NUCLEAR POWER CORPORATION OF INDIA LTD. (A GOVT. OF INDIA ENTERPRISE) SPECIFICATION NO.PB-E-542/REV. No.0

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1 REVISION NO. 0 NUCLEAR POWER CORPORATION OF INDIA LTD. (A GOVT. OF INDIA ENTERPRISE) SPECIFICATION NO.PB-E-542/REV. No.0 PAGE NO. 1 OF 24 DATE OF ISSUE (MONTH/YEAR) TOTAL NO. OF PAGES (Including cover sheet) JAN TECHNICAL SPECIFICATION FOR HR PVC INSULATED FRLS PVC SHEATHED ARMOURED CONTROL CABLES FOR TAPP-3,4 REF. USI NO:60110 PREPARED BY : P.K.BHATTACHARYYA CHECKED BY : ASIS DAS REVIEWED BY : V.K.AGARWAL APPROVED BY : R.K.KULKARNI (NAME SIGNATURE DATE) (FOR REVISION SEE REVISION CONTROL SHEET) FILE NAME: PBE542-R0.DOC FLOPPY NO:PKB-502

2 REVISION CONTROL SHEET PAGE NO. 2 OF 24 DOCUMENT TYPE: TECHNICAL SPECIFICATION NO. : PB-E-542/REV. NO.0 TITLE : TECHNICAL SPECIFICATION FOR HR PVC INSULATED FRLS PVC SHEATHED ARMOURED CONTROL CABLES FOR TAPP-3,4 Rev. No. & Date Description of Revision Prepared By Checked By Reviewed By Approved By

3 PAGE NO. 3 OF SCOPE Manufacture, testing, packing delivery and guarantee of various sizes of annealed bare copper conductor, HR PVC insulated and FRLS PVC sheathed galvanized steel round wire armoured 500 V grade control cables for use in Nuclear Power Plant generally conforming to IS-1554, Part-I. 2. CONTENTS Requirements of this specification are presented under the following section headings: Description Clause Applicable specifications and drawings 3 Materials & workmanship 4 General Function and Description 5 Design requirements 6 Inspection, Tests and Reports 7 Shop Tests 8 Packing and Shipment 9 Information required with the bid 10 Colour & Numbering Scheme for the cores, inner & outer sheaths Technical details to be supplied with the technical bid Delivery Schedule and Price details Quality Assurance Plan Annexure-A Annexure-B Annexure-C Annexure-D

4 PAGE NO. 4 OF APPLICABLE SPECIFICATIONS AND DRAWINGS 3.1 IS 1554 (Part I): Specification for PVC insulated (heavy duty) electric cables. 3.2 ASTM-D-2843: Standard test method for density of smoke from the burning or decomposition of plastics. OR 3.3 IS : Measurement of Smoke density of electric cables under fire conditions (supplier to indicate the acceptance criteria which is equivalent to ASTM-D-2843 vide clause no.6.7 of specification.) 3.4 ASTM-D-2863: Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastic (oxygen index and temperature index). 3.5 IS : Oxygen Index Test OR 3.6 IEC-754-1: Determination of the amount of halogen acid gas evolved during the combustion of polymeric materials taken from cables. 3.7 IS : Determination of the amount of halogen acid gas evolved during the combustion of polymeric materials taken from cables. 3.8 Swedish Svensk-Standard (Class F-3): Swedish Chimney Flame Test 3.9 IS : Flame Retardant Test 3.10 IS-5831: Specification for PVC insulation and sheath of electric cables IS-8130: Specification for conductors for insulated electric cables and flexible cords IS-3975: Specification for mild steel wires, strips, and tapes for armouring of cables IS-10810: Methods of tests for cables. OR OR

