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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:-

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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 :

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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

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The following tests shall be carried out on the bare messenger wire in accordance with IS:398 (part IV). i ii Breaking load Test (on finished wire). Elongation test

iii Resistance test 9.2 However, the PSPCL reserves the right to demand repetition of same or all the type tests in presence of PSPCLs representative. 9.3 The bidder must also clearly indicate various testing facilities available at their works for testing the material as per relevant standards. In case of otherwise particulars of the place where such testing is proposed to be conducted during the course of inspection shall be indicated . 10 INSPECTION (TEST BEFORE DISPATCH): 10.1 No material will be allowed to be dispatched without prior inspection and approval. In case, inspection of the consignment is waived off by the PSPCL, the bidder will be required to furnish the test certificate of the material, in triplicate for approval. The material consumed/destroyed during testing will be to the account of the bidder. 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 following Acceptance tests as per Clause No.18.2 of IS:7098 (Part.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). Wrapping Test (If applicable). Conductor Resistance Test (Phase Conductor & Messenger). Breaking load test for messenger conductor. Elongation test for messenger conductor. Test for thickness of insulation & sheath. Hot Set Test for XLPE Insulation. Tensile strength & elongation at break test for insulation and sheath. Carbon Black: a. Contents. b. Dispersion Partial Discharge Test (for screened cables only). High voltage test and Insulation resistance (Volume resistivity) Test.

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

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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 following shall constitute optional test:Bending test on complete cable: The test shall be performed on a sample of complete cable. The sample shall be bent around a test mandrel at room temperature for at least one complete turn. It shall then be unwound and the process shall be repeated after turning the sample around its axis by 180 degrees. The cycle of these operations shall then be repeated twice. The diameter of the mandrel shall be: 10(D+d) Where: D= actual diameter of the cable, for example, minimum circumscribing diameter in mm ; And d= actual diameter of the phase conductor in mm. Requirement: No cracks visible to the naked eye are allowed. 10.2 ROUTINE TEST: - The following shall constitute routine tests. The tests shall be done as per relevant ISS: a) b) c) d) 11. Conductor resistance test Partial discharge test High voltage test. Messenger Resistance

SEQUENTIAL MARKING. 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, the length of

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cable for acceptance shall be based on length of finished cable and not on the basis of sequential marks. The cores shall be identified as per relevant IS.
12. 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%. The cable shall be wrapped with polythene under wooden covering. Each meter length shall be embossed with the trade name of manufacturer, Size in mm2, word ELECTRIC, Voltage rating, year of manufacture and the word PSPCL CABLE. The wooden drums should be provided with cast iron bushing & painted form outside with suitable paint of any colour. The drums should be such that the cable wound on the same is transported without any damage. The cable shall be supplied in standard length of 1000 mtr./500 Mtr. depending upon the size.
The ends of the cable shall be sealed by means of non-hygroscopic sealing material. In addition to this each drum shall carry the following information either stenciled on flange or label attached to it. a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) Manufacturers name. Trade mark, if any. A reference to IS i.e. IS -7098 (Part-II)/1985. Length of the cable on the drum & no. of lengths. Position of outer end of cable Voltage grade and type of the cable. Colour of outer sheath. Nominal cross-sectional area of the cable conductor. Work order No. & Date. Name and address of consignee. Number of cores. Gross weight of packed and net weight of the power cable. Drum No. & its direction of rotation (with an arrow) Year of manufacture. Property of PSPCL

13. TOLERANCE 13.1 TOLERANCE ON PACKING The standard drum length may have tolerance of + 5%. 13.2 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.

14. 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. Out of total quantity of drums offered for inspection, the Inspecting Officer of the PSPCL shall carry out inspection as under:TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

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, minimum 5% drums of the offered lot shall be considered subject to minimum of 2 numbers. 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, or at random. 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. 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, by the Inspecting Officer and declared quantity will be reduced accordingly. The verification of length to be done by the consignee; as in para-13 above of this specification shall be over and above the results obtained in this checking.
15. SCHEDULE OF GUARANTEED AND GUIDING TECHNICAL PARTICULARS:-

The bidders must supply the detailed guaranteed and other technical particulars as detailed in Annexure. alongwith the tender.

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

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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. No. 1 2. 3 i) ii) iii) iv) v) vi) vii) viii) ix) 4. i) ii) iii) iv) v) vi) vii) 5. i) a.

Particulars Size (sq. mm.) Maker's Name & Address Rated Voltage Phase conductor details No. 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). 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. & size of strands (mm) (Before Stranding) Diameter of compact conductors along with tolerance (in mm) Approx. mass (Kg/Km) Minimum Tensile strength in KN Max. 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.

