Download Technical Specifications for LT/HT, XLPE insulated Aluminium

ANNEXURE TO TENDER NO. DPS/MRPU/CWMF/ELE/8320/PT-2157
Technical Specifications for LT/HT, XLPE insulated
Aluminium/Copper Cables
This technical specification intends to cover the following:
1. Technical specifications for design, engineering, manufacturing, inspection, testing at
manufacturer’s works, packaging and delivery by road (properly packed in nonreturnable steel drums), various sizes of aluminium/copper conductor, XLPE
insulated, voltage upto and including 1100 Volts, extruded PVC inner sheathed,
extruded FRLS PVC outer sheathed, GI round wire armoured cables, suitable
for solidly grounded system. The cables shall confirm to IS 7098-Part 1 with latest
amendments. For cable list refer Table-1 (Sl. no. 1.1 to 1.19).
2. Technical specifications for design, engineering, manufacturing, inspection, testing at
manufacturer’s works, packaging and delivery by road (properly packed in nonreturnable steel drums), 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm
Stranded Compacted Circular Shaped Aluminium Conductor of H4 Grade,
Shielded with extruded Semi-conducting compound, XLPE insulated, PVC sheathed,
GI Round wire armoured Power Cables for effectively grounded system. The cable
shall confirm to the latest revisions of IS: 7098 (Part –2). For cable list refer Table-1
(Sl. no. 2.0).
Note:
1. Tenders will only be considered from the cable manufacturers and any one supplier to
whom manufacturer can authorize. The bidder shall have adequate experience of at least 5
years in manufacturing of LT/MV & HT cables.
2. Copper & Aluminium samples from the finished cable drums shall be tested at any 3 rd
party NABL accredited lab to ensure its purity.
3. The following document shall be attached with technical part of the bid:
i. Duly filled & Signed copy of Annexure-I, II, III & IV
ii. Deviation sheet, if any
1
Contents
CABLE QUANTITY ........................................................................................................................ 3
SECTION-A
General Terms & Conditions ............................................................................................................. 5
SECTION-B
Technical Specifications for 1.1KV, Aluminium/Copper Conductor, Power cable .............................. 8
SECTION-C
Technical Specification for 6.35/11 kV (Uo/U), 3-Core, 185 Sq. mm Aluminium Cable .................. 17
ANNEXURE-I
Technical data Format for 1.1KV, Power Cable ............................................................................... 30
ANNEXURE-II
Technical data Format for 6.35/11 kV (Uo/U), 3-Core, 185 Sq. mm Aluminium Cable .................... 34
ANNEXURE-III
Vendor Evaluation Criteria .............................................................................................................. 38
ANNEXURE-IV
Check List ....................................................................................................................................... 42
DEVIATION SHEET ...................................................................................................................... 45
2
CABLE QUANTITY
TABLE-1
Sl.No.
1.0
1.1.
Quantity
No. of Drums
(in meters)
Power cable of 1.1 kV grade, Multi-stranded Aluminium/Copper
conductor, XLPE insulated, extruded PVC inner sheathed, GI roundwire armoured, extruded FRLS PVC ST2 outer sheathed, conforming to
IS: 7098 (Part-I), 1988 ad as per the technical specifications listed in
Section-A of the tender document.
Cable Specification
3.5C X 95 Sq.mm, Aluminium Conductor
1000
500 Mtr x 2
500
500 Mtr x 1
500
500 Mtr x 1
500
500 Mtr x 1
1000
500 Mtr x 2
500
500 Mtr x 1
1000
500 Mtr x 2
1000
500 Mtr x 2
1000
500 Mtr x 2
1000
500 Mtr x 2
Power Cable Type:A2XWY
1.2.
3.5C X 50 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.3.
3.5C X 35 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.4.
3C X 35 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.5.
3.5C X 25 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.6.
3C X 25 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.7.
4C X 16 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.8.
4C X 10 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.9.
4C X 6 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.10.
4C X 4 Sq.mm, Aluminium Conductor
3
Power Cable Type:A2XWY
1.11.
3C X 2.5 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.12.
4C X 2.5 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.13.
3C X 4 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.14.
4C X 4 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.15.
3C X 6 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.16.
4C X 6 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.17.
3C X 10 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.18.
4C X 10 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.19.
3C X 16 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
2.0
6.35KV/11KV (U0/U) Voltage grade, 3core, 185 Sq.mm, Stranded, compact
circular shaped Aluminium Conductor of
H4 grade, Water Tree free XLPE
Insulated, PVC sheathed, GI round wire
armoured, Longitudinal and radial water
tight power cables, confirming to IS: 7098
(Part-II), and as per the technical
specifications listed in Section-B of the
tender document.
2500
500 Mtr x 1
4
SECTION-A
General Terms & Conditions
1.
PROJECT DATA
These cables are required for CWMF/NRB/BARC, Government of India, Kalpakkam.
The site is accessible by Road from Chennai via Chengalpattu, Thirukkazhukundram
and also via Mamallapuram. The nearest Broad Gauge railway station is at
Chengalpattu.
a. Purchaser
:
Centralized Waste Management Facility,
Kalpakkam
b. Climatic Condition
:
The site is located about 500 meters from the
seacoast and the atmosphere is laden with salt
spray. The climate is tropical with high
humidity, heavy rainfall and prone to rust and
fungus growth.
c. Ambient Air
Temperature
:
i.
ii.
iii.
iv.
Maximum
Maximum Daily Average
Max. Weighted Yearly
Average
Max. Relative Humidity
450C
400C
320C
90%
The maximum temperature and relative humidity likely to occur
simultaneously are 420C and 80% respectively.
d. Installation Location
2.
:
The cables may be laid/buried directly in
ground, covered cable trenches, cable
racks/ladders in open air
SCOPE OF THE TENDER
The scope includes the jobs to be performed for all equipment and materials furnished
under this specification. The scope is however not limited to the items detailed below:
·
Design, manufacture, testing at manufacturers works packing and dispatch.
·
Transportation to site and insurance.
·
Receiving at site, unloading, handling, opening, inspecting, reporting and
submitting claims in case of damages and short supply items.
5
·
3.
Arranging to repair and/or reordering all damaged and short supply items.
GENERAL CONDITIONS FOR TENDERING
Please refer to the commercial bidding document for complementary information.
Tenders will only be considered from the cable manufacturers or supplier to whom
manufacturer can authorize. The bidder shall have adequate experience (at least 5
years) of manufacturing LT/MV & HT cables.
If the bidder finds that any part of this Technical Specification is difficult, or very
costly to meet, he is free to propose an alternative solution, provided that the
deviations from technical Specification, together with the reasons and advantages, are
clearly indicated in the deviation sheet. Such alternative solution shall always be
made in addition to the basic offer, which must comply fully with this Technical
Specification. BARC/CWMF reserves the right to accept or reject the proposed
alternative solutions without any justification.
Test Equipment
The bidder shall have the necessary arrangement of test equipment for type tests,
acceptance tests and routine tests as specified in the tender. In case, test is required to
be done at other lab, the tenderer shall clearly specify in the deviation sheet.
Subcontractors
The bidder shall declare in the tender document any subcontractors whose service is
intended to be used in the event of the contract. If the contract is awarded, the bidder
shall restrict to the subcontractors as mentioned in the tender document.
Deviations from Technical Specification:
No deviations to this specification shall be acceptable unless specifically indicated in
the offer in the relevant schedule. All deviations shall be clearly spelt out by the
Bidder and the price implications thereof if any. Bidder must furnish List of Technical
Deviations mentioning the specification clause nos. against which deviations have
been sought for. Compliance with this specification will be taken for granted in
absence of any specific mention of deviations in the said list of deviations. Any
implied deviation or any deviation mentioned elsewhere in the offer shall not be
considered. The engineer-in-charge at their discretion will decide regarding
acceptance of deviation looking to standard and project requirement.
Technical Questionnaire:
The technical questionnaire attached to this technical specification shall be completely
filled and submitted. The bidder shall also submit in written a detail plan for the
manufacturing & testing schedule.
