ACCELARATED POWER DEVELOPMENT AND REFORM PROGRAMME. Technical Specification (T.S)

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1 ACCELARATED POWER DEVELOPMENT AND REFORM PROGRAMME SECTION - V Technical Specification (T.S) 37

2 (SCHEDULE I) TECHNICAL SPECIFICATION FOR SUPPLY OF AB CABLE 38

3 1. SCOPE: TECHNICAL SPECIFICATION This specification covers manufacturing, testing before dispatch and delivery at destination store(s) of XLPE insulated aluminum cables twisted over a central bare aluminum alloy messenger wire for use on LT overhead lines of sizes indicated under the heading of SCHEDULE OF REQUIREMENT. 2. DESCRIPTION OF MATERIALS : XLPE insulated aluminum cables twisted over a central bare aluminum alloy messenger wire for use on LT overhead lines, of different sizes as mentioned below along with it s accessories for working voltage up to and including 1100 volts as per schedule of requirements. Sizes of AB Conductor: 1. 3 X X X X X X X X STANDARDS : Unless otherwise stated in this specification, the following standards as amended from time to time shall be applicable. (a) IS : 10810/1984 : Methods of test for cables. (b) IS : 8130/1984 : Conductors for insulated cables. (c) IS : 398(Pt.IV/1979 : Aluminum alloy Conductor. (d)is: 14255/ 1995 : AB Cable (e) NFC : 1996 : Methods of Test for weather resistance for AB Cable 4. SYSTEM PARAMETERS & CLIMATIC CONDITIONS: (a) System Parameters. Nominal Voltage. 400/230 Volt. 54

4 System highest Voltage. System Frequency. Method of Earthing. System Fault Level. 400 Volt. 50 Hz Effective Earthing MVA (b) Climatic Condition The climatic condition at site under which the stores shall operate satisfactorily, are as follows: (a) Maximum temperature of air in shade 45 0 C (b) Minimum temperature of air in shade 0 0 C (c) Maximum temperature of air in sun 50 0 C (d) Maximum humidity 100% (e) Average No. of thunder storm days per annum 70 (f) Average No. of dust storm days per annum 20 (g) Maximum rainfall per annum 2000 mm (h) Average rainfall per annum 1500 mm (i) Maximum ambient temperature (daily average) 45 0 C (j) Wind Pressure 200 Kg/m 2 (k) Altitude Less than 1000 meter 5. TECHNICAL: (A) GENERAL: The XLPE insulated phase conductors with additional street lighting conductor (wherever applicable) shall be twisted around the bare aluminum alloy messenger wire, which shall take all the mechanical stress. The messenger wire shall also serve as the earth-cum-neutral wire. (B) PHASE CONDUCTORS: - The phase conductors with additional street lighting conductor (wherever applicable) shall be insulated with black weather resistant XLPE suitable for 1100 Volt insulation. The insulated conductors shall generally confirm to the standard (a),(b), (d)& (e) quoted in clause-3 above. 55

5 The phase conductors shall be suitably compacted and the outer diameter shall be within the limits specified in table given below. The phase conductors shall be provided with one, two and three ridges for quick identification. The tensile strength of the aluminum wires used in the conductors shall not be less than 100N/mm2. The standard sizes and technical characteristics of the phase and street lighting conductors shall be as per the following table. Nominal No. of Dia. Approx. Max. D.C Insulation Sectional Area Strands of Compacted Mass Resistance at Thickness (sq. mm.) Conductor (Kg./ Km.) 20deg. Cen. (mm.) (in mm.) (Ohm/ Km.) (Max.) 1.2 (Nom.) (Max.) 1.2 (Nom.) (Max.) 1.50 (Nom.) Note: Tolerance of +/-3% is allowable on diameter. MESSENGER (NEUTRAL CONDUCTOR) :- The bare messenger were shall be made of Aluminum Alloy confirming to IS-398 (part-iv/1979 & latest revision composed of 7 strands & shall be suitably compacted to have smooth, round surface to avoid damage to the XLPE insulation of the phase conductors twisted around the messenger. There shall be no joints in any wire of the stranded messenger conductor except those made in the base rod or wires before final drawing. 56