Insulation TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION Material Nominal Thickness (in mm) c. Insulation Screening Material Non Metallic Metallic Thickness Non Metallic (Nominal) (in mm) Metallic (Nominal) (in mm) d. Sheathing of Core Material Colour Nominal Thickness (in mm) e. ii) Identification of power cores Whether all properties as mentioned in the technical Specifications are guaranteed if not indicate deviations in properties . Standared specification to which this material shall conform Finished cable (Complete bunched cable) Overall diameter (approx.) in mm Total mass (approx.) 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.) Total length of cable in a drum and its tolerance(Mtrs.) 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. Continuous current carrying capacity (Amp.) Max. Continuous conductor temperature due to load TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

399

iii) 6. i) ii) 7. i) ii) iii) 8. 9 i) ii) 10. 11. 12. 13

ANNEXURE-F PART 3 DISTRIBUTION 14 15. Embossing Any other particulars

400

Note:- Notwithstanding any error and omission in GTP shall conform to PSPCLs Technical Specification/relevant ISS.

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

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47. TECHNICAL SPECIFICATIONS FOR 11KV THREE CORE XLPE CABLES

1. SCOPE This specification covers the design, manufacture, testing at manufacturers works, packing, supply and delivery of ISI marked three core, 11KV, stranded Aluminum conductor, XLPE insulated, PVC sheathed, screened, armoured cable suitable for earthed system manufactured with CCV (Dry Cure) OR SIOPLAS Technology . The cable shall be used underground in distribution system. 2. STANDARD The cable shall comply with IS: 7098(Part-II)/1985 (with latest amendments/revisions if any). The Aluminum conductor shall be of H2 Grade as per IS: 8130/1984(with latest amendments/revisions if any). 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). SIZE OF CABLE Design, manufacture, testing at manufacturers works, packing ,supply and delivery of ISI marked, 11 KV, Three Core, stranded Aluminum conductor, XLPE insulated, PVC sheathed, screened, armoured cable manufactured with CCV/SIOPLAS technology (Dry Cure) and confirming to IS-7098(Part-2) /1985 & the specification No.QQ-1241/2010 11 /PO/C&S. The size are as under: Sr. No. 1 2 3 Size 3C x 35mm 3C x 150mm 3C x 300mm

MATERIALS a. CONDUCTOR The conductor shall be of stranded construction and of high conductivity H2 grade aluminum of plain wires, conforming to flexibility class as mentioned in Table-2 of IS-8130/1984 (with latest amendments/ revisions if any). b. 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). c. 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 .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. The conductor shall be insulated by CCV/SIOPLAS technology. The thickness of insulation shall not be less than the nominal value as specified in relevant IS. d. INSULATION SCREENING The insulation screening shall consist of two parts, namely metallic and non-metallic part as specified in the relevant clauses of IS: 7098 (Part-2)/1985 (with latest amendments/revisions if any).

e. FILLERS & INNER SHEATH Fillers & inner sheath shall be of vulcanised or unvulcanised rubber or thermoplastic materials. 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

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to be compatible with temperature rating of the cable and shall have no adverse effect on any other component of the cable. 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. It shall be ensured that the shape is as circular as possible. Further it should be possible to remove inner sheath without damage to insulation. 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). f. g. ARMOURING OUTER SHEATH The cables shall be armoured as per IS:7098 (Part-2) /1985 (with latest amendments/revision if any). The cables shall be provided with outer sheath by Pressure Extrusion Process, of PVC compound confirming to type ST-2 of IS-5831/1984 (with latest amendment/revisions if any). The colour of outer sheath shall be grey & thickness will be as per provisions of relevant IS. 5. IMPULSE LEVEL The impulse level shall be 75KVp ( to be certified by the manufacturer). 6. 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, 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.

Measurement of Weights of Various Parts of Cables. The number of samples to be taken for the measurement of weights of various parts ,as per GTPs, shall be 50 % of the total no. of samples b. TYPE TESTS TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION

403

The cables shall comply with Type Tests as classified under clause-18.1 of IS: 7098(Part-2)-1985 (with latest amendments/revisions if any). Complete Type Tests Certificates from a Govt. approved/Recognized Test House indicating the results of Type tests conducted, in respect of each size of cable offered, should be sbmitted within 1 month of allotment of order to the respective office of PSPCL. Type Tests should be conducted on the tendered item manufactured only at works from where material is to be supplied. PSPCL, however , reserve its right to carryout the Type Tests wherever felt necessary at bidders cost. Complete Type Tests as per IS: 7098 (Part-2)-1985(with latest amendments/revisions if any. 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. c. ROUTINE TESTS The manufacturer shall carry out/conduct routine tests as specified in relevant IS on the cables manufactured before pre-despatch inspection. d. 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. 7. IDENTIFICATION The word PSPCL` and manufacturers trade mark or name, size in mm, voltage rating and word ELECTRIC` in English shall be embossed on the outer sheath of the cable at regular intervals of not more than 1.5 metres, as may be convenient. The cable should also be sequentially marked to display the length at a distance not more than 1 m. The cores shall be identified as per relevant IS. 8. PACKING & MARKING 8.1 PACKING The cable is required to be supplied in standard lengths of 500 mtrs up to 70 mm and 250 mtrs for other sizes. 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. The drums should be such that the cable wound on the same is transported without any damage. 8.2 MARKING The following particulars shall be specified clearly with indelible ink or paint on each drum :Length of drum Name of manufacturer, Brand Name & Trade Mark Gross weight of drum Size of cable in mm No. of cores. Type of cable and voltage rating ISI certification mark Cable code No. of lengths in drum (if more than one) Direction of rotation of drum TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION Year of manufacturing 9. 9.1 TOLERANCE TOLERANCE ON PACKING

