ANNEXURE-F PART 3 DISTRIBUTION390 46. TECHNICAL SPECIFICATION FOR 11 KV AERIAL BUNCHED XLPE INSULATED CABLES FOR OVERHEAD LINES (CROSSED LINKED POLYETHYLENE DRY GAS CURED) 1. SCOPE This specification covers requirements of 11 KV Aerial Bunched XLPE insulated Aluminium Cables for use in overhead lines under PSPCL. The sizes are as under:Sr. No. 1 2 3 4 2. COMPOSITION OF THE CABLE Size mm2 3Cx50+35 3Cx95+70 3Cx120+70 3Cx150+150 The composite cable shall comprise three single-core cables twisted around a bare aluminium alloy messenger wire, which will carry the weight of the cable. 3. RATED VOLTAGE The rated voltage of the cables shall be 6.35KV/11KV and the maximum operating voltage shall be 12 KV. 4. APPLICABLE STANDARDS Unless otherwise stipulated in this Specification, the following Standards with the latest amendments shall be applicable. Any deviation from the standards should be indicated specifically and with recorded reasons. Sr.No. 1 2 3 4 5 6 7 8 5. Applicable IS IS:7098(Part-II)-1985 IS:8130-1984 IS:10810/1984 (series) IS:10418/1982 IS:398 (Part-4) 1994 IS:5831/1984 IS:14255 : 1995 IEC-60502(Part-II) Description Cross linked Polyethylene Insulated PVC Sheathed Cables. Conductors for Insulated Cables Methods for tests for cables Drums for electric cables Aluminium Alloy conductors PVC Insulation and sheath of electric cable Aerial Bunched Cables for working voltage upto& including 1100 V Polyethylene Outer Sheath CLIMATIC CONDITIONS : The service / climatic conditions are given in 1.2 of part-A. The material shall be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth . TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B ANNEXURE-F PART 3 DISTRIBUTION 6. DETAILS OF SINGLE CORE CABLE:- 391 6.1 CONDUCTORS : The cable conductors shall be of round, stranded and compacted aluminium conductors of minimum cross sectional area 50mm2/95mm2/120mm2/150mm2. The aluminium conductors shall comply with the requirements as specified in IS. 8130-1984 with up to date amendments. The standard conductor shall be clean and reasonably uniform in size and shape and its surface shall be free from sharp edges. Not more than two joins shall be allowed in any of the wires form and every complete length of conductor and no joint shall be within 300 mm of any other joint in the same layer. Joints shall be blazed, silver soldered or electric or gas welded. No joint shall be made in the conductor once, it has been stranded. 6.2 CONDUCTOR SCREENING : Conductor screening shall be non-metallic and shall consist of a layer of extruded-semiconducting cross linked polyethylene (XLPE) compound of thickness not less than 0.5mm. 6.3 INSULATION : The insulation shall be chemically cross linked polyethylene (XLPE) applied by extrusion conforming to IS : 7098 (Part-II) / 1985 and as required in the specification, Cross-linking may be done by exposure to organize peroxide with nitrogen curing CCV line method with the intention to ensure lowest free formation. Only natural unfilled compound shall be used for insulation of cables. The average thickness of insulation when measured in accordance with relevant clause of the specification shall not be less than the standard thickness value specified. The smallest of the measured values of thickness shall not fall below the standard thickness values as specified in IS : 7098 (Part-II) / 1985 by more than 0.1+0.1 standard thickness in mm. The thickness of insulation shall be as under:Sr. No. 1 2 3 4 Nominal Area of Conductor (mm2) 50 95 120 150 Phase Nominal Thickness (mm) 3.6 3.6 3.6 3.6 Minimum (mm) 3.14 3.14 3.14 3.14 Thickness 6.4 INSULATION SCREENING : The insulation screening shall consist of non-metallic semi-conducting part in combination with a metallic part. Non- metallic part shall be applied directly over the insulation of each core and shall consist of a layer of extruded semi-conducting compound. The minimum thickness of non-metallic screening should be 0.6 mm. 6.5 METALLIC SCREENING : TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B ANNEXURE-F PART 3 DISTRIBUTION 392 The metallic part shall be applied over the individual core. Metallic screening shall consist of copper tape sheath and shall be non-magnetic. The thickness of metallic screening should not be less than 0.2mm. 6.6 OUTER SHEATH : Over the metallic screen the cable shall be provided with extruded PVC outer sheath. The composition of the PVC compound for outer sheath shall be Pre-Type ST2 of IS-5831-1984. The colour of the outer sheath shall be grey. The average thickness of the sheath shall not be less than the standard values specified in the IS when measured as laid in IS-7098 (Part-II)/ 1985. The smallest thickness of the measured values of sheath shall not fall below the standard value (s) specified, by more than 0.2+0.2 (ts) mm. 6.7 CORE IDENTIFICATION : The Core identification shall be done by providing coloured strip under Copper Tape. 7. MESSENGER WIRE : The bare messenger wire shall be of 35mm2/70mm2/150mm2 (nominal area). Messenger wire, shall consist of Aluminium alloy wires generally confirming to IS : 398 ( Part-IV)/ 1979and wire shall be tested as per relevant IS. Strands shall be suitably compacted and have smooth round surface to avoid damage to the outer insulating sheath of single-core phase cables twisted around the messenger. There shall be no joints in any wire of the stranded messenger conductor except those made in the base rod or wires before finally drawing. 8. LAYING UP : Three Power Cores shall be twisted over bare messenger wire with right hand direction of lay. This will form the Aerial Bunched Cable. 9. TESTS: 9.1 TYPE TESTS:The material offered, shall be fully type tested as per relevant standard of specification of IS:7098 (Part-II/1985) amended up to date. The bidder must furnish type test reports of similar rating & design of tendered material within 1 month of allotment of order. The following shall constitute type tests: a) Tests of Conductor: i. Annealing test (for copper) not applicable ii. Tensile test (for aluminium) iii. Wrapping test (for aluminium) iv. Resistance Test b) Test on Messenger Conductor: (as per IS: 14255/1995) i. Breaking load test for messenger conductor. ii. Elongation test for messenger conductor. iii. Conductor resistance test c) Tests for thickness of insulation and sheath. d) Physical tests for insulation: i. Tensile strength and elongation at break. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B ANNEXURE-F PART 3 DISTRIBUTION ii. Ageing in air oven. iii. Hot test. iv. Shrinkage test. Water absorption (gravimetric). v. e) Physical test for outer sheath: (as per IS: 14255/1995) Tensile strength and elongation at break. Melt Flow Index Vicat softening test. Carbon Black: Contents. Dispersion v. Environmental Stress Cracking f) Partial discharge test. g) Bending test. h) Dielectric power factor test: a. As a function of voltage. b. As a function of temperature. c. Insulation resistance (volume resistivity test). i) Insulation resistance (volume resistivity test) j) Heating cycle test. k) Impulse withstand test. l) High voltage test. m) Flammability test. n) Any other test as per relevant IS. 9.2 ACCEPTANCE TESTS i. ii. iii. iv. v. vi vii ix a) Tensile test Wrapping test Conductor Resistance Test Test for thickness of insulation and sheath Hot set test for insulation Tensile strength and elongation at break test for insulation and sheath Partial discharge test Insulation resistance (volume resistivity test) i. ii. iii. iv. a) b) 393 viii High voltage test 9.3 ROUTINE TESTS i Conductor Resistance Test ii Partial discharge test iii High voltage test TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B 3 The bidder must also clearly indicate various testing facilities available at their works for testing the material as per relevant standards. 10 INSPECTION (TEST BEFORE DISPATCH): 10. b. Conductor Resistance Test (Phase Conductor & Messenger). Tensile strength & elongation at break test for insulation and sheath. Breaking load test for messenger conductor. in triplicate for approval. i ii Breaking load Test (on finished wire). Contents. x) xi) xii) In addition to above following type tests shall also be considered as acceptance tests and shall be conducted on any two samples drawn from the lot offered for pre-despatch inspection:TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . Hot Set Test for XLPE Insulation. 