Factory Access
BARC/CWMF and its representative shall have free access during normal working
hours to the manufacturing or testing sites, including any subcontractor’s premises,
during the contract period.
6
·
·
·
The inspection may be carried out by the purchaser at any stage of
manufacture. The successful bidder shall grant free access to the purchaser’s
representative at a reasonable time when the work is in progress. Inspection
and acceptance of any equipment under this specification by the purchaser
shall not relieve the supplier of his obligation of furnishing equipment in
accordance with the specifications and shall not prevent subsequent rejection
if the equipment is found to be defective.
The supplier shall keep the purchaser informed well in advance, about the
manufacturing programme so that the arrangement can be made for inspection.
No equipments shall be dispatched before all tests and inspection have been
carried out unless otherwise instructed by the purchaser.
Evaluation criteria:
· The cable manufacturer shall have minimum annual turnover of 7 Crores in
the last three years. The company shall not have incurred loss during last 3
consecutive years. This shall be substantiated by submitting relevant
documents.
· The bidder shall be Original Equipment Manufacturer (OEM) of XLPE cable
up to 11 kV for the past 5 years.
· Manufacturer shall have completed all the type tests at CPRI / ERDA / NABL
accredited lab. Type test certificates for longitudinal and water tight cables of
11kV or higher voltage rating as per IEC shall be furnished along with the
offer.
· The manufacturer shall have ISO 9001 & 14001 certification for quality
management system and environmental management system.
· The company shall have valid IS certification for production of the specified
cable.
· The manufacturer shall have a single point triple extrusion process with gas
curing.
· The vendor shall carry out copper & aluminium (samples will be selected from
finished lot of cables) 3 rd party lab test to confirm its purity.
Tender Evaluation
· Item wise L1 will be considered for placing purchase order.
· All prices quoted by the TENDERER shall be firm.
7
SECTION-B
Technical Specifications for 1.1 kV grade, Aluminium/Copper conductor, Power
cables
This section covers the technical specifications for design, engineering, manufacturing,
inspection, testing at manufacturer’s works, packaging and delivery by road (properly packed
in non-returnable steel drums), 1.1KV grade, Multi-stranded Aluminium/Copper conductor,
XLPE insulated, extruded PVC inner sheathed, GI round-wire armoured, extruded FRLS
PVC ST2 outer sheathed. Power Cables for effectively grounded system, conforming to the
latest revisions of IS: 7098 (Part –I), 1988 & as per the technical specifications attached
herewith.
1.
2.
STANDARDS
The design, manufacture and testing of the cable shall comply with the latest
editions/amendments of the following Indian Standards, unless otherwise specified.
Equipments complying with equivalent standards shall also be acceptable.
a.
IS-7098, 1998 (Part-I)
:
b.
IS-3961
:
c.
IS 8130-1984
:
d.
IS-3975, 1999
:
e.
IS-4759
:
f.
IS-5831
:
g.
h.
IS-10418
IS-10810
(Part 0 to 64)
:
:
Cross linked polyethylene insulated
PVC sheathed cables for working
voltages upto 1100V.
Recommended current ratings for
cables
Specification for conductors for
insulated electric cables and flexible
cords.
Low Carbon galvanized steel wires,
formed wires & tapes for armouring
of cables
Specifications for Hot dipped
galvanized coating on round steel
wires
PVC insulation and sheath of electric
cables.
Drums for electric cables.
Method of test for cables.
SERVICE CONDITION
The cable shall be designed with the following service conditions into consideration:
8
a. Cables shall be capable of satisfactory operation under a power supply system
frequency variation of +3% and voltage variation of ±10%.
b. Cables shall be suitable for laying in conduits, ducts, trenches, channels, trays,
racks or for direct buried in ground in both dry and wet locations with chances
of flooding by water.
c. The cables shall be suitable for the following ambient condition:
Ambient Air temperature: 400C
Ambient ground temperature: 300C
d. The current rating shall be based on maximum conductor temperature
depending on the type of insulation for continuous at the rated current.
e. The one second short circuit current rating values shall be furnished and shall
be subjected to the purchaser’s approval.
f. The cables will have current ratings and de-rating factors as per relevant
Indian Standards.
Full technical details and descriptive literature shall be furnished indicating the
construction details, standard applicable for the components of the cable and current
ratings of the cables in air and ground. De-rating factors to be considered for the
ambient temperature, ground temperature, de-rating due to cable location in air and
ground shall also be furnished. The certificates for the type tests conducted on cables
similar to the cables covered herein shall be submitted along with the tender.
3.
DESIGN AND CONSTRUCTION PERTICULARS
3.1. General
The cables supplied under this specification shall be adequate insulated to operate
continuously at the specified voltage with a high degree of safety and reliability
throughout the life of the cables. The sheathing material shall be high quality PVC
based compound. The construction of cable shall be as per IS: 7098 (Part I) – 1988.
Cable shall be designed and manufactured to prevent damage during transportation,
installation & operation under all climatic & operating conditions to which cable may
be subjected to.
3.2. Technical parameters
i.
Quantity
:
ii.
Packaging
:
iii.
Cable Type
:
iv.
No. of Cores
:
v.
vi.
Voltage Level
System Grounding
:
:
9
Refer Table-1, Sl. No: 1.1 to
1.19
Steel drum packaging, each
having single length cable ≥
500 metres.
A2XWY/ 2XWY (refer Table1 for details)
3/3.5/4 (refer Table-1 for
details)
1.1kV
Solidly Grounded
vii.
viii.
ix.
Nominal System voltage
Nominal System Frequency
Maximum conductor temperature at
rated current
Maximum conductor temperature at
Short-circuit
Conductor
Conductor Material
:
:
:
400V ±10%
50Hz ±3%
90 oC
:
250oC
:
Conductor type
:
xii.
Insulating material
:
xiii.
Core Identification Strips
:
xiv.
xv.
Material of Inner Sheath
Armour
:
:
xvi.
Outer Sheath
:
H4-Grade Aluminium of
purity > 99.6%
Electrolytic grade Copper,
Purity > 99.97%
Stranded with number of
strands as per IS 8130 (Part-I)
1984
Cross-Linked-Polyethylene
(XLPE) Compound
Red, Yellow, Blue & Black
(for neutral)
FRLS, PVC ST-2 Compound
Single layer of Galvanized
Steel Round Wire according to
IS-3975
FRLS, PVC ST-2 Compound
according to IS-5831
x.
xi.
3.3. Conductor
ALUMINIUM
The Aluminium conductor used shall be of H-4 grade (Tensile strength above 150
N/mm2). High conductive aluminium, stranded (Class-II, stranded circular shaped),
uniform in quality and free from scale, inequalities, spills, splits and other defects.
The aluminium used shall have purity meeting the criteria for maximum resistance
allowed. Two sample conductor randomly selected from finished lot of cables, shall
be tested for its purity at any 3rd party NABL accredited lab.
COPPER
The conductors shall be made from high conductivity copper rods complying with IS:
613-1964. The conductor material used shall be electrolytic grade with high purity.
Two sample conductor randomly selected from finished lot of cables, shall be tested
for its purity at any 3 rd party NABL accredited lab.
Cable Joints:
Joints shall be permitted in the individual wires of which the conductor is formed, but
no joint shall be within 300 mm of any other joint within the same layer. The joints
shall be made by resistance butt welding, fusion welding, cold pressure welding,
10
electric welding, gas welding, brazing or silver soldering. No joint is allowed in the
conductor after stranding. A maximum of two joint shall be allowed in any strand
forming complete length of the cable.
The conductors shall conform to appropriate dimensions, resistance and number of
wire in the conductor (number of strands) as given in IS 8130 (Part I): 1984.
