CONTENTS

1. SCOPE. .......................................................................................................... 3

2. APPLICABLE DOCUMENTS ....................................................................... 3

3. DESIGN REQUIREMENTS .......................................................................... 5

3.1. CLASSIFICATION IN TERMS OF SAFETY ............................................................ 5

3.2. GENERAL TECHNICAL REQUIREMENTS ............................................................ 5
3.3. SPECIFIC TECHNICAL REQUIREMENTS.............................................................. 7
3.4. MARKING REQUIREMENTS .............................................................................. 8
3.5. OPERATIONAL REQUIREMENTS ....................................................................... 9
3.6. PACKING, TRANSPORTATION AND STORAGE REQUIREMENTS ............................ 9

4. MANUFACTURER'S WARRANTY ........................................................... 10

5. CABLE MANUFACTURING, OBLIGATIONS OF THE

MANUFACTURER, QUALITY ASSURANCE .......................................... 11

6. TESTS .......................................................................................................... 11

7. DOCUMENTATION TO BE SUPPLIED BY THE CABLE

MANUFACTURER ..................................................................................... 14

APPENDIX 16

TABLE .1 500 V SMALL-SIZE CABLES WITH POLYETHYLENE INSULATION,

POLYVINYLCHLORIDE SHEATH AND OVERALL SCREEN FOR KUDANKULAM NPP

UNIT 2. DELIVERY QUANTITY

TABLE .2 500 V SMALL-SIZE CABLES WITH POLYETHYLENE INSULATION,

SCREEN FOR EACH CORE, POLYVINYLCHLORIDE SHEATH AND OVERALL SCREEN FOR

KUDANKULAM NPP UNIT 2. DELIVERY QUANTITY

LIST OF ABBREVIATIONS ........................................................................... 17

Page 2 of 17
1. SCOPE
This document defines technical requirements for small-size control, signal,
communication cables rated for A. C voltages up to 1000 V., frequency no more
than 200 kHz, or D.C voltages up to 1500 V, which are intended for operation out-
side the Reactor building containment of Kudankulam NPP units 1 and 2, in India
and establishes requirements for the cable manufacturing, quality assurance, manu-
facturer's warranty, content of the documentation to be submitted by the manufac-
turer and delivery quantity.
The quantities of cables to be delivered shall be as per Appendix A to this doc-
ument.

2. APPLICABLE DOCUMENTS
The small-size control, signal, communication, connecting cables rated for A
C voltages up to 1000 V, frequency no more than 200 kHz, or DC voltages up to
1500 V shall meet requirements of the present document and the following stan-
dards:
IEC 60228 Conductors of insulated cables;
IEC 60344 Guide to the calculation of resistance of plain and coated copper
conductors of low-frequency cables and wires;
IEC 60227-1 Polyvinylchloride insulated cables of rated voltages up to and
including 450/750 V. Part 1. General requirements;
IEC 60227-7 Polyvinyl chloride insulated cables of rated voltages up to and
including 450/750 V - Part 7: Flexible cables - screened and unscreened
with two or more conductors;
IEC 60189-1 Low-frequency cables and wires with PVC insulation and
PVC sheath. Part 1: General test and measuring methods;
IEC 60708 Low-frequency cables with polyolefin insulation and moisture
barrier polyolefin sheath;

Page 3 of 17
IEC 60332-3-22 Group safety publication. Test for vertical flame spread of
vertically-mounted bunched wires or cables Category ;
IEC 60754-1 Test on gases evolved during combustion of electric cables.
Part 1. Determination of the amount of halogen acid gas;
IEC 61034-1 Measuring of smoke density of electric cables burning under
defined conditions. Part 1. Test apparatus;
IEC 61034-2 Measuring of smoke density of electric cables burning under
defined conditions. Part 2. Test procedure and requirements;
IEC 60811-1-1 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section
One: Measurement of thickness and overall dimensions. Tests for determin-
ing of mechanical properties;
IEC 60811-1-2 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section
Two: Thermal ageing methods;
IEC 60811-1-3 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section 3:
Methods for determining the density. Water absorption tests. Shrinkage test;
IEC 60811-1-4 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 1. Methods for general application. Section 4:
Test at low temperature;
IEC 60811-3-1 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 3. Methods specific to PVC compounds. Sec-
tion One: Pressure test at high temperature. Tests for resistance to cracking;
IEC 60811-3-2 Common test methods for insulating and sheathing mate-
rials of electric cables. Part 3. Methods specific to PVC compounds. Sec-
tion Two: Loss of mass test. Thermal stability test;
IEC 60811-4-2 Insulating and sheathing materials of electric and optical
cables Common test methods Part 4-2: Methods specific to polyethylene
and polypropylene compounds Tensile strength and elongation at break