5 4.0 MATERIALS AND WORKMANSHIP 4.1 Materials PAGE NO. 5 OF 24 The materials and processes for the components of cables and their assembly shall be chosen as specified here-in. Use of any substitute materials shall be suitably qualified in terms of its electrical, mechanical and physical properties and the details shall be are not specified herein shall be chosen so as to enable the purchased product to meet the performance requirements of this specification. The construction of cable shall in general conform to IS-1554-(Part I). 4.2 Workmanship Workmanship shall be of high industrial quality to ensure the product to be uniform in quality and free from all defects and deformities so as to perform its required function in the specified environment as mentioned in this specification over an expected plant life of 40 years. 5.0 GENERAL FUNCTIONS AND SPECIFICATION 5.1 The cables shall be suitable for continuous and reliable operation at maximum conductor temperature of 85 0 C and voltage upto and including 300 V for core to earth and 500 V for core to core. 5.2 Environment conditions (a) Ambient Temperature.. 45 degree C max. (b) Relative Humidity.. 95% max. 6.0 DESIGN REQUIREMENTS All materials used shall be first class and of standard conforming to the requirements of this specification. 6.1 Conductor Conductor shall be 1.5 sq.mm solid annealed uncoated high conductivity copper as per IS:1554 (Part-I). Joints of any kind in the conductor are not allowed.

6 PAGE NO. 6 OF Insulation Insulation shall be Type C, HR PVC compound meeting the electric and physical requirements specified in IS:5831 and shall be applied by extrusion process. Joints of any kind of the insulation is not permitted. Insulation thickness shall be 0.60mm (nominal) + 10%. 6.3 Core Identification Insulation of Cores of all cables shall be colour coded as per Annexure-A of this specification. 6.4 Inner Sheath The individual cores shall be laid up as per IS:1554 (Part-I) and then shall be surrounded by common covering of FRLS PVC compound applied by extrusion. The sheath shall meet the applicable requirements specified in IS:1554 (Part-I) and it should also meet the special requirements mentioned in clause 6.7 of this specification. It should be possible to strip the sheath easily from the cores without damaging the insulation of the cores. Inner sheath shall be of black colour. Inner sheath thickness shall be 0.3mm(nominal) + 20%. 6.5 Armouring The armouring shall be arranged over the inner sheath. The armour shall consist of galvanized round steel wires. Armouring shall meet the dimensional requirements specified in IS:1554 (Part-I) and physical requirements specified in IS:3975. Diameter of armour wire shall be 0.90mm/1.4mm for 2 core and 3 core armoured cables and 1.4mm for 4 core and 7 core armoured cables. Please note that 0.90mm dia. armour wire is preferable for 2 core and 3 core armoured cables. 6.6 Outer Sheath The outer sheath shall consist of FRLS PVC Compound for use as a sheath on armour. The sheath shall meet the applicable requirements specified in IS:1554 (Part-I) and it shall also meet special requirements mentioned in clause 6.7 of this specification. It should be possible to strip the sheath easily without damaging the insulation. Sheath shall be of black colour. Outer sheath shall be applied by extrusion process. Thickness of outer sheath shall be 1.5mm(nominal) + 20%.

7 PAGE NO. 7 OF Special Requirements for Inner & Outer sheath Materials Limiting Oxygen index of inner and outer sheath shall not be less than 29% and the temperature index shall be 250 deg.c as per ASTM-D-2863/IS Smoke density rating of sheaths shall be maximum 60% as per ASTM-D-2843 or Smoke density test may be conducted as per IS Supplier to indicate the acceptance criteria which is equivalent to 60% smoke density as per ASTM-D-2843 if test is done as per IS Halogen (HCL) emission of the sheaths shall be maximum 20% as per IEC:754-1/IS Complete cable shall be flame retardant and it shall pass Swedish Chimney Flame Test as per Swedish Svensk Standard (Class F-3)/IS Construction Details of Cables sq.mm 7 core Cable Each conductor shall be 1.5 sq.mm solid annealed uncoated copper conductor insulated with extruded HRPVC compound. Each core shall be colour coded as per clause 6.3 of this specification. The cores shall be laid up as per IS-1554 (Part-I) and then FRLS PVC compound applied by extrusion as inner sheath of 0.3 mm thickness. Then galvanized steel wire armouring of wire diameter 1.4 mm shall be provided as per IS-1554 (Part-I) and finally outer sheath of FRLS PVC compound shall be applied by extrusion of thickness 1.5 mm. Overall diameter shall not exceed 17 mm sq.mm 4 Core Cable Same as but 4 core and overall diameter not to exceed 15 mm sq.mm 3 core cable Same as but 3 core, armouring with wire diameter of 0.90 mm and overall diameter not to exceed 14 mm sq.mm 2 core cable Same as but 2 core, armouring with wire diameter of 0.90 mm and overall diameter not to exceed 13 mm.