3.4. Insulation
The insulating material for power cables shall be extruded cross linked polyethylene
(XLPE) compound as per IS-7098(Part-I)-1988. The minimum thickness of
insulation shall not be less than the values specified in Table-2 of IS-7098 (Part-I)1988. No negative tolerance shall be applicable for the thickness. The insulation of
the cable shall be designed and manufactured for the specified system voltage. The
manufacturing process shall ensure that insulation shall be free from voids. The
insulation shall withstand mechanical and thermal stress under steady state and
transient operating conditions. The cores shall be identified as per the following
colour scheme:
3-Core - Red, Yellow & Blue
3 ½ or 4-Core - Red, Yellow, Blue & Black
3.5. Inner Sheath
The inner sheath shall be extruded FRLS PVC, Type ST2, compatible with thermal
rating of insulation conforming to IS-6380-1984. The sheath shall have adequate
thickness, mechanical strength and elasticity, as specified in IS 5831. The material
shall be soft thermoplastic type, applied by extrusion method. The thickness of the
inner sheath shall be as per IS: 7098 (Part I) and the color of the inner sheath shall be
Grey. The inner sheath shall be so formed that it fits closely on the laid up cores and
could be easily removed without damaging insulation. One or more layer of proofed
plastic tape shall be provided over the laid up core before extrusion.
3.6. Armouring
The armouring arranged over the inner sheath shall consist of one layer of galvanized
round steel wires for all sizes of cable. The armour round wire used on the cable shall
conform to IS: 3975 for all requirements. The direction of lay of armour shall be
opposite to that of the cores. The zinc coating on the galvanized steel strip shall
comply with relevant standards.
The joints in armour wires/strips shall be made by brazing or welding and the surface
irregularities shall be removed. A joint in any wire/strip shall be at least 300 mm away
from the nearest joint in any other wire/strip in the completed cable.
3.7. Outer Sheath
Extruded outer sheath shall be provided over the armouring. The material used for
sheathing shall be FRLS PVC sheath, Type ST-2 base compound conforming to IS
1554/ IS 5831 for power cable. The outer sheath shall be so formed that it fits closely
on the laid up armour and could be easily removed without damaging the intermediate
sheath and insulation. The colour of the outer sheath shall be black. The thickness of
11
outer sheath shall be in accordance with the IS 1554 (Part-I)-1988. Suitable additives
shall be added to prevent attack by rodents and termites. All serving must be given
anti-termite treatment.
Cables shall have suitable fillers laid up with the conductor to provide a substantially
circular cross section before the sheath is applied. Fillers shall be suitable for the
temperature of the cable and compatible with the insulating material. The material
shall be of the best quality and workmanship. The fillers and sheath material shall be
non-hygroscopic. All materials shall be new, unused and of the finest quality.
4.
TESTS
All the tests specified below shall be carried out in accordance with the Indian
Standards by the manufacturer in the presence of Purchaser’s representative. If the
cable fails to pass the test specified, the Purchaser shall have the option to reject it.
Shipping release shall be obtained from the Purchaser's representative. The Purchaser,
however reserves the right to waive off the inspection.
The tests at works shall include electrical, mechanical and hydraulic tests in
accordance with the appropriate clauses of Statutory Regulation, relevant codes and
standards, in addition any test called for by the Purchaser or his representative to
ensure that the equipment being supplied fulfils the requirement of the specification.
For test not covered by any code or specifically mentioned in this specification, the
test procedures are to be agreed with the Purchaser.
Pre Dispatch Inspection
The manufacturer shall be given at least 15 days advance notice prior to the
commencement of testing, so that Purchaser’s representative can plan to witness the
tests.
All the tests indicated in the test clause of this specification shall be carried out in the
presence of Purchaser’s representative by the manufacturer and shall provide all the
facilities and equipment for testing.
Six copies of the Test Certificate shall be furnished to the Purchaser for approval prior
to dispatch of cables from factory.
Visual check to conform the details given in this specification is to be done. In
addition to the above, the general workmanship of the cable drums and cables laid in
drums shall be checked.
Manufacturer shall have proper test set up for testing all the routine tests & type tests
on finished cables as per IEC.
List of type tests mentioned in the tender specifications shall be conducted on four
drum irrespective of type test certificates given or not.
4.1.
Type Test
12
Type tests on four randomly selected cable drums will have to be conducted in the
presence of the department’s representative. The test samples will be taken from
finished cables. This test shall be in accordance to IS: 7098, Part-1,1988.
a. Test on Conductor
· Annealing test for copper conductors
· Tensile test for aluminium conductor
· Wrapping test for aluminium conductor
· Conductor Resistance Test
b. Test on Insulation
· Physical dimension measurement
· Tensile strength and elongation at break
· Hot set test
· Shrinkage test
· Ageing in air oven
· Water absorption test
c. Test on round Armour
· Physical dimension measurement
· Tensile strength
· Elongation at break
· Torsion test for round wires
· Winding test for firmed wire
· Mass of zinc coating.
· Uniformity of zinc coating
· Resistivity measurement, Resistance test for armour
d. Test on Sheath
· Physical dimension measurement
· Tensile strength & Elongation at break test
· Ageing in air oven
· Loss of mass in air oven
· Shrinkage test
· Hot deformation test
· Heat shock test
· Thermal stability test
e. Insulation Resistance Test
f. High Voltage Test at room temperature
g. Volume resistivity at room temperature & at 90 o C. (IS-10810-Part 43)
h. Flammability test
i. Test requirement of FRLS inner and outer sheath
The inner and outer sheath of cables shall meet the following test
requirements related to flame retardant, low smoke emission, low acid and
toxic gas emission. The BIDDERs shall have proper test apparatus to
conduct all the relevant tests as per the applicable standards:
· Flame retardant test on single cable
13
· Oxygen Index Test
The critical oxygen index value shall be minimum 29 when tested at
27+2ºC as per ASTMD-2863
· Temperature index test
Temperature index value shall be minimum 250ºC at oxygen index of
21 when tested as per NES 715.
· Flammability test
Cables shall pass test under fire conditions as per IS-10810- Part-53.
Cables shall also pass tests as per IS-10810 Part- 61 & Part-62.
Flammability shall be as per IEC 332-1 and IS 694: 1990.
· Smoke Density Test
The cables shall satisfy the tests conducted to evaluate the percentage
obscuration by smoke in an optical system placed in the path of the
smoke. The maximum smoke density rating shall not be more than
60% when tested as per ASTM-D-2843.
· Acid Gas Generation test (halogen acid gas evolution)
The hydrochloric acid generation when tested as per IEC 754-1 shall
be less than 20% by weight.
· Test for specific optical density of smoke
· Anti termite and rodent property test
The sequence of electric tests shall be as per the relevant Indian/International
standards. The Bidder shall submit the sequence of tests for the approval of the
purchaser before conducting the tests. A copy of the adopted standard shall also be
supplied.
4.2.
Routine Test (On each drum)
The following routine tests shall be carried out by the Manufacturer on each and every
length of the cable in the presence of Purchaser’s representative at manufacturer’s
works.
a. Resistance test for conductors
b. Insulation resistance test
c. High voltage test
4.3.
Conductor purity test
Two samples of aluminium and copper shall be taken from any of the finished set of
cables at random and the sample shall be tested for its purity at a NABL accredited
lab.
14
Qualifying Criteria:
The test results should be within limits as per IS 7098. All the routine tests as per IS
7098 / IEC shall be conducted and passed as per the limits given in the standards. All
the bought out certificates will be verified and the test results shall be as per
respective standards.
5.
IDENTIFICATION
The following details shall be marked sequentially for each meter run length of the
cable by non-erasable embossing on the outer sheath:
a. Reference to Indian Standard
b. Name of the manufacturer/ Trade Name
c. Name of the project: CWMF, BARC (K)
d. Configuration of the cable: viz. Voltage grade, no. of Core, Sq. mm,
A2XWY/2XWY/YWY / YY as applicable
e. Year of manufacturing
f. Sequential marking of running meter length
The running length of the cable shall be identified at regular intervals of one
meter (Increasing order from inner end to outer end of the cable)
6. PACKAGING
· Each drum shall consist of single length cable ≥ 500 metres.
· The cable shall be wound on non-returnable steel drums of suitable size,
packed and marked.
