Hy28593 Rev01
Hy28593 Rev01
SIGNAL CABLES
1.0. SCOPE:
This specification covers the technical & quality requirements for design, manufacture,
assembly, testing of signal cables at manufacturer works, packing and delivery to site.
2.0 STANDARDS:
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
The cable shall conform to the latest editions of various standards mentioned in the
It must not be used directly or indirectly in any way detrimental to the interest of the company.
specification.
In case of conflict between any standard and these specifications the matter shall be
referred to the Purchaser before proceeding with the manufacturing of the cables.
IS 1554 Part 1 PVC Insulated (heavy duty) electric cables working voltage up to
and including 1100V.
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IS 3975 Mild steel wires, formed wires and tapes for armouring of cables.
ASTM D 2863 Test method for measuring the minimum oxygen concentration to
support candle like combustion of plastics (oxygen index).
3.0 OFFERS:
3.1 Vendor’s offer shall include complete datasheet as per the attached format, type test
certificates, various testing methods, pair identification methods, technical literature and
cross sectional dimensional drawings for each type of cables considered in the offer.
Revisions: Issued :
Brought upto date. STANDARDS ENGINEERING
DEPARTMENT
Rev.No. 01 Amd. No. Reaffirmed: Prepared: Approved: Date of 1st Issue:
Dt. NOV.2005 Dt. Year: SR.MANAGER, SR.DGM
TC>-INST. (P,T&IS) AUG. 99
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3.2 Vendor’s offer shall include a list of deviations if any from Purchaser’s specifications and
also shall indicate the reasons for such deviations for consideration.
3.3 Vendor shall quote unit price per meter for each type of cable.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
types of cables shall be furnished by vendor along with offer for cables similar to those
It must not be used directly or indirectly in any way detrimental to the interest of the company.
being offered. The type test certificates shall not be older than two years as on date of
submission of technical offer.
These tests shall be carried out by vendor during various stages of manufacturing.
Purchaser will review the related documents during inspection.
4.2.1 Insulation and sheaths: All tests as per IS-5831 shall be conducted as part of routine tests,
except for insulation resistance, voltage and spark test.
4.2.2 Insulation resistance, voltage and spark test shall be as per BS-5308 part-2
4.2.5 Electrical tests including cable capacitance (core-core) and (core –screen)
These tests shall be carried out in the presence of the purchaser or their authorized
representative.
4.3.10 Acid gas generation test as per IEC – 754. (for FRLS)
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
It must not be used directly or indirectly in any way detrimental to the interest of the company.
4.3.12 Flame Retardant test as per IEEE 383 / IEC – 332.3, Part 3, Category-A.
4.3.13 Dimensional checks overall diameter, under armour and over armour diameter. Overall
diameter shall be within ± 1 mm over offered value.
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4.3.17 Electrostatic noise rejection test, type wise for each lot.
5.1 Type of cable Shielded, armoured, single / multi pair signal cable.
5.2 Voltage grade(UO/U) 600 / 1100 V
5.3 No. of pairs/triad As per enquiry.
5.4 Conductors Annealed tinned electrolytic grade stranded copper conductor.
of 1.5 mm² (7x0.53mm) or 0.5 mm² (7x0.3mm) as per IS 8130
required size as per enquiry.
5.5 Primary insulation Extruded, type C, 85° C, HR PVC compound as per IS 5831.
The thickness shall be 0.5 mm minimum for 0.5 mm² conductor
& 0.8 mm for 1.5 mm² conductor. Negative tolerance on
insulation thickness is not acceptable.
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5.6 Pair Twisting Positive and negative conductors shall be twisted together to form
a pair with no. of twists per meter > 13.
5.7 Core identification Colour of core insulation shall be normally black & blue in pair,
black, blue and brown for triad. It is subject to change during
datasheet approval.
5.8 Pair Identification By number printing on both cores of each pair at an interval of
(For multi pair not more than 200 mm.
cables)
5.9 Pair /triad Screening Each pair/triad individually shielded with 0.05 mm thick (min)
Aluminium mylar tape with 25% overlap giving 100% coverage.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
It must not be used directly or indirectly in any way detrimental to the interest of the company.
Plus annealed tinned stranded copper drain wire of size 0.5mm2
(7x0.3 mm) in continuous contact with aluminium side of shield.
5.10 Cable bundling (For Each pair/triad of individual shielding as above shall be
multi pair cables) individually wrapped with mylar / polyster tape of thickness
0.075 mm & bundled together to form a cable with 4 to 6 twists
per meter. Plus a pair of communication wire of annealed tinned
5.11 Overall Screening Aluminum mylar tape of minimum thickness 0.075 mm (100%
(For multi pair coverage with 25% overlapping) along with annealed tinned
cables) stranded copper drain wire of size 0.5mm2 (7x0.3 mm) in
continuous contact with aluminum side of the shield shall be
provided.
