g3ir-1050-65-sp-9020_r0

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12

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LOW VOLTAGE POWER & CONTROL CABLES

G3IR-1050-65-SP-9020 Page 1 of 11

Project Document No: G3IR-1050-65-SP-9020

Unit: General Discipline: Electrical Document Type: Specification

Document Title: SPECIFICATION FOR LOW VOLTAGE POWER & CONTROL CABLES.

1 30-Jul-12 Re-Issued for Design (RFQ) RR NG VP

0 18-Jul-12 Issued for RFQ HS NG VP

Fluor BASF Revision Date Purpose Prepared By Checked By

Approved By

ISSUED FOR DESIGN02 Aug 2012



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Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions.

Revision

No. Date Description

0 18-Jul-12 Issued for RFQ

1 30-Jul-12 General Revision



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TABLE OF CONTENTS

1.0 GENERAL.................................................................................................................................................. 4

1.1 Scope......................................................................................................................................................... 4

1.2 References ................................................................................................................................................ 4

1.3 Service Conditions................................................................................................................................... 5

2.0 TECHNICAL REQUIREMENTS ................................................................................................................ 5

2.1 General Requirement............................................................................................................................... 5

2.2 Conductors ............................................................................................................................................... 6

2.3 Insulation................................................................................................................................................... 6

2.4 Fillers ......................................................................................................................................................... 6

2.5 Inner Sheath.............................................................................................................................................. 6

2.6 Armouring ................................................................................................................................................. 7

2.7 Outer Sheath............................................................................................................................................. 7

2.8 Core Identification.................................................................................................................................... 8

2.9 Equipment Identification ......................................................................................................................... 8

2.10 Cable Drums ............................................................................................................................................. 9

3.0 TEST AND INSPECTION .......................................................................................................................... 9

4.0 DRAWINGS AND DOCUMENTS ............................................................................................................ 11



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1.0 GENERAL

1.1 Scope

This specification is intended to cover design, engineering, manufacture, inspection and

testing at manufacturer’s works, packing, loading, forwarding, transport and delivery to site of

flame retardant XLPE insulated LV power cables and PVC insulated control cables.

1.2 References

1.2.1 The LV Power and control cable shall conform to the latest editions of following

standards issued by BIS (Bureau of Indian Standards) unless otherwise specified.

Each publication shall be the latest revision and addendum in effect on the date this

specification is issued for Purchase, unless noted otherwise. Except as modified by

the requirements specified herein or the details of the drawings, as a minimum, Work

included in this specification shall conform to the applicable provisions of these

publications:

PVC insulated (heavy duty) electric cables for working

voltages upto and including 1100V.

IS :1554 - I

Cross linked polyethylene insulated PVC sheathed cables for

working voltages up to and including 1100V.

IS:7098 (Part -I)

Recommended current ratings for cables IS : 3961

Low carbon galvanized steel wires, formed wires and tapes for

armouring of cables

IS : 3975

PVC insulation and sheath of electrical cables. IS : 5831

Conductors for insulated electrical cables and flexible cords. IS : 8130

Specification for drums for electric cables. IS : 10418

Methods of tests for cables. IS : 10810

Standard test method for density of smoke from the burning or

decomposition of plastics.

ASTM-D –2843

Standard method for measuring the minimum oxygen

concentration to support candle like combustion of plastics.

ASTM-D-2863

Test on gases evolved during combustion of electric cables. IEC-60754 (Part-I)

Standard for type test of Class IE Electric Cables. IEEE-383

Tests on Electric cables under fire conditions. Part-3 : Tests

on bunched wires or cables (category -B)

IEC –60332

1.2.2 In case of any contradiction between various referred standards/specification/data

sheets and statutory regulations, it shall be brought to the notice of Client for



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resolution, before taking a decision. Generally the following order of priority shall

govern :

Statutory regulations

BASF Guidelines

Data Sheets

This specification

Codes and standards

1.2.3 The Manufacturer shall inform/consult the owner / consultant in case there is a

conflict among the above documents.