9.2 of IS:7098 (Part. the bidder will be required to furnish the test certificate of the material. Elongation test for messenger conductor. In case. High voltage test and Insulation resistance (Volume resistivity) Test.18. Elongation test iii Resistance test 9. In case of otherwise particulars of the place where such testing is proposed to be conducted during the course of inspection shall be indicated .II)/1985 & IS: 14255/1995 shall be conducted in presence of the PSPCL 's authorized representative / agency on each lot of offered cables: i) ii) iii) iv) v) vi) vii) viii) ix) Tensile Test (If applicable). The material consumed/destroyed during testing will be to the account of the bidder. Dispersion Partial Discharge Test (for screened cables only).2 However.ANNEXURE-F PART 3 DISTRIBUTION 394 The following tests shall be carried out on the bare messenger wire in accordance with IS:398 (part –IV). Wrapping Test (If applicable). Test for thickness of insulation & sheath. 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. the PSPCL reserves the right to demand repetition of same or all the type tests in presence of PSPCL’s representative. The following Acceptance tests as per Clause No.1 No material will be allowed to be dispatched without prior inspection and approval. inspection of the consignment is waived off by the PSPCL. Carbon Black: a. The following shall constitute routine tests. The sample shall be bent around a test mandrel at room temperature for at least one complete turn. The cycle of these operations shall then be repeated twice. the length of TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . 10. for example.ANNEXURE-F PART 3 DISTRIBUTION 395 i) i) ii) iii) iv) v) Shrinkage Test Shrinkage Test Heat shock Test Hot deformation Test Thermal Stability Test Flammability Test For XLPE insulation (For outer sheath as per IS: 5831/1984 with latest amendments/revision if any) The lot shall be considered as passed if the test results of both the samples for above tests conform to relevant clauses of IS. The tests shall be done as per relevant ISS: a) b) c) d) 11. And d= actual diameter of the phase conductor in mm. minimum circumscribing diameter in mm . Messenger Resistance SEQUENTIAL MARKING. Conductor resistance test Partial discharge test High voltage test. It shall then be unwound and the process shall be repeated after turning the sample around its axis by 180 degrees. Requirement: No cracks visible to the naked eye are allowed. The following shall constitute optional test:Bending test on complete cable: The test shall be performed on a sample of complete cable. The diameter of the mandrel shall be: 10(D+d) Where: D= actual diameter of the cable. Supplier shall provide non erasable sequential marking on one core of AB Cable at every one meter distance before assembly of different cores to form the cable. However.2 ROUTINE TEST: . a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) Manufacturer’s name. IS -7098 (Part-II)/1985. depending upon the size. The cable shall be supplied in standard length of 1000 mtr. The wooden drums should be provided with cast iron bushing & painted form outside with suitable paint of any colour. Number of cores. The cable shall be wrapped with polythene under wooden covering. 13. In addition to this each drum shall carry the following information either stenciled on flange or label attached to it. Voltage rating. of lengths. Trade mark.e. & its direction of rotation (with an arrow) Year of manufacture. Out of total quantity of drums offered for inspection. word ELECTRIC. Property of PSPCL 13. 12. A reference to IS i.1 TOLERANCE ON PACKING The standard drum length may have tolerance of + 5%. & Date. PACKING & MARKING The cable shall be supplied in suitable non-returnable wooden drums of suitable size in standard lengths subject to a tolerance of +/-5%./500 Mtr.2 NON-STANDARD LENGTH Non-standard lengths not less than 50% of the standard length of cable to the extent of 5% of the total ordered quantity (size wise) will be acceptable. Work order No. Each meter length shall be embossed with the trade name of manufacturer. The ends of the cable shall be sealed by means of non-hygroscopic sealing material. CHECKING OF LENGTHS/ WEIGHTS DURING INSPECTION The bidder shall at his own cost provide the necessary arrangements for the purpose of physical and accurate checking of lengths and weights of the cables in drum(s) at the time of inspection by the Inspecting Officer of the PSPCL.ANNEXURE-F PART 3 DISTRIBUTION 396 cable for acceptance shall be based on length of finished cable and not on the basis of sequential marks. Position of outer end of cable Voltage grade and type of the cable. Drum No. Nominal cross-sectional area of the cable conductor. if any. 14. the Inspecting Officer of the PSPCL shall carry out inspection as under:TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . TOLERANCE 13. Name and address of consignee. year of manufacture and the word “PSPCL CABLE”. The cores shall be identified as per relevant IS. Colour of outer sheath. The drums should be such that the cable wound on the same is transported without any damage. Length of the cable on the drum & no. Size in mm2. Gross weight of packed and net weight of the power cable. iii) The drums for length measurement shall be selected either by keeping in view the maximum difference in weight as recorded on the drums/packing list and actually measured. as in para-13 above of this specification shall be over and above the results obtained in this checking.ANNEXURE-F PART 3 DISTRIBUTION i) ii) 397 He will carry out 100% checking of all the drums offered for inspection by weight. For check measurement of length. The verification of length to be done by the consignee. by the Inspecting Officer and declared quantity will be reduced accordingly. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . 15. alongwith the tender. Normally half of drums to be checked for length/weight shall be selected at random and the remaining half by difference in observed/declared weight method. or at random. SCHEDULE OF GUARANTEED AND GUIDING TECHNICAL PARTICULARS:- The bidders must supply the detailed guaranteed and other technical particulars as detailed in Annexure. minimum 5% drums of the offered lot shall be considered subject to minimum of 2 numbers. iv) Maximum shortage observed in length in any of the drums check measured shall be applied on all the drums offered in a particular lot. No. mass (Kg/Km) Minimum Tensile strength in KN Max. 3 i) ii) iii) iv) v) vi) vii) viii) ix) 4. 1 2. i) ii) iii) iv) v) vi) vii) 5. Particulars Size (sq. of Phase conductors Nominal cross-sectional area of each conductor-mm2 No. & Size of strands (mm) (Before Stranding) Minimum tensile strength of each strandN/mm2 Diameter of compacted conductor along with tolerance (mm).ANNEXURE-F PART 3 DISTRIBUTION 398 ANNEXURE SCHEDULE OF GUARANTEED PARTICULARS GUARANTEED TECHNICL PARTICULARS FOR HT AERIAL BUNCHED CABLE WITH CROSS-LINKED POLYETHYLENE (XLPE) INSULATION & BARE MESSENGER WIRE (FOR NEUTRAL & EARTHING) Sr.) Maker's Name & Address Rated Voltage Phase conductor details No. DC resistance at 200 C (Ohm/Km) Standard specification to which this material conform Insulation of phase conductor Conductor Screening Material Nominal Thickness (in mm) 3Cx50+35 HT Aerial Bunched Cables 3Cx95+70 3Cx120+70 3Cx150+150 b. Approximate mass per phase (Kg/Km) Maximum DC resistance at 200 C (Ohm/Km) Insulation thickness (mm) Standard to which this material conforms Messenger (Neutral conductor) Nominal sectional area of each conductor in mm2 No. Insulation TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . i) a. & size of strands (mm) (Before Stranding) Diameter of compact conductors along with tolerance (in mm) Approx. mm. 12. i) ii) iii) 8.) Mass of finished cable in a drum and its tolerance(Kg) Whether material bears ISI certification mark Serial number of ISI license and its validity Max.) Total length of cable in a drum and its tolerance(Mtrs.) Max. ii) Identification of power cores Whether all properties as mentioned in the technical Specifications are guaranteed if not indicate deviations in properties . i) ii) 7.) in Kg/Km Drum Total weight of drum(Kg) Whether drum is wheel mounted Standard specification to which drum shall conform Standard length of each cable and its tolerance(Mtrs. Standared specification to which this material shall conform Finished cable (Complete bunched cable) Overall diameter (approx. 