Page 4 of 17
 after conditioning at elevated temperature Wrapping test after condition-
ing at elevated temperature Wrapping test after thermal ageing in air
Measurement of mass increase Long-term stability test Test method for
copper-catalysed oxidative degradation;
IEC 60068-2-10 Basic environmental testing procedures. Part 2. Tests
Test J. And guidance: Mouldgrowth;
50-/SG-Q (IAEA) Code and Safety Guides. Quality Assurance for Safety
in Nuclear Power Plants and Other Nuclear Installations;
ISO 9001-2000 Quality management system. Requirements;
IS 8130 : 1984 Conductors for insulated electric cables and flexible cords

3. DESIGN REQUIREMENTS
3.1. Classification in terms of safety
The cables are intended for operation as part of the NPP system equipment,
classes 2, 3and 4, as per PB88/97 NP-001-97 (PNAEG-01-011-97).

3.2. General technical requirements

3.2.1. All climatic conditions for macroclimatic regions on land and sea, except
macroclimatic regions with a very cold climate, for indoor operation (inside
enclosed spaces) with elevated humidity (for example, in unventilated
underground areas, including basements where long-lasting exposure to
water or partial moisture condensation on walls and ceilings can take place).
3.2.2. The cables are rated for A.C voltages up to 1000 V, frequency up to 200
kHz, or D.C. voltages up to 1500 V.
3.2.3. The cable construction shall meet all the requirements of this document.
Cables of the following types are envisaged:
- with an overall screen and with unscreened conductors (KMPVEVng-LS)
or with screened conductors (KMPEVEVng-LS).

Page 5 of 17
3.2.4. The cables shall be manufactured with Copper conductors (stranded). The
conductors shall comply with IEC 60344 for 0.35 mm2 cross-section and
class 5 as per IEC 60228 for other cross-sections.
3.2.5. The insulation shall be with low density polyethylene as per IEC 60708.
The nominal cable insulation thickness shall comply with IEC 60708 re-
quirements. However, the manufacturer shall mention thicknesses proposed,
in the data sheet, for review and approval of NPCIL.

3.2.6. The screen over the insulated conductors shall be of braided of tinned Cop-
per wires of 0.10 0.15 mm nominal diameter.
The coefficient of the screen/surface coverage shall be no less than 70%.
3.2.7. The cable shall be made up of screened insulated conductors or conductor
pairs stranded in concentric layers of opposite directions, as applicable.
3.2.8. An inner sheath shall be provided over the twisted core of insulated and
screened conductors in KMPVEVng-LS and KMPEVEVng-LS cables.
The inner sheath thickness shall meet the requirements of IEC 60227-7.
3.2.9. The screen over the inner sheath shall be made in the form of a braid of
tinned copper wires with a diameter as specified in IEC 60227-7.
The coefficient of the screen/surface coverage shall be no less than 70%.
3.2.10. Outer sheath shall be provided over the overall screen of KMPVEVng-LS
and KMPEVEVng-LS cables.
3.2.11. The inner and outer cable sheaths shall be extruded from polyvinylchloride
compounds of PVC-ST5 and PVC-ST9 types respectively, as per
IEC 60227-1, with low hydrogen chloride emission.
The polyvinylchloride compounds for the inner and outer sheaths shall have
low hydrogen chloride emission during testing as per IEC 60754-1 and shall
not exceed 14 %.
The nominal outer sheath thickness shall comply with IEC 60227-7 re-
quirement.
3.2.12. The outer cable diameters shall comply with IEC 60227-7 requirement.