6 Nominal Sectional Area No. of strands Diameter of Compacted Conductor Approximate Mass Max. D.C. resistance at 20 0 C Minimum Tensile Strength (mm 2 ) (mm) (Kg/Km) (Ohm/Km) (KN) (C) COMPOSITION AND DESIGNATION OF FINISHED CABLES: The composition and designation of finished cables are given in the following table. Sl. No Designation Approx. Overall dia. Approx. total mass Of Of Complete Bunch Complete Bunch (Kg./Km) (mm.) 1 3 X X X X X X X X Note: Tolerance of +/-3% is allowable on diameter/ mass (D) TESTS : (a) All type tests, acceptance test & routine test shall be as per the given standards in clause 3 of this specification (b) The material offered, shall be fully type tested as per the relevant standards. The bidder must furnish two sets of type test report ( of the offered size 0 along with bid in respect of material offered. the type test certificates should be from CPRI INDIA Or any other recognized independent testing Authority acceptable to purchaser. 6. Tests to be Conducted: TESTS FOR PHASE/STREET LIGHT CONDUCTORS 57

7 6.1 Type Tests a) Tensile Test (IS: 8130) b) Wrapping Test (IS: 8130) c) Conductor Resistance Test (IS: 8130) d) Test for thickness of insulation (IS: ) e) Physical tests for cross linked polyethylene insulation (IS: 4255) g) Insulation resistance test (IS: ) h) Carbon Black Content of the XLPE insulation (weathering est for insulation & resistance NFC ) I) High voltage test including water immersion test (IS: Part ) j) Water absorption Test as IS To ensure that water can not rise by capillary action. k) Hot set Test as per IS L) Carbon Black contains 1 to 2.5 percent. 6.2 Acceptance Tests All tests as per IS , check of diameter value as per clause TEST FOR MESSENGER 7.1 Type Tests a) Breaking Load test (to be made on the finished conductors) IS: ) b) Elongation test (IS: ) c) Resistance Test (IS: ) 7.2 Acceptance Tests All the tests indicated in Clause 6.1 above, In addition, check of diameter values as per clause BENDING TEST ON THE COMPLETE CABLE The test shall be performed on a sample of complete cable. The sample shall be bent around a test mandrel at room temperature for at least one complete turn. It shall then be unwound and the process shall be repeated after turning the sample around it axis 180 o. The cycle of these operation shall then be repeated twice more. The diameter of the mandrel shall be 10 (D + d) 58

8 Where D = actual diameter of the cable (i.e. the minimum circumscribing Circle diameter), mm d = actual diameter of the conductor No cracks visible to the naked eye are allowed. 9. PACKING AND MARKING 9.1 The cable shall be wound in non-returnable drums conforming to IS: 'Specification for Reels and Drums for bare Wire'or the latest version thereof. The drum shall be marked with the following: a) Manufacturer's name b) Trade mark, if any c) Drum number or identification number d) Size of conductors e) Size of messenger f) Voltage grade g) Number and lengths of pieces of cable in each drum h) Gross mass of the packing i) Net mass of cable 9.2 The drums shall be of such construction as to assure delivery of conductor in the field free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that cable surface is not dented, scratched or damaged in any way during transport and erection. The cable shall be properly lagged on the drums. 9.3 The cable drum should be suitable for wheel mounting. 9.5 The normal length of each cable shall be 1 Km +/- 5%. While longer lengths shall be acceptable, shorter lengths not less than 50% of the standard lengths shall be acceptable to the extent of 10% of the ordered quantity. 9.6 Marking of NESCO-APDRP/ WESCO-APDRP/ SOUTHCO- APDRP (as the case may be), type & grade of Cable shall be marked on the cable insulation along with phase conductors shall be provided with one, two and three ridges for quick identification. 59

