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

Specification G3IR-1050-65-SP-9019 Date 25-Jul-12 Page 1 of 9

MV POWER CABLE (6.6 kV)

Document No: G3IR-1050-65-SP-9019

Unit: Discipline: Document Type:

General Electrical Specification

Document Title: SPECIFICATION FOR MV POWER CABLE (6.6 kV)

DISCLAIMER
THIS DOCUMENT DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS DOCUMENT CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.

ISSUED FOR DESIGN

02 Aug 2012

0 A Revision

25-Jul-12 20-Jul-12 Date

Issued for Design (RFQ) Issued for Review Purpose

RR RR Prepared By

NG NG Checked By

VP VP Fluor BASF Approved By

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

Specification G3IR-1050-65-SP-9019 Date 25-Jul-12 Page 2 of 9

MV POWER CABLE (6.6 kV) 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. A Date Description

25-Jul-12

Issued for Review

25-Jul-12

Issued for Design (RFQ)

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

Specification G3IR-1050-65-SP-9019 Date 25-Jul-12 Page 3 of 9

MV POWER CABLE (6.6 kV)

TABLE OF CONTENTS
1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 3.0 4.0 GENERAL............................................................................................................................................... 4 Scope ..................................................................................................................................................... 4 References............................................................................................................................................. 4 Service Conditions................................................................................................................................ 5 TECHNICAL REQUIREMENTS ............................................................................................................. 5 Design Criteria....................................................................................................................................... 5 Special Requirements .......................................................................................................................... 6 Cable Drums .......................................................................................................................................... 7 Equipment Identification ...................................................................................................................... 7 INSPECTION AND TESTS..................................................................................................................... 8 DRAWINGS AND DOCUMENTS ........................................................................................................... 9

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

Specification G3IR-1050-65-SP-9019 Date 25-Jul-12 Page 4 of 9

MV POWER CABLE (6.6 kV) 1.0 GENERAL 1.1 Scope 1.1.1 This specification is intended to cover design, engineering, procurement,

manufacture, inspection and testing at manufacturers works, packing, loading, forwarding, transport and delivery to site of 6.6 kV power cable. 1.1.2 Supplier is required to carefully examine and understand the specifications and seek clarifications, if required, to ensure that he has understood the specifications as intended by the Owner. In the absence of any specific clarifications made by the Supplier during bidding stage, the interpretation of Owner shall be final. The Suppliers offer should not carry any sections like clarifications, interpretations and/or assumptions. All such points are required to be clarified during bidding stage. 1.2 References 1.2.1 The MV Power 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. S.No. 1 Description Cross linked polyethylene insulated PVC sheathed cables for working voltages from 3.3 KV upto and including 33 KV Conductors for insulated electric cables and flexible cords PVC insulation and sheath of electric cables. Low carbon galvanised steel wires, formed wires and tapes for armouring cables Recommended current ratings for cables. Specification for PVC insulated (heavy duty) electric cables :for working voltages from 3.3 kV up to and including 11 kV Design and dimension of Cable drum Ignition Resistance and flame tests on FRLS Cable Ignition Resistance and flame propagation tests on bunch of FRLS Cable. Guide for selection of HV Cables.

IS 7098

2 3 4 5 6

IS 8130 IS 5831 IS 3975 IS 3961 IS 1554(Part-2)

7 8 9 10

IS 10418 IEC 60332-1 IEC 60332-3 IEC 60183

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

Specification G3IR-1050-65-SP-9019 Date 25-Jul-12 Page 5 of 9

MV POWER CABLE (6.6 kV) 11 12 13 14 1.2.2 Extruded solid dielectric insulated power cables for rated voltages from 1KV to 30 KV Test methods for Electrical cables. Common Test methods for insulating and sheathing materials for electric cable. Methods of test for cables IEC 60502 IEC 60885 IEC 60811 IS 10810

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 resolution. Generally the following order of priority shall govern : Statutory regulations BASF Guidlines Data Sheets This specification Codes and standards

1.3

Service Conditions 1.3.1 The Equipment shall be designed for a design ambient temperature of +45C and an altitude not exceeding 1000 meters above mean sea level. Relative humidity of 92% shall be considered for design. 1.3.2 The cables shall be suitable for laying on racks, trenches and under ground buried installation with chances of flooding by water.

2.0

TECHNICAL REQUIREMENTS 2.1 Design Criteria 2.1.1 All cables shall be with Aluminium conductor XLPE insulated, screened, sheathed, armoured and over all extruded FRLS, PVC sheathed. Insulation of cables shall be 6.6 kV unearthed grade. 2.1.2 The construction of the conductors shall be stranded and compacted circular for all cables. 2.1.3 Aluminium conductor used in power cables shall have tensile strength of minimum 100 N/ sq.mm. 2.1.4 2.1.5 The cables shall be provided with both conductor screening and insulation screening. The conductors screening shall be of non- metallic extruded semi-conducting material. 2.1.6 The core insulation shall be with cross-linked polyethylene insulating compound. It shall be free from void and shall withstand all mechanical and thermal stresses under steady state and transient operating conditions and insulation shall be dry cured.

