NEW POL DEPOT AT HINDUSTAN PETROLEUM CORPORATION LIMITED ENGINEERING & S GRESHAM ASSURANCE HOUSE, 2 ND FLOOR, A-1595(3) 1-A, SIR P M ROAD, FORT MUMBAI-400 001 TECHNICAL SPECIFICATION OF XLPE, FRLS LT CABLES FOR DEPOT 1
NEW POL DEPOT AT 1.1 GENERAL : a) The cables will be used for connection of power, control and instrumentation circuits of the auxiliary electrical systems. b) Cables are to be suitable for transmission of signals and measuring values, which require protection against disturbances caused by stray fields. c) Cables will be generally laid in ladder type trays or, drawn through rigid steel conduits. For interplant connection cables may be directly buried in ground. d) The insulation and sheath materials shall be resistant to oil, acid and alkali and shall be tough enough to withstand mechanical stresses during handling. e) For continuous operation at specified rating, maximum conductor temperature shall be limited to permissible value as per relevant standard and / or this specification. f) Armoring shall be single round wire of galvanized steel for multicore cables and aluminium for single core cables g) Core identification for multicore cables shall be provided by colour coding. h) Multicore control cables shall generally have commissioning spare cores in accordance with the following chart when used for control and indication, interlock and annunciation purpose 1.2 OPERATING CONDITION : All equipment and materials will be selected and rated for use at the following site conditions. a) Electric system b) System Voltage : 433 V +/- 10% c) Frequency : 50 Hz. +/- 3% Environment 2
NEW POL DEPOT AT d) Ground temperature : 40 C. e) Ambient air temperature : 45 C. f) Earth resistivity : 120 C. cm/w presssumed g) Atmospheric conditions : Humid, salty and dusty 1.3 SCOPE : The scope shall cover supplying, testing, Inspection, Transport and loading of low voltage power and control XLPE FRLS cables. This specification gives the general requirement of cables. However, it is the responsibility of the vendor to take the joint measurement and obtain client s approval before the placement of orders to the main supplier / manufacturer. 1.4 DESIGN CONDITION : The following standards and rules shall be applicable: IS: 7098 Part I - XLPE Insulated electric cables (heavy duty). IS: 8130 - Aluminum conductors for insulated cables. IS : 8130-1984 Conductors for insulated electric cables and flexible cords. IEC : 228 Conductors of Insulated Cables. IS: 10810 (Pt 58) Methods of test for cables : Part 58 Oxygen Index test IS: 10810 (Pt 61) Methods of test for cables : Part 61 Flame retardant test IS: 10810 (Pt 62) Methods of test for cables : Part 62 Flame retardant test for bunched cables IEC : 502 Extruded solid dielectric-insulated power cables for rated voltage from 1 KV upto 30 KV. IS:1885-(Part32) Electro Technical vocabulary - electric cables (1993) IS:3961-(Part4) Recommended current ratings for Polyethylene insulated cables. 3
NEW POL DEPOT AT (1968) IS:3975-(1988) Mild steel wire, formed wires and tapes for armouring of cables. IS: 5831-(1984) Specification for PVC insulation and sheath of electric cables. IS: 6474-(1984) Specification for Polyethylene insulation and sheath of electric cables. IS: 10418-(1982) Drums for electric cables. IS:10462(Part1) Fictitious calculation method for determination of dimensions of protective (1983) coverings of cables IEC:60540&60540A Test methods for insulation & sheaths of electric cables IEC:230 (1966) Impulse tests on cables and their accessories IEC:60332(3Parts) Tests on electric cables under fire conditions IEC:811(5Parts) Test methods for insulating and sheathing materials of electric cables. ASTM:D2863 Standard method for test for flammability of plastics using oxygen index Method IECAS-61-402 Thermoplastic insulated wire & cable for transmission & distribution of NEMA-WC5 electrical energy IECAS-66-524 Cross linked thermosetting poly ethylene insulated wire & cable for NEMA-WC5 transmission & distribution of electrical energy IEC : 287 Calculations of continuous current rating of cables (100% load factor). IS : 5831 1984 PVC insulation & sheath of electrical cables. Indian Electricity Act and Rules. 1.5 MEASUREMENTS : The cables will be measured in meters. The unit rate shall include packing, loading, insurance, transportation, delivery to stores/site as per work order, testing of cables at their works etc. of low voltage cable. 4