1.3 Service Conditions

1.3.1 The cable shall be designed for a design ambient temperature of +45°C and an

altitude not exceeding 1000 meters above mean sea level. The cables shall be

suitable for operating continuously at the rated capacity as specified in relevant I.S.

code under the above ambient conditions without exceeding the permissible

temperature rise and without any detrimental effect on any part.

1.3.2 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and

under ground buried installation with chances of flooding by water.

2.0 TECHNICAL REQUIREMENTS

2.1 General Requirement

2.1.1 Cables shall be flame retardant, low smoke (FRLS) type designed to withstand all

mechanical, electrical and thermal stresses develop under steady state and transient

operating conditions as specified elsewhere in this specification.

2.1.2 LV Power cable shall be 1.1 kV XLPE insulated power cables, PVC inner-sheathed

(as applicable), armoured, PVC outer-sheathed conforming to IS: 7098. (Part-I).

2.1.3 Control Cables shall be 1.1KV Grade, multicore, PVC insulated, PVC inner-sheathed,

armoured PVC outer-sheathed conforming to IS: 1554. (Part-I).

2.1.4 Earthing cables shall be single core, unarmoured, aluminium conductors with overall

PVC insulation (1.1kV grade). PVC compound shall conform to the requirements of

type ST-l compound as per IS: 5831.

2.1.5 Bidder shall have to furnish the minimum length of cable per drum for each type of

cable with bid.

2.1.6 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum

over the declared value in the technical data sheets.



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2.1.7 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc.

are not acceptable

2.2 Conductors

2.2.1 The conductors shall comply with the requirements of IS: 8130.

2.2.2 LV power cables shall be of stranded copper conductors up to 16 mm2 and stranded

Aluminium conductors above 16 mm2.

2.2.3 Control cables shall be of annealed high conductivity stranded copper round

conductors.

2.2.4 Aluminium conductor used in power cables shall have tensile strength of minimum

100 N/ mm2.

2.2.5 The conductors shall be solid for conductor of nominal area up to and including

1.5mm2 and stranded beyond 1.5 mm2.

2.2.6 Conductors of nominal area less than 16 mm2 shall be circular only. Conductors of

nominal area 16 mm2 and above may be circular or shaped as per IS 8130. Cables

with reduced neutral conductor shall have sizes as per Table 1 of IS 1554 (Part-I).

2.3 Insulation

2.3.1 XLPE insulation shall be suitable for a continuous conductor temperature of 90 Deg.C

and short circuit conductor temperature of 250 Deg.C.

2.3.2 PVC insulation shall be suitable for continuous conductor temperature of 70 Deg.C

and short circuit conductor temperature of 160 Deg.C.

2.4 Fillers

2.4.1 The cables shall have suitable fillers wherever required, laid up with conductors to

provide substantially circular cross section before the inner sheath is applied.

2.4.2 Fillers between the cores shall not stick to insulation and inner sheath.

2.5 Inner Sheath

2.5.1 The PVC inner sheath shall be applied over the laid up cores by extrusion.

2.5.2 Inner sheath shall conform to the requirements of type ST 2 compound of IS: 5831 for

LV Power cable and type ST 1 compound of IS: 5831 for LV control cable.

2.5.3 All the cables, other than single core unarmoured cables, shall have distinct extruded

PVC inner sheath of black colour as per IS: 5831.



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2.6 Armouring

2.6.1 For single core armoured cables, armouring shall be of aluminium wires.

2.6.2 For multicore armoured cables armouring shall be of galvanized steel as follows: -

Calculated nominal dia

of cable under armour

Size and Type of armour

i) Upto 13 mm 1.4mm dia GS wire

ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire

iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire

iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia GS wire

v) Above 55 & upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire

vi) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

2.6.3 Aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum

resistivity of 0.028264 ohm mm2 per meter at 20OC. The size of aluminium

wires/formed wires for armouring shall be same as indicated above for galvanized

steel.

2.6.4 The gap between armour wires / formed wires shall not exceed one armour wire /

formed wire space and there shall be no cross over / over-riding of armour wire /

formed wire. The minimum area of coverage of armouring shall be 90%.