· Packing shall be sturdy to protect the cable from any injury during
transportation, handling and storage. The cut ends of the cable shall be sealed
by means of non hygroscopic sealing material preferably Heat shrinkable end
caps.
· One end of the cable shall be brought out of the drum and suitably clamped to
the drum flange with proper mechanical protection. Location of the other end
may be marked on the drum.
· The cable shall be placed on drums in such a manner that it will be protected
from injury during transit. Each end of the cable shall be firmly and properly
secured to the drum. No undue stress shall appear on cables when laid on
drums.
· The cable drum shall carry the following information stencilled on a metallic
label, securely attached to each end of the drum:
i.
Reference to the Indian standard
ii.
Manufacturer’s name, brand or trade mark
iii.
Type of cable and voltage grade
iv.
No. of cores
v.
Nominal cross-sectional area of conductor
vi.
Cable code
vii.
Length of cable on drum
viii.
No. of lengths on reel, drum or coil (if more than one)
15
ix.
x.
xi.
xii.
xiii.
Gross weight
Country of manufacture
Year of manufacture
Direction of rotation of drum (an arrow)
ISI certification mark
7. PREFERRED MAKE
FINOLEX/POLYCAB/KEI/RRKable or reputed brand possessing system
certification of ISO 9001:2008, ISO14001:2004, OHSAS18001:2007 & EN 160012009 and product certifications IS: 7098 (Part-I), CE, UL etc. Quotations without
these certification details will not be considered for technical evaluation.
Preferred make of bought out material:
a. Aluminium for Conductor
b. Copper for Conductor
c. XLPE compound of
Insulator
d. Armour Steel
:
:
:
Hindalco/Balco/Nalco
Hindustan Copper/Hindalco
Dow/Borealis
:
TATA/Jindal.
8. GUARANTEE
All the cables shall be guaranteed against faulty material, defective design & poor
workmanship for a period of 18 months from the date of supply. The materials
becoming defective during the guarantee period shall be replaced free of cost and the
defects arising out of the works shall be rectified free of charge without delay.
16
SECTION-C
Technical Specifications for 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm
Aluminium Cable
This section covers the technical specifications for design, engineering, manufacturing,
inspection, testing at manufacturer’s works, packaging and delivery by road (properly packed
in non-returnable steel drums), 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm
Stranded Compacted Circular Shaped Aluminium Conductor of H4 Grade, Shielded with
extruded Semi-conducting compound, XLPE insulated, PVC sheathed, GI Round wire
armoured, longitudinal and radial water tight Power Cables for effectively grounded system,
conforming to the latest revisions of IS: 7098 (Part –2) & as per the technical specifications
attached herewith.
1.
STANDARDS
The design, manufacture, inspection, testing & performance of the 11KV (E), HV power
cable shall comply with the latest editions/amendments of the following standards,
unless otherwise specified. Where no standards are available, the supply items shall be of
good quality and workmanship, backed by test results. Other National Standards are
acceptable if they are established as equivalent or superior to the standards (listed below)
and subject to approval by the purchaser.
a.
IS-7098 (Part –2)
:
b.
IEC-60502-2 1998
:
c.
IS-5819
:
d.
IS-3961
:
e.
IS-8130
:
f.
IS-3975
:
g.
IS-4759
:
h.
IS-5831
:
17
Specification for cross linked
polyethylene insulated PVC sheathed
cables for working voltages from
3.3.kV up to and including 33 kV
Power
Cables
with
extruded
insulation and their accessories for
rated voltages from 1 kV up to 30 kV
Recommended Short circuit Current
ratings for High voltage cables
Recommended current ratings for
cables
Specification for conductors for
insulated electric cables and flexible
cords.
Low Carbon galvanized steel wires,
formed wires & tapes for armouring
of cables
Specifications for Hot dipped
galvanized coating on round steel
wires
PVC insulation and sheath of electric
cables.
i.
2.
IS-10418
:
Drums for electric cables.
SERVICE CONDITION
The cable shall be designed with the following service conditions into consideration:
a. Cables shall be capable of satisfactory operation under a power supply system
frequency variation of +5% and voltage variation of ±10%.
b. Cables shall be suitable for laying in vertical installation, built in trench,
conduits, ducts, cable tray or for direct burial in ground in both dry and wet
locations with chances of flooding by water.
c. The cables shall be suitable for the following ambient condition:
Ambient Air temperature: 400C
Ambient ground temperature: 300C
d. The material used for cable construction shall be suitable for specified limits
of temperature rise.
e. The current rating shall be based on maximum conductor temperature
depending on the type of insulation for continuous operation at the rated
current.
f. The one second short circuit current rating values shall be furnished and shall
be subjected to the purchaser’s approval.
g. The cables will have current ratings and de-rating factors as per relevant
Indian Standards.
Full technical details and descriptive literature shall be furnished indicating the
construction details, standard applicable for the components of the cable and current
ratings of the cables in air and ground. De-rating factors to be considered for the ambient
temperature, ground temperature, de-rating due to cable location in air and ground shall
also be furnished. The certificates for the type tests conducted on cables similar to the
cables covered herein shall be submitted along with the tender.
3.
DESIGN AND CONSTRUCTION PERTICULARS
3.1. General
The cables supplied under this specification shall be adequate insulation to operate
continuously at the specified voltage with a high degree of safety and reliability
throughout the life of the cables. The sheathing material shall be high quality PVC based
compound. The construction of cable shall be as per IS: 7098 (Part-2). No hygroscopic
material/paper shall be used in cable construction.
Cable shall be designed and manufactured to prevent damage during transportation,
installation & operation under all climatic & operating conditions to which cable may be
subjected to.
3.2. Technical parameters
18
a.
b.
Quantity
Packaging
:
:
c.
d.
e.
f.
g.
h.
i.
Cable Type
No. of Cores
Voltage Grade (U0/U)
System Grounding
Nominal System voltage
Nominal System Frequency
Maximum conductor temperature at
rated current
Maximum conductor temperature at
Short-circuit
Maximum continuous rated current
in Air
Maximum continuous rated current
in Ground
1.2/50 microsecond lightning
impulse withstand voltage wave
value
Short circuit current for 1 sec with
initial conductor temperature of
90 oC and final temperature after
short-circuit 250 oC
Conductor
Nominal Cross-section area
Conductor Material
Conductor type
:
:
:
:
:
:
:
2.5KM
5 steel drums, each having
single length cable ≥ 500
metres.
A2XWY
3
6.35kV / 11kV
Effectively Grounded
11kV ±10%
50Hz ±5%
90 oC
:
250oC
:
325
:
270
:
75 kVp
:
17.5 kA
:
:
:
p.
Conductor Screening Material
:
q.
Insulating material
:
r.
Insulator Screening
:
185 mm2
H4-Grade Aluminium
Class-2 Stranded Compacted
Circular shaped
Extruded semiconducting
compound
Water-Tree-resistant CrossLinked-Polyethylene (XLPE)
Extruded Semiconducting
compound followed by a
water swell-able
semiconducting tape, metallic
screening of a layer of plain
copper tape, followed by water
swell-able semiconducting
tape
j.
k.
l.
m.
n.
o.
19
s.
Core Identification Strips
:
t.
Material of Inner Sheath
:
u.
Armour
:
v.
Outer Sheath
:
Red, Yellow and Blue colored
strips
Pressure Extruded PVC Type
ST-2 conforming to IS-5831
followed by a layer of water
swell-able non-conducting
tape over inner sheath,
followed by Poly-Aluminium
Laminated Tape & HDPE
Type ST-7 according to IEC60502-2
Single layer of Galvanized
Steel Round Wire according to
IS-3975
PVC Type ST-2 according to
IS-5831
Cable Voltage Rating
The cables shall be suitable for Voltage grade (Uo/U) 6.35/11 kV, 3 phase, 50 Hz
frequency, effectively grounded system and capable of continuous operation at their
rated currents.
Cable Insulation Level
The power cables shall withstand power frequency voltage, impulse voltage and
partial discharge extinction level as per IS: 7098 part – 2.
