TECHNICAL SPECIFICATION FOR 66 KV (CROSS LINKED POLYETHYLENE INSULATED

POWER CABLE:

1.1 SCOPE

1.1.1 The scope under this section covers design, manufacturer, testing, packing, supply,
delivery and laying of 66 KV, XLPE, insulated power cable for use with effectively earthed
distribution systems.
1.2 STANDARDS: ​Unless otherwise specified, the cables shall conform, in all respects, to
IEC-60840 and IS:7098 (Part-III)/1993 with latest amendment or latest edition for cross
linked polyethylene insulated PVC sheathed cable for working voltage of 66KV.

1.3 CLIMATIC CONDITIONS: The climatic conditions under which the cable shall operate
satisfactorily are as follows:-
a) Location : IN THE STATE OF HARYANA
0​
b) Maximum ambient temperature of air in shade C : 50

0​
c) Minimum ambient temperature of air in shade C : -2.5

0​
d) Maximum daily average ambient temperature C : 40

0​
e) Maximum yearly average ambient temperature C : 30

f) Maximum relative humidity % : 100

g) Minimum relative humidity % : 26

h) Average number of thunder storm days per annum : 35

i) Average annual rain fall mm : 900

j) Max. wind pressure kg/m2 : 195

k) Altitudes not exceeding above MSL Meter : 1000

0​
l) Max. soil temp. at cable depth C : 30

m) Isoceranic level days/year : 50

n) Seismic level (horizontal acceleration) : 0.3g

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1.4 PRINCIPAL PARAMETERS:
1.4.1 66 kV (E) grade XLPE single core power cable conductor electrolytic grade copper of
single length, with formation of stranded compacted circular conductor for size upto
800mm​2 and segmental type for size above 800mm​2 as per IEC-60228, tapped with semi
conducting tap, shielded with extruded semi-conducting layer, insulated with cross linked
polyethylene (XLPE) insulation, screened with extruded semi-conducting layer, lapped
with a combination of semi-conducting water swell able tape & copper-woven semi
conducting tape and extruded aluminium sheath with anti-corrosive layer & graphite
coating HDPE outer sheathed, confirming to IEC-60840 for construction and also
confirming to IS:7098 (Part-III)/1993 or any latest amendments thereof.

1.4.2 Outer sheathing should be designed to afford high degree of mechanical protection and
should also be heat, oil chemicals and weather resistant. Common acid. Alkalis and saline
solution should not have adverse effect on the PVC sheathing material used.
1.4.3 The cable should be suitable for laying in covered trenches and/or under ground for
outdoor.
1.4.4 The sheath/screen bonding system shall provide a continuous current path through the
cable sheath and jointing kits and shall be bonded. The bonding ends shall be suitably
earthed with/without SVL as per approved configuration/design. The sheath voltage under
full load condition shall not exceed the voltage specified/allowed in relevant standard for
safety of personal as well as satisfactory