9 10. GURANTEED TECHINICAL PARTICULARS TO BE FURNISHED BY THE BIDDER Guaranteed Technical Particulars Sr. NO. PARTICULARS SPECIFIED/ REQUIREMENT Bidder's Data 1 Name of Manufacturer 2 Type of Cable LT AB Cable 3 Applicable Standards IS : 1995, IS 398 (Pt. IV): 1994, IS 8130 : 1984, IS : 1984, NFC : Voltage Grade 1.1 kv grade 5 Cable Description a) Phase (No. of Cores) 3 b) Cross - Section (mm 2 ) c) Neutral 1 d) Cross - Section (mm 2 ) e) Street Lighting Conductor 1 f) Cross - Section (mm 2 ) 6 Conductor (for Phase) a) Material b) Cross Sectional Area (mm 2 ) c) Number of Strands d) Stranding Lay Ratio for Inner Layer e) Stranding Lay Ratio for Outer Layer f) Max. Diameter of Conductor (mm) g) Minimum Diameter of Conductor (mm) h) Max. D.C. Resistance at 20 0 C ( /km) E.C. grade Al. H2/H4 as per IS : 8130: 1984 As per IS :

10 i) Continuous Current Carrying Capacity in air (at 50 0 C ambient) j) Maximum Short Circuit Current Rating for 1 Sec k) Co-efficient of Linear Expansion of Al (/ 0 C) 7 Insulation (for Phase) a) Material b) Nominal Thickness (mm) XLPE as per clause 6 of the tender document Clause 6 of the tender document c) Minimum Thickness (mm) d) Nominal Insulated Outside Diameter (mm) e) Min. Insulated Outside Diameter (mm) 8 Conductor (for Street Lighting ) a) Material b) Cross Sectional Area (mm 2 ) c) Number of Strands 1 d) Nominal Diameter of Conductor (mm) e) Max. D.C. Resistance at 20 0 C ( /km) f) Continuous Current Carrying Capacity in air (at 50 0 C ambient) g) Max. Short Circuit Current Rating for 1 Sec h) Min. Breaking Load (kn) Clause 6 of the tender document E.C. grade Al. H2/H4 as per IS : 8130: 1984, As per IS : Insulation (for Street Lighting Conductor) a) Material b) Nominal Thickness (mm) XLPE as per clause 6 of the tender document Clause 6 of the tender document 61

11 c) Minimum Thickness (mm) Clause 6 of the tender document d) Nominal Insulated Outside Diameter (mm) e) Min. Insulated Outside Diameter (mm) 10 Neutral Messenger a) Material b) Cross Sectional Area (mm 2 ) c) Number of Strands d) Stranding Lay Ratio e) Max. Diameter of Conductor (mm) f) Mini. Diameter of Conductor (mm) g) Minimum Breaking Load (kn) h) Co-efficient of Linear Expansion of Al Alloy (/ 0 C) 11 Completed Cable a) Assembly Lay Length (mm) b) Assembly Lay Direction Al Alloy Conductor as per IS 398 (Part - 4) & IS : As per IS :14255 Clause 7 of the tender document As per IS : 398 (Part - 4) & IS:14255 c) Core Identifications d) Bending Radius of the Cable e) Approx. Overall Diameter of complete cable f) Standard Packing Length (m) g) Size of the Drum (flange x barrel x traverse) h) Approx. Weight of Cable (kg/km) i) Approx. Gross Weight of Drum (kg) Note: Offers without GTP filled in shall be liable for rejection. Above similar format should be filled in for all sizes/ configuration of cable sizes separately. 62

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13 SCHEDULE II TECHNICAL SPECIFICATION FOR SUPPLY OF AB CABLE ACCESORIES 64

