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 ...................................................................... 10
3.6. PACKING, TRANSPORTATION AND STORAGE REQUIREMENTS ......................... 11

4. MANUFACTURER'S WARRANTY ................................................................. 12

5. CABLE MANUFACTURING - OBLIGATIONS OF MANUFACTURER.

QUALITY ASSURANCE .................................................................................. 12

6. TESTS ................................................................................................................. 13

7. DOCUMENTATION TO BE SUPPLIED BY CABLE MANUFACTURER .... 16

APPENDIX A ......................................................................................................... 17

TABLE A.1 FIRE-RESISTANT SMALL-SIZE CABLES WITH CROSS-LINKED

POLYETHYLENE INSULATION AND POLYVINYLCHLORIDE

SHEATH, WITH OVERALL SCREEN, RATED FOR 450/750 V, FOR

KUDANKULAM NPP UNIT 2. DELIVERY QUANTITY ........................... 17

TABLE A.2 FIRE-RESISTANT SMALL-SIZE CABLES WITH CROSS-LINKED
POLYETHYLENE INSULATION, BRAIDED EACH CORE AND

POLYVINYLCHLORIDE SHEATH, WITH OVERALL SCREEN, RATED

FOR 450/750 V, FOR KUDANKULAM NPP UNIT 2. DELIVERY

QUANTITY.17

LIST OF ABBREVIATIONS ................................................................................. 18

Page 2 of 18
1. SCOPE
This Specification defines technical requirements for fire resistant small-size
cables used in control, signal, communication circuits and instrument
interconnections, operating at nominal alternating voltage up to 1000 V, frequency
up to 200 kHz, or direct voltage up to 1500 V, intended for operation outside the
containment of Kudankulam NPP units 1 and 2 in India and establishes the
requirements for the cable manufacturing, quality assurance, manufacturer's
warranty, content of the documentation to be submitted by the manufacturer 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 cables shall meet the requirements of the present document and
the following normative documents:
IEC 60780 Nuclear power plants Electrical equipment of the safety sys-
tem Qualification;
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 Polyvinyl chloride 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 60502-1 Power cables with extruded insulation and their accessories
for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV).

Page 3 of 18
 Part 1. Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um =
3,6 kV);
IEC 60331-21 Tests for electric cables under fire conditions - Circuit integr-
ity - Part 21: Procedures and requirements - Cables of rated voltage up to
and including 0,6/1,0 kV;
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;

Page 4 of 18
 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 60216 Electrical insulating materials. Properties of thermal endurance;
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;

3. DESIGN REQUIREMENTS

3.1. Classification in terms of safety

The cables are intended for operation as part of the NPP system equipment,
class 2, 3 and 4, as per PB 88/97 NP-001-97 (PNAEG-01-011-97).

3.2. General technical requirements

3.2.1. All climatic for macroclimatic regions on land and sea, except
macroclimatic regions with a very cold climatefor indoor operation (inside
enclosed spaces) with elevated humidity (for example, in unventilated
underground spaces, 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 alternating voltage up to 1000 V, frequency up to
200 kHz, or up to 1500 V d.c.
3.2.3. The cable constructions shall meet all the requirements of this document.
Cables of the following types are envisaged:
- in an overall screen with unscreened or screened conductors or conductor
pairs (KMPvEVEVng-FRLS, KMPvVEVng-FRLS).
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.

Page 5 of 18
3.2.5. The cable insulation shall be extruded cross-linked polyethylene (XLPE
type) as per IEC 60502-1.
The nominal cable insulation thickness shall comply with IEC 60502-1 re-
quirement. However, the manufacturer shall provide thicknesses proposed in
the data sheet, for review and approval of NPCIL.

3.2.6. The screen over the insulated conductors or the conductor pair shall be made
as a braid of tinned copper wires with 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.
3.2.8. An inner sheath shall be provided over the core of twisted insulated and
screened conductors or conductor pairs in KMPvVEVng-FRLS and KMPvE-
VEVng-FRLS cables.
The inner sheath thickness shall comply with IEC 60227-7 requirements.
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. An outer sheath shall be provided over the overall screen of
KMPvVEVng-FRLS, and KMPvEVEVng-FRLS cables.
3.2.11. The inner and outer cable sheaths shall be from extruded 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 shall not
exceed 14 %.
The nominal outer sheath thickness shall comply with IEC 60227-7 require-
ment.
3.2.12. The outside cable diameters shall comply with IEC 60227-7 requirement.

Page 6 of 18
3.2.13. The physical and mechanical characteristics of the cross-linked polyethy-
lene insulation before and after thermal ageing shall comply with the re-
quirements of IEC 60502-1 (Table 15).
3.2.14. The non-electrical characteristics of the insulation material shall comply
with the requirements of IEC 60502-1.
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 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 cables with screened conductors.
3.2.19. The insulation resistance shall not be less than 1000 hmkm.
3.2.20. The capacitance of 1 m long cable shall be, pF, no more than:
for a pair of unscreened conductors 100;
for a single screened conductor 260.

3.3. Specific technical requirements

3.3.1. All cables shall be flame-retardant when tested in bunches as perIEC 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.
3.3.3. FRLS cables shall be fire resistant as per IEC 60331-21 with three hours
fire survival rating.

