TECHNICAL SPECIFICATION FOR X-LINKED POLYTHYLENE INSULATED

AND PVC SHEATHED H.T CABLES

1.SCOPE: -
This specification briefly provides a for the manufacture, testing before
dispatch. Transportation, supply and delivery of ISI marked, 33 KV grade
XLPE sheathed power cables conforming to IS-7098 (Part-II) / 1985 with
up to date amendments, suitable for solidly earthed system manufactured
with dry cure (Nitrogen gas i.e. with inert gas curing using CCV system or
sioplas technology.

2. STANDARDS:-
a) The 33KV cables shall meet the requirements of the latest edition of the Bureau
of Indian standards, (generally referred as IS) IS 7098 (Part-II) 1985. The cables
manufactured to and meeting the testing requirements of international
standards, like B.S.S. IEC or equivalent standards are also acceptable. The
bidders shall enclose a copy of the equivalent international standard, in
English Language, along with the Bid.
b) 33KV cables shall be manufactured to the highest quality, best work man ship
with scientific material management and quality control.
c) Bidder shall furnish the quality plan, giving in details the quality control
procedures/management system.
3. GENERAL TECHNICAL PARTICULERS:-
1. Nominal system voltage (rms) () 33KV
2. Highest System voltage (rms) (m) 36KV
3. Phase to Earth voltage (o) 19KV
4. Number of phases (for 3 core cables) 3
5. Frequency 50Hz
6. Variation in frequency +-3%
7. Type of earthing Non effectively earthed
system
8. Basic impulse level (1.2/50 micro second wave) 170KV peak (no break
down of the insulation
shall occur during the
test.
9. One minute power frequency with stand voltage 48KV
10. Approx. length in cable drum As per ISS
11. Short circuit current (I=0.094xArea of cable)
i 185 mm2 17.39 KA (994 MVA) for
1 sec.
2
Ii 300 mm 28.2 KA (1612 MVA) for
1 sec.
12 Continuous current rating at maximum When laid in air 40 deg.
conductor temp. of C.
90 deg. C.
i 185 mm2 310
2
Ii 300 mm 396
Maximum temperature permissible emergency 130 deg.C for one hrs.
overload temp. At 25% overload to 100 Hrs. per
year or 500hrs. in life of cable.
13. Maximum permissible short circuit temperature. 250 deg. C for onr sec.
14. Conductor material Material to IS:8130,14
 grude Alu. Conductor,
stranded compacted
circular
15. Conductor screening As per IS:7098 (part-II)
1985 or update
amendments
16. Inner sheathing -Do-
17. Armouring -Do-
18. Overall sheathing -Do-
19. End sealing ISS/REC standards
20. Maximum tan-delta at room temp. At nominal 0.004 (at ambient
phase to neutral voltage (Uo) temperature and 0.008
at 90 deg. C.
21 High voltage test between conductor and screen The cable shall with
/Armour stand without
breakdown and AC
voltage equal to 3Uo (as
per ISS)
22. Maximum D.C. Resistance per KM As per relevant ISS

4. INSTALLATION CONDITIONS:-
a) These are used directly buried in ground, partly in RCC/Hume pipes or stoneware
pipes at road crossing in case of 3 core cable.
b) Normal depth of lying is 900mm to 1000mm (from top of round to entre of cable).
c) Soil resistivity variable 18 to 100 Ohm-meter.
d) Soil thermal resistivity (assumed) 120 to 150 deg. C. Cm/w.