Cable Current Carrying capacity
The cable shall be suitable for use where combination of ambient temperature and
temperature rise due to load, results in conductor temperature not exceeding 90oC
under normal operation. The cables shall have the following continuous current
ratings when laid in ground 1100 mm below ground level and in air with the ground
temperature being 30oC and air temperature being 40° C and assuming that thermal
resistivity of soil is 150°C.cm/W and a maximum operating temperature of 90 o C.
11 KV, XLPE, 3C X 185 Sq. mm – 270 Amps (in ground), 325 Amps (in air)
Cable Short Circuit withstand capacity
The cable shall withstand the short-circuit current of 17.5KA for 1 second, assuming
the initial conductor temperature of 90° C and final temperature of 250° C.
3.3. Conductor
Aluminium Conductor:
The Aluminium conductor used shall be of H-4 grade (Tensile strength above 150
N/mm2). High conductive aluminium, stranded (Class-II, stranded circular shaped),
uniform in quality and free from scale, inequalities, spills, splits and other defects. The
20
aluminium used shall have purity meeting the criteria for maximum allowable
resistance. Number of strands and strand diameter for the cable shall be indicated.
Cable Joints:
Joints are permitted for individual wires of which the conductor is formed, but no joint
shall be within 300 mm of any other joint within the same layer. The joints shall be
made by resistance butt welding, fusion welding, cold pressure welding, electric
welding, gas welding, brazing or silver soldering. No joint is allowed in the conductor
after stranding. A maximum of two joint shall be allowed in any strand forming
complete length of the cable.
The conductors shall conform to appropriate dimensions, resistance and number of wire
in the conductor (number of strands) as given in IS 8130 (Part I).
One sample conductor randomly selected from finished lot of cables, shall be tested for
its purity at any 3 rd party NABL accredited lab.
3.4. Conductor Screening
The Conductor screening shall be provided over the conductor by extrusion of semiconducting compound and shall be so applied that it fits closely on the conductor and it
shall be possible to remove it without damaging the conductor. Strippable screening
shall be provided. The screening material shall be non-metallic semi-conducting
compound.
3.5. Insulator
The conductor insulation shall be of extruded layer of water tree free cross-linked
polyethylene (XLPE), meeting the requirements of IS: 7098 (part–2). The method of
cross-linking of polyethylene shall be indicated in the offer. Cross linking will be by
Dry Gas Curing process.
The average thickness and tolerance of insulation when measured in accordance with IS
shall not be less than the values specified in IS: 7098- Part -2.
3.6. Insulator Screening
Insulation screening shall be by means of extruded bonded strippable semi-conducting
layer followed by a semi-conduction-water swell able tape and metallic screening by
means of wrapped copper tape.
The cable core shall be triple extruded and cross-linked in fully enclosed process such
that the inner semi-conducting screen, XLPE insulation and outer semi-conducting
screen are applied simultaneously on the pre heated cable conductor. In-line inspection
mechanism shall continuously monitor the dimensional accuracy of the extruded core.
The cable will be tested for partial discharges after application of the copper tape screen
as part of the Quality Control Procedure.
21
3.7. Core Layout
The core identification for the 3-core cable shall be done by using coloured strips of
Red, Yellow & Blue colours respectively for each phase. The three cores shall be laid
up together with a suitable right hand lay as per IS: 7098 (Part-2).
The interstices shall be filled with Non-hygroscopic material. The filler at the centre of
the three cores shall be of vulcanised rubber. The filler shall be fresh material, recycled
PVC material is not acceptable. The filling material shall be suitable for the operating
temperature of the cable and compatible with the insulating material. The filler material
should be non-hygroscopic, fire retardant and compatible with sheath.
3.8. Inner Sheath
The inner sheath shall be PVC Type ST2 as specified in Latest IS: 5831, soft
thermoplastic material applied by pressure extrusion. Over the inner sheath, non
conducting water swell able tape shall be provided, followed by poly-aluminiumlaminate tape and extruded type HDPE-ST-7 intermediate sheath.
The colour of the inner sheath shall be gray. The inner sheath shall be so applied that it
fits closely on the laid up cores, circular in shape and easy to remove without damaging
the insulation.
The thickness and tolerance of the inner sheath shall be as per table-3 of latest IS: 7098,
Part-2.
3.9. Armouring
Armouring shall be applied over the inner sheath and shall consist of one layer of
galvanised steel round wire. The armour wire being put on the cable shall conform to
latest revisions of IS: 3975 for all requirements. The armour wires shall be applied as
closely as practicable & the direction of lay of armour shall be opposite to that of the
cores lay. The zinc coating on the galvanised steel wires shall comply with relevant
Standards. The dimensions of galvanised steel wires shall be as specified in Table - 4 of
IS: 7098 (Part 2).
The joints in armour wires/strips shall be made by brazing or welding and the surface
irregularities shall be removed. A joint in any wire/strip shall be at least 300 mm away
from the nearest joint in any other wire/strip in the completed cable.
3.10. Outer Sheath
Extruded outer sheath shall be provided over the armouring. The material used for
sheathing shall be PVC Type ST2 as specified in Latest IS 5831. The colour of the
outer sheath shall be BLACK. The thickness of outer sheath shall be as per Table 5 of
Latest IS: 7098 (Part 2). The outer sheath shall be so applied that it fits closely over the
armouring. It shall be possible to remove it without damage to the inner sheath and
insulation.
The PVC compound used shall be abrasion proof, chemical resistant, provide protection
against ants, termites, rodent and fungal growth.
22
3.11. End Sealing, Joining and Joining Material
End Sealing Materials:
The two ends of the cable shall be sealed by means of non-hygroscopic sealing
materials preferably by Heat shrinkable end caps. Each drum shall be supplied with two
numbers additional heat shrinkable end caps.
Jointing & Jointing Materials:
Supplier shall indicate jointing procedures for terminal joints / straight joints of XLPE
cables at motors, transformers and in switchgear. Detailed write-up shall be given along
with the bid detailing the procedure for jointing along with drawings.
4.
INSPECTION & TESTING
All the tests specified below shall be carried out in accordance with the Indian Standards
by the manufacturer in the presence of Purchaser’s representative. If the cable fails to
pass the test specified, the Purchaser shall have the option to reject it. Shipping release
shall be obtained from the Purchaser's representative. The Purchaser, however reserves
the right to waive off the inspection.
The tests at works shall include electrical, mechanical and hydraulic tests in accordance
with the appropriate clauses of Statutory Regulation, relevant codes and standards, in
addition any test called for by the Purchaser or his representative to ensure that the
equipment being supplied fulfils the requirement of the specification.
For test not covered by any code or specifically mentioned in this specification, the test
procedures are to be agreed with the Purchaser.
4.1. Stage Inspection
i.
The Purchaser’s representative shall have access to the Supplier’s works for
the purpose of witnessing the tests and to ascertain that the cable being
manufactured conforms to the requirements of this specification.
ii.
The Purchaser’s representative shall have a stage inspection during the
following, important stages of production processes at manufacturer’s works.
a. During Triple Extrusion process.
b. The cables will be tested for partial discharges after application of the
copper tape screen as part of the stage inspection.
iii.
During stage inspection the following tests shall be carried out.
a. Tensile strength
b. Elongation at break
c. Hot set test
d. Permanent set
e. Partial discharge test
f. IR before and after HV test
23
g. High voltage test
h. Conductor resistance test.
iv.
Purchaser will witness triple extrusion process. Advance intimation shall be
given to the Purchaser before starting of triple extrusion process. Ensure that
online thickness monitoring unit (SIKORA) is in working condition. If online
thickness monitoring unit is not working at triple extrusion point then
production and as well as stage inspection shall not be carried out.
v.
The customer will see the stabilizing point during triple extrusion process.
Bubbles and other uneven surfaces shall not appear on the cable coming out of
CCV line. If any bubbles or any other abnormality observed on the triple
extruded single core cable at the end of the triple extrusion process then upto
that point cable shall be cut and shall not become part of supply.
vi.