404

The standard drum length may have tolerance of + 5%. 9.2 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. 10. 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 . No material will be allowed to be despatched without prior inspection and approval. In case, inspection of any consignment is waived off by the PSPCL /Agency, the bidder will be required to furnish routine & acceptance test certificates in triplicate, of the same for approval. It will be the responsibility of the bidder to make adequate arrangement for testing of material at their works. All testing instruments and appliances duly calibrated from Govt. Recognised test house will be made available and material consumed/ destroyed during testing will be to the account of the supplier. 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, cost of which shall be borne by the bidder. The material shall be sealed with lead seals and lash wire to be provided by the manufacturer / bidder. Random testing of material on receipt in the stores irrespective of fact whether or not it was inspected before despatch, shall be carried out by PSPCL and in case of failure, entire lot shall be rejected at the cost and risk of supplier. 10. SCHEDULE OF GURANTEED TECHNICAL PARTICULARS Bidder / Bidder must supply the detailed guaranteed technical alongwith the tender 11. ISI MARK The bidders must supply photocopy of valid ISI licence, 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. The above license should preferably be valid during the validity of the offer also. In case, the license is expiring within the validity period of the offer, it will be the responsibility of the bidder to get the same re-validated from time to time.

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48. TECHNICAL SPECIFICATION FOR LT AERIAL BUNCHED CABLES

1. SCOPE: 1.1 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. No. 1 2 3 4 5 6 Size mm2 3Cx16+25 3Cx25+25 3Cx35+25 3Cx 50+35 3Cx 95+70 3Cx 120+70

1.2 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. Note: The cables conforming to this standard may be operated continuously at a power frequency voltage to percent higher than the rated voltage. 1.3 The cables covered in this standard are suitable for use where the combination of ambient temperature and temperature rise due to load, 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, which will carry the weight of the cable. 3. 4. RATED VOLTAGE The rated voltage of the cables shall be 1100 volts. APLICABLE STANDARDS: The following standards with latest amendments shall be applicable. 1. 2. 3. 4. 5. IS: 1596 1984: Polyethylene insulated cable 1100 volts IS: 8130 - 1984: Conductors for insulated cables IS: 6474 - 1984: Polyethylene insulation of cables. IS: 398 - 1994: (Part IV) Aluminium alloy conductor. IS: 398 1996: (part II) For ACSR conductor. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION 6. 7. 5. IS: 14255 1995: Arial Bunched Cable Specification IS: 7098 (PI) 1988 with latest version.

406

TERMINOLOGY For the purpose of this standard the following definition to those given in IS 1885 (Part 32): 1993 shall apply.

6.

TESTS: 6.1 Routine Tests Tests made by the manufacturers on all finished cable lengths to Demonstrate the integrity of the cables. 6.2 Type Tests Tests required to be supplied within 1 month of allotment of order. Note: These tests are of such a nature that after they have been made, they need not be repeated unless changes are made in the cable materials of design, which might change the performance characteristics. 6.3 Acceptance Tests Tests carried out on samples taken from a lot for the purpose of acceptance of the lot. 6.4 Optional Tests Special tests to be carried out, when required by agreement between the PSPCL and the supplier. 6.5 Earthed System All electric system, which fulfills any of the following conditions: a) The neutral point or midpoint connection is earthed in such a manner that even fault conditions, the maximum voltage that can between any conductor and earth docs not exceed 80 percent of the nominal system voltage; 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; or c) In case of ac system only, 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. 6.6 Unearthed System An electric system which does not fulfill the requirements of earthed system (see 3.5 (a), (b), (c).