9 i) ii) 10.ANNEXURE-F PART 3 DISTRIBUTION Material Nominal Thickness (in mm) c. 13 . 11. Continuous current carrying capacity (Amp. Sheathing of Core Material Colour Nominal Thickness (in mm) e.) in mm Total mass (approx. Continuous conductor temperature due to load TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B 399 iii) 6. Insulation Screening Material Non Metallic Metallic Thickness Non Metallic (Nominal) (in mm) Metallic (Nominal) (in mm) d. Notwithstanding any error and omission in GTP shall conform to PSPCL’s Technical Specification/relevant ISS. Embossing Any other particulars 400 Note:. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .ANNEXURE-F PART 3 DISTRIBUTION 14 15. c. The Aluminum conductor shall be of H2 Grade as per IS: 8130/1984(with latest amendments/revisions if any). 1 2 3 Size 3C x 35mm² 3C x 150mm² 3C x 300mm² MATERIALS a. The thickness of insulation shall not be less than the nominal value as specified in relevant IS.QQ-1241/2010 –11 /PO/C&S. stranded Aluminum conductor. XLPE insulated. PVC sheathed. CONDUCTOR SCREENING The cable shall be provided with conductor screening by applying non-metallic semi conducting tape or by extrusion of semi conducting compound or combination of two as per IS-7098 (Part 2)/1985(with latest amendments/ revisions if any). XLPE insulated. b. testing at manufacturer’s works. SIZE OF CABLE Design. screened. d. supply and delivery of ISI marked three core. SCOPE This specification covers the design. packing . The conductor shall be insulated by CCV/SIOPLAS technology. No. manufacture. STANDARD The cable shall comply with IS: 7098(Part-II)/1985 (with latest amendments/revisions if any). The size are as under: Sr. testing at manufacturer’s works. 11 KV. 11KV. The cable shall be used underground in distribution system. packing.supply and delivery of ISI marked. e. manufacture. Three Core. screened. These materials shall not be harder than XLPE/PVC used for insulation & outer sheath respectively and these shall be so chosen TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .ANNEXURE-F PART 3 DISTRIBUTION 401 47. INSULATION SCREENING The insulation screening shall consist of two parts. armoured cable suitable for earthed system manufactured with CCV (Dry Cure) OR SIOPLAS Technology . 2. CONDUCTOR The conductor shall be of stranded construction and of high conductivity H2 grade aluminum of plain wires. namely metallic and non-metallic part as specified in the relevant clauses of IS: 7098 (Part-2)/1985 (with latest amendments/revisions if any). stranded Aluminum conductor. conforming to flexibility class as mentioned in Table-2 of IS-8130/1984 (with latest amendments/ revisions if any). PVC sheathed.if any) in such a way that it fits closely on the conductor screening and it shall be possible to remove it without damaging the conductor. armoured cable manufactured with CCV/SIOPLAS technology (Dry Cure) and confirming to IS-7098(Part-2) /1985 & the specification No. INSULATION The Aluminum conductor shall be insulated with cross-linked polyethylene insulating compound conforming to relevant clause of IS-7098(Part-2)/1985 (with latest amendments/revisions . TECHNICAL SPECIFICATIONS FOR 11KV THREE CORE XLPE CABLES 1. FILLERS & INNER SHEATH Fillers & inner sheath shall be of vulcanised or unvulcanised rubber or thermoplastic materials. The XLPE insulation shall conform to IS: 7098 (Part –2) /1985(with latest amendments /revisions if any) and PVC sheathing will be of PVC compound conforming to the requirements of type ST-II of IS-5831/1984(with latest amendments/revisions if any). 5. ARMOURING OUTER SHEATH The cables shall be armoured as per IS:7098 (Part-2) /1985 (with latest amendments/revision if any). Further it should be possible to remove inner sheath without damage to insulation. TESTS a. ACCEPTANCE TESTS All the acceptance tests as specified under relevant clause of IS-7098(Part-2)/1985(with latest amendment/revision if any) shall be carried out by the inspecting officer on the samples drawn as per sampling plan stated in IS. The inner sheath on the laid up cores shall be applied either by extrusion or by wrapping and the method actually adopted should be clearly defined in the tender. The thickness of the inner sheath shall be as per the relevant clause of IS-7098 (Part-2)/1985 (with latest amendments/revisions if any). from the lot offered for pre-despatch inspection. In addition to above following type tests shall also be considered as acceptance tests and shall be conducted on any two samples drawn from the lot offered for pre-despatch inspection:i) i) ii) iii) iv) v) Shrinkage Test Shrinkage Test Heat shock Test Hot deformation Test Flammability Test ) ) ) ) For XLPE insulation (For outer sheath as per IS: 5831/1984 with latest amendments/revision if any) Thermal Stability Test ) The lot shall be considered as passed if the test results of both the samples for above tests conform to relevant clauses of IS. The cables shall be provided with outer sheath by Pressure Extrusion Process. f. shall be 50 % of the total no.ANNEXURE-F PART 3 DISTRIBUTION 402 to be compatible with temperature rating of the cable and shall have no adverse effect on any other component of the cable. of PVC compound confirming to type ST-2 of IS-5831/1984 (with latest amendment/revisions if any).as per GTPs. g. The number of samples to be taken for the measurement of weights of various parts . 6. It shall be ensured that the shape is as circular as possible. IMPULSE LEVEL The impulse level shall be 75KVp ( to be certified by the manufacturer). The colour of outer sheath shall be grey & thickness will be as per provisions of relevant IS. of samples b. Measurement of Weights of Various Parts of Cables. TYPE TESTS TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . 8. Type Tests should be conducted on the tendered item manufactured only at works from where material is to be supplied. Type of cable and voltage rating ISI certification mark Cable code No.1 PACKING The cable is required to be supplied in standard lengths of 500 mtrs up to 70 mm² and 250 mtrs for other sizes. IDENTIFICATION The word ‘PSPCL` and manufacturer’s trade mark or name. PSPCL. d. approved/Recognized Test House indicating the results of Type tests conducted. 8. size in mm². as may be convenient. OTHER TESTS Any other tests becoming necessary with the amendment in relevant IS or otherwise agreed between the manufacturer/ bidder & PSPCL shall also be carried out without any extra financial burden upon the PSPCL. should be sbmitted within 1 month of allotment of order to the respective office of PSPCL. c. PACKING & MARKING 8.2 MARKING The following particulars shall be specified clearly with indelible ink or paint on each drum :Length of drum Name of manufacturer. The drums should be such that the cable wound on the same is transported without any damage. The cable should also be sequentially marked to display the length at a distance not more than 1 m. of cores. in respect of each size of cable offered. The cores shall be identified as per relevant IS. ROUTINE TESTS The manufacturer shall carry out/conduct routine tests as specified in relevant IS on the cables manufactured before pre-despatch inspection. Complete Type Tests Certificates from a Govt. will be conducted on one number sample in the first lot of each sizse (only one time for full ordered quantity of each size) at the works of the manufacturer during pre-despatch inspection at the cost of the bidder. however . Complete Type Tests as per IS: 7098 (Part-2)-1985(with latest amendments/revisions if any. voltage rating and word ‘ELECTRIC` in English shall be embossed on the outer sheath of the cable at regular intervals of not more than 1.ANNEXURE-F PART 3 DISTRIBUTION 403 The cables shall comply with Type Tests as classified under clause-18. of lengths in drum (if more than one) Direction of rotation of drum TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . 