 120
Average annual rainfall 1500 mm
Maximum wind pressure 260Kg/m²
Note: The atmosphere is generally laden with mild acid and dust in suspension during the dry months and is
subjected to fog and snow in cold months. The design of equipment and accessories shall be suitable to withstand
seismic forces corresponding to an acceleration of 0.3 g.
GENERAL REQUIRMENT:
a) The ISI marked XLPE Insulated Un-un-armored cables shall conform to IS: 7098(PT-I) /1988 with latest
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amendment and bear BIS certification mark. The material used for construction of the cables shall be of
best quality complying with the requirement of IS: 7098(Pt-I)/1988 and other relevant standards. The
cables shall be suitable for outdoor/indoor installation free in air and shall be capable of withstanding
the normal stresses associated with transportation, erection, reeling and unreeling operations without
getting deformed.
b) The cable shall be suitable for use where combination of ambient temperature and temperature rise due to
load results in a conductor temperature not exceeding 90 degree C under normal operation and 250 degree
C under short circuit condition.
c) The XLPE Insulated Un-Un-armored LT Cable shall be ISI marked. The (MANUFACTURER) must
furnish valid ISI certificate along with offer.
MATERIAL:
1) CONDUCTOR:
The conductor shall be composed of aluminum wire complying with IS: 8130/1984 with latest
amendments.
2) INSULATION
Insulation shall be cross linked Polyethylene (XLPE) conforming to the requirements Table-I of IS:
7098/1984 with latest amendments.
3) FILLERS
The central hole/void, if any, of the cable shall be invariably filled with suitable filler material so
that there is no gap in the center.
The filler shall be of vulcanized rubber, un-vulcanized rubber or Thermoplastic material and shall be
provided to fill the gaps between cores.
The filler material shall be so chosen so as to be compatible with temperature of the cable and shall
have no deleterious effect on other components of the cable. These shall not be harder than XLPE
and PVC used for insulation and outer sheath respectively.
4) OUTER SHEATH
The outer sheath shall consist of type ST-2 PVC Compound conforming to the requirements of IS:
5831/1984.
CONSTRUCTION:
1) CONDUCTOR
The construction of the conductor shall be stranded for cable size 10 Sq. mm and above, as per Clause No. 8.1
of IS:7098(Pt-I)/1988 & relevant clause of IS:8130/1984.
A protective barrier may be applied between the conductor and insulation. Such barriers when used shall be
compatible with insulating material and suitable for the operating temperature of the cable.
2) INSULATION:
The conductor (with protective barrier, wherever applied) shall be provided with Cross-Linked Polyethylene
(XLPE) insulation applied by extrusion. The insulation shall be so applied that it fits closely on the conductor and
it shall be possible to remove it without damage to the conductor. The thickness and tolerance on thickness of
insulation shall be as per clause No. 9.2 of IS: 7098 (Pt- I)/1988.
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3) CORE IDENTIFICATION:
The core shall be identified by different coloring of XLPE insulation as per Clause No. 10.1 of IS: 7098 (Pt-I)/
1988.
4) LAYING UP OF CORES :
The cores shall be laid up together with the suitable right hand lay. The interstices shall be filled with non-
hygroscopic material.
5) INNER SHEATH (COMMON COVERING):
i. The laid up cores shall be provided with an inner sheath applied either by extrusion or by wrapping.
It shall be ensured that it is as circular as possible. The thickness of inner sheath shall be as given in
Table-5 of IS: 7098(Pt-I)/1988.
ii. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible
to remove it without damage to the insulation.
6) OUTER SHEATH
i. The outer sheath shall be applied over the armouring.
ii. The color of the outer sheath shall be black.
iii. The minimum thickness of XLPE outer sheath shall not fall below the thickness specified in Table
-8 of IS: 7098 (Pt-I) /1988.
The cable should meet the requirement of all tests including optional tests as specified at Clause No. 15.4 of IS:
7098 (Pt. I) / 1988.
INSPECTION:
1) The inspection may be carried out by the purchaser at any stage of manufacture. Free access should be
granted to the purchaser’s representatives at a reasonable time when the work is in progress. Inspection
and acceptance of any equipment / material under this specification by the purchaser shall not relieve
the supplier of his obligation of furnishing equipment in accordance with the specification and shall
not prevent subsequent rejection if the equipment/material is found to be defective.
2) The supplier shall keep the purchaser informed in advance about the manufacturing program so that
arrangement can be made for inspection.