2.6.5 The breaking load of armour joint shall not be less than 95% of that of armour wire /

formed wire. Zinc rich paint shall be applied on armour joint surface of G.S.

wire/formed wire.

2.7 Outer Sheath

2.7.1 The outer sheath of the cables shall be FRLS, black in colour and applied by

extrusion over the armouring. It shall be of PVC compound conforming to the

requirements of Type ST 2 compound of IS: 5831 for LV power cable and Type ST 1

compound of IS: 5831 for LV control cable. The minimum thickness of outer sheath

for armoured cables shall be as per IS: 7098 (Part-2).

2.7.2 FRLS PVC compound for outer sheaths of all the cables shall meet the following

performance requirements and cables shall pass these test.

The critical oxygen index value shall be minimum 29 at room temperature

and the temperature index value shall be minimum 250°C at oxygen index of

21 when tested as per IS-10810 (part-58).

The maximum total acid gas generation as determined by titration shall be

less than 20% by weight, when tested as per IEC 754-1.



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The maximum smoke density rating expressed in percentage light absorption

at any point on the curve during testing period shall not exceed 60% when

tested as per ASTM-D-2843-77.

The cables shall pass the hydrolytic stability and ultraviolet test as per DIN

53387. The measured values of ultimate and ultraviolet test as per elongation

after the test shall not be less than 60% of that measured before the test.

The finished cables shall pass the flammability test as per IEC-332-1 and

IEC-383. In addition it shall also pass flammability test as per class F3 of

Swedish Standard S5-424-1475.

2.8 Core Identification

2.8.1 Cores of the cables shall be identified by colouring of insulation. Colour scheme shall

be adopted as per requirement given in IS 1554 / 7098.

2.8.2 Colour coding shall be acceptable for all cables upto 5 cores. Cables with more than

5 cores shall have printed numerals on each core.

2.8.3 Core numbers with a minimum letter size of 3mm shall be printed serially on each

core of the control cable at intervals of not more than 200 mm.

2.8.4 Core numbers with a minimum letter size of 2 mm shall be printed serially on each

core of the instrumentation cable at intervals of not more than 200 mm and each core

shall be colour coded as per IEC-189 Part-2.

2.8.5 Earthing conductor shall be coloured green.

2.9 Equipment Identification

2.9.1 All warning, identification and instruction labels shall be inscribed in both the English

and local languages.

2.9.2 The individual cores of cables shall be coloured as per relevant IS. Where it is not

possible to distinguish the cores by colour, coloured strip shall be applied on the

cores or core nos. shall be marked on each core at regular intervals.

2.9.3 The outer sheath of all cables shall be embossed throughout the cable length at

every one-meter at two sides with the following information.

Manufacturer’s name

Cable standard identification e.g. ‘’ISI’’ Symbol.

Year of manufacture

Cable designation (cores, size, voltage grade, insulation)

Running meter markings

A legend “FRLS” at every 5 meter to indicate that the cable is Fire Retardant

Low Smoke type.



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2.9.4 The embossing shall be progressive, automatic, in line and marking shall be legible

and indelible.

2.10 Cable Drums

2.10.1 Cables shall be supplied in non returnable wooden or steel drums of heavy

construction. The surface of the drum and the outer most cable layer shall be covered

with water proof layer. Both the ends of the cables shall be properly sealed with heat

shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water

during transportation, storage and erection. Wood preservative anti-termite treatment

shall be applied to the entire drum. Wooden drums shall comply with IS : 10418.

2.10.2 A label shall be securely attached to the end of the reel indicating the customer’s

order number, length of cable and size of conductor. All the details as per relevant IS

shall be printed on each Cable reeling drum.

Each drum shall carry minimum manufacturer's name, purchaser's name, address

and contract number, item number and type, size and length of cable and net gross

weight stenciled on both sides of the drum

2.10.3 A tag containing same information shall be attached to the leading end of the cable.

An arrow and suitable accompanying wording shall be marked on one end of the reel

indicating the direction in which it should be rolled.

2.10.4 Cables shall be supplied in specified drum lengths during order. Where no such

indication is given, standard drum lengths may be offered.