After completion of water cooling of triple extruded line, residual moisture on
the cable shall be removed with sufficient number of heaters. At the end of the
CCV line, heaters in all the angles shall be placed to remove the residual
moisture on the cable.
vii.
Hot air blower shall be provided at the end of the CCV line, so that moisture
on surface of the triple extruded core will get evaporated. It has to be ensured
that there shall not be any water on surface of the core of the cable before
winding it on to a cable drum. Sufficient delay (1 day) shall be given between
end of triple extrusion process and winding of water swellable tape. & copper
foil. (To avoid trapped moisture in copper foil).
4.2. Pre-dispatch Inspection
i.
The manufacturer shall be given at least 15 days advance notice prior to the
commencement of testing, so that Purchaser’s representative can plan to
witness the tests.
ii.
All the tests indicated in the test clause of this specification shall be carried out
in the presence of Purchaser’s representative by the manufacturer and shall
provide all the facilities and equipment for testing.
iii.
Six copies of the Test Certificate shall be furnished to the Purchaser for
approval prior to dispatch of cables from factory.
iv.
Visual check to conform the details given in this specification is to be done. In
addition to the above, the general workmanship of the cable drums and cables
laid in drums shall be checked.
v.
Manufacturer shall have proper test set up for testing all the routine tests, type
tests and longitudinal water tightness test on finished cables as per IEC.
vi.
List of type tests mentioned in the tender specifications shall be conducted in
one drum irrespective of type test certificates given or not.
24
vii.
Longitudinal water immersion test shall be conducted on the sample on which
bending test is conducted. Test procedure shall be as per IEC 60502.The test
shall be conducted on first day of final inspection.
viii.
Six Copies of test reports shall be submitted after approval of preliminary copy
is received from the Purchaser
4.3. Type Test
Type tests on one randomly selected cable drums will have to be conducted in the
presence of the department’s representative. The test samples will be taken from
finished cables.
The sequence of tests shall be as follows on one particular cable sample:
a. Bending tests
b. Water tightness tests
c. Remaining type tests (as listed below)
d. Routine tests mentioned in the routine test clause shall be conducted on this
particular sample which underwent bending tests, water tightness tests and
type tests.
The following tests will be conducted on selected samples from the lot for acceptance
of the material. This test shall be in accordance to IS: 7098, Part-2, 1985.
a. Test on Conductor
· Tensile test for aluminium conductor
· Wrapping test for aluminium conductor
· Conductor Resistance Test
b. Test on Insulation & Sheath
· Physical dimension measurement/Test for thickness of insulation &
sheath
· Tensile strength and elongation at break
· Hot set test
· Shrinkage test
· Ageing in air oven
· Water absorption test
c. Test on round Armour
· Physical dimension measurement
· Tensile strength
· Elongation at break
· Torsion test for round wires
· Winding test for firmed wire
25
· Mass of zinc coating.
· Uniformity of zinc coating
· Resistivity measurement, Resistance test for armour
d. Test on Outer Sheath
· Physical dimension measurement
· Tensile strength & Elongation at break test
· Ageing in air oven
· Loss of mass in air oven
· Shrinkage test
· Hot deformation test
· Heat shock test
· Thermal stability test
e. Partial discharge test
f. Dielectric power factor test
· As a function of voltage
· As a function of temperature
g. Insulation resistance (volume resistivity test)
h. Heating cycle test
i. Impulse withstand test
j. High voltage test
k. Flammability test
l. Water tightness test in longitudinal and radial direction
(Manufacturer shall submit detailed procedure for this test and shall take
prior approval of the engineer-in-charge).
m. Conductor purity test
One sample of aluminium shall be taken from any of the finished set of
cables at random and the sample shall be tested for its purity at a NABL
accredited lab.
4.4. Routine Test
The following routine tests shall be carried out by the Manufacturer on each and every
length of the cable in the presence of Purchaser’s representative at manufacturer’s
works.
a. Resistance test for conductors
b. Insulation resistance (Dry) test
c. High voltage test
d. Partial discharge test.
26
Qualifying Criteria:
The test results should be within limits as per IS 7098. All the routine tests as per IS
7098 / IEC shall be conducted and passed as per the limits given in the standards. All
the bought out certificates will be verified and the test results shall be as per respective
standards.
5.
IDENTIFICATION
The following details shall be marked sequentially for each meter run length of the cable
by non-erasable embossing on the outer sheath:
a. Reference to Indian Standard
b. Name of the manufacturer/ Trade Name
c. Name of the project: CWMF, BARC (K)
d. Configuration of the cable: viz. Voltage grade, no. of Core, Sq. mm
e. Year of manufacturing
f. Sequential marking of running meter length
The running length of the cable shall be identified at regular intervals of one
meter (Increasing order from inner end to outer end of the cable)
6. PACKAGING
i.
Cables shall be supplied in non-returnable steel drums. The cable drums shall
comply to relevant Indian standards.
ii.
Cable drums shall be so constructed as to have required mechanical strength so
that the drum flanges and other components do not break during transport, in
actual use or in storage.
iii.
The flanges and the outside surface of the barrel shall be free from protruding
materials or projections or unevenness capable of damaging the cable or hands
of operator during rotation of drums.
iv.
A metal preservation shall be applied to the entire drum. All ferrous parts used
shall be treated with a suitable rust free finish or coating to avoid rusting
during transit or storage.
v.
The barrel diameter of the drum shall be greater than 15 times of OD of the
cable.
vi.
3 rounds of black colour high density plastic sheet shall be wrapped on cable
on cable drum.
vii.
Wrapping of plastic cover is required for storing the cable for longer time at
site.
viii.
Name plate on Painted 2 mm thick MS plate on cable drum for identification
shall be provided.
ix.
Proper drum rotation mark shall be marked on the finished cable drums.
27
x.
Each drum shall consist of single length cable ≥ 500 metres.
xi.
Packing shall be sturdy to protect the cable from any injury during
transportation, handling and storage. The cut ends of the cable shall be sealed
by means of non hygroscopic sealing material preferably Heat shrinkable end
caps.
xii.
One end of the cable shall be brought out of the drum and suitably clamped to
the drum flange with proper mechanical protection. Location of the other end
may be marked on the drum.
xiii.
The cable shall be placed on drums in such a manner that it will be protected
from injury during transit. Each end of the cable shall be firmly and properly
secured to the drum. The drums shall be secured firmly in position so that they
will not shift during transit. No undue stress shall appear on cables when laid
on drums.
xiv.
The cable drum shall carry the following information stencilled on a metallic
label, securely attached to each end of the drum:
a. Reference to the Indian standard
b. Manufacturer’s name, brand or trade mark
c. Type of cable and voltage grade
d. No. of cores
e. Nominal cross-sectional area of conductor
f. Cable code
g. Length of cable on drum
h. Gross weight
i. Country of manufacture
j. Year of manufacture
k. Direction of rotation of drum (an arrow)
l. ISI certification mark
7. PREFERRED MAKE
FINOLEX/POLYCAB/KEI/RRKable or reputed brand possessing system certification of
ISO 9001:2008, ISO14001:2004, OHSAS18001:2007 & EN 16001-2009 and product
certifications IS: 7098 (Part-I), CE, UL etc. Quotations without these certification details
will not be considered for technical evaluation.
Preferred make of bought out material:
a. Aluminium for Conductor
b. XLPE
compound
of
Insulator
c. Armour Steel
d. Semiconducting Compound
:
:
Hindalco/Balco/Nalco
Dow/Borealis
:
:
TATA/Jindal.
Dow/Borealis
28
e.
f.
for screening
Semiconducting
water :
swell-able tape
Heat Shrinkable End cap
:
Lantor/Scapa Cable Solution
Raychem
8. GUARANTEE
All the cables shall be guaranteed against faulty material, defective design & poor
workmanship for a period of 18 months from the date of supply. The materials becoming
defective during the guarantee period shall be replaced free of cost and the defects
arising out of the works shall be rectified free of charge without delay.