Page 7 of 18
3.3.4. 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 standards /procedure.
3.3.5. Inner and outer sheaths - oxygen index shall be 29% minimum and tem-
perature index 250 C minimum.
3.3.6. 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.

The colour marking of the insulated conductors in pair-twisted cables is

allowed to be as specified in Table 2.
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
from 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

Page 8 of 18
 1)
The width of numeral 1 is equal to 0,5 of the value specified in the Table column .

Table 2. Insulation coding for conductor pairs in layer-twisted cables

Conductor coding
Colour of conductor insulation
Number of pair conductor ""
conductor ""
main colour / stripe colour
1 blue (BU)
2 orange (OG)
white (WT)/
3 green (GN)
4 brown (BN)
5 grey (GY)
6
blue (BU)
7
orange (OG)
8 red (RD)/
green (GN)
9
brown (BN)
10
grey (GY)
11 blue (BU)
12 orange (OG)
black (BK)/
13 green (GN)
14 brown (BN)
15 grey (GY)
16 blue (BU)
17 orange (OG)
yellow (YE)/
18 green (GN)
19 brown (BN)
20 grey (GY)
21 blue (BU)
22 orange (OG)
white (WT)/
23 green (GN)
blue (BU)
24 brown (BN)
25 grey (GY)
26 blue (BU)
27 orange (OG)
red (RD)/
28 green (GN)
blue (BU)
29 brown (BN)
30 grey (GY)
31 blue (BU)
32 black (BK)/ orange (OG)
33 blue (BU) green (GN)
34 brown (BN)

Page 9 of 18
 35 grey (GY)
36 blue (BU)
37 orange (OG)
yellow (YE)/
38 green (GN)
blue (BU)
39 brown (BN)
40 grey (GY)

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 fire resistant cable with cross-linked polye-

thylene insulation and polyvinylchloride sheath, with overall screen over in-
ner sheath, with seven copper conductors of 0.75 mm2 cross-section, rated
for 450/750 V:
Cable KMPvVEVng-FRLS 70.75-450/750 V, 2012, manufacturer.

An example of designation for a fire resistant cable with cross-linked polye-

thylene insulation and polyvinylchloride sheath, with overall screen over in-
ner sheath with screened conductors, with seven screened copper conductors
of 0.35 mm2 cross-section, rated for 450/750 V:
Cable KMPvEVEVng-FRLS 70.35-450/750 V, 2012, manufacturer.

An example of designation for a fire resistant cable with cross-linked polye-

thylene insulation and polyvinylchloride sheath, with overall screen over in-
ner sheath with screened conductors, with sixteen screened pairs of
0.75 mm2 copper conductors, rated for 450/750 V:
Cable KMPvEVEVng-FRLS 1620.75-450/750 V, 2012, 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.

Page 10 of 18
3.5.2. The minimal permissible radius of cable bending during installation shall not
be lesser than 6 D, where D is the nominal overall cable diameter.
3.5.3. The permissible cable conductor temperatures in operation shall not be
above:
under normal conditions 90 ;
under short circuit 250 ;
the limit cable conductor temperature for cable non-flammability conditions
under short circuit 400 .

3.6. Packing, transportation and storage requirements

3.6.1. The cables shall be wound on drums.
The drum length shall be minimum 1000m with the tolerance of +5% , how-
ever in case NPCIL prefer to have different drum length, than shall be mu-
tually agreed
3.6.2. The cables ends shall be hermetically sealed with heat shrinkable caps/3.5.3
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 in cable drums to avoid 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 the 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 of atmosphere.

Page 11 of 18
3.6.5. The cable drums may be stored in specially equipped outdoor areas, indoors
or in a shed. The cables ends shall be protected against ingress of moisture.
During storage the cables shall be protected against mechanical actions, ex-
posure 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 precipitation and dust.

4. MANUFACTURER'S WARRANTY
4.1. Warranty shall be as per standard warranty clause of GCCshall be applica-
ble / complied .

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 the rele-
vant standards for the materials and the material quality certificates;
- conduct the required checks and tests (Section 6).
5.2. The manufacturer shall prepare a Quality Assurance Program (QAP) based on
the relevant standards and shall be approved by NPCIL. A sample QAP has been
included in the tender under annexure 1. Cable shall pass all the tests indicated in
QAP.
5.3. The manufacturer shall have a certified quality management system as per ISO
9001-2000 standard.5.4. The manufactures scope of supply covers design, manu-
facture, inspection, testing, packing in drums and safe delivery to KKNPP site
(Kudankulam Nuclear Power Project, Kudankulam P. O. Radhapuram Taluk, Ti-
runelveli Distt., Tamil Nadu-627106).

Page 12 of 18
 6. TESTS
The cables shall be checked and tested according to the approved plan at the
manufacturer's premises or in NPCIL approved laboratories .
The following minimum tests are specified to prove the cable compliance with
the requirements of this document
- Routine tests;
- Type tests.
- Acceptance tests.