2.10.5 A tolerance of ± 2 % shall be permissible for each drum. However, overall tolerance

on each size of cable shall be limited to ± 2%. Offers with short / non-standard

lengths are liable for rejection. If non-standard drum lengths are specified in the data

sheet, the same shall be supplied.

3.0 TEST AND INSPECTION

A) All equipments to be supplied shall be of type tested quality. The supplier shall submit for

Owner’s approval the reports of all the type tests as listed in this specification and carried out

within last five years from the date of bid opening. These reports should be for the tests

conducted on the equipment similar to those proposed to be supplied under this contract and

the test(s) should have been either conducted at an independent laboratory or should have

been witnessed by owner.

B) In case the supplier is not able to submit report of the type test(s) conducted within last five

years from the date of bid opening, or in case the type test report(s) are not found to be


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meeting the specification requirements, the supplier shall conduct all such tests under this

contract, free of cost to the Owner and submit the reports for approval.

C) Type Tests for LV Power Cable

The reports for the following type tests shall be submitted on one size each of XLPE LVPower

cables :

S.No. Type Test Remarks

For Conductor

1. Annealing test For copper conductor only.

2. Tensile test For aluminium conductor only.

3. Wrapping test For aluminium conductor only.

4. Resistance test

For Armour Wires/ Formed Wires

5. Measurement of Dimensions

6. Tensile Test

7. Elongation test

8. Torsion test For round wires only

9. Wrapping test For aluminium wires/formed wires only

10. Resistance test

11.(a) Mass of Zinc Coating test For G.S. Formed wires /wires only.

11.(b) Uniformity of zinc coating For G.S. Formed wires /wires only.

12 Adhesion test For G.S. Formed wires /wires only.

For XLPE insulation & PVC Sheath

13. Test for thickness

14. Tensile strength & elongation tests before ageing and after ageing

15. Ageing in air oven

16. Loss of mass test For PVC sheath only

17. Hot deformation test For PVC sheath only

18. Heat shock test For PVC sheath only

19. Shrinkage test

20. Thermal stability test For PVC sheath only

21. Hot set test For XLPE insulation only

22. Water absorption test For XLPE insulation only

23. Oxygen index test For outer sheath only

24. Smoke density test For outer sheath only

25. Acid gas generation test For outer sheath only

For completed cables

26. Insulation resistance test (Volume resistivity method)

27. High voltage test

28. Flammability test as per clause “Flammability test”

29. Flammability test as per IEC - 60332 Part-3 (Category -B)


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D) Type Tests for LV Control Cable

The reports for the following type tests shall be submitted on one size each of LT Control

cables :

S. No. Type Test Remarks

For Conductor

1. Annealing test

2. Resistance test

For Armour Wires / Formed Wires

3. Measurement of Dimensions

4. Tensile Test

5. Elongation test

6. Torsion test For round wire only

7. Wrapping test

8. Resistance test

9(a). Mass of zinc Coating test For GS wires/formed wires only

9(b). Uniformity of zinc coating For GS wires/formed wires only

10. Adhesion test For GS wires/formed wires only

For PVC insulation & PVC Sheath

11. Test for thickness

12. Tensile strength and elongation test before ageing and after ageing

13. Ageing in air oven

14. Loss of mass test For PVC insulation and sheath only

15. Hot deformation test For PVC insulation and sheath only

16. Heat shock test For PVC insulation and sheath only

17. Shrinkage test

18. Thermal stability test For PVC insulation and sheath only

19. Oxygen index test For outer sheath only

20. Smoke density test For outer sheath only

21. Acid gas generation test For outer sheath only

For completed cables

22. Insulation resistance test(Volume resistivity method)

23. High voltage test

24. Flammability test as per clause” Flammability test”

25. Flammability test as per IEC - 60332 Part-3 (Category-B)

E) Flammability Test

This test shall generally be carried out as per IEEE 383. The cable installation to be tested

shall consist of as many cables as are necessary to give at least 10 kg of organic material per

meter run.

4.0 DRAWINGS AND DOCUMENTS

The Vendor shall furnish drawings in accordance with SDDC form, enclosed with the Bid.

g3ir-1050-65-sp-9020_r0

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