7. reserve its right to carryout the Type Tests wherever felt necessary at bidder’s cost. Brand Name & Trade Mark Gross weight of drum Size of cable in mm² No.5 metres. The length shall be supplied in non-returnable standard wooden drums provided with cast iron bushing painted form outside with suitable paint of any colour.1 of IS: 7098(Part-2)-1985 (with latest amendments/revisions if any). inspection of any consignment is waived off by the PSPCL /Agency. The above license should preferably be valid during the validity of the offer also. indicating item for which it has been issued (valid on original date of opening of tender) along with their tender failing which their price bid will not be opened.1 TOLERANCE TOLERANCE ON PACKING 404 The standard drum length may have tolerance of + 5%. ISI MARK The bidders must supply photocopy of valid ISI licence. it will be the responsibility of the bidder to get the same re-validated from time to time. SCHEDULE OF GURANTEED TECHNICAL PARTICULARS Bidder / Bidder must supply the detailed guaranteed technical alongwith the tender 11. The PSPCL has the right to have the tests carried out by independent test house/laboratory/agency whenever there is a dispute regarding the quality of material. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .ANNEXURE-F PART 3 DISTRIBUTION Year of manufacturing 9. 9. In case. entire lot shall be rejected at the cost and risk of supplier. Recognised test house will be made available and material consumed/ destroyed during testing will be to the account of the supplier. shall be carried out by PSPCL and in case of failure. It will be the responsibility of the bidder to make adequate arrangement for testing of material at their works. No material will be allowed to be despatched without prior inspection and approval. All testing instruments and appliances duly calibrated from Govt. 10. of the same for approval. 10. the bidder will be required to furnish routine & acceptance test certificates in triplicate. In case. the license is expiring within the validity period of the offer.2 NON-STANDARD LENGTH Non-standard lengths not less than 100 M each to the extent of 5% of the total ordered quantity (size wise) will be acceptable. cost of which shall be borne by the bidder. Random testing of material on receipt in the stores irrespective of fact whether or not it was inspected before despatch. INSPECTION The material offered for supply will be inspected by a fully authorised representative of the PSPCL or an outside Agency nominated by PSPCL within two weeks from the date of receipt of intimation regarding readiness of the material . 9. The material shall be sealed with lead seals and lash wire to be provided by the manufacturer / bidder. 3 The cables covered in this standard are suitable for use where the combination of ambient temperature and temperature rise due to load. APLICABLE STANDARDS: The following standards with latest amendments shall be applicable. 1.1994: (Part IV) Aluminium alloy conductor. Note: The cables conforming to this standard may be operated continuously at a power frequency voltage to percent higher than the rated voltage. RATED VOLTAGE The rated voltage of the cables shall be 1100 volts. 1 2 3 4 5 6 Size mm2 3Cx16+25 3Cx25+25 3Cx35+25 3Cx 50+35 3Cx 95+70 3Cx 120+70 1. 1. IS: 1596 1984: Polyethylene insulated cable 1100 volts IS: 8130 .1984: Polyethylene insulation of cables. 5. 2. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . TECHNICAL SPECIFICATION FOR LT AERIAL BUNCHED CABLES 1.1984: Conductors for insulated cables IS: 6474 . 4. IS: 398 1996: (part II) For ACSR conductor. 3. including temperature on exposure to direct sunlight results in conductor temperature not exceeding the following: Type of Insulation Polyethylene Cross linked Polyethylene 2 COMPOSITION OF THE CABLE Normal Operation 700 C 900 C Continuous Short Circuit Operation 1600 C 2500 C The composite cable shall comprise three single-core cables twisted around a bare/insulated aluminium alloy messenger wire.ANNEXURE-F PART 3 DISTRIBUTION 405 48. IS: 398 .1 This specification covers the requirements of LT Ariel Bunched cross linked polyethylene insulated cables with aluminium conductors twisted over a central bare/insulated aluminium alloy messenger wire for use as overhead distribution feeders of the following sizes: Sr. SCOPE: 1. No. 3. which will carry the weight of the cable.2 The cables covered in this standard are suitable for use on three-phase ac (earthed or unearthed) system for rated voltage up to and including 1100 V. 4. which fulfills any of the following conditions: a) The neutral point or midpoint connection is earthed in such a manner that even fault conditions. or c) In case of ac system only. Note: These tests are of such a nature that after they have been made.4 Optional Tests Special tests to be carried out.3 Acceptance Tests Tests carried out on samples taken from a lot for the purpose of acceptance of the lot. IS: 14255 1995: Arial Bunched Cable Specification IS: 7098 (PI) 1988 with latest version. 6. 6.ANNEXURE-F PART 3 DISTRIBUTION 6.2 Type Tests Tests required to be supplied within 1 month of allotment of order. they need not be repeated unless changes are made in the cable materials of design. The messenger (Neutral conductor) or otherwise shall be either stranded circular or compacted circular type and shall have minimum 7 strands. 6. CONDUCTOR 7. which might change the performance characteristics. The surface of the conductor shall be smooth. the neutral point is earthed through an ARC suppression coil with arrangement for isolation within 1 hour of occurrence of the fault provided that total of such periods in a year does not exceed 125 hours.1 7. 6. (c). 7.1 Routine Tests Tests made by the manufacturers on all finished cable lengths to Demonstrate the integrity of the cables. MATERIALS 7.2 The power/outer insulated neutral/street lighting conductors shall conform to flexibility class 2 of IS 8130: 1984.5 (a). 406 TERMINOLOGY For the purpose of this standard the following definition to those given in IS 1885 (Part 32): 1993 shall apply. 5. 6. TESTS: 6. 6.6 Unearthed System An electric system which does not fulfill the requirements of earthed system (see 3. when required by agreement between the PSPCL and the supplier. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . b) The neutral point or midpoint connection is not earthed but a protective device is installed which automatically cuts out part of the system which accidentally becomes earthed. the maximum voltage that can between any conductor and earth docs not exceed 80 percent of the nominal system voltage. (b).5 Earthed System All electric system. PHASE CONDUCTOR & NEUTRAL CONDUCTOR Phase Conductors TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . when used.7 There shall be no joints in any wire of the messenger conductor.689 0. The direction of lay shall be right hand. Nominal Sectional Area of conductor mm2 1 2 3 4 5 6 7 7.5 SIZE AND REQUIREMENTS OF MESSENGER CONDUCTOR Sr.492 KN 7.0c 7. if required. CORE IDENTIFICATION: The phase conductors shall be provided with one. Such barrier.7 16 25 35 50 70 95 120 Cross Nominal Cross phase Sectional Area mm2 25 25 25 35 50 70 70 Messenger Conductor Maximum de Minimum Resistance at 20 O Breaking Load C Ohm/km 1. 7.492 0. is also permissible. The direction of outer layer of wires in messenger conductors shall be right hand.8 ASSEMBLY (LAYING UP): Three insulated phase conductors. as agreed between the supplier and PSPCL.7 19.8 14.986 0. Identification by other means.6 7. shall have four 'ridges' as shown in Fig.ANNEXURE-F PART 3 DISTRIBUTION 7. The size of street lighting conductor shall be (16 sq mm) The size of messenger conductor and its breaking load shall be as under: 7. I for quick identification.38 1. if provided.0 7.0 9.38 1.4 7. two or three 'ridges' and Outer neutral insulated conductor. one insulated neutral conductor (if required) and a street lighting conductor (if required) shall be twisted around the bare (or insulated) as required messenger conductor without fillers with a lay not exceeding 35 times the diameter of the insulated phase conductor. No. shall be compatible with insulating material and suitable for the operating temperature of the cable.0 19.3 407 A protective barrier may be applied between the conductor and insulation. The street lighting conductor and messenger conductor (if insulated) shall not have any identification mark.38 0. 