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MV POWER CABLE (6.6 kV) 2.1.7 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. 2.1.8 The insulation screening shall consist of non metallic extruded semi-conducting compound in combination with helically wrapped screening of copper. The insulation screen shall be strippable without application of heat. 2.1.9 The conductor screen, XLPE insulation and insulation screen shall all be extruded in one operation by Triple extrusion process to ensure perfect bonding between the layers. The core identification shall be coloured strips or by printed numerals. 2.1.10 The inner sheath shall be applied over the laid up cores by extrusion and shall confirm to the requirements of Type ST2 compound of IS: 5831. The extruded inner sheath shall be of uniform thickness of size not less than 0.7mm for all sizes of cables and of black colour. 2.1.11 The inner PVC sheath of multi core cable shall be designed such that it can safely withstand the voltage gradient between copper tape and armour when the cable is carrying rated current continuously as well as when the cable is carrying system fault current. 2.1.12 For three core cables, the armouring shall be by galvanized steel strips armouring and for single core cables shall be with hard drawn aluminium round wire. 2.1.13 The outer FRLS PVC Sheath shall be designed such that it can safely withstand induced voltage in the armour when the cable is carrying specified system fault current. 2.1.14 The outer sheath of the cable shall be supplied by extrusion over the armouring and shall be of fire retardant low smoke(FRLS) type PVC compound confirming to the requirements of type ST2 compound of IS: 5831. To protect the cable against rodent and termite attack, suitable chemicals shall be added into the PVC compound of the outer sheath. 2.1.15 The overall dia. and dia. under armour of the cables shall be indicated by the vendor in the technical particulars. These shall be guaranteed with a tolerance of 5% but not exceeding 2 mm. 2.2 Special Requirements 2.2.1 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 250C at oxygen index of 21 when tested as per IS 10810. 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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MV POWER CABLE (6.6 kV) 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. 2.2.2 Temperature index at minimum 250OC as per ASTM-D-2863.

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 S5424-1475.

2.3

Cable Drums 2.3.1 The cable drums shall be non-returnable wooden drums of heavy construction. The wood used for the construction of the drums shall be properly seasoned, sound and free from defects. Wood preservative shall be applied to the entire drum. All ferrous parts shall be treated with suitable rust preventive coating. 2.3.2 A label shall be securely attached to the end of the reel indicating the customers 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 2.3.3 Cables shall be supplied in specified drum lengths. Where no such indication is given, standard drum lengths may be offered. 2.3.4 No negative tolerance on HV cables is acceptable.

2.4

Equipment Identification 2.4.1 All warning, identification and instruction labels shall be inscribed in both the English and local languages. 2.4.2 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. 2.4.3 2.4.4 Running meter markings shall also be provided throughout the length of the cable. The outer sheath of all cables shall be embossed throughout the cable length at every one-meter at two sides with the following information.

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

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MV POWER CABLE (6.6 kV) Manufacturers name Cable standard identification e.g. ISI Symbol. Year of manufacture Cable designation (cores, size, voltage grade, insulation) A legend FRLS to indicate that the cable is Fire Retardant Low Smoke type. 3.0 INSPECTION AND TESTS a) The cables shall be tested and examined at the manufacturers works. All the materials employed in the manufacture of the cable shall be subjected to examination, testing and approval by customer or their representative both before and after manufacturing the cable. b) After completion of manufacture of cables and prior to despatch, cables shall be subjected to type, routine, acceptance and special tests as detailed below. The test reports for all cables shall be approved by customer or their representative before despatch of the cables. c) The inner and outer sheath of XLPE cables shall be subjected to all the tests applicable for PVC cables and the tests shall be as per latest revision of IS 5831. d) The following tests shall be carried out on XLPE cables as per IS 7098, Part I / II. I). Routine / Acceptance Tests II). Conductor Tensile Test Wrapping Test Conductor Resistance Test Test for thickness of insulation and sheath. Partial Discharge Test High voltage Test Tensile strength and elongation test for insulation & sheath Insulation resistance test

Type Tests S.No. 1. 2. 3. 4. 5. 6. Type Test For Conductor Tensile test Wrapping test Resistance test For Armour Wires/ Formed Wires Measurement of Dimensions Tensile Test Elongation test For aluminium conductor only. For aluminium conductor only. Remarks

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MV POWER CABLE (6.6 kV) 7. 8. 9. 10.(a) 10.(b) 11 Torsion test Wrapping test Resistance test Mass of Zinc Coating test Uniformity of zinc coating Adhesion test For XLPE insulation & PVC Sheath 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. e) Test for thickness Tensile strength & elongation tests before ageing and after ageing Ageing in air oven Loss of mass test Hot deformation test Heat shock test Shrinkage test Thermal stability test Hot set test Water absorption test Oxygen index test Smoke density test Acid gas generation test For completed cables Insulation resistance test (Volume resistivity method) High voltage test Flammability test as per clause Flammability test Flammability test as per IEC - 60332 Part-3 (Category -B) For PVC sheath only For XLPE insulation only For XLPE insulation only For outer sheath only For outer sheath only For outer sheath only For PVC sheath only For PVC sheath only For PVC sheath only For G.S. Formed wires /wires only. For G.S. Formed wires /wires only. For G.S. Formed wires /wires only. For round wires only For aluminium wires/formed wires only

Copies of evidence of tests shall be submitted with any other data relevant to the tests carried out. Cables shall not be despatched unless the test certificates have been approved by the buyer.

4.0

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

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