Page 6 of 17
3.2.13.The physical and mechanical characteristics of the low density polyethylene
insulation measured before and after thermal ageing shall meet the
requirements of IEC 60708.
3.2.14. The non-electrical characteristics of the insulation material shall comply
with the requirements of IEC 60708.
3.2.15. The physical and mechanical characteristics of the polyvinylchloride com-
pounds for the inner and outer cable sheaths before and after thermal ageing
shall comply with the requirements of IEC 60227-1.
3.2.16. The non-electrical characteristics of the sheath materials shall comply with
the requirements of IEC 60227-1.
3.2.17. The d.c. resistance of 0.35 mm2 conductors shall not exceed 58,3 Ohm/km,
for the rest of conductor cross-sections this value shall be as specified in
IEC 60228.
3.2.18. The cables shall withstand a 5 min test with a.c. voltage of 50 Hz nominal
frequency:
2,5 kV for cables with unscreened conductors;
1,9 kV for cable with screened conductors.
3.2.19. The insulation resistance shall not be less than 1000 hm km.
3.2.20. The capacitance of 1 m long cable shall be, pF, no more than:
for pair of unscreened conductors 100;
for single screened conductor 260.
3.2.21. The physical and mechanical properties of tinned Copper wires used as a
screening shall comply with the requirements of IS 8130.

3.3. Specific technical requirements

3.3.1. All cables shall be flame-retardant when tested in bunches as per IEC 60332-
3-22, for category .
3.3.2.Smoke emission during cable burning and smouldering shall not cause any
decrease in translucence in the test chamber by more than 40% during tests as
per IEC 61034-1 and IEC 61034-2..

Page 7 of 17
3.3.3. The cables shall be resistant to mould growth. The degree of bio-mould
growth shall not be more than 2 points when tested as per IEC 60068-2-10 /
equivalent / procedures.
3.3.4. Inner and outer sheaths - oxygen index shall be 29% minimum and tempera-
ture index shall be 250 C minimum.
3.3.5. The cable service life shall not be shorter than 40 years under normal opera-
tion condition/temperature.

3.4. Marking requirements

3.4.1.The cables shall have an identification marking of the insulated conductors.
The conductors shall be marked with numerals starting from 1. The size, co-
lour and arrangement of numerals shall correspond to Table 1 and Fig.1.
e

h i
1 1
9 9
D
1
9

i

d d

Fig. 1. Arrangement of marking along the longitudinal axis

Table 1. Dimensions and intervals of the marking along the longitudinal axis
Nominal diameter Dimensions and intervals, mm
over conductor in-
e1) h i d
sulation D, mm
Up to 2,4 0,6 2,3 2 20
Over 2,4 to 5 1,2 3,2 3 35
" 5 1,5 4,6 4 50
Colour of numerals:
- black (BK) on white (WT) or grey (GY) insulation;
- white (WT) or yellow (YE) on black (BK) insulation
1)
The width of numeral 1 is equal to 0.5 of the value specified in the Table column.

Page 8 of 17
3.4.2. The identification marking of the cable, year of manufacture and trademark
or manufacturer's name shall be provided on the cable sheath at an interval
not exceeding 500 mm.
An example of designation for a cable with polyethylene insulation, polyvi-
nylchloride sheath, with overall screen over the inner sheath, with seven
screened copper conductors of 0,35 mm2 cross-section, rated for 450/750 V:
Cable KMPEVEVng-LS 70.35-450/750 V, 2013, manufacturer.

An example of designation for a cable with polyethylene insulation, polyvi-

nylchloride sheath, with overall screen over the inner sheath with screened
conductors, with seven copper conductors of 0.75 mm2 cross-section, rated
for 450/750 V:
Cable KMPEVEVng-LS 70.75-450/750 V, 2013, manufacturer.

3.5. Operational requirements

3.5.1.The cables are intended for operation at an elevated ambient temperature up
to 50 C, as well as at relative air humidity up to 98 % at a temperature up to
35 C.
3.5.2. The minimum admissible radius of cable bending in installation shall not be
lesser than 6 D, where D is the nominal outer cable diameter.
3.5.3. The permissible cable conductor temperature under normal operation condi-
tions is plus 70 .

3.6. Packing, transportation and storage requirements

3.6.1. The cables shall be wound on drums. The cables ends shall be hermetically
sealed with heat shrinkable caps/ tape wrapped.
The drum length shall be minimum 1000m with the tolerance of +5% , how-
ever in case NPCIL prefers to have different drum lengths, the same shall
be mutually agreed.