14 SPECIFICATION FOR AB CABLE FITTINGS: ITEMS to be supplied: The following are the meaning of the commonest terms used in this specification: Dead end Clamp assembly without Pole Clamp: A clamp designed to terminate a main line conductor bundle and to transfer it s tensile loading to the support structures. Suspension Clamp Assembly without Pole Clamp: A clamp designed to support the conductor bundle at intermediate positions and angle positions with up to 60 deg line deviation. Insulator piercing connector for sq. mm. XLPE cable and service side sq. mm: A tap off connector which is designed to be applied to the conductors in the bundle without first removing the insulation. Universal Pole Clamp with Eye Hook: This pole clamp will be used with the suspension clamp & dead end clamp assembly & shall be suitable for both joist poles as well as PSC poles. Neutral Connector: This will be used for providing service connection & will be placed for neutral line. 65

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16 5. Materials for AB Cable fittings: The materials used for manufacturing the fittings, accessories and apparatus covered by this specification shall be compatible with the materials of the conductor bundle such that the reliability of either will not be impaired by their association. Materials shall be resistant to climatic stress. All insulating materials shall be ultra violate stabilized and coloured black. Thickness of steel parts shall not be less than 2 mm and shall be hot dip galvanized as per the surface treatment section of this specification. Other metallic parts shall be non corrosive type. Non metallic materials shall be fire retardant. All threaded parts shall comply with ISO metric standard and hexagonal headed bolts and nuts shall conform with ISO metric standard 272, 885, 888, 4759/1. Particular attention shall be paid to prevent bimetallic corrosion at the junction of dissimilar metals. All the piercing connector shall be marked with NESCO-APDRP/ WESCO-APDRP/ SOUTHCO-APDRP as the case may be. 1. PACKING & MARKING: The cable shall be wound in non-returnable drums confirming to IS 1778/ 1961 or latest amendments thereof. The drums shall be marked as per clause-12 of REC Specification No.32/1984. The fittings shall also be packed as per standard packing terms. 2. INSPECTION: Pre dispatch inspection will be conducted as per relevant I.S. All the acceptance tests shall be carried out at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser. 67

17 The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with the relevant specifications. The successful tenderer shall grant free access to the purchaser s representative at a reasonable time when the work is in progress. Inspection and acceptance of any materials under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing the materials in accordance with the specification and shall not prevent subsequent rejection if the materials are found defective. The supplier shall keep the purchaser informed in advance, about the manufacturing programme so that the arrangement can be made for inspection. The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought-out items. a. DRAWING & DESCRIPTIVE LITERATURE: Three copies of detailed dimensional drawings indicating various components used and descriptive literature should accompany the tender giving the full details of the stores to be supplied. b. GUARANTEED TECHNICAL PARTICULARS: The guaranteed technical particulars as called for in this specification shall be furnished along with the tender. Offer without guaranteed technical particulars or incomplete in any manner is liable to be rejected. c. SAMPLE: One sample of cable measuring 1 Mtr. In length from each size & one sample each from the AB cable fittings shall be furnished along with the offer. Offers without samples are liable for rejection. Bidders are required to furnish performance reports from users. The 68