0 1. Of compacted Conductor (mm) 4.7 Approx. 1. 5 are the max.868 0. applicable standards.0 1.5% is .9 Phase/Street Lighting Conductor The conductor shall be of H2 or H4 grade aluminium complying with the Requirements of IS 8130: 1984.ANNEXURE-F PART 3 DISTRIBUTION 408 Neutral Conductor Fig. mass (Kg/km) 42 65 95 127 191 259 329 Max. resistance NCE at 20 C 1.9 9. polyethylene suitable for1100 v insulation.253 O Insulation Thickness (mm) 1. Core Identification 7.3 7. The phase conductor and street lighting conductors shall be insulate with black weather resistant.91 1.320 0.8 7. two and three 'ridges' for quick identification. PHASE CONDUCTOR 1. 2. The phase conductors shall be provided with one.0 1. the insulated Conductors shall generally confirm to the standards. permissible Tolerance allowable on diameters shown in col. 3. The phase conductors shall be suitable compacted and the outer diameter shall be within the limits specified.443 0.C.20 0. 4. of strands 1 7 7 7 12 19 19 Dia. The standard sizes and technical characteristics of the phase and street lighting conductors shall be as shown as under: Nominal sectional area (mm2) 16 25 35 50 70 95 120 No. 5. The tensile strength of aluminium wire used in the conductors shall not be less the 90 N/ sqmm.D.2 Note: The resistance value given in Col.641 0.8 6.10 Messenger (Neutral Conductor or Otherwise) TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B of +/.4 5. 3 14. Mass (kg/km) Max.5% magnesium and approximately 0. The number of the insulated Phase Conductor in an ABC cable will vary depending on the specifications and requirement of customer. D. Messenger wire can be either bare OR insulated as per requirement.986 0.4 10. (mm) Note: While the limiting values in col. In addition to this. Tensile Strength (KN) compacted cond.7 65 95 127 191 1.6 Min. resistance NCE at 20% ohm /km 25 35 50 70 7 7 7 12 5.492 7.7 20. There shall be no joints in any wire of the stranded messenger conductor and other technical characteristics of the messenger wire (bare) shall be given as under: Normal Sectional area No.5 & 6 are to be guaranteed and 5% plus tolerance will be permissible on values in col.8 6. The bare messenger wire shall be generally made of aluminium alloy wire/ACSR confirming to IS: 398 (Part IV) 1994/398 (Part-II) 1996 with latest amendment composed of 7 strands and shall be suitably competed to have smooth surface to avoid damage to the polyethylene insulation of the phase conductors twisted around the messenger. 2. of Dia strands of (min) Approx.11 The composition and designation of finished cables are given as under. the one with two insulated Conductors is called Triplex. COMPOSITION AND DESIGNATION OF FINISHED CABLES 7. Customers can opt for ACSR as messenger wire.3. and the one with three insulated Conductors is called Quadruple. Designation Complete Bunched Cables overall Dia in mm 1 2 3 4 3X16+25 3X16+16+25 3X25+25 3X25+16+25 19 19 22 22 250 310 330 390 Total Mass approx in Kg/km TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .380 0.8 7.ANNEXURE-F PART 3 DISTRIBUTION 409 The conductor shall be of heat-treated aluminium magnesium-silicon alloy wires containing approximate 0. no.5% silicon conforming to IS 398 (Part-4): 1979. a street lighting or an emergency service conductor may also be provided public amenities such as street lighting. Whereas. the ABC Cable with a single Insulated conductor is called Duplex. Sr.C.689 0. 1.9 9. (1) 1 2 3 Tests (2) Tensile strength Elongation at break Ageing in air oven: a) Treatment: Temperature Duration b) Tensile strength variation c) Elongation variation Requirements (3) 12. Min 135 oC. the middle to the street lighting conductor(were provided) and the last to the bare messenger wire.3oC 1 hour 4 Hot set: a) Treatment: Temperature Time under load Mechanical Stress b) Elongation under load c) Permanent elongation (set) after cooling 5 Shrinkage: a) Treatment: Temperature Duration TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . INSULATION: 8. 3. Max 25 percent.3oC 15 Min 20 N/cm2 175 percent.5 N/ mm2. Cable Phase or street Lightening will confirm to IS-8130/1984 duly compacted. Max 15 percent. Sr. +/. 1. Polyethylene insulation will generally confirming to IS1596 1984 and IS-6474-1984 and XLPE insulation confirming IS 7098 (P. 8. 2. The messenger (neutral conductor) will generally confirm to IS-398 (Part 4) 1994/ IS 398 Part II /1996 for Aluminium Alloy Conductors or ACSR Conductors duly compacted.Min 200 percent.+/.I)/ IS 14255.3oC 7 days 25 percent. No. The sixes shown are the nominal sectional areas. Max 130 oC. Max 200 oC.ANNEXURE-F PART 3 DISTRIBUTION 5 6 7 8 3X35+25 3X35+16+25 3X50+35 3X50+16+35 24 24 32 32 430 490 580 640 410 Note: The first part of the designation refers to the number and size of the phase conductor. +/.1 The insulation shall be either of cross-liked polyethylene compound or of polyethylene insulation applied by extrusion. Confirming to requirement given in Tables 1 and 2 respectively. ANNEXURE-F PART 3 DISTRIBUTION b) Shrinkage: 6 Water absorption (Gravimetric): a) Treatment: Temperature Duration b) Water absorbed 7 Volume resistively: a) at 27 oC b) at 90 oC 1X1013ohm-cm. Max 85 oC. Max 4 percent. Min 1 X 1012 ohm-cm.2 1.Min Under consideration 2 3 4 5 6 Tensile Strength Elongation at break Melt flow index Vacant softening point Carbon black: a) Content b) Dispersion 7 Environmental stress cracking No cracks shall be visible to marked eye The conductor (with protective barrier. wherever applied) shall be provided with cross-linked polyethylene or polyethylene insulation applied by extrusion. THICKNESS OF INSULATION Nominal Area of Conductor (mm ) 16 25 35 2 Nominal Thickness (ti) (mm) 1. Min 300 percent Min 3.2 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . Min 85 oC.2oC 14 days 1 mg/cm2.+/.1) Sr. Max 411 PROPERTIES OF PE INSULATION (CLAUSE 5. Min 10 N/mm2. Min 1X1011ohm-cm. 1 Property Volume /resistively: a) at 27 oC b) at 70 C o Requirements 1 X 1014 ohm-cm. Thickness of Insulation This average thickness of insulation shall be not less than the nominal value (t) specified as under.No.2 1. 1 Sr. if any) and it shall be possible to remove it without damaging the conductor. Application of Insulation The insulation shall be so applied that it this closely on the conductor (or barrier.5 or less Not less than 8n/mm2 Not less than 350 Between 2 &3 Not less than 850 C Tests on phase/street light conductor i) Tensile test ii) Wrapping test iii) Resistance test See IS 8130: 1984 See IS 8130: 1984 See IS 8130: 1984 2 3 b. No. POLYETHYLENE INSULATION The Polyethylene insulation shall generally confirm to IS: 6474-1971. CLASSIFICATION OF TESTS: 9. Test on messenger conductor: i) Breaking load Section table 1 2 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .5 1.5 412 The smallest of measured values of thickness of insulation shall not fall below the nominal value (ti) specified above by more than 0. The color of insulation shall be GREY.ANNEXURE-F PART 3 DISTRIBUTION 50 70 95 Tolerance on Thickness of Insulation 1. a.1 mm + 0.1 (ti).5 1.The following properties shall be guaranteed: Melt Flow Index: Yield Stress: Percentage Elongation: Carbon Black Content: Vicat Softening Point: Volume At 270 C At 700 C : 9. TYPE TESTS Tests Requirement Test method (Ref to part IS 10801) THE FOLLOWING SHALL CONSITITUTE TYPE TEST 1 X 1015 Ohm Cm (min) 1 X 1013 Ohm Cm (min) 0. Breaking load test for messenger conductor.ANNEXURE-F PART 3 DISTRIBUTION ii) Elongation test iii) Resistance test c.3 Sec Table 1 11. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . Insulation resistance test.2 22 2 8 43 45 See Table 3 See Table 3 See Table 3 7 23 32 Under Consideration See Table 2 See Table 2 See Table 2 See Table 2 Under Consideration See Table 2 See Table 2 See Table 2 See Table 2 See Table 2 Under Consideration Sec 11.3 5 413 High voltage test 9. Conductor resistance test. Wrapping test (for phase/streetlight conductor). Tensile strength and elongation at break test. f.2 Acceptance Test The following shall constitute acceptance tests: a) b) c) d) e) f) g) i) h) Tensile test (for phase/street light conductor). Elongation test for messenger conductor. and Hot set test for XLPE insulation. Physical test for PE Insulation: i) Tensile strength and elongation at See Table 3 break ii) Melt flow index iii) Carbon black: 1) Content 2) Dispersion iv) Vicat softening Point v) Environmental stress cracking e. Test for thickness insulation Insulation receptivity) resistance See Table 3 See Table 3 See Table 4 (Volume See Table 2 & 3 See 6. Physical tests for XLPE Insulation: i) Tensile strength and elongation at See Table 2 break ii) Ageing in air oven iii) Hot set test iv) Shrinkage test v) Water absorption (Gravimetric) vi) Carbon Black: 1) Content: 2) Dispersion d. g. Test for thickness of insulation. 