MATERIALS 7. CONDUCTOR 7.1 7.2 The power/outer insulated neutral/street lighting conductors shall conform to flexibility class 2 of IS 8130: 1984. The messenger (Neutral conductor) or otherwise shall be either stranded circular or compacted circular type and shall have minimum 7 strands. The surface of the conductor shall be smooth. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION 7.3

407

A protective barrier may be applied between the conductor and insulation, if required. Such barrier, when used, shall be compatible with insulating material and suitable for the operating temperature of the cable. The size of street lighting conductor shall be (16 sq mm) The size of messenger conductor and its breaking load shall be as under:

7.4 7.5

SIZE AND REQUIREMENTS OF MESSENGER CONDUCTOR Sr. No. Nominal Sectional Area of conductor mm2 1 2 3 4 5 6 7 7.6 7.7 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 1.38 1.38 1.38 0.986 0.689 0.492 0.492 KN 7.0 7.0c 7.0 9.8 14.0 19.7 19.7

There shall be no joints in any wire of the messenger conductor. The direction of outer layer of wires in messenger conductors shall be right hand. CORE IDENTIFICATION: The phase conductors shall be provided with one, two or three 'ridges' and Outer neutral insulated conductor, if provided, shall have four 'ridges' as shown in Fig. I for quick identification. The street lighting conductor and messenger conductor (if insulated) shall not have any identification mark. Identification by other means, as agreed between the supplier and PSPCL, is also permissible.

7.8

ASSEMBLY (LAYING UP): Three insulated phase conductors, 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. The direction of lay shall be right hand.

PHASE CONDUCTOR & NEUTRAL CONDUCTOR Phase Conductors

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION

408

Neutral Conductor

Fig. 1, Core Identification 7.9 Phase/Street Lighting Conductor The conductor shall be of H2 or H4 grade aluminium complying with the Requirements of IS 8130: 1984. PHASE CONDUCTOR 1. The phase conductor and street lighting conductors shall be insulate with black weather resistant, polyethylene suitable for1100 v insulation, the insulated Conductors shall generally confirm to the standards, applicable standards. 2. The phase conductors shall be suitable compacted and the outer diameter shall be within the limits specified. 3. The phase conductors shall be provided with one, two and three 'ridges' for quick identification. 4. The tensile strength of aluminium wire used in the conductors shall not be less the 90 N/ sqmm. 5. 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. of strands 1 7 7 7 12 19 19

Dia. Of compacted Conductor (mm) 4.4 5.8 6.8 7.9 9.7

Approx. mass (Kg/km) 42 65 95 127 191 259 329

Max.D.C. resistance NCE at 20 C 1.91 1.20 0.868 0.641 0.443 0.320 0.253
O

Insulation Thickness (mm) 1.0 1.0 1.0 1.2

Note: The resistance value given in Col. 5 are the max, permissible Tolerance allowable on diameters shown in col.3 7.10 Messenger (Neutral Conductor or Otherwise) TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

of +/- 5% is

ANNEXURE-F PART 3 DISTRIBUTION

409

The conductor shall be of heat-treated aluminium magnesium-silicon alloy wires containing approximate 0.5% magnesium and approximately 0.5% silicon conforming to IS 398 (Part-4): 1979. Customers can opt for ACSR as messenger wire. Messenger wire can be either bare OR insulated as per requirement. 1. 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. 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. of Dia strands of (min) Approx. Mass (kg/km) Max. D.C. resistance NCE at 20% ohm /km 25 35 50 70 7 7 7 12 5.8 6.8 7.9 9.7 65 95 127 191 1.380 0.986 0.689 0.492 7.4 10.3 14.7 20.6 Min. Tensile Strength (KN)

compacted cond. (mm)

Note: While the limiting values in col.5 & 6 are to be guaranteed and 5% plus tolerance will be permissible on values in col.3. The number of the insulated Phase Conductor in an ABC cable will vary depending on the specifications and requirement of customer. Whereas, the ABC Cable with a single Insulated conductor is called Duplex, the one with two insulated Conductors is called Triplex, and the one with three insulated Conductors is called Quadruple. In addition to this, a street lighting or an emergency service conductor may also be provided public amenities such as street lighting. COMPOSITION AND DESIGNATION OF FINISHED CABLES 7.11 The composition and designation of finished cables are given as under. Sr. no. 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

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, the middle to the street lighting conductor(were provided) and the last to the bare messenger wire. The sixes shown are the nominal sectional areas. 1. Polyethylene insulation will generally confirming to IS1596 1984 and IS-6474-1984 and XLPE insulation confirming IS 7098 (P.I)/ IS 14255. 2. Cable Phase or street Lightening will confirm to IS-8130/1984 duly compacted. 3. 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. 8. INSULATION: 8.1 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.