NEW POL DEPOT AT 1.6 MATERIAL : The low voltage cable shall be XLPE insulated. PVC outer sheathed, aluminium or copper conductor, armoured conforming to IS: 7098 Part I. 1.7 TYPE : The cables shall be circular, single/multi core, annealed copper or aluminium conductor, XLPE/ FRLS insulated and PVC outer sheathed, armoured. 1.8 GENERAL DESCRIPTION: A) The LT power cable shall be designed, manufactured and tested in accordance with IS: 1554, IS: 8130, IS: 5831, IS: 3975. The cable shall be 1100 V grade, 85 Deg.C rating heavy duty, HR (Heat Resistant) PVC power cable. Conductor : Stranded and compacted plain Aluminium of grade H2 and class 2 for all sizes. Insulation : Extruded XLPE Compound conforming to type C. The insulation shall be of cross linked polyethylene (XLPE) compound with anti oxidant stabilisers and shall conform to IS-7098, Part-1. (As applicable) Inner Sheath: Inner sheath is provided over the laid up cores. It is provided to give circular shape to the cable and it provides bedding for the armouring. PVC Compound conforming to type ST2 for three core cables. Single core cables shall have no inner sheath. Armour: Galvanized single round steel wire armour for three core cables. Non- magnetic hard-drawn aluminium single round wire conforming to H4 grade for single core cable. (1) Armouring shall be one of the following: - 5
NEW POL DEPOT AT (a) (b) (c) Galvanized round steel wire Galvanized steel strip Any metallic non-magnetic wire/strip. (2) Where the cable diameter below armour does not exceed 13mm, the armour shall consist of galvanized round steel wires. Where the diameter below armouring is greater than 13mm, the armour shall consist of either galvanized round steel wires or galvanized steel strips. (3) The joints in armour wires or strips shall be made by brazing or welding and any surface irregularities shall be removed. Overall Sheath: Extruded PVC compound conforming to ST2. Outer sheath shall be of an extruded type layer of suitable PVC material compatible with the specified ambient temp. 50 deg. C and operating temperature of cables. The sheath shall be resistant to water, ultraviolet radiation, fungus, termite and rodent attacks. The colour of outer sheath shall be black. Sequential length marking required at every 1.0 mtr. interval on outer sheath. B) The LT control cable shall be designed, manufactured and tested in accordance with IS: 1554, IS: 8130, IS: 5831, IS: 3975. The cable shall be 1100 V grade, 70 Deg.C rating ordinary PVC control cable. Conductor: Stranded, non-compacted and circular, class 2 high conductivity untinned annealed copper. Insulation: Extruded XLPE Compound conforming to type A Inner Sheath :PVC Compound conforming to type ST1 for three core cables. Single core cables shall have no inner sheath. Armour: Galvanized single round steel wire armour for three core cables. Non-magnetic harddrawn aluminium single round wire conforming to H4 grade for single core cable. In case of armoured cables, generally galvanized steel wire / strip armouring is provided over the inner sheath in multicore cables and Aluminium Round Wire or Aluminium Strip over the insulation in 6
NEW POL DEPOT AT single core cables. It provides mechanical protection to inside cores and it carries earth return current in case of a short circuit of a core with armour. As per I.S. 1554 (Part I) 1988, round wire armouring is provided in cable, where calculated diameter under armour is up to 13 mm. Above this the armouring is either with round wire or strip of size 4 mm x 0.80 mm. As strip construction is economical, the manufacturers always provide steel strip armouring unless wire armouring is specially specified. 1.9 CORE IDENTIFICATION : Cores of cable shall be identified by colour coding of PVC insulation by adopting the following scheme. 1 core : Red, black, yellow, blue or natural Two core : Red and Black Three core : Red, Yellow and Blue Three & Half core : Red, Yellow, Blue and Black Four core : Red, Yellow, Blue and Black Single core : Green, Yellow for earthing Black shall always be used for neutral. The core identification shall be done by printing numbers or by providing colored strips all along cores. The insulation of cores shall be of the same colour and numbered sequentially. The numbers shall be printed in Hindu-Arabic numerals on the outer surface of cores. The numbers shall be repeated at regular intervals along the core and the spacing between consecutive numbers shall not exceed 50mm. 1.10 ASSEMBLY : Two, three or four insulated conductors shall be laid up, filled with non-hygroscopic material and covered with an additional layer of thermoplastic material. 7