5.12 Inner Sheath Extruded PVC or Fire Retardant (FR) Extruded PVC as per
material code, 90° C, type- ST2 as per IS:5831 with nonmetallic
rip cord under the sheath. The thickness shall be as per IS 1554
Part 1. Inner sheath colour shall be normally black subject to
change during drawing approval.
5.13 Armour Armour over inner sheath shall be galvanised round steel wire or
flat strips as per IS 1554, Part-I, latest revision.
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5.14 Outer Sheath Extruded PVC with Flame Retardant Low Smoke (FRLS) or
Flame Retardant (FR) properties as per material code, 90° C,
type- ST2 as per IS 5831. The thickness shall be as per IS 1554
Part 1. Colour shall be normally black for non-intrinsic safe &
light blue for intrinsic safe cable, subject to change during
drawing approval.
5.15.1 Multipair cable with overall shield only. This cable construction shall be as above except
that the individual pair shall not have the shielding.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
It must not be used directly or indirectly in any way detrimental to the interest of the company.
6.1 The quantity indicated against each type of cable in the enquiry may vary by ± 25% at the
time of placement of order. Vendor shall confirm that there shall not be any price
implication on this account in the unit prices type wise.
6.2 Drum length for each type of cable shall be 1000 metres min. & cable length < 1000
metres shall be in single length. The actual produced drum length shall not vary by more
than ± 5%.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
It must not be used directly or indirectly in any way detrimental to the interest of the company.
± 2% for total length more than 5 km
6.4 Outer sheath marking: Following shall be marked on outer sheath at 1 meter interval.
i) Incremental length.
ii) Cable size.
iii) Cable type
6.5 All cables shall be suitable for laying in open air, corrosive hydrocarbon plant
environment, direct sun and in trenches. The cable shall be designed for prolonged use in
tropical atmosphere.
8.0 DOCUMENTATION :
8.1 With offer: 2 copies of filled in technical data sheets, catalogues, type test certificates,
and signed & stamp copy of this specification to be furnished with the bid.
8.2 After order: 4 copies of datasheets, Quality Assurance Plan shall be furnished within 1
week of placement of Purchase Order or LOI for Purchasers approval.
8.3 After Inspection: 7 copies of final datasheets, all test certificates including material test
certificates inspection reports shall be furnished within 1 week of completion of Inspection
by Purchaser’s representative.
8.4 Vendor shall provide all the certificates for all tests indicated in cl. 4 of this specification.
The document shall be as per DIN 50049 for material test. Vendor shall provide the
manufacturer’s certificate of conformity to purchaser’s specification as per cl. 2.2 of DIN
50049.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
It must not be used directly or indirectly in any way detrimental to the interest of the company.
9.1 Each cable drum shall be marked with the following information at a visible place
a) Manufacturer’s name
b) Details of cable
c) Length of the cable
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d) Gross weight
e) Direction of rotation of drum by means of an arrow for unwinding
f) Purchase order number
g) BHEL Material code
h) BHEL dispatch no. (to be informed after order placement)
10.1 Cables shall be dispatched in wooden drums, securely battened with take off end fully
protected against damage.
10.2 The ends of the cable shall be sealed with suitable PVC/rubber caps to prevent ingress of
moisture.
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DATA SHEET
(To be filled in separately for each type of cable by vendor and shall be enclosed with the bid.
The following format must be used, otherwise the offer shall not be considered.)
1. Name of manufacturer :
2. Standards applicable :
3. Voltage grade :
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
4. Conductor
It must not be used directly or indirectly in any way detrimental to the interest of the company.
a) Material :
b) Size (mm²) :
c) No. of strands x diameter in mm. :
5. Insulation
7. Pair screening
a) Material :
b) Thickness :
c) Drain wire size :
d) Drain wire (No. of strands x diamater in mm):
8. Cable bundling
a) Binding material :
b) No. of twists/meter :
c) Tape thickness :
d) Communication cable :
i) Conductor materials :
ii) Size (mm²) :
iii) Insulation materials :
iv) Insulation thickness (mm) :
v) Colour of cores :
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9. Overall screening
a) Material :
b) Thickness :
c) Drain wire material :
d) Drain wire size (sq. mm.) :
e) Overlapping % :
a) Material :
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
11. Armour
b) Flat/wire thickness :
c) Dia over armour :
a) Material :
b) Thickness of outer sheath :
c) Dia of cable over outer sheath :
d) Colour :
17. Type test, routine test, acceptance test : As per BHEL spec. no. HY28593 Cl. No. 4
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