Sr. No. (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) 12.5 N/ mm2,Min 200 percent, Min 135 oC, +/- 3oC 7 days 25 percent, Max 25 percent, Max 200 oC, +/- 3oC 15 Min 20 N/cm2 175 percent, Max 15 percent, Max 130 oC,+/- 3oC 1 hour

Hot set: a) Treatment: Temperature Time under load Mechanical Stress b) Elongation under load c) Permanent elongation (set) after cooling

Shrinkage: a) Treatment: Temperature Duration

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

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, Min 1X1011ohm-cm, Min 85 oC,+/- 2oC 14 days 1 mg/cm2, Max 4 percent, Max

411

PROPERTIES OF PE INSULATION (CLAUSE 5.1)

Sr.No. 1

Property Volume /resistively: a) at 27 oC b) at 70 C

o

Requirements 1 X 1014 ohm-cm, Min 1 X 1012 ohm-cm, Min 10 N/mm2, Min 300 percent Min 3, Max 85 oC,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

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 This average thickness of insulation shall be not less than the nominal value (t) specified as under. THICKNESS OF INSULATION Nominal Area of Conductor (mm ) 16 25 35
2

Nominal Thickness (ti) (mm) 1.2 1.2 1.2

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION 50 70 95 Tolerance on Thickness of Insulation 1.5 1.5 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 0.1 mm + 0.1 (ti). Application of Insulation The insulation shall be so applied that it this closely on the conductor (or barrier, if any) and it shall be possible to remove it without damaging the conductor. The color of insulation shall be GREY.

POLYETHYLENE INSULATION The Polyethylene insulation shall generally confirm to IS: 6474-1971.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. CLASSIFICATION OF TESTS: 9.1 Sr. No. a. 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) 0.5 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.

Test on messenger conductor: i) Breaking load Section table 1 2

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION ii) Elongation test iii) Resistance test c. 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. 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. f. g. Test for thickness insulation Insulation receptivity) resistance See Table 3 See Table 3 See Table 4 (Volume See Table 2 & 3 See 6.2 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 Sec Table 1 11.3 5

413

High voltage test

9.2

Acceptance Test The following shall constitute acceptance tests: a) b) c) d) e) f) g) i) h) Tensile test (for phase/street light conductor). Wrapping test (for phase/streetlight conductor). Breaking load test for messenger conductor. Elongation test for messenger conductor. Conductor resistance test, Test for thickness of insulation, Tensile strength and elongation at break test. Insulation resistance test, and Hot set test for XLPE insulation, TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION j) INSPECTION: High voltage test,

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. The manufacturer shall afford the inspector representing the PSPCL all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 9.2.1 A probable sampling plan for acceptance tests is given in AnnexA ANNEX A (Clause 9.2.1) SAMPLING OF CABLES A-1 LOT A-1.1 In any consignment the cables of the same size manufactured under essentially similar conditions of production shall be grouped together to constitute a lot. A-2 SCALE OF SAMPLING A-2.1 Sample shall be taken and tested from each lot for ascertaining the Conformity of the lot to the requirements of the specification. A-2.2 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. These samples shall be taken at random. In order to ensure the randomness of selection, random number labels shall be used (see IS 4905: 1968 Methods of random sampling). A-3 NUMBER OF TESTS AND CRITERION FOR CONFORMITY A-3.1 Suitable length of test sample shall be taken from each of the drums selected. These test samples shall be subjected to each of the acceptance to each of the acceptance tests (see 12.2) A. test sample is called defective if it fails in any of the acceptance tests. 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, otherwise not. NUMBER OF DRUMS TO BE SELECTED FOR SAMPLING AND PERMISSIBLE NUMBER OF DEFECTIVES. 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

ANNEXURE-F PART 3 DISTRIBUTION 101 to 300 301 to 500 501 and above 9.3 Routine Tests The following shall constitute routine tests: a) Conductor resistance test, and b) High voltage test. 9.4 Optional Test The following shall constitute optional test: Bending test 10. DETAILS OF TEST: 10.1 General 13 20 32 0 1 2

415

Unless otherwise stated in this standard, the tests shall be carried out in accordance with appropriate parts of IS 10810 taking into account additional information given in this standard. 10.2 High Voltage Test High voltage at room temperature (Type, 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 7.2 kV between conductor for 5 minutes. 10.3 Elongation Test on Messenger Conductor Test shall be carried out on wires before stranding. The specimen shall be straightened by hand and an original gauge length of 200 mm shall be marked on the wire. A tensile load shall be applied by means of a suitable tensile testing machine. The load shall be applied gradually and the rate of separation of the jaws of the testing machine shall be not less than 25, per minute and not greater than 100 mm per minute. The elongation shall be measured after the fractured ends have been fitted together. If the fractured occurs outside the gauge marks, of within 25 mm of either mark, or the required elongation is not obtained, the test shall be disregarded and another test made. The elongation of the specimen shall be not less than 4 percent on a gauge length of 200 mm. The test shall be performed on a sample of complete cable. The sample shall be bent around a test mandrel at room temperature for at least one complete turn. It shall then be unwound and the process shall be repeated after turning the sample around its axis by 180 degrees. The cycle of these operations shall then be repeated twice. The diameter of the manderel shall be 10 (D + d) Where D = actual diameter of the cable, for example, Minimum circumscribing diameter, mm; and d = actual diameter of the phase conductor, mm. Requirement: No cracks visible to the naked eye are allowed. SECTIONS IDENTIFICATION, PACKING AND MARKING 11. IDENTIFICATION: 11.1 Manufactures, Identification TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