2 The number of drums (n) to be selected from the lot of drums (N) of Consignment of cable shall be in accordance with col 2 and 1 of Table 5 respectively. A-3 NUMBER OF TESTS AND CRITERION FOR CONFORMITY A-3. A-2. These samples shall be taken at random. test sample is called defective if it fails in any of the acceptance tests.1 A probable sampling plan for acceptance tests is given in Annex”A” ANNEX A (Clause 9. Number of Drums in The Lot N Up to 50 51 to 100 Number of Drums Permissible Number of to be Taken Defectives as Sample N 2 5 a 0 0 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . otherwise not. A-2 SCALE OF SAMPLING A-2. These test samples shall be subjected to each of the acceptance to each of the acceptance tests (see 12.ANNEXURE-F PART 3 DISTRIBUTION j) INSPECTION: High voltage test. The manufacturer shall afford the inspector representing the PSPCL all reasonable facilities.1 Suitable length of test sample shall be taken from each of the drums selected.2) A.1 Sample shall be taken and tested from each lot for ascertaining the Conformity of the lot to the requirements of the specification. If the number of defectives is less than or equal to the corresponding permissible number (a) given in col 3 of following Table the lot shall be declared as conforming to the requirements of acceptance test.1) SAMPLING OF CABLES A-1 LOT A-1. NUMBER OF DRUMS TO BE SELECTED FOR SAMPLING AND PERMISSIBLE NUMBER OF DEFECTIVES. to satisfy him that the material is being furnished in accordance with this specification. In order to ensure the randomness of selection. 9.2. without charge. 414 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and PSPCL at the time of PSPCL at the time of purchase. random number labels shall be used (see IS 4905: 1968 Methods of random sampling).1 In any consignment the cables of the same size manufactured under essentially similar conditions of production shall be grouped together to constitute a lot.2. 9. the tests shall be carried out in accordance with appropriate parts of IS 10810 taking into account additional information given in this standard. PACKING AND MARKING 11. The specimen shall be straightened by hand and an original gauge length of 200 mm shall be marked on the wire.1 General 13 20 32 0 1 2 415 Unless otherwise stated in this standard. DETAILS OF TEST: 10. The test shall be performed on a sample of complete cable. mm. It shall then be unwound and the process shall be repeated after turning the sample around its axis by 180 degrees. the test shall be disregarded and another test made. per minute and not greater than 100 mm per minute. for example. mm. 10. 10. Requirement: No cracks visible to the naked eye are allowed.3 Elongation Test on Messenger Conductor Test shall be carried out on wires before stranding. or the required elongation is not obtained. IDENTIFICATION: 11. Identification TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .1 Manufactures. SECTIONS IDENTIFICATION. and b) High voltage test. Minimum circumscribing diameter. The load shall be applied gradually and the rate of separation of the jaws of the testing machine shall be not less than 25. Acceptance and Routine Test): The cable shall withstand a voltage of (3kvac (rms) at a frequency of 40 to 60 Hz or a dc voltage of 7. The cycle of these operations shall then be repeated twice. and d = actual diameter of the phase conductor.3 Routine Tests The following shall constitute routine tests: a) Conductor resistance test. If the fractured occurs outside the gauge marks.4 Optional Test The following shall constitute optional test: Bending test 10. A tensile load shall be applied by means of a suitable tensile testing machine.2 High Voltage Test High voltage at room temperature (Type. The elongation shall be measured after the fractured ends have been fitted together. The sample shall be bent around a test mandrel at room temperature for at least one complete turn. The diameter of the manderel shall be 10 (D + d) Where D = actual diameter of the cable. The elongation of the specimen shall be not less than 4 percent on a gauge length of 200 mm. of within 25 mm of either mark.2 kV between conductor for 5 minutes.ANNEXURE-F PART 3 DISTRIBUTION 101 to 300 301 to 500 501 and above 9. ANNEXURE-F PART 3 DISTRIBUTION 416 The manufacturer shall be identified throughout the length of the cable by means of a tape bearing the manufacturers name or trademark and year of manufacture. Ref IS14255: Manufacturer's name or trade-mark: Type of cable and voltage grade: Nominal cross-sectional area of phase conductor: Length of cable on the drum: Number of lengths on the drum (if more than one): Direction of rotation of drum (by means of an arrow): Gross mass.1 The cable (drum or label) may also be marked with the Standard Mark. or if the PSPCL so desires. The cable shall carry the following information either stenciled on the drum or contained in a label attached to it: a) b) c) d) e) f) g) h) i) j) Reference to this Indian Standard. Country of manufacture.2 shall be given on any one of the insulated conductor of cables. Identification required in 11. No identification is required for polyethylene insulation. that is. The ends of the cable shall be sealed by non-hygroscopic material. if provided shall be acceptable against the requirement of 11. 11.1 and 11. XLPE 90. 12. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . 12.2.2 Cable Identification Cables with cross-linked polyethylene insulation shall be identified throughout the length of the cable by the legend 'XLPE 90' and year of manufacture by a printed tape. The details of conditions under which the license for the use of Standard Mark may be granted to manufacturers of producers may be obtained from the Bureau of Indian Standards. PACKING AND MARKING: 12.3 12.2 The cable shall be wound on a drum (see IS 10418: 1982) of suitable size and packed. Non Standard Length: Non Standard Length not less than 50% of the standard length shall be accepted to the extent of 10% of the ordered quantity.1 and 11. 1986 and the Rules and Regulations made there under. Note: The use of the Standard Mark is governed by the provision of Bureau of Indian Standards Act. colour identification threads in accordance with a scheme to be approved by the Bureau of Indian Standards (BIS) shall be employed. 2.4 Standard Length: The standard length of 500 with +5% and longer length shall be acceptable. 12. In case the above method cannot be employed. for example.2. NOTES: 1 Single tape bearing manufacturer's name or trademark and the cable identification.1 12. and Year of manufacture. 40 C 99 (Amp. cross sectional area (Sq. resistance of conductor at 25 20 C (i) Power cores (Ohm/Km) (ii) Neutral core (Ohm/Km) c) Approx.) : 1 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .3 7.) : 3 (No.0 12. breaking load (KN) 35 41 55 62 55 62 3 Current ratings: Continuous current carrying capacity of cable in Air at Ambient temp.0 0.20 6.) Number of cores: (i) Power cores (ii) Neutral core (iii) Bare messenger 610 (No.1 2 Messenger Wire (Bare): (i) Nom.320 12.) : 1 (No.20 1.868 7.) 0 122 725 149 880 190 1270 235 1570 4 5 Approx. cross sectional area (i) Power cores (mm2) 25 (ii) Neutral core (mm2) b) Max. Description 3x25 + 1x25 + 1x35 3x35 + 1x35 + 1x35 3x50 + 1x50 + 1x35 3x70 + 1x70 + 1x55 3x95 + 1x95 + 1x55 1. weight (kg. Reference standard: Generally to IS: 7098(1)88.0 35 41 1.641 0.9 0.35 8.1 10.641 8.1 1.2 1.1 Power/Neutral core: Conductors a) Nom. diameter of Conductor (i) Power cores (mm) (ii) Neutral core (mm) Insulation: Minimum thickness: (i) Power cores (mm) (ii) Neutral core (mm) 0 35 35 50 50 70 70 95 95 1.868 0.9 35 41 1./km.9 0.0 1. 