8 PAGE NO. 8 OF Cable Identification The following particulars shall be embossed on the cable outer sheath throughout the length of all the cables at a span of 1 metre. (a) (b) Name of the manufacturer Year of manufacture (c) HR PVC FRLS PVC (d) Voltage grade: 500 Volts rms. It may be noted that embossing on the cable outer sheath is preferred to printing Coil Lengths The total quantity of cables of each type shall be supplied in drums of coil lengths 500 m + 10%. Coil lengths of 100 m to 449 m are considered as non standard lengths. Non standard lengths of only 10% ordered quantity are acceptable. Lengths of less than 100 m are not acceptable. 7.0 INSPECTION TESTS & REPORTS The supplier shall be responsible for and shall perform all the tests and inspection as mentioned in this specification and any other tests which may be necessary to assess the required performance of the cable. The characteristic and performance of the cable shall conform to this specification on completion of tests. The purchaser or his representative shall have right to access to at all reasonable times for following up the manufacturing activities and validation of testing procedures to ensure that quality of performance meets this specification. The purchaser shall have right to conduct at his own expenses any additional inspection and testing deemed necessary by him. Quality surveillance relating to all aspects of manufacture shall be carried out by the purchaser. The supplier shall provide all the testing and inspection services and facilities satisfactorily as required. Inspection shall be carried out in satisfactory manner and shall be subjected to approval by the purchaser. Quality Assurance Plan (QAP) has been

9 PAGE NO. 9 OF 24 enclosed with the specification. The supplier shall prepare an inspection plan based on enclosed QAP and submit to purchaser for approval. Five copies of test reports and certificates of compliance stating the material is in accordance with the requirement specified in the specification shall be furnished by the supplier. 8. SHOP TESTS The following tests shall be carried out: 8.1 Type Tests Applicable Standard Annealing test for copper IS Conductor Resistance Test IS Measurement of diameter of conductor IS Test for armour wires IS Tests for thickness of Insulation and sheaths IS Tensile test on Insulation & Sheath IS Elongation test on insulation and sheath IS Hot deformation test on insulation and sheath IS Heat shock test on insulation and sheath IS Accelerated ageing test on insulation and sheath IS Loss of mass test on sheaths IS Cold bend test on insulation & sheath IS Shrinkage test on Insulation and sheath IS Thermal stability test on insulation and sheath IS-5831

10 PAGE NO. 10 OF Measurement of overall diameter IS Test for bleeding and blooming Pigments IS Insulation Resistance Test IS High Voltage Test (Water Immersion Test) at 1.5 KV IS-1554 (Part-I) Oxygen Index & Temperature Index tests on sheaths ASTM-D-2843/ IS Smoke density rating test on Sheaths ASTM-D-2843/ IS (Supplier to indicate the acceptance criteria which is equivalent to ASTM-D-2843 vide clause no.6.7of spec. if test is done as per IS ) HCL Emission Test on sheaths IEC-754-1/IS Swedish Chimney Flame Test SS (F-3)/IS Acceptance Tests The following acceptance tests shall be carried out on samples taken from the lot of each type of cable. The total number of drums of each type of cable offered at a time shall be treated as lot size. The sample size for the acceptance test shall be as per Appendix-A of IS-1554-Part Annealing test for copper IS Conductor Resistance Test IS Measurement of diameter of Conductor IS Test for thickness of Insulation and sheaths IS Insulation resistance test IS High voltage test (water immersion test) at 1.5 KV IS-1554(Part-I)

11 PAGE NO. 11 OF Oxygen Index & Temperature Index tests on sheaths ASTM-D-2863/IS Smoke density rating test on sheaths ASTM-D-2843/IS (Supplier to indicate the acceptance criteria which is equivalent to ASTM-D-2843 vide clause no.6.7of spec. if test is done as per IS ) HCL Emission Test on sheaths IEC-754-1/IS Swedish Chimney Flame Test SS F-3/IS Routine Tests Conductor resistance test IS Insulation resistance test IS High voltage test IS-1554(Part-I) 9.0 PACKING AND SHIPMENT The cables shall be so packed as not to suffer deterioration, damage or breakage during shipment. The ends of the cables shall be sealed to prevent ingress of moisture. Packing should be such that the ingress of moisture, dirt and other foreign material can be avoided. Packing method shall be adequate to withstand a period in transit for more than two months and storage at site under a tropical climate for minimum period of one year without suffering any damage or deterioration. Each package shall be properly labelled to indicate the type and quantity of material it contains, purchase order number, dimensions, weight, and any other necessary data to identify the equipment and relate it to the contract. Contractor shall not ship the material without the prior approval of the purchaser or his authorised representative and subsequent instruction to do so. Complete instructions relating to shipping and documentation will be furnished with the P.O.