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. In case the above method cannot be employed, or if the PSPCL so desires, colour identification threads in accordance with a scheme to be approved by the Bureau of Indian Standards (BIS) shall be employed. 11.2 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. No identification is required for polyethylene insulation. NOTES: 1 Single tape bearing manufacturer's name or trademark and the cable identification, that is, XLPE 90, if provided shall be acceptable against the requirement of 11.1 and 11.2. 2. Identification required in 11.1 and 11.2 shall be given on any one of the insulated conductor of cables. 12. PACKING AND MARKING: 12.1 12.2 The cable shall be wound on a drum (see IS 10418: 1982) of suitable size and packed. The ends of the cable shall be sealed by non-hygroscopic material. 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, for example, 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; Country of manufacture; and Year of manufacture.

12.2.1 The cable (drum or label) may also be marked with the Standard Mark. Note: The use of the Standard Mark is governed by the provision of Bureau of Indian Standards Act, 1986 and the Rules and Regulations made there under. 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. 12.3 12.4 Standard Length: The standard length of 500 with +5% and longer length shall be acceptable. 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. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION

417

TECHNICAL PARTICULARS LT Aerial Bunched Cable 1100 Volts (4 core). Reference standard: Generally to IS: 7098(1)88. Sl No. Description 3x25 + 1x25 + 1x35 3x35 + 1x35 + 1x35 3x50 + 1x50 + 1x35 3x70 + 1x70 + 1x55 3x95 + 1x95 + 1x55

1. 1.1

Power/Neutral core: Conductors a) Nom. cross sectional area (i) Power cores (mm2) 25 (ii) Neutral core (mm2) b) Max. D.C. resistance of conductor at 25 20 C (i) Power cores (Ohm/Km) (ii) Neutral core (Ohm/Km) c) Approx. 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

1.2

1.20 1.20 6.2 6.2

0.868 0.868 7.3 7.3

0.641 0.641 8.35 8.35

0.443 0.443 10.1 10.1

0.320 0.320 12.0 12.0

0.9 0.9

0.9 0.9 35 41

1.0 1.0 35 41

1.1 1.1

1.1 1.1

Messenger Wire (Bare): (i) Nom. cross sectional area (Sq. mm) (ii) Approx. breaking load (KN) 35 41 55 62 55 62

Current ratings: Continuous current carrying capacity of cable in Air at Ambient temp. 40 C 99 (Amp.)
0

122 725

149 880

190 1270

235 1570

4 5

Approx. weight (kg./km.) Number of cores: (i) Power cores (ii) Neutral core (iii) Bare messenger

610 (No.) : 3 (No.) : 1 (No.) : 1

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION 6 Derating factor: Derating factors for variation In air Temp. Air Tedmprature in (0C) 30 Rating factor 1.12

418

35 1.06

40 1.0

45 0.94

50 0.88

55 0.83

(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.T. Steel Messenger. /AAAC.

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. Conductor to IS: 398 (II) & (IV) respectively Stranded circular/compacted circular.

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION

419

TECHNICAL PARTICULARS LT Aerial Bunched Cable 1100 Volts (5 core) with Street Lighting Conductor. Reference Standard: Generally to IS: 6474-71 Sl No. Description 3x16 + 1x16 + 1x25 3x25 + 1x16 + 1x25 3x35 + 1x16 + 1x25 3x50 + 1x16 + 1x35 3x70 + 1x16 + 1x50 3x95 + 1x16 + 1x70 3x120 + 1x16 + 1x70

1. 1.1

Power/Neutral core: Conductors a) Nom. cross sectional area (i) Phase conductor (mm2) 16 (ii) Street lighting conductor (mm2) b) Max. D.C. resistance of conductor at 16 20 C (i) Phase conductor (Ohm/Km) (ii) Street lighting conductor (Ohm/Km) c) Approx. 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

1.91 1.91 6.2 6.2

1.20 1.91 6.2 6.2

0.868 0.641 0.443 1.91 1.91 1.91 7.3 7.3 8.35 8.35 10.1 10.1

0.320 0.253 1.91 1.91 12.0 12.0 12.0 12.0

1.0 1.0

1.0 1.0

1.0 1.0

1.2 1.0 35 10.3

1.4 1.0 50 14.7

1.4 1.0 70 20.6

1.6 1.0 70 20.6

Messenger Wire (Bare): (i) Nom. cross sectional area (Sq. mm) (ii) Approx. breaking load (KN) 25 7.4 25 7.4 25 7.4

Current ratings: Continuous current carrying capacity of cable in Air at Ambient temp. 40 C 51 (Amp.)
0

70 390

86 490

105 640

130 890

155 1180

180 1430

4 5

Approx. weight (kg./km.) Number of cores: (i) Power cores (ii) street lighting core (iii) Bare messenger

310 (No.) : 3 (No.) : 1 (No.) : 1

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION 6 De-rating factor: De-rating factors for variation In air Temp. 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 1.12

420

35 1.06

40 1.0

45 0.94

50 0.88

55 0.83

By providing ridges on the insulation Three power cores and one neutral core shall be suitably twisted around bare H.T. Steel Messenger. /AAAC.