29
ANNEXURE-I
Technical Data Format for 1.1KV, XLPE Insulated, Aluminium/Copper Cable
The tenderer shall furnish all technical details as called for in the following format for
all sizes of cables (Refer: 1.1 to 1.19, Table-1) failing which the tender shall be
considered as incomplete. The details shall be furnished separately for all the cables.
30
Cable Type & Sl.No. as per Table-1
Sl.No.
:
Particulars
Details
a.
Cores
a.
No. of cores
:
b.
Nom. Area of conductor in Sq. mm
:
c.
Voltage grade
:
b.
Conductor
a.
Standard applicable
:
b.
Material copper/aluminium/grade
:
c.
Purity
:
d.
Nominal cross-sectional area
:
e.
Form of conductor circular/shaped
:
f.
No. of strands
:
g.
Nominal dia of each strand
:
h.
Temperature co-efficient of
resistance at 20 deg.C.
:
c.
Insulation
a.
Standard applicable
:
b.
Material (mention type)
:
c.
XLPE is cured by steam process or
gas process?
Minimum average thickness
:
:
i.
Tolerance on the smallest of the
measured values of thickness of
insulation
Minimum volume resistivity at 27
deg. C
Minimum volume resistivity at 70
deg.C.
Color scheme for identification of
cores
Average dielectric strength
d.
Inner Sheath
d.
e.
f.
g.
h.
31
:
:
:
:
:
a.
Standard applicable
:
b.
Material for inner sheath
:
c.
Minimum thickness of inner sheath
:
d.
Whether extruded
:
e.
Armour
1.
Standard applicable
:
2.
Shape
:
3.
Size
:
4.
Material for Armour
:
f.
Outer Sheath/Overall Covering
a.
Standard applicable
:
b.
Material (mention type if any)
:
c.
Whether extruded
:
d.
Minimum average thickness
:
e.
Whether anti-termite treatment has
been given in the outer sheath
Whether flame retardant low smoke
compound added in outer sheath
:
f.
:
g.
Electrical Properties
1.
Maximum DC resistance of
conductor at 20°C in ohms/km
Maximum DC resistance of armour
at 20°C in ohms/km
Maximum permissible conductor
temperature
Under continuous full load
:
Under transient conditions
:
4.
Loss tangent at normal frequency
:
5.
Reactance at maximum operating
temperature, 50 Hz (Ώ/km.)
Capacitance at maximum operating
temperature, 50 Hz (Ώ/km.)
Total impedance at maximum
operating temperature, 50 Hz
(Ώ/km.)
Recommended continuous current
rating
:
2.
3.
6.
7.
8.
32
:
:
:
:
9.
10.
11.
In Ground at 30°C Ground
Temperature (Amps)
In Trench/Ducts at 40 °C (Amps)
:
In Air at 40°C ambient Temperature
(Amps)
Short circuit current rating for 1 sec.
duration (in kA)
Conductor
:
Armour
:
Minimum volume Resistivity of
insulation
At 27 °C in Ohm cm
:
:
:
At Max operating temperature in
Ohm-cm
Approximate AC resistance at max.
Operating temperature
Phase
:
Neutral
:
:
h.
Mechanical Data
a.
Overall dia of the cable
:
b.
Dia of the cable under the sheath
:
c.
Diameter under armour
:
d.
Diameter over the stranded cores
:
e.
Wight of cable per km.
:
f.
Drum length
:
g.
Tolerance on drum length
:
h.
Total weight of the drum
:
i.
Dimension of the drum
:
j.
Recommended minimum
installation radius/ bending radius
Maximum safe pulling force
:
Whether identification as per clause
of the specification is being
provided
Whether packing has been done as
per clause of the specification
:
k.
l.
m.
:
:
(Seal & Signature of the supplier)
33
ANNEXURE-II
Technical Data Format for 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm
Aluminium Cable
The tenderer shall furnish all technical details as called for in the following format for
6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm Aluminium Cable (Refer:
2.0, Table-1) failing which the tender shall be considered as incomplete.
34
Sl.No.
Particulars
Details
1.
Voltage grade
:
2.
Reference Standard
:
3.
No of cores
:
4.
Conductor
a.
Material as per IS : 8130
:
b.
Nominal cross section area (Sq.mm)
:
c.
No. of Strands
:
d.
Nominal dia. of each strand
:
e.
Flexibility Class (as per IS:8130)
:
f.
Shape of conductor
:
g.
Purity of Aluminium
:
h.
Density of Aluminium
:
i.
Tensile strength
:
j.
Make of Conductor
:
k.
:
5.
Material & Thickness of Water swellable
compound material between each layer except
outermost layer of conductor
Material & Thickness of Water swellable
compound at the outermost layer of the
conductor
Conductor Screening
a.
Material
:
b.
Min. thickness (mm)
:
c.
:
6.
Make, grade & brand name of the semiconducting compound
Insulation
a.
Material as per IS : 7098/II/2011
:
b.
Nominal thickness (mm)
:
c.
:
7.
Make, grade & brand name of the insulation
compound
Insulation Screening
a.
Material
:
b.
Nominal thickness (mm)
:
c.
Make, grade & brand name of semiconducting
compound
:
l.
35
:
d.
Water swellable compound material
:
e.
Water swellable compound thickness
:
f.
Approx. thickness of Copper tape (mm)
:
g.
Core identification
:
h.
Filler material
:
i.
Laying Up
:
8.
Inner Sheath
a.
Material as per IS : 5831/84
:
b.
Min. thickness (mm)
:
c.
Color of inner sheath
:
d.
water swellable tape over inner sheath material
:
e.
water swellable tape over inner sheath
thickness
Poly Al tape over inner sheath thickness
:
:
9.
Intermediate sheath Material
Min. thickness (mm)
Armouring
a.
Material as per IS : 3975
:
b.
Nom. dimension of armour
:
c.
Short circuit current carrying capacity
:
10.
Outer Sheath
a.
Material as per IS : 5831/84
:
b.
Min. thickness of outer sheath (mm)
:
c.
Color of outer sheath
:
11.
End Cap material
:
12.
:
a.
Recommended continuous current ratings
under standard IS conditions
In ground, at 30 deg C Ground temp
b.
In Air, at 40 deg C ambient temp.
:
13.
:
14.
Short circuit current carrying capacity of
conductor for one second duration (KA)
Cable type designation
15.
Mechanical Data
a.
Overall dia of the cable
:
b.
Dia of the shaped conductor
:
c.
Dia. over conductor screening
:
f.
g.
36
:
:
:
d.
Dia. over Insulation
:
e.
Dia. over Insulation Screen
:
f.
Dia. over armour
:
g.
Wight of cable per km.
:
h.
Dimension of the drum
:
i.
:
j.
Recommended minimum installation radius/
bending radius
Maximum safe pulling force
16.
Electrical Properties
a.
Loss tangent at normal frequency
:
b.
:
17.
AC resistance at maximum operating
temperature, 50 Hz (Ώ/km.)
Reactance at maximum operating temperature,
50 Hz (Ώ/km.)
Capacitance at maximum operating
temperature, 50 Hz (Ώ/km.)
Total impedance at maximum operating
temperature, 50 Hz (Ώ/km.)
Maximum permissible conductor temperature
a.
Under continuous full load
:
b.
Under transient conditions
:
c.
d.
e.
37
:
:
:
:
ANNEXURE-III
Vendor evaluation Criteria
Sl.No.
Particulars
Details
1.
Name of Manufacturer
:
a.
Address of firm
:
b.
e-mail
:
c.
Telephone/fax nos.
:
d.
Ownership of premises with address
:
e.
f.
Nature of Business
:
(Stockiest/General order
Supplier/Manufacturer/Importer/Indenter/Service
Provider etc.)
Company Registration details
:
g.
Year of Establishment
:
h.
Years of Operation/ Number of year experience
in the business
Type of ownership of the company
(Sole Proprietor/Partnership/Private/Public)
Company ISO certificate available
:
i.
j.
38
:
:
k.