NEW POL DEPOT AT 1.11 GENERAL REQUIREMENT : All cables shall be adequately protected against any risk of mechanical damage to which they may be liable in normal conditions of handling during transportation, loading, etc. The cable shall be supplied in single length i.e. without any intermediate joint or cut unless specifically approved by the client. The cable ends shall be suitably sealed against entry of moisture, dust, water etc. with cable compound as per standard practice. 1.12 INSPECTION & TESTING : 1 Inspection and testing shall be carried out in accordance with relevant standards. Routine tests shall be witnessed by HPCL approved Third Party Inspection Agency like BV/ EIL/ IRS/ DNV/ TUV. Test certificates for type test shall be furnished. Vendor shall quote unit rate for witnessing such type test by TPI Agency. 2 Vendor shall submit blank formats where in the test results/readings are to be entered. This format shall give minimum acceptable value as per the relevant standards. 3 The inspector shall have free access to the manufacturer s works for the purpose of inspecting the process of manufacture in all stages and he will have the power to reject any material which appears to him to be of unsuitable description or of unsatisfactory quality. The vendor shall give at least 2 weeks prior notice to the purchaser, regarding the date of testing to enable him or his representative to witness the tests. A) FINISHED CABLE TESTS AT MANUFACTURER S WORKS: All routine tests, acceptance tests, type tests & additional type tests for improved fire performance shall be carried out as listed in IS-7098 (Part-1). 8
NEW POL DEPOT AT The finished cables shall be tested at manufacturer s works. Following routine tests for each and every length of cable and copy of test results shall be furnished for each length of cable along with supply. If specified, the cables shall be tested in presence of client s representative. a) VOLTAGE TEST: Each core of cable shall be tested at room temperature at 2.5 KV A.C. for duration as specified in relevant IS. b) CONDUCTOR RESISTANCE TEST: The D.C. Resistance of each conductor shall be measured at room temperature and the results shall be corrected to 20 c. to check the compliance with the values specified in IS 8130-1976. c) THE TEST FOR RESISTANCE TO ULTRAVIOLET RADIATION: This test shall be carried out as per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile strength & ultimate elongation value after the test shall be minimum 60% of the tensile strength and elongation value before the test. The test certificates with respect to this test (not older than 1 year) from recognized testing laboratory to be furnished for review by PMC before dispatch clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to be carried out one for each order, provided the outer sheath remains the same. d) Acceptance tests as per IS-1554 Part-1 and IS-7098 Part-1 and the following special tests to be performed on the cables as per the sampling plan. This tests are to be witnessed by PMC/ Owner before the dispatch of cables: a) Accelerated Water absorption test for insulation as per NEMA WC-5 (For PVC insulated cables) and as per NEMA WC-7 (For XLPE insulated cables). Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in- 9
NEW POL DEPOT AT house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order. 1. Dielectric Retention test: The dielectric strength of the cable insulation tested in accordance with NEMA WC-5 at 75 ± 1 o C shall not be less than 50% original dielectric strength. Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order. 2. Oxygen Index Test: The test shall be carried out as per ASTM D2863 or applicable Indian Standard specifications. Sampling to be done for every offered lot / size as per sampling plan. 3. Flammability Test: The test shall be carried out on finished cable as per IS-10810 (part 61 & 62). Sampling for this test is to be carried out one for each order, provided the outer sheath remains the same. The acceptance criteria for tests conducted shall be as under: Part-61: The cable meets the specifications if there is no visible damage on the test specimen within 300 mm from its upper end. Part-62: The maximum extent of charred portion measured on the test sample should not have reached a height exceeding 2.5m above the bottom edge of the burner at the front of the ladder. 4. Test for rodent & termite repulsion property: The vendor shall furnish details to analyze the property by chemical method. Sampling to be done for every offered lot / size as per the sampling plan. e) CABLE TEST BEFORE AND AFTER LAYING OF CABLES AT SITE: a) Insulation Resistance test between phases and phase to Neutral and phase to earth. b) Continuity test of all the phases, neutral and earth continuity conductor. 10