Aluminium to IS: 8130/84 Class-2 Compacted circular Cross linked Polyethylene to IS: 7098(I)88 Black ACSR/AAAC. Conductor to IS: 398 (IV) respectively Stranded circular/compacted circular.

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION TECHNICAL PARTICULARS LT Aerial Bunched Cable 1100 Volts (4 core). Reference standard: Generally to IS: 6474-71. Sl No. Description 3x16 + 1x25 Power/Neutral core: Conductors a) Nom. cross sectional area (i) Phase conductor (mm2) (ii) Neutral conductor (mm2) b) Max. D.C. resistance of conductor at 20 C (i) Phase conductor (Ohm/Km) (ii) Neutral conductor (Ohm/Km) c) Approx. 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. 1.1

16 25

25 25

35 25

50 35

1.2

1.91 1.38 4.4 5.8

1.20 1.38 5.5 5.8

0.868 1.38 6.8 5.8

0.641 0.968 7.9 6.8

1.0 1.0 2 Messenger Wire (Bare): (i) Nom. cross sectional area (Sq. mm) (ii) Approx. breaking load (KN) 3 Current ratings: Continuous current carrying capacity of cable in Air at Ambient temp. 40 C (Amp.) 4 5 Approx. weight (kg./km.) Number of cores: (i) Power cores (ii) Neutral messenger core
0

1.2

1.0 25 7.4 25 7.4 35 10.3

25 7.4

60 250 (No.) : 3 (No.) : 1

76 330

92 430

110 580

De-rating factor: De-rating factors for variation In air Temp. Air Temperature in (0C) 30 35 40 Rating factor 1.12 1.06 1.0

45 0.94

50 0.88

55 0.83

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

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.

Aluminium to IS: 8130/84 Class-2 Compacted circular Cross linked Polyethylene to IS: 7098(I)88 Black ACSR/AAAC. Conductor to IS: 398 respectively Stranded circular/compacted circular. (IV)

Prior to dispatch, cable is subjected to rigorous testing. Test procedures followed at manufacturers works are according to various national & International specifications and are covered in this paper. Following tests are performed on Aerial Bunched Cables:1. 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. 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. 2. Test for messenger conductor: (a) Breaking load test (b) Elongation test (c) Resistance test

IS: 10810 pt - 2 IS: 10810 pt - 3 IS: 10810 pt - 5 IS: 10810 pt - 6 IS: 10810 pt - 7 IS: 10810 pt - 23 IS: 10810 pt - 22 IS: 10810 pt - 32 IS: 10810 pt - 18 IS: 10810 pt - 29 IS: 10810 pt - 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

ANNEXURE-F PART 3 DISTRIBUTION

423

3. Dimensional test as per the parameters specified in the technical particulars. 4. Bending test on completed cable shall also as performed. 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

ANNEXURE-F PART 3 DISTRIBUTION

424

49. 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, manufacture and testing of Accessories for Low Voltage Aerial Bundled Conductor (LT ABC) with Bare/ insulated Messenger & Service cables. 1. General conditions 2. Standard References 3. Technical Specifications of ABC Accessories a. Dead End Clamps (DEC) b. Suspension Clamps (SC) c. Service Anchoring Clamps (SAC) d. Insulation Piercing Connectors (IPC) e. Distribution Box (DB) f. Hardware: Eye Hooks & Pole Clamps 1.

1. 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. Marking: Each product shall be clearly identified with Manufacturer name or trade mark, reference and capacity of the item and batch No. Packaging: Manufacturer shall mention the packaging of each item. Installation instruction should be included in the packaging. Type tests: Each supplier should provide type test reports with, carried out in accordance with one of the referenced standards in NABL or any govt test house / accredited laboratory. Routine tests: Suppliers shall provide a control plan, which will be implemented on each item. Routine Test reports should be submitted by the manufacturer with the Inspection Call. Anchoring and Suspension clamps should be installable on existing poles using appropriate devices (hooks, brackets etc.) All crimped connectors should be installed with mechanical or hydraulic hand crimping tools.