Page 9 of 17
3.6.2. The cable drums shall be made from wooden battens as per IS and shall be
provided with anti termite treatment.
The outer cable layer under the battening shall be wrapped with a polymer
film or water-proof paper and secured with a cord of antiseptized yarn or
synthetic material.
3.6.3. The cables shall be transported and stored on cable drums so as not to cause
the cable damage.
The drums shall always be kept in a vertical position.
The cables may be transported by any types of transport. During transporta-
tion the cables shall not be subject to exposure of acid or alkali vapours and
other corrosive media that may have a detrimental effect on the package and
the cables.
3.6.4. As for the exposure to ambient climatic conditions, the cables may be trans-
ported and stored out doors in any macroclimatic area, including tropical
climatic regions, in any type atmosphere.
3.6.5. The cable drums may be stored in specially equipped outdoor areas, indoors
or in a shed.
The cable ends shall be protected against ingress of moisture. During storage
the cables shall be protected against mechanical actions, exposure to acid or
alkali vapours and other corrosive media that may have a detrimental effect
on the packages and the cables, as well as against sun rays, atmospheric pre-
cipitation and dust.

4. MANUFACTURER'S WARRANTY
4.1. Standard warranty / guarantees clauses of the GCC shall be applicable /
complied

Page 10 of 17
5. CABLE MANUFACTURING - OBLIGATIONS OF THE MANUFAC-
TURER QUALITY ASSURANCE
5.1. The cable manufacturer shall:
- fulfil all the technical requirements of this document;
- submit list of all the provided/ used materials with the indication of relevant
standards for the materials and the material quality certificates;
- conduct the required checks and tests (Section 6).
5.2. The manufacturer shall have a Quality Assurance Program (QAP) which is to
be based on the relevant standards and shall be approval by NPCIL. A sam-
ple QAP has been included in the tender under annexure 1. Cable shall pass
all the tests indicated in QAP.
5.3. The manufacture shall meet the guaranteed technical particular requirements
included as annexure - 2.
5.4. The manufacturer shall have a certified quality management system prefera-
bly as per ISO 9001-2000 standard.
5.5. The manufactures scope of supply covers design, manufacture, inspection,
testing, packing in drums and safe delivery at KKNPP site (Kudankulam
Nuclear Power Project, Kudankulam P. O. Radhapuram Taluk, Tirunelveli
Distt., Tamil Nadu-627106).

6. TESTS
The cables shall be checked and tested according to the approved quality plan,
at the manufacturer's premises or in any NPCIL approved laboratory.
The following minimum tests are established to prove the cable compliance
with the requirements of this document:
- Routine tests;
- Type tests;
- Acceptance tests.

Page 11 of 17
 6.1. Acceptance/ Routine tests be conducted
The tests shall be carried out within the scope specified in Table 3 and as per
QAP.

Table 2. Acceptance / Routine tests

Kind of Applicable documents

Test or check
test Requirements Test method
1. Check of construction and S IEC 60227-7, items IEC 60811-1-1,
geometrical dimensions 2.3.4, 2.3.5; item 8
items 3.2.4 3.2.13
of this technical re-
quirements
2. Measurement of conductor re- R IEC 60228, IEC 60189-1,
sistance item 3.2.17 of this item 5.1
technical require-
ments
3. Voltage test of cables R item 3.2.18 of this IEC 60189-1,
technical require- item 5.2
ments
4. Measurement of insulation re- R item 3.2.19 of this IEC 60189-1,
sistance at 20 technical require- item 5.3
ments
Note: R tests are carried out on each manufactured length;
S tests are carried out on specimens

Page 12 of 17
 6.2. Type tests
The cables shall be subjected to the type tests described in Table 4 and as per
QAP.
Table 3. Type tests
Applicable documents
Test or check
Requirements Test method
1. Electrical tests
1.1. Capacitance measurement item 3.2.20 of IEC 60189-1,
this technical re- item 5.4
quirements
2. Non-electrical tests
2.1. Determination of insulation elon- IEC 60708, IEC 60811-1-1,
gation at break item 5.2 item 9
2.2. Test of insulation for resistance to IEC 60708, IEC 60811-4-2, Ap-
thermal oxidation item 6.1.1 pendix