3) The acceptance tests as per IS: 7098(Pt-I)/1988 shall also be conducted by the manufacturer before
dispatch in the presence of purchaser’s Representative / Inspecting Officer as per relevant clause of
“General Conditions of Contract” along with verification of lengths & weight and checking the
manufacturing defects, if any of samples coils .The mass of aluminum, XLPE, PVC & Filler in
sample coils shall also be verified by the Inspecting Officer(s). Cold bend/ cold impact test (IS: 5831/
1984) shall constitute the optional tests and shall be conducted on each offered lot of the cables of
each size as per Clause No. 15.4 of IS: 7098(Pt- I)/1988.
4) TYPE TESTS:
a. The first lot offered shall not be less than 10% of ordered quantity of each size of LT XLPE UN-
ARMORED & ARMOURED CABLE.
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b. One sample from the 1st Lot of LT XLPE UN-ARMORED/ARMOURED Cable of each size as
received in purchaser’s store shall be selected and sealed by the inspecting officer nominated by
purchaser’s for getting it type tested at any NABL accredited testing laboratory. The charges
incurred towards type test of the material received in our stores shall be borne by Supplier.
c. In case sample from first lot fails then:
i. Supplier shall have to replace the full quantity of the respective inspected lot supplied
to various stores and lying unused at stores.
ii. For the quantity already utilized against the order in field a deduction @ 15% (Fifteen
Percent) of F.O.R. Destination prices of the material supplied shall be made.
iii. Sample from next lot shall be selected again for type test. All test charges incurred
towards type test of the material for second time shall be borne by the Supplier. In case
sample again fails in the type test then further supplies shall not be accepted.
5) The purchaser reserves the right to insist for witnessing the acceptance /routine tests of the bought out
items.
6) At least 5% of total numbers of drums subject to minimum of 2 in each lot put up for inspection shall
be selected at random to ascertain the length/workmanship of cable by the following method:
a. At the work of the manufacture, the cable shall be transferred from one drum to another for
checking any manufacturing defects in the cable drum selected for conducting acceptance tests,
at the same time measuring its length with the help of pulley & cyclometer graduated in
presence of inspector. The difference in the measured length thus obtained from the declared
length by the supplier in the packing list shall be applied to all the drums if the cable is found
short during checking the sample lot (s).
7) The supplier shall present the latest Calibration Certificate(s) of testing instruments/equipment to be used
for the testing of the material covered in the Purchase Order to the authorized inspecting officer
/inspecting agency of the purchaser. The testing instruments / meters /apparatus etc. should be got
calibrated by the supplier from time to time from an independent testing laboratory / house having valid
accreditation from National Accreditation Board for testing and calibrating laboratories for the testing
equipment or from original manufacturers having trace ability to NABL /NPL. The calibration
certificate(s) should not in any case be older than one year at the time of presenting the same to the
inspecting officer / inspecting agency of the purchaser. The testing instruments / equipment should be
duly sealed by the Calibrating Agency and mention thereof shall be indicated in the calibration
certificate(s).
8) TEST CHECKING OF MATERIAL AT STORES:
a. SAMPLING: One number out of each lot / sub-lot of 25 Nos. drums or pert thereof for cables of
size 10 Sq. mm. and above.
b. TESTS: The following tests shall be carried out:
i. Measurement of Resistance of conductor.
ii. Tensile & Elongation test for insulation.
iii. Thickness of Insulation.
c. CRITERIA FOR ACCEPTANCE:
i. If the measured conductor resistance of the sample(s) exceeds beyond 2% as per the
resistance specified in the contract, the material shall be rejected and the same shall have
to be replaced by the supplier.
ii. If the measured conductor resistance of the sample(s) exceeds the value specified in
the contract but does not exceed by more than 2% of the resistance value specified
in the contract, the material pertaining to the relevant lot/ sub-lot to shall be accepted
with a deduction @ 1.5% of the cost of cable for increase in resistance for every 1% or
part thereof.
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iii. If the sample(s) fails in any other test, the material contained in the pertinent lot/sub-lot
shall be rejected and shall have to be replaced by the supplier.
d. TEST CHARGES: All test charges incurred towards test checking of the material received in our
stores shall be borne by the PURCHASER.
9) The manufacturer shall be responsible to pay penalty of Rs 20,000/- for each occasion at which the
fake inspection call has been made or the material is rejected during testing/inspection by the authorized
agency/representative of the Purchaser. This penalty would be in addition to the expenses incurred by
the Purchaser in deputing the Inspecting Officer, carrying out such inspection.