12 PAGE NO. 12 OF INFORMATION REQUIRED WITH THE BID The supplier should give the technical details of the cables as per the format given in Annexure-B. Delivery schedule and price details shall be furnished as per format given in Annexure-C Validity of Offer

13 PAGE NO. 13 OF 24 ANNEXURE-A COLOUR CODES REQUIRED FOR THE CORES, INNER SHEATH & OUTER SHEATH 1. COLOUR CODE FOR CORES CORE Black Blue CORE Black Blue Orange CORE Black Blue Orange Green

14 PAGE NO. 14 OF CORE Black Blue Orange Green Brown Grey Red 2. COLOUR FOR INNER AND OUTER SHEATH

15 PAGE NO. 15 OF 24 TECHNICAL DETAILS TO BE SUPPLIED WITH THE TECHNICAL BID 1. COMPLETE CABLE 1.1 Make 1.2 Type Reference 1.3 Minimum bending/radius 1.4 Weight of cable (kg/km) 1.5 Voltage grade 1.6 Continuous working temperature 1.7 Max. overall diameter of cable (mm) 1.8 Coil lengths offered 1.9 Construction details of the cable ANNEXURE-B 1.10 Cable can pass Swedish Chimney test as per Swedish Standard (class F-3)/IS CONDUCTOR MATERIAL 2.1 Nominal conductor resistance per km at 20 deg.c 2.2 Conductor diameter 2.3 Conductor Material 3. INSULATION 3.1 Insulation resistance at 27 deg.c 3.2 Insulation Material

16 PAGE NO. 16 OF Insulation wall thickness in mm 4. ARMOURING 4.1 Material used for Armouring 4.2 Diameter of the galvanized armouring wire 5. SHEATH (INNER & OUTER) 5.1 Sheath Material (Inner & Outer) 5.2 Nominal sheath wall thickness (Inner) 5.3 Nominal sheath wall thickness (Outer) 5.4 Colour of the Inner and Outer sheaths 5.5 Oxygen index as per tests mentioned in ASTM-D-2863/IS Smoke density rating as per tests mentioned in ASTM-D-2843/ IS Halogen (HCL) Emission as per tests mentioned in IEC-754-1/ IS DEVIATIONS 6.1 Deviation from the specification 6.2 Any deviation in test procedure from the specification. 6.3 Any deviation in cable offered. 7. COLOUR CODE Whether colour code is followed as per Annexure-A of our specification.

17 PAGE NO. 17 OF PROOF OF ABILITY (a) (b) (c) (d) (e) The bidders shall submit a list of similar supplies made by him to standards and tolerances specified in this tender document. The bidder shall submit with the offer, a list of inhouse test facilities available with them for carrying out all tests specified in this specification. The bidder shall submit along with the offer, the test reports of all the tests specified in this specification carried out by him on similar type of cable. Bidder shall submit along with the offer descriptive and illustrative literature covering construction and materials used for the cables offered. The Vendor information form enclosed shall be filled and submitted along with the bid. 9. INFORMATION REQUIRED AFTER AWARD OF CONTRACT Five (5) copies of certified test reports for the tests mentioned in clause 8.0 of this specification.

18 PAGE NO. 18 OF 24 DELIVERY SCHEDULE & PRICE DETAILS ANNEXURE-C 1. The entire quantity ordered shall be delivered within 8 months from the date of Purchase Order. 2. The supplier shall give his detailed delivery schedule. 3. The supplier shall give price details as per following table. Item No. Description Total Qty. Rate per Km. Rs. Total Price Rs Core 1.5 sq.mm armoured cable Core 1.5 sq.mm armoured cable Core 1.5 sq.mm armoured cable Core 1.5 sq.mm armoured cable 7.8 Note: Quantity of cable will be mentioned at the time of raising the requisition.

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