2.3. Shrinkage test of insulation IEC 60708, IEC 60811-1-3, sec-

item 6.1.2 tion 10
2.4. Measurement of physical and me- IEC 60227-1, IEC 60811-1-1,
chanical characteristics of sheath be- table 2 item 9;
fore and after thermal ageing IEC 60811-1-2,
items 8, 9
2.5. Measurement of sheath mass loss IEC 60227-1, IEC 60811-3-2,
due to thermal ageing table 2 item 8
2.6. Heat shock test of sheath IEC 60227-1, IEC 60811-3-1,
table 2 item 9.2
2.7. Pressure test of sheath at high IEC 60227-1, IEC 60811-3-1,
temperature table 2 item 8.2
2.8. Test of cable for flame retardance item 3.3.1 of this IEC 60332-3-22,
technical re- category
quirements
2.9. Measurement of hydrogen chloride item 3.2.11 of IEC 60754-1
emission during inner and outer this technical re-
sheaths burning quirements
2.10. Measurement of optical smoke item 3.3.2 of this IEC 61034-1;
density during cable burning and technical re- IEC 61034-2
smouldering quirements
2.11. Mould-growth test item 3.3.3 of this IEC 60068-2-10
technical re-
quirements

Page 13 of 17
6.3 Acceptance test

Following tests and tests as per QAP shall be carried out within the scope spe-
cified.
6.3.1 Test on conductor
a. Annealing test
b. Conductor resistance test

6.3.2 Test on insulation

a. Thickness (Minimum & Average)
b. Tensile strength & Elongation at break before and after ageing
c. Volume resistivity at room temperature

6.3.3 Test on inner and outer sheaths

a. Thickness (Minimum & Average)
b. Tensile strength & Elongation at break before and after ageing.

6.3.4 Test on cables

a. IR test
b. HV test

6.3.5 FRLS Tests

a. Smoke density test
b. Oxygen index
c. Temperature index
d. HCL gas generation
e. Flammability test

7. DOCUMENTATION TO BE SUPPLIED BY CABLE MANUFACTURER

The set of documents to be supplied by the cable manufacturer to the Customer
shall consist of the following:
7.1. passport for each cable drum with the following information duly pre-
sented:
passport number, cable type, manufacturer;
basic technical characteristics (within the scope of acceptance tests);
approved data on acceptance tests;
manufacturer's warranty.

Page 14 of 17
7.2. construction and dimension tables, including design mass and overall di-
ameters;
7.3. tables of drum dimensions and mass (net and gross values);
7.4. test protocols and technical report with type test results to prove cable
compliance with these technical requirements; compliance certificate
7.5. tables of cable combustion specific heat values in MJ/m.
7.6. operating instructions;
7.7. cable installation instructions.

Page 15 of 17
 APPENDIX
Table .1 500 V small-size cables with polyethylene insulation,
polyvinylchloride sheath and overall screen for Kudankulam NPP
units 2. delivery quantity

Cable
Core and size Quantity, meters
description
Control cable with Copper conductors, low densi-
ty polyethylene insulation (PE), PET tape under
inner sheath (if required), polyvinylchloride
(PVC-ST5) compound inner sheath, overall
screen of tinned Copper wire braiding over inner
sheath, PET tape under outer sheath (if required), -C X - sqmm -
polyvinylchloride (PVC-ST9) compound outer
sheath, flame retardant, with low smoke and low
gas (maximum 14% HCL content in sheath) emis-
sion
KMPVEVng-LS
Total -

Table .2 500 V small-size cables with polyethylene insulation, braided each

core, polyvinylchloride sheath and overall screen for Kudankulam
NPP units 2. delivery quantity

Cable
Core and size Quantity, meters
description
Control cable with Copper conductors, low densi-
ty polyethylene insulation (PE), screen of tinned
Copper wire braiding over each core insulation,
PET tape under inner sheath (if required), poly-
vinylchloride (PVC-ST5) compound inner sheath,
screen of tinned Copper wire braiding over inner
sheath, PET tape under outer sheath (if required), -C X - sqmm -
polyvinylchloride (PVC-ST9) compound outer
sheath, flame retardant, with low smoke and low
gas (maximum 14% HCL content in sheath) emis-
sion
KMPEVEVng-LS
Total -

Page 16 of 17
 LIST OF ABBREVIATIONS

NPP Nuclear Power Plant

IEC International Electrotechnical Commission
IAEA International Atomic Energy Agency
ISO International Standardization Organization
cable meeting the smoke emission in burning requirements
LS of IEC 61034-1, 2

Page 17 of 17