1.3 0.320 0.35 0.2 6.1 1.443 10.443 0. Sl No.9 0.C.1 0. mm) (ii) Approx.1 1.ANNEXURE-F PART 3 DISTRIBUTION 417 TECHNICAL PARTICULARS LT Aerial Bunched Cable 1100 Volts (4 core).2 0. D. Conductor to IS: 398 (II) & (IV) respectively Stranded circular/compacted circular.12 418 35 1.88 55 0. Air Tedmprature in (0C) 30 Rating factor 1. /AAAC. 9 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .T.94 50 0. 8 Details of the Power/Neutral core: (i) Conductor: (a) Material (b) Flexibility class as per IS: 8130/84 (c) Form of conductor (ii) Insulation: (a) Material (b) Colour of Insulation Details of the Messenger wire (Bare) (i) Material (ii) Form of conductor Aluminium to IS: 8130/84 Class-2 Compacted circular Cross linked Polyethylene to IS: 7098(I)88 Black ACSR/AAAC.83 7 (a) Identification of Power core: (b) Laying By providing ridges on the insulation Three power cores and one neutral core shall be suitably twisted around bare H.ANNEXURE-F PART 3 DISTRIBUTION 6 Derating factor: Derating factors for variation In air Temp.0 45 0.06 40 1. Steel Messenger. 91 1.868 0.0 1. resistance of conductor at 16 20 C (i) Phase conductor (Ohm/Km) (ii) Street lighting conductor (Ohm/Km) c) Approx.0 1.0 12.0 1.7 1.3 7. cross sectional area (Sq. 40 C 51 (Amp.4 1.2 6.0 12.0 1.0 50 14.0 35 10.443 1.3 8. diameter of Conductor (i) Phase conductor (mm) (ii) Street lighting conductor (mm) Insulation: Minimum thickness: (i) Phase conductor (mm) (ii) Street lighting conductor (mm) 0 25 16 35 16 50 16 70 16 95 16 120 16 1.2 1.3 1. Reference Standard: Generally to IS: 6474-71 Sl No.0 70 20.320 0. D.91 6.4 25 7.4 25 7.6 1.2 1.) 0 70 390 86 490 105 640 130 890 155 1180 180 1430 4 5 Approx./km.6 2 Messenger Wire (Bare): (i) Nom.91 6. Description 3x16 + 1x16 + 1x25 3x25 + 1x16 + 1x25 3x35 + 1x16 + 1x25 3x50 + 1x16 + 1x35 3x70 + 1x16 + 1x50 3x95 + 1x16 + 1x70 3x120 + 1x16 + 1x70 1.0 1.641 0.4 3 Current ratings: Continuous current carrying capacity of cable in Air at Ambient temp.) : 1 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . mm) (ii) Approx. cross sectional area (i) Phase conductor (mm2) 16 (ii) Street lighting conductor (mm2) b) Max.) : 3 (No.91 1.0 1.0 1.253 1. weight (kg.) Number of cores: (i) Power cores (ii) street lighting core (iii) Bare messenger 310 (No.91 1.0 70 20.4 1.6 1.1 10.91 7.20 1. 1.) : 1 (No.1 0. breaking load (KN) 25 7.35 8.35 10.0 12.C.91 12.2 0.91 1.ANNEXURE-F PART 3 DISTRIBUTION 419 TECHNICAL PARTICULARS LT Aerial Bunched Cable 1100 Volts (5 core) with Street Lighting Conductor.1 Power/Neutral core: Conductors a) Nom.2 1.2 6. 12 420 35 1.88 55 0. 9 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .83 By providing ridges on the insulation Three power cores and one neutral core shall be suitably twisted around bare H.ANNEXURE-F PART 3 DISTRIBUTION 6 De-rating factor: De-rating factors for variation In air Temp. Conductor to IS: 398 (IV) respectively Stranded circular/compacted circular.0 45 0.94 50 0. Aluminium to IS: 8130/84 Class-2 Compacted circular Cross linked Polyethylene to IS: 7098(I)88 Black ACSR/AAAC. Steel Messenger.T.06 40 1. /AAAC. Air Temperature in (0C) 30 Rating factor 7 (a) Identification of Power core: (b) Laying 8 Details of the Power/Neutral core: (i) Conductor: (a) Material (b) Flexibility class as per IS: 8130/84 (c) Form of conductor (ii) Insulation: (a) Material (b) Colour of Insulation Details of the Messenger wire (Bare) (i) Material (ii) Form of conductor 1. 91 1.3 25 7.4 35 10.8 5.88 55 0./km. 40 C (Amp.9 6.5 5.0 45 0.2 1.2 1.0 1.4 60 250 (No. Description 3x16 + 1x25 Power/Neutral core: Conductors a) Nom.83 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .12 1. mm) (ii) Approx.38 5.0 25 7.06 1. weight (kg.8 1.C. 1. breaking load (KN) 3 Current ratings: Continuous current carrying capacity of cable in Air at Ambient temp.4 5.4 25 7.38 6.20 1.968 7. Reference standard: Generally to IS: 6474-71.868 1.ANNEXURE-F PART 3 DISTRIBUTION TECHNICAL PARTICULARS LT Aerial Bunched Cable 1100 Volts (4 core).1 16 25 25 25 35 25 50 35 1. Sl No. diameter of Conductor (i) Phase conductor (mm) (ii) Neutral conductor (mm) Insulation: Minimum thickness: (i) Phase conductor (mm) 0 421 3x25 + 1x25 3x35 + 1x25 3x50 + 1x35 1.8 0. Air Temperature in (0C) 30 35 40 Rating factor 1. D.38 4. resistance of conductor at 20 C (i) Phase conductor (Ohm/Km) (ii) Neutral conductor (Ohm/Km) c) Approx.8 0. cross sectional area (Sq.) Number of cores: (i) Power cores (ii) Neutral messenger core 0 1.) 4 5 Approx.) : 3 (No.0 2 Messenger Wire (Bare): (i) Nom.641 0.) : 1 76 330 92 430 110 580 6 De-rating factor: De-rating factors for variation In air Temp.94 50 0. cross sectional area (i) Phase conductor (mm2) (ii) Neutral conductor (mm2) b) Max.8 1. 19 IS: 10810 pt .43 IS: 1596 IS: 398 (pt-IV) IS: 398 (pt-IV) IS: 398 (pt-IV) TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . Test (ii) Melt flow Index (iii) Vicat softening Point (iv) Carbon Black Content & dispersion (v) Colour factness (vi) Environmental stress cracking (vii) Bleeding & Blooming (viii) Volume Resistivity test (f) High Voltage test including water immersion test.7 IS: 10810 pt . Aluminium to IS: 8130/84 Class-2 Compacted circular Cross linked Polyethylene to IS: 7098(I)88 Black ACSR/AAAC.23 IS: 10810 pt . (IV) 9 Prior to dispatch. Test for messenger conductor: (a) Breaking load test (b) Elongation test (c) Resistance test IS: 10810 pt . Conductor to IS: 398 respectively Stranded circular/compacted circular. Test on Phase/Street lighting conductor TESTS METHOD OF TESTING a) Tensile test b) Wrapping test c) Conductor Resistant Test d) Test for thickness of insulation e) Physical test for polyethylene insulation (i) Tensile strength & Elong.ANNEXURE-F PART 3 DISTRIBUTION 7 (a) Identification of Power core: (b) Laying 8 Details of the Power/Neutral core: (i) Conductor: (a) Material (b) Flexibility class as per IS: 8130/84 (c) Form of conductor (ii) Insulation: (a) Material (b) Colour of Insulation Details of the Messenger wire (Bare) (i) Material (ii) Form of conductor FINISHED AERIAL BUNCHED CABLE TESTING 422 By providing ridges on the insulation Three power cores and one neutral core shall be suitably twisted around bare AAAC Messenger.18 IS: 10810 pt .3 IS: 10810 pt .2 IS: 10810 pt . 2.22 IS: 10810 pt .5 IS: 10810 pt . cable is subjected to rigorous testing. Following tests are performed on Aerial Bunched Cables:1.32 IS: 10810 pt . Test procedures followed at manufacturer’s works are according to various national & International specifications and are covered in this paper.29 IS: 10810 pt .6 IS: 10810 pt . Bending test on completed cable shall also as performed.ANNEXURE-F PART 3 DISTRIBUTION 423 3. Dimensional test as per the parameters specified in the technical particulars. 4. The diameter of mandrel shall be 10 (D+d). Where D = Overall diameter of the cable d = Dia over conductor TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . 1. Service Anchoring Clamps (SAC) d. 2. Insulation Piercing Connectors (IPC) e. Technical Specifications of ABC Accessories a. General conditions 2. Dead End Clamps (DEC) b. Installation instruction should be included in the packaging. Anchoring and Suspension clamps should be installable on existing poles using appropriate devices (hooks. reference and capacity of the item and batch No. Routine tests: Suppliers shall provide a control plan. Distribution Box (DB) f.ANNEXURE-F PART 3 DISTRIBUTION 424 49. Suspension Clamps (SC) c. Standard References i) REC Construction Standard E-34: For Suspension Clamp & Eye Hook ii) REC Construction Standard E-35: For Dead End Clamp & Eye Hook TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . Hardware: Eye Hooks & Pole Clamps 1. Standard References 3. TECHNICAL SPECIFICATION FOR LT & HT AB (ARIAL BUNCHED) CABLE ACCESSORIES CONNECTORS AND FITTINGS (C&F) LOW VOLTAGE AERIAL BUNDLED CABLE (LTABC)& HIGH VOLTAGE AERIAL BUNDLED CABLE ACCESSORIES Scope This specification covers the design. General Conditions The products shall be in accordance with Indian standards and most of the European recognised standards used in LT ABC (NFC for example) or with any relevant standard. 