2. 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

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, of rated voltage 0,6/1 kV NFC 33-041:1998 "Anchoring devices for Overhead Distribution with bundle assembled cores, of rated voltage 0,6/1 kV" NFC 33-042:1998 "Service Anchoring devices for overhead and underground services with insulated cables, of rated voltage 0,6/1 kV" NFC 33-020:1998 "Insulation piercing connectors for overhead distributions and services with bundle assembled cores, of rated voltage 0,6/1 kV". NFC 33-021:1998 "Pre-insulated compression type connecting equipment for Overhead Distributions and Services with bundle assembled cores, of rated voltage 0.6/1 kV" NFC 33-004:1998 "Electrical ageing test" NFC 33-003:1998 "Corrosion test" NFC 20-540:1998 "Climatic ageing test"

3. 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. The clamp should consist of an Aluminium alloy corrosion resistant body with bolted / self-adjusting plastic wedges clamping. The clamp should be installed properly with no losable part. The clamp should not damage the conductor/ insulation of conductor For insulated messenger, it shall conform to the standard NFC 33-041 or equivalent I.S., if any. The clamp body should be made of corrosion resistant Aluminium alloy. It should be fixed with pole by eye hook / bracket. Ultimate Tensile Strength of the clamp should not be less than 15 KN for 25-70 sq.mm messenger wire. Slip load of the clamp should not be less than 5KN for 50/70 sq.mm bare messenger & 3KN for 25/35 sq.mm bare messenger wire. Detailed design/ drawing to be furnished by the bidder / manufacturer. REC construction standard drawing mentioned below are indicative drawing, may be followed.

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

ANNEXURE-F PART 3 DISTRIBUTION

426

TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

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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. The suspension clamp range to accommodate messenger shall be 25-70mm2 and shall be as per similar design of REC E-34. For insulated messenger, it shall conform to the standard NFC 33-040 or equivalent I.S., if any. The clamp shall be made up of Aluminium Alloy. Clamps should be fixed with pole by eye hook/bracket. The Suspension Clamp & the eye hook/bracket will be preferably delivered together in order to minimize abrasion between two materials. Ultimate Tensile Strength of the clamp should not be less than 12 KN for 25-70 sq.mm bare / insulated messenger wire. Slip load of the clamp should not be less than 300N for 25-70 sq.mm bare messenger wire The clamp should sustain to maximum angle of deviation of 60 degrees of the conductors. Detailed design/ drawing to be furnished by the bidder/manufacturer. REC construction standard drawing mentioned below are indicative drawing, may be followed.

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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. The clamp should be installed properly. No losable parts & should have a rigid bail. The clamp shall conform to the standard NFC33-042 or equivalent I.S., if any. Breaking load of the clamp should not be less than 1 KN. Detailed design/ drawing to be furnished by the bidder/manufacturer. Reference standard: NFC 33 021 or equivalent I.S., if any. Detailed design/ drawing to be furnished by the bidder/manufacturer.

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d)
Scope

Insulation Piercing Connectors (IPC) For proper method of providing service connection from AB Cables to our consumers without damaging the cable, the Insulating Piercing Connectors are required a) for providing 1-2 service connections from 8 / 9 mtr. PCC LT pole, b) for providing supply to Junction/ Distribution Box from AB Cable c) for establishing Tee connection from LT ABC to LT ABC. It must have Shear Head type mechanism to control the effective Torque during connection and to ensure perfect installation. Connectors should not have any losable parts, which may drop and then lost while installation at overhead conditions. Torque required for Proper Installation should be mentioned on IPC, should be 10-12 N-m. As per NF C 33-020 & NFC33-003, or equivalent I.S., if any. The connectors should be totally insulated with no loose parts. The connectors should be totally Weather & Moisture proof so that no water or moisture can enter through the pierced holes on the cable insulation. The maximum voltage withstand capacity should be 6 KV. The connectors should work at 30 cm under water bath for 30 min. & voltage applied of 6KV for 1 min in underwater condition. No flashover/ failure should occur during voltage application. Designed for installation from -10C upto +60C & operation experience with temperature from -20C upto +75C. 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 contact plates should be made of tinned Copper / Aluminium Alloy as per IPC current rating. Connector teeth should be factory greased & sealed to retard water or moisture ingress & corrosion. The insulation material should be made of weather & UV resistance, reinforced polymer. The outer metallic part should have potential free tightening bolts to allow safe Live-Line installation. 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. The connector should not have any losable component. The cable end cap should be attached to the body. Should have attached flexible end caps without Grease in order to seal the open end of tap cable or in-built type. The end of tap should be felt from outside end cap, to ensure proper installation. Should be designed with encapsulated bolt heads or round head in order to avoid damaging other conductor insulation during installation. TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B

Standards Construction:

Moisture Ingress:

Working Temp.: Materials:

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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. The Insulating Piercing Connector should conform to following std.As per NF C 33-020, NFC33-003 & NFC33-004, or equivalent I.S., if any. 1. Corrosion Qualification Test 2. Electrical Ageing Test 3. Underwater High Voltage Test 4. Mechanical Tests 5. Voltage Test

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