5. MANUFACTURE PROCESS, CROSS LINKING OF INSULATION:-

a) Cross linking of the insulation materials (pre compounded polyethylene) shall be
conforming to IS: 7098 (part-II).
b) The conductor screen shall consist of the non-metallic part extruded semi
conducing compound with non magnetic metallic part XLPE insulation and the
shields for conductor and insulation shall be extended in one operation.
c) Process of curing is of Dry curing.
6. MATERIALS GENERAL CONDITIONS AND FEATURE OF CABLES.
a.) CONDUCTORS:-
The conductor shall be stranded, compact and circular of aluminium wires of H2
or H4 grade plain aluminium wires. Conductor construction and testing shall
comply to IS:8130/1984 as amended up to date and IEC: 60228.
b.) INSULATION :-
The insulation shall be chemically cross linked polyethylene conforming to the
physical, electrical and ageing properties as required in the specification. Cross
linking may be done by exposure to organize peroxide with nitrogen curing CCV
line of sioplas technology, method with the intention to ensure lowest tree
formation. Insulation thickness value shall not fall below standard thickness value
as specified in IS:7098 (part-II) 1985 and applicable tolerance as specified in the
table 2 of IS 7098 (part-II).
c.) SCREENING:-
 The screening of insulated cables shall consist of conductor screening and
insulation screening.
i) CONDUCTOR SCREENING:-
Conductor screening shall be non-metallic and shall consist of either semi-
conducting compound or a layer of extruded-semi-conducting compound or
combination of the two.
ii) INSULATION SCREENING:-
The insulation screening shall consist of non-metallic semi-conducting part in
combination with a metallic part non-metallic part shall be applied either
directly over the insulation of each core and shall consist of either a semi-
conducting tape or a layer of extruded semi-conducting compound or a
combination of these materials. The metallic part shall be applied over the
individual core, metallic screening shall consist of either tape or braid or
concentric serving of wires or a sheath and shall be non magnetic and applied
over the non-metallic parts either in single core or multi-core cables.
iii) CORE SHIELDING:-
XLPE insulation and insulation shielding are all extruded in one operation by a
special process called triple extrusion this ensures perfect bonding of inner
and outer shielding. The bond prevents the cavities at the surface of the
conductor, when the cable is subjected to bends. The void formation at the
interface of the semiconducting layer and insulation too is eliminated even
during heating and cooling cycles in the operation.
d.) INNER SHEATH:-
In multi-core cables the individual core shall be laid up and then be surrounded
by common covering applied either by extrusion or wrapping of a filling
material containing thermoplastic material. A proofed or plastic tape may be
applied over the common covering. When a wrapped common covering is
employed, it shall be ensured that the circularity of the cable is maintained.
The thickness of inner sheath (common covering) shall be as given in table 3
of IS 7098 (part-2) 1985.
e.) ARMOURING:-
The armour shall consist of either galvanized round steel wires or galvanized
steel strips, depending upon the nominal diameter under the armouring. The
dimensions of galvanized steel wire or strip shall be as specified in the IS and
shall be conform to IS-3975-1979, for all requirements . A binder tape may be
applied on the armour.
f.) OUTER SHEATH:-
Over the armouring , the cable shall be provided with extruded PVC outer
sheath. The composition of the PVC compound for outer sheath shall be pre-
type ST2 of IS-5831-1984. The colour of the outer sheath shall be black. The
average thickness of the sheath shall not be less than the standard values
specified in the IS when measured as laid in IS-7098 (part-II) /1985. The
smallest thickness of the measured values of sheath shall not fall below the
standard value (ts) specified by more than 0.2+0.2(ts) mm.
g.) FILLER AND INNER SHEATH FOR MULTI CORE CABLES:-
For Multi Core cables, the interstices at the centre shall be filled with a non-
hygroscopic material, The interstices around the laid up cores shall be
covered with PVC compound type ST-2, This will form the inner sheath for Multi
Cores Cables.
I) CORE IDENTIFICATION: The core identification shall comply with the
requirements of IS: 7098 part-2 as shown below:
a) By numerals (1, 2, 3) either by applying numbered strips or by printing.
Or
b) coloured strips applied on the cores.
7 CONSTRUCTION:- The general constructional features of the cables shall be
as follows:
a) 3 CORE CABLES: Stranded, Compacted Circular, Aluminium Conductor,
Conductor Screen of extruded semi conducting compound, Cross linked
polyethylene insulation, cross linked, shall be conforming to IS:7098(Part-II).
Insulation screen consisting of non-metallic part of extruded semi- conducting