Weather finished product is ISI marked?
2.
Proof of ability
a.
Capacity of works
:
b.
Commercial performance over last three years
:
c.
Anticipated performance for the present year
:
d.
Annual production capacity of Cables in km.
:
e.
Licensed production capacity
:
f.
Maximum capacity reached so far and period
during which it was achieved
Raw Material Handling
:
What is your current annual consumption of
major raw materials
:
Describe your company’s raw material
procurement policy
Describe your companies ram material supplier
evaluation policy
Do you have any long term product purchase
agreement with your current supplier for raw
materials?
Do you have any approved specifications for the
incoming material?
Do you get certificate of analysis for all
incoming material from suppliers?
What are the testing methods/processes for
incoming material?
Quality Management
:
g.
h.
:
:
:
:
:
:
Does your company have a (documented) system :
to manage Quality in your organization and is
this system implemented?
Does your company have a Quality Policy?
:
Please provide copy of policy
What are the checks conducted on your finished
39
products
Field feed-back on laid cable
(Supporting documents shall be attached)
:
i.
Details of machinery available
(Machine model number & Sl.No. shall be
provided)
:
j.
Details of collaboration for Technology
:
k.
Testing Equipments available
(Machine model number & Sl.No. shall be
provided)
:
l.
Manpower available and qualifications
m.
Total number of permanent staff
:
Total number of temporary/contract staff
:
Manpower Qualification
Graduates
Engineers
Skilled
Non Skilled
Number of personnel in your organization
responsible for quality Assurance
Provide details of technical qualification &
experience of key persons in quality control
Are employees provided with any training for
performance of the job?
R&D Facilities
:
40
:
:
:
3.
Manufacturing & Delivery schedule
a.
Period required for arranging the required raw
material and start of production after placement
of purchase order
Period required for total production of final
finished product
Period required for inspection & testing at site
:
Period required for delivery to the site after
inspection and verification of finished material
:
b.
c.
d.
:
:
(Seal & Signature of the supplier)
41
ANNEXURE-IV
CHECK-LIST
Sl.No.
Yes/No
Description
i.
Whether the bidder is an Original Equipment
Manufacturer (OEM) of XLPE cable up to 11 kV
for the past 5 years.
:
ii.
Whether annual turnover for last 3 years is above 7
crores and no loss has been incurred during this
period.
:
iii.
Whether the OEM has completed all the type tests
at CPRI /ERDA / NABL accredited lab.
:
(Attach relevant document)
iv.
Whether OEM have their own R&D lab.
:
v.
Whether OEM has ISO9001 & 14001 certification.
:
vi.
Whether the OEM has submitted Quality
Assurance plan meeting the technical requirement.
:
vii.
Whether the OEM is agreeing for complete tender
technical specifications.
:
viii.
Whether OEM has Established ISO procedure for
selecting & monitoring a sub-vendor for
procurement of raw materials.
:
ix.
Whether the manufacturer has a single point triple
:
Extrusion process with dry curing. (For HT cables)
x.
Whether the OEM has Established plant standards
:
(Validated with IS / IEC) in process inspection for
manufacturing of cable.
xi.
Confirm that no outsourced man power is
employed in manufacturing sections of triple
extrusion, QA process & R&D facility.
:
xii.
Confirm: Recycled PVC are not used in the cable
manufacturing.
:
xiii.
Confirm whether the manufacturer has proper test
set up for testing all the routine & type tests
:
42
Document Attached
(Yes/No)
xiv.
Do you agree to conduct all the tests as per the
specifications?
xv.
Do you have in-house facility to conduct
Longitudinal water tightness test on finished
cables as per IEC.
:
xvi.
Do you agree to conduct copper & aluminium
conductor purity test at a 3 rd party NABL
accredited lab?
(Two copper samples from LT cable, Two
Aluminium samples from LT cable & one
Aluminium sample from HT cable)
:
xvii.
Confirm whether the Entire testing equipments
have NABL accreditation.
:
xviii.
Confirm whether indoor raw material storage is
available for storage of armour wire, conductor
wire drums, PVC and XLPE materials.
:
xix.
Confirm whether the manufacturer considered
supply of two number additional heat shrinkable
end covers per drum
:
xx.
Confirm the vendor has duly filled “Technical
particulars/specification details” for all the LT
cables as listed in Annexure-I
:
xxi.
Confirm the vendor has duly filled “Technical
particulars/specification details” for the HT cable
as listed in Annexure-II
:
xxii.
Confirm the vendor has duly filled & submitted
the Vendor evaluation criteria as listed in
Annexure-III
:
xxiii.
Deviation Sheet
:
(Bidder must furnish List of Technical Deviations
mentioning the specification clause nos. against
which deviations has been sought for. Compliance
with this specification will be taken for granted in
absence of any specific mention of deviations in
the said list of deviations)
xxiv.
The vendor shall submit details of minimum three
similar supplies to any Govt./PSU organisation.
:
The vendor shall submit the feedback and test
report details.
xxv.
Company’s Catalogues/Leaflets to be submitted
43
:
xxvi.
Cable De-rating chart for LT & Ht cables to be
submitted separately
:
(Group laying, UG laying, ambient temperature,
ground temperature, de-rating factors for cable
laying in ground, air, cable trenches etc.)
(Seal & Signature of the supplier)
44
DEVIATION SHEET
Sl.No.
Clause no. as per tender
document
Deviation
Reason
(Seal & Signature of the supplier)
45
Sl.No.
Clause no. as per tender
document
Deviation
Reason
(Seal & Signature of the supplier)
46
Sl.No.
Clause no. as per tender
document
Deviation
Reason
(Seal & Signature of the supplier)
47
Price Bid for E-Tender
(Rates shall be uploaded only in the online price bid)
Tender no:
Sl.No.
1.0
Cable Specification
Quantity
(in meters)
No. of Drums
The bidder shall quote for design, manufacture, testing, delivery at site, for Power
cable of 1.1 kV grade, Multi-stranded Aluminium/Copper conductor,
XLPE insulated, extruded PVC inner sheathed, GI round-wire armoured,
extruded FRLS PVC ST2 outer sheathed, conforming to IS: 7098 (Part-I),
1988 and as per the technical specifications listed in Section-A of the
tender document.
1.1.
3.5C X 95 Sq.mm, Aluminium Conductor
1000
500 Mtr x 2
500
500 Mtr x 1
500
500 Mtr x 1
500
500 Mtr x 1
1000
500 Mtr x 2
500
500 Mtr x 1
1000
500 Mtr x 2
1000
500 Mtr x 2
1000
500 Mtr x 2
1000
500 Mtr x 2
Power Cable Type:A2XWY
1.2.
3.5C X 50 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.3.
3.5C X 35 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.4.
3C X 35 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.5.
3.5C X 25 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.6.
3C X 25 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.7.
4C X 16 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.8.
4C X 10 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.9.
4C X 6 Sq.mm, Aluminium Conductor
Power Cable Type:A2XWY
1.10.
4C X 4 Sq.mm, Aluminium Conductor
48
Power Cable Type:A2XWY
1.11.
3C X 2.5 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.12.
4C X 2.5 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.13.
3C X 4 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.14.
4C X 4 Sq.mm, Copper
Power Cable Type: 2XWY
1000
500 Mtr x 2
1.15.
3C X 6 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.16.
4C X 6 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.17.
3C X 10 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.18.
4C X 10 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
1.19.
3C X 16 Sq.mm, Copper
Power Cable Type: 2XWY
500
500 Mtr x 1
2.0
The bidder shall quote for design, manufacture,
testing, delivery at site, for 6.35KV/11KV
2500
500 Mtr x 1
(U0/U) Voltage grade, 3-core, 185 Sq.mm,
Stranded, compact circular shaped
Aluminium Conductor of H4 grade, Water
Tree free XLPE Insulated, PVC sheathed,
GI round wire armoured, Longitudinal and
radial water tight power cables, confirming
to IS: 7098 (Part-II), and as per the
technical specifications listed in Section-B
of the tender document.
49