NEW POL DEPOT AT c) Sheathing continuity test. d) Earth resistance test of all the phases and neutral. All tests shall be carried out in accordance with relevant Indian Standard Code of practice and Indian Electricity Rules. The Vendor shall provide necessary instruments, equipments and labour for conducting the above test and shall bear all expenses in connection with such tests. B) TEST REPORTS: The report from third party inspecting agency shall be submitted to HPCL for along with the material. No material will be accepted without third party inspection clearance report. C) TEST CERTIFICATES: Test reports shall be completed with all details and shall also contain IS specified limit values, wherever applicable, to facilitate review. 1.2 CABLE MARKING : EMBOSSING ON OUTER SHEATH: The outer sheath shall be legibly embossed with following legend throughout the length. i) Manufactures name or Trademark ii) Voltage Grade iii) Size : 3.5 C x ----- mm ² iv) Year of Manufacture v) Type of Insulation vi) vii) viii) Type of outer sheath ISI mark Owner s identification 11
NEW POL DEPOT AT 1.3 CABLE LAYING : The cables shall be laid in trenches, trays, racks or conduits/pipes. No cable shall be directly buried in the ground. The cables of different voltage grade shall be laid in different trays. Power & control cables shall be laid in different trays. 1.4 SEALING, DRUMMING & PACKING: 1 After tests at the manufacturer s works, both ends of the cable shall be sealed by means of nonhygroscopic sealing material to prevent the ingress of moisture during transportation and storage. Also, PVC /Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length. 2 Cable shall be supplied in length of 500 ± 5% meters, packed non-returnable drums of sufficiently sturdy construction. The vendor shall indicate in the offer, the maximum length of cable, which can be accommodated on one drum. The actual length supplied on each drum shall be within tolerance limit of +5%. The drum length shall be as per the cable quantity list. 3 Cables of length more than 250 meters shall also be supplied on non-returnable drums. The wood used for construction of the drum shall be properly seasoned, free from defects and wooden preservatives shall be applied to the entire drum. All ferrous parts shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage. 4 The spindle hole shall be 110 mm minimum diameter. 5 Each drum shall bear on the outside flange, legibly and indelibly in the English literature, a distinguishing number, the manufacturer s name and particulars of the cable i.e. voltage grade, length, conductor size, cable type, insulation type and gross weight shall also be clearly visible. The direction for rolling shall be indicated by an arrow. The drum flange shall also be marked with manufacturer s name and year of manufacturing etc. 6 The following information shall be stencilled on each drum. 12
NEW POL DEPOT AT (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) Name of manufacturer, brand name or trademark. Nominal cross sectional area of conductor Number of cores. Type of cable and voltage grade. Cable code Length of cable on the drum. Number of lengths on drum (if more than one). Drum number. Direction of rotation of drum (by means of an arrow). Reference standard Approx. gross weight. Job number. Country of manufacture Year of manufacture. A tolerance of +/- 3% shall be permissible for each drum. However, overall tolerance for each size of cable shall be limited to +/ - 2%. Offer with short / non-standard lengths are liable for rejection. If non- standard drum lengths are specified in the data sheet, then same shall be supplied. 1.5 CABLE QUANTITY The bidder shall quote unit rates for all types of cables as indicated in the Job Schedule List. 1.6 TRANSPORTATION & DELIVERY: The cable shall be supplied in the actual length as per detailed purchase order. The cable shall be dispatched at client s stores or at site as per detailed instructions given by client at later stage. 13
NEW POL DEPOT AT The cable shall be loaded from the main vendor s store and properly stacked as per instruction of client s local representative. All such labour and transportation charges shall be clearly mentioned in the offer. 14