IDENTIFICATION:
1) The manufacture shall be identified through-out the length of cables as per Clause No. 17.1 of IS: 7098(Pt-
1)/1988.
2) In order to distinguish these electric cables from telephone cables, the word ELECTRIC shall be indicated,
printed or embossed throughout the length of the cable on outer sheath.
3) The cable code shall be provided as per Clause No. 17.3 of IS: 7098 (Pt- I)/1988.
4) The cable shall also be required to be embossed with the word Name of Manufacture or trade name, Cable
code, Voltage Grade, Utility name, size of cable, year of manufacture and ISI certification mark at every
meter length for which no extra charges shall be paid.
5) The cable shall be colour coded as per requirement of the Utility.
STANDARD LENGTH:
1) The cables shall be supplied in the standard length of 500 Meter for, 4CX16 Sq. mm2, and 1000 Meter for
size 4CX10Sq. mm2, 2CX16Sq. mm2 2CX10 Sq. mm2.
2) A tolerance (+/-) 5 % shall be allowed in standard length.
3) Only one cable length shall be acceptable by non-standard length measuring not less than 50% of standard
length to complete the ordered quantity in each size.
CHALLENGE CLAUSE:
The material offered/received after the inspection by the authorized inspecting officer may again be subjected to
the test for or any parameter from any testing house/in-house technique of the Purchaser & the results if found
deviating un-acceptable or not complying to approved GTPs the bidder shall arrange to supply the replacement
within thirty (30) days of such detection at his cost including to & fro transportation. In addition, penalty @10%
of cost of the inspected lot of material shall be imposed.
WARRANTY PERIOD:
The supplier shall be responsible to replace, free of cost, with no transportation or insurance cost to the purchaser,
up to destination, the whole or any part to the material which in normal and proper use proves the defective in
quality or workmanship, subject to the condition that the defect is noticed within 18 months from the date of receipt
of material in stores or 12 months from the date of commissioning whichever period may expire earlier. The
consignee or nay other officer of Purchaser actually using the material will give prompt notice of each such defect
to the supplier. The replacement shall be effected by the supplier within a reasonable time, but not, in any case,
exceeding 45 days/ The supplier shall, also, arrange to remove the defective within a reasonable period, but not
exceeding 45 days from the date of issue of notice in respect thereof, failing which, the purchaser reserve the right
to dispose of defective material in any manner considered fit by him (purchaser), at the sole risk and cost of the
supplier. Any sale proceeds of the defective material after meeting the expenses incurred on its custody, disposal
handling etc., shall however be credited to the supplier’s account and set off against any outstanding dues of the
purchaser against the supplier. The warranty for 12/18 months shall be one time.
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RATED VOLTAGE:
The rated voltage of the cable shall be 1100 Volts AC with the highest system voltage of 1100 Volts between
phases of the effectively earthed three-phase transmission system.
The cables shall be capable of operating continuously under the system frequency variation of ± 3 Hz, voltage
variation of ± 10% and a combine d frequency – voltage variation of ± 10%.
APPLICABLE STANDARDS:
i) Unless otherwise stipulated in the specifications, the latest version of the following Standards shall be
applicable:
o IS 3975-Specification for mild steel wires, strips and tapes for armouring of cables.
ii) The cables manufactured to any other International Standards like BSS, IEC or equivalent standards
not less stringent than Indian Standards are also acceptable. In such cases the Manufacturer shall
enclose a copy of the equivalent international standard, in English language.
CONSTRUCTION:
Conductor: - The cable conductor shall be made from stranded aluminum to form compact sector shaped
conductor having resistance within the limits specified in IS:8130/1984 and any amendment thereof. The wires
shall be laid up together with a suitable right hand lay. Stranded Class 2 – as per the IS:8 130 / IEC 60228/ BS
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6360 standards.
Insulation: - The insulation shall be cross linked polyethylene applied by extrusion and shall be steam (wet) cured
as pre IS:7098(1)1988 and curing in hot water tank/bath is not accepted.:
5. Shrinkage:
a) Treatment: Temperature 130±3°C
Duration 1 hour
b) Shrinkage 4 percent, Max
6. Water absorption (Gravimetric):
a) Treatment: Temperature: 85±2°C
Duration 14 days
b) Water absorbed 1 mg/cm², Max
7. Volume Resistivity 1x1014 ohm-cm, Min
a) at 27°C
b) at 70°C 1x1013 ohm-cm, Min
8 Thermal Resistivity 350 degrees C cm/W
The XLPE insulation should be suitable for specified 1.1 KV system voltage.