compound and the metallic part of copper tape (s).
Extruded PVC inner sheath.
Armour (Galvanized Steel strip).
Outer PVC sheath with anti-termite treatment.
b.) LAYING UP OF CORES:- For, multi-core cables, the cores shall be laid
together with a suitable right hand lay. The interstices at the centre shall be
filled with a suitable non-hygroscopic material.
8. QUALITY ASSURANCE PLAN:-
a. The successful bidder shall submit following information to the owner:
b. Test certificates of the raw materials and bought out accessories.
c. Statement giving list of important raw materials, their grades along with
names of sub-suppliers for raw materials, list of standards according to which
the raw materials are tested. List of tests normally carried out on raw
materials in. presence of bidders representative.
d. List of manufacturing facilities available.
e. Level of automation achieved and lists of areas where manual processing
exists.
f. List of areas in manufacturing process, where stage inspections are normally
carried out for quality control and details of such tests and inspections.
g. List of testing equipments available with the bidder for final testing of
equipment along with valid calibration reports.
h. The manufacture shall submit manufacturing quality plan (MPQ) for approval &
the same shall be followed during manufacture and testing.
i. The successful bidder shall submit the routine test certificates of bought out
raw material / accessories and central excise passes for raw material at the
time of inspection.
9. TESTS:-
I Copies of the type test certificates in respect of all the typo-tests as per
IS:7098 (part-2)/ 1985 for similar type of XL1PE cables, from any Government
recognized testing labs, shall be submitted along with the tender; However
after receipt of material in RVUNL stores , the RVUNL may sent the sample
from received material for type test in any Govt. /NABL/CPRI laboratory at
RVUNL cost and if the test material fails, the entire lot will be rejected and the
supplier will have to lift back the rejected material from RVUNL stores at its
own cost within 20 days failing which the RVUNL shall not be held accountable
for any loss whatsoever. The purchaser will effect the purchases for the
 balance quantity along with material rejected at the risk and cost of the
supplier For these reasons, the firm can also be blacklisted for future supplies.
LIST OF TYPE TESTS:-
a) Tests on conductor refer is 7098 (part-2) 1985:-
i) Annealing test (for copper)
ii) Tensile test (for Aluminium)
iii) Wrapping test (for Aluminium)
iv) Resistance test.
b) Tests for armouring wires/strips [IS7098, part-2, clause-7, table -4
and IS 3975-1989).
c) Test for thickness of Insulation and sheath (clauses 11,15 & 17 , table
-2,3&5).
d) Physical tests for insulation IS 7098 (PART-2)1985/refer part no. of IS
10810).
i) Tensile strength and elongation at break.
ii) Ageing in air Oven.
iii) Hot test.
iv) Shrinkage test.
v) Water absorption (Gravimetric)
e) Physical tests for outer sheath IS 7098 (PART-2) 1985/for requirement
IS 3831-1994.
i) Tensile strength and elongation of break.
ii) Ageing in air oven
iii) Shrinkage test.
iv) Hot deformation,
f) i) Bleeding and Blooming test (for outer sheath).
ii) Loss of mass in air over, heat shock and thermal stability tests will be carried
out as per IS: 7098, Part-II/1985,
g) Partial discharge test.
h) Bending test.
i) Di-electric power factor test.
i) As a function of vo1tge.
ii) As a function of temperature.
j) Inu1ation resistance (Volume resistivity test IS 7098 (PART-2) 1985
table -I.
k) Heating cycle test IS 7098 (PART-2) 1985 clause 19.5.
l) Impulse withstand test IS 7098 (PART-2) 1985 clause 19.6.
m) High voltage test IS 7098 (PART-2) 1985 clause 19.7.
n) Flammability test IS 7098 (PART-2) 1985 clause 19.8.
o) Cold Impact test IS 7098 (Part-2) 1985/IS 5831-1984.

Note:- The cable shall be inspected at suppliers works before dispatch as per IS-
7098 (part-II)/ 1985 (with up-to-date amendments, all the acceptance tests
embodied in the above IS shall be performed by the Inspection Officer. The
supplier shall arrange without making any extra charges all the necessary
machinery, apparatus and labour requirement for the testing purpose. The
cable requirement for testing shall be to firms account.
II. ACCEPTANCE TESTS refer IS 7098:-
The following shall constitute the acceptance test.
a) Tensile test for aluminium.
b) Wrapping test for aluminium.
c) Conductor resistance test.
d) Test for thickness of insulation.
e) Test for thickness of inner and outer sheath.
f) Hot-set test for insulation.
g) Tensile strength and elongation at break test for insulation and sheath.
h) Partial discharge test (on full drum length).
I) High voltage test.
j) Insulation resistance (volume resistivity) test.

III. Routine Tests The routine test shall be carried out on all cable
manufactured in accordance with this specification.
a) Conductor resistance test.
b) Partial discharge test.
c) High voltage test.