1. manufacture and testing of Accessories for Low Voltage Aerial Bundled Conductor (LT ABC) with Bare/ insulated Messenger & Service cables. • • • • • • Marking: Each product shall be clearly identified with Manufacturer name or trade mark. Type tests: Each supplier should provide type test reports with.) All crimped connectors should be installed with mechanical or hydraulic hand crimping tools. brackets etc. Routine Test reports should be submitted by the manufacturer with the Inspection Call. Packaging: Manufacturer shall mention the packaging of each item. which will be implemented on each item. carried out in accordance with one of the referenced standards in NABL or any govt test house / accredited laboratory. mm bare messenger wire. Technical Specifications of ABC Accessories a) Dead End Clamp for Bare / Insulated Messenger (DEC) The clamps should be designed to Anchor Bare / Insulator Messenger of LT ABC.mm bare messenger & 3KN for 25/35 sq. The clamp should consist of an Aluminium alloy corrosion resistant body with bolted / self-adjusting plastic wedges clamping.6/1 kV" NFC 33-042:1998 "Service Anchoring devices for overhead and underground services with insulated cables.6/1 kV NFC 33-041:1998 "Anchoring devices for Overhead Distribution with bundle assembled cores.S. of rated voltage 0. may be followed. of rated voltage 0. Slip load of the clamp should not be less than 5KN for 50/70 sq.6/1 kV" NFC 33-004:1998 "Electrical ageing test" NFC 33-003:1998 "Corrosion test" NFC 20-540:1998 "Climatic ageing test" 3. of rated voltage 0.. Ultimate Tensile Strength of the clamp should not be less than 15 KN for 25-70 sq. The clamp should not damage the conductor/ insulation of conductor For insulated messenger. if any.6/1 kV". of rated voltage 0.6/1 kV" NFC 33-020:1998 "Insulation piercing connectors for overhead distributions and services with bundle assembled cores. The clamp body should be made of corrosion resistant Aluminium alloy. of rated voltage 0. It should be fixed with pole by eye hook / bracket. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . NFC 33-021:1998 "Pre-insulated compression type connecting equipment for Overhead Distributions and Services with bundle assembled cores. REC construction standard drawing mentioned below are indicative drawing.ANNEXURE-F PART 3 DISTRIBUTION iii) iv) v) vi) vii) viii) ix) x) xi) REC Construction Standard E-36: For LT Cable Tapping Connections 425 NFC 33-040:1998 "Suspension Equipments for Overhead distribution with Bundle assembled cores. it shall conform to the standard NFC 33-041 or equivalent I.mm messenger wire. • • • • • • • • The clamp should be installed properly with no losable part. Detailed design/ drawing to be furnished by the bidder / manufacturer. ANNEXURE-F PART 3 DISTRIBUTION 426 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . ANNEXURE-F PART 3 DISTRIBUTION 427 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . if any.ANNEXURE-F PART 3 DISTRIBUTION 428 b) • • • • Suspension clamp for Bare / Insulator neutral messenger(SC) The clamp should be designed to hang LT-ABC with bare / insulated neutral messengers. The neutral messengers should be fixed by an adjustable grip device /1 or 2 bolted.. may be followed. REC construction standard drawing mentioned below are indicative drawing. For insulated messenger. Detailed design/ drawing to be furnished by the bidder/manufacturer.mm bare messenger wire The clamp should sustain to maximum angle of deviation of 60 degrees of the conductors. • • • • TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . it shall conform to the standard NFC 33-040 or equivalent I. The clamp shall be made up of Aluminium Alloy.S.mm bare / insulated messenger wire. Slip load of the clamp should not be less than 300N for 25-70 sq. Ultimate Tensile Strength of the clamp should not be less than 12 KN for 25-70 sq. The Suspension Clamp & the eye hook/bracket will be preferably delivered together in order to minimize abrasion between two materials. The suspension clamp range to accommodate messenger shall be 25-70mm2 and shall be as per similar design of REC E-34. Clamps should be fixed with pole by eye hook/bracket. ANNEXURE-F PART 3 DISTRIBUTION 429 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . ANNEXURE-F PART 3 DISTRIBUTION 430 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . ANNEXURE-F PART 3 DISTRIBUTION 431 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . S. Reference standard: NFC 33 021 or equivalent I. if any. The clamp shall conform to the standard NFC33-042 or equivalent I. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B . The clamp should be installed properly.S. Detailed design/ drawing to be furnished by the bidder/manufacturer.ANNEXURE-F PART 3 DISTRIBUTION 432 c) Service Anchoring Clamp (SAC) The clamps should be designed to anchor insulated service lines (armoured or unarmoured) with 2/4 conductors.. • • • • • • • • The clamps should be made of weather and UV resistant polymer & should be of wedge / bolted type design. if any.. No losable parts & should have a rigid bail. Breaking load of the clamp should not be less than 1 KN. Detailed design/ drawing to be furnished by the bidder/manufacturer. b) for providing supply to Junction/ Distribution Box from AB Cable c) for establishing Tee connection from LT ABC to LT ABC. The connectors should be totally Weather & Moisture proof so that no water or moisture can enter through the pierced holes on the cable insulation. Connector teeth should be factory greased & sealed to retard water or moisture ingress & corrosion. to ensure proper installation. or equivalent I. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B Standards Construction: Moisture Ingress: Working Temp. The end of tap should be felt from outside end cap. The connectors should be totally insulated with no loose parts.ANNEXURE-F PART 3 DISTRIBUTION 433 d) Scope Insulation Piercing Connectors (IPC) For proper method of providing service connection from AB Cables to our consumers without damaging the cable. Torque required for Proper Installation should be mentioned on IPC. The outer metallic part should have potential free tightening bolts to allow safe Live-Line installation.: Materials: . Designed for installation from -10˚C upto +60˚C & operation experience with temperature from -20˚C upto +75˚C. The cable end cap should be attached to the body. reinforced polymer. should be 10-12 N-m.. PCC LT pole. The bolts should be of Metallic Shear Head type so that it controls the effective applied Torque during installation & break off at a specified torque after establishing proper connection. It must have Shear Head type mechanism to control the effective Torque during connection and to ensure perfect installation. if any. No flashover/ failure should occur during voltage application. The contact plates should be made of tinned Copper / Aluminium Alloy as per IPC current rating. Material used in the manufacturing process of the components of this product should be specified in the respective product drawings & can be summarized as follows: • • • • • • • • • All the metallic part of the connector should be Corrosion resistance & should be proven in Corrosion Test. The maximum voltage withstand capacity should be 6 KV. Should be designed with encapsulated bolt heads or round head in order to avoid damaging other conductor insulation during installation. The insulation material should be made of weather & UV resistance. The connector should not have any losable component.S. The connectors should work at 30 cm under water bath for 30 min. Connectors should not have any losable parts. Should have attached flexible end caps without Grease in order to seal the open end of tap cable or in-built type. As per NF C 33-020 & NFC33-003. the Insulating Piercing Connectors are required a) for providing 1-2 service connections from 8 / 9 mtr. & voltage applied of 6KV for 1 min in underwater condition. which may drop and then lost while installation at overhead conditions. Electrical Ageing Test 3. Mechanical Tests 5. 1. NFC33-003 & NFC33-004.S. Underwater High Voltage Test 4.ANNEXURE-F PART 3 DISTRIBUTION • 434 Testing Should have an anti rotation device which ensures that the tap blades will not turn in front of main blades mainly in case of service application. if any. Corrosion Qualification Test 2. or equivalent I.. The Insulating Piercing Connector should conform to following std. Voltage Test TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .As per NF C 33-020. ANNEXURE-F PART 3 DISTRIBUTION 435 TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B .