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 3. 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 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
5. Check of cross-linked polyethy- S IEC 60502-1, IEC 60811-2-1,
lene insulation resistance to Table 17 section 9
hot set
Note: R tests are carried out on each manufactured length;
S tests are carried out on specimens

Page 13 of 18
 6.2. Type tests
The cables shall be subjected to the type tests described in Table 4 and as per
QAP.
Table 4. Type tests
Applicable documents
Test or check
Requirements Test method
1. Electrical tests
1.1. Measurement of capacitance item 3.2.20 of this IEC 60189-1,
technical require- item 5.4
ments
2. Non-electrical tests IEC 60502-1,
item 18
2.1. Measurement of insulation IEC 60502-1, IEC 60811-1-1,
physical and mechanical charac- Table 15 sections 8; 9,
teristics before and after thermal IEC 60811-1-2,
ageing section 8
2.2. Insulation shrinkage test IEC 60502-1, IEC 60811-1-3,
Table 17 section 10
2.3. Measurement of sheath IEC 60227-1, IEC 60811-1-1,
physical and mechanical charac- Table 2 item 9;
teristics before and after thermal IEC 60811-1-2,
ageing items 8, 9
2.4. Insulation water absorption IEC 60502-1, IEC 60811-1-3, item 9.2
test item 18.13, Table 17 (gravimetric method)

2.5. Measurement of sheath IEC 60227-1, IEC 60811-3-2,

mass loss due to thermal ageing Table 2 item 8
2.6. Sheath heat shock test IEC 60227-1, IEC 60811-3-1,
Table 2 item 9.2
2.7. Pressure test of sheath at IEC 60227-1, IEC 60811-3-1,
high temperature Table 2 item 8.2
2.8. Test of cable for flame re- item 3.3.1 of this IEC 60332-3-22,
tardant technical require- category
ments
2.9. Measurement of hydrogen item 3.2.11 of this IEC 60754-1
chloride emission during inner technical require-
and outer sheaths burning ments
2.10. Measurement of optical item 3.3.2 of this IEC 61034-1;
smoke density during cable technical require- IEC 61034-2
burning and smouldering ments

Page 14 of 18
2.11. Test of cable for fire- item 3.3.3 of this IEC 60331-21
resistant technical require-
ments
2.12. Mould-growth test item 3.3.4 of this IEC 60068-2-10
technical require-
ments

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
f. Fire resistance

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:

Page 15 of 18
 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.
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 reports and technical report with type test results to prove cable com-
pliance 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.

APPENDIX
Table .1 Fire-resistant small-size cables with cross-linked polyethylene insula-
tion and polyvinylchloride sheath, with overall screen, rated for
450/750 V, for Kudankulam NPP units 1 and 2 - delivery quantity

Cable
Core and size Quantity, meters
description

Page 16 of 18
Control cable with Copper conductors, two layers
of mica tapes over each conductor, cross-linked po- 2C X 0.5 sqmm 2000
lyethylene insulation (XLPE), PET tape under in-
ner sheath (if required), polyvinylchloride (PVC-
ST5) compound inner sheath, glass mica tape over
inner sheath, screen of tinned Copper wire braiding 19C X 0.5 sqmm 8000
over inner sheath, PET tape under outer sheath (if
required), polyvinylchloride (PVC-ST9) compound
outer sheath, fire resistant (fire survival rating of
180 minutes), flame retardant, with low smoke and
low gas (maximum 14% HCL content in sheath) 27C X 0.5 sqmm 2000
emission
KMPvVEVng-FRLS
Total 12000

Table .2 Fire-resistant small-size cables with cross-linked polyethylene insula-

tion, with screen over each core and polyvinylchloride sheath, with
overall screen, rated for 450/750 V, for Kudankulam NPP units 1 and 2
- delivery quantity

Cable
Core and size Quantity, meters
description
Control cable with Copper conductors, two layer of
mica tapes over each conductor, cross-linked polye- 12C X 0.35 sqmm 4500
thylene insulation (XLPE), screen of tinned Copper
wire braiding over each core insulation, PET tape 12C X 1 sqmm 1500
under inner sheath (if required), polyvinylchloride
(PVC-ST5) compound inner sheath, glass mica 16C X 2 X 0.35
1000
tape over inner sheath (if required), screen of sqmm
tinned Copper wire braiding over inner sheath,
4C X 0.35 sqmm 16000
PET tape under outer sheath (if required), polyvi-
nylchloride (PVC-ST9) compound outer sheaths,
fire resistant (fire survival rating of 180 minutes),
flame retardant, with low smoke and low gas (max- 7C X 0.5 sqmm 500
imum 14% HCL content in sheath) emission
KMPvEVEVng-FRLS
Total 23500

Page 17 of 18
 LIST OF ABBREVIATIONS

NPP Nuclear Power Plant

IEC International Electrotechnical Commission
IAEA International Atomic Energy Agency
ISO International Standardization Organization
ng cable meeting the flame retardant requirements for group
laying specified in IEC 60332-3
LS cable meeting the smoke emission in burning requirements
of IEC 61034-1, 2
FR cable meeting the fire resistance requirements specified in
IEC 60331
QA Quality Assurance Category

Page 18 of 18