18 samples thus submitted shall be tested as independent laboratories. The cost of testing shall be borne by the bidders. d. SCHEDULE OF QUANTITY & DESIRED DELIVERY: As per enclosure. 3. SURFACE TREATMENT A full description of the corrosion prevention system proposed by the Bidder shall be given in the schedule and this is subject to acceptance by the Purchaser. This description shall include details of surface preparation, rust inhibition, paint thickness, treatment of fasteners and painting of surfaces in contact with oil. All machining, drilling, welding, engraving, scribing, or other manufacturing activities which would damage the final surface treatment shall be completed before the specified surface treatment is carried out. Any subsequent damage occurring to the surface treatment up to the final delivery, off-loading and acceptance shall be made good by the Supplier. Galvanising All galvanising shall be carried out by the hot dip process, in accordance with Specification ISO: 1460 or IS: However, high tensile steel nuts, bolts and spring washers shall be electro galvanised to service condition four. The zinc coating shall be smooth, continuous and uniform. It shall be free from acid spots and shall not scale, blister or be removable by handling or packing. There shall be no impurities in the zinc or additives to the galvanic bath which could have a detrimental effect on the durability of the zinc coating. Before pickling, all welding, drilling, cutting, grinding and other finishing operations must be completed and all grease, paint, varnish, oil, welding slag and foreign bodies completely removed. All protuberances, which would affect the life of galvanising, shall also be removed. The weight of zinc deposited shall be in accordance with BS 729 and shall not be less than 0.61kg/m 2 with a minimum thickness of 86 microns for items of thickness more than 5 mm, 0.46 kg/m 2 (64 microns) for items of thickness between 2 mm and 5 mm and 0.33 kg/ m 2 (47 microns) for items less than 2 mm thick. Parts shall not be galvanised if their shapes are such that the pickling solution cannot be removed with certainty or if galvanising would be unsatisfactory or if their mechanical strength would be reduced. Surfaces in contact with oil shall not be galvanised unless they are subsequently coated with an oil resistant varnish or paint. 69

19 In the event of damage to the galvanising the method used for repair shall be subject to the approval of the Purchaser or his representative. The threads of all galvanised bolts and screwed rods shall be cleared of spelter by spinning or brushing. A die shall not be used for cleaning the threads unless specifically approved by the Purchaser. All nuts shall be galvanised. The threads of nuts shall be cleaned with a tap and the threads oiled. Partial immersion of the work shall not be permitted and the galvanising tank must therefore be sufficiently large to permit galvanising to be carried out by one immersion. After galvanising no drilling or welding shall be performed on the galvanised parts of the equipment excepting that nuts may be threaded after galvanising. To avoid the formation of white rust, galvanised material shall be stacked during transport and stored in such a manner as to permit adequate ventilation. Sodium dichromate treatment shall be provided to avoid formation of white rust after hot dip galvanisation. The galvanisation shall be subjected to tests as per IS: 2633 and BS: GUARANTED TECHICAL PARTICULARS: POLE CLAMP WITH EYE HOOK Sl. Particulars Bidder's Offer 1 Dimension 2 Thickness of Zinc Coating (Micron) Eye Hook U Bar Nut Pole Clamp Screw DEAD END CLAMP 1 Dimension 2 Thickness of Zinc Coating (Micron) U Bar Nut 3 Slip (kn) 4 Ultimate tensile Strength INSULATED PIERCING CONNECTOR 1 Dimension 2 Thickness of Zinc Coating (Micron) Screw Nut 3 Material Identification Plastic component (Top) Plastic component (bottom) 70

20 Rubber items 4 Continuity Test (-20 Deg, 2 Hrs) 5 Dielectric Test NEUTRAL CONNECTOR 1 Dimension 2 Thickness of Zinc Coating (Micron) Screw Nut 3 Slip (kn) SUSPENSION CLAMP 1 Dimension 2 Thickness of Zinc Coating (Micron) 3 Slip (kn) 4 Thickness of Insulation 5 Ultimate Tensile Strength (kn) Note: Offers without GTP filled in shall be liable for rejection. Above similar format should be filled in for all sizes/ configuration of cable sizes separately. 71

21 13. TEST CERTIFICATES SCHEDULE On this schedule a list of the test certificates included with the bid shall be provided. This list should include type test certificates and sample routine test reports. Each certificate listed shall be referred to the relevant specification clause and item of equipment to which the test applies. Clause No Type Test Certificate or Routine Test Report 72

TECHNICAL SPECIFICATION FOR L. T. XLPE POWER CABLE

TECHNICAL SPECIFICATION FOR L. T. XLPE POWER CABLE SEAL & SIGNATURE OF THE TENDERER PAGE 1 OF 14 TECHNICAL SPECIFICATION FOR LT XLPE POWER CABLES (SPECIFICATION NO.MM/I/LTXLPE/2006) 1. SCOPE: The specification