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The manufacturing process shall ensure that insulations shall be free from voids.
The insulation shall withstand mechanical and thermal stresses under steady state and transient operating
conditions.
The insulation of the cable shall be high stranded quality, specified in IS:7098 (Part-II/1985). Withstand
continuous conductor temperature of 90 deg C, which means higher continuous rated current carrying capacity.
The cables can operate even at conductor temperature of 130 deg C continuously and 250 deg C during a Short
Circuit condition.
SHEATH :
The sheath shall be suitable to withstand the site conditions and the desired temperature. It should be of adequate
thickness, consistent quality and free from all defects. The PVC sheath shall be extruded as per IS:7098 (Part –
I/1988). IEC:60502 Part– I,BS:6622, LSOH to BS:7835.
The cable shall be without armouring shall also be accepted of type detailed in price schedule.
OUTER SHEATH : Extruded PVC ST2, outer sheath as per IS:5831/1984, IS:7098 Part 1, IEC:60502 Part – 1,
BS:6622, LSOH to BS:78 35. shall be applied over armoring with suitable additives to prevent attack by rodents
and termites. Outer sheathing shall be designed to offer high degree of mechanical protection and shall also be
heat, oils, chemicals, abrasion and weather resistant. Common acids, alkalis, saline solutions etc., shall not have
adverse effects on the PVC sheathing material used.
The power cables shall be manufactured to the highest quality, best workmanship with scientific material
management and quality control. The Manufacturer shall furnish the quality plan, giving in detail the quality
control procedure / management system.
The cable shall be suitable for laying in covered trenches and/or buried underground to meet the outdoor
application purposes.
SYSTEM DETAILS:
CLIMATIC CONDITIONS:
MATERIALS:
Conductor: -The conductor shall be of stranded construction. The material for conductor shall consist of the plain
aluminum of H2 or H4 grade as per clause – 3 of IS 8130/ 1984.
The minimum number of wires shall be 53 for circular compacted 400 sq. mm aluminum conductor as per table –
2 of IS 8130/ 1984.
The Manufacturer shall furnish a complete and detailed quality plan for the manufacturing process of the cable.
All raw materials shall conform to relevant applicable standards and tested for compliance to quality and
requirement. During the manufacturing process, at all stages, inspections shall be made to check the physical and
dimensional parameters, for verification to compliance to the standards. The Manufacturer shall arrange, for
inspection by the purchaser, during manufacture with one month advance notice for verifying the various stage
inspections as specified in the quality assurance plan enclosed to verify the quality control process of the
Manufacturer.
TYPE TESTS:
Type test certificates from Accredited NABL Testing Laboratories for 1.1 kV XLPE, shall be submitted along
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with Purchase order. The Type Tests should have been conducted not later than 5 years as on the date of supply.
1. Stage wise Inspection: The Manufacturer shall offer the stage wise inspection as detailed in the in the
quality assurance plan
2. All acceptance tests shall be conducted in the presence of the Employer’s representative.
3. The supplier shall give 10 days advance notice for inspections, and witnessing of tests by the Employer
representative.
4. The following type tests shall be conducted on the cable.
ACCEPTANCE TEST:
The sampling plan for acceptance test shall be as per IS 7098 part -II, Appendix ‘A’. The following shall constitute
the acceptance test.
ROUTINE TEST:
The following shall constitute routine tests:
i. Conductor resistance test.
ii. High voltage test.
PACKING:
The cables, as per specified delivery lengths, shall be securely wound /packed in non-returnable wooden drums,
capable of withstanding rough handling during transport by Rail, Road, etc. The packing should withstand storage
conditions in open yards. The cable drums shall conform to IS 10418-1982 or equivalent standard. The dimensional
drawings of wooden drums shall be furnished with the Purchase order. The drum shall be provided with
circumferential lagging of strong wooden planks. The end of the cable shall be sealed with good quality heat shrink
sealing caps. The sufficiently required additional sealing caps shall be supplied for use of testing during laying
and jointing at site and to seal spare lengths of cable. The packing should be able to withstand the rigorous of
transport. The following information in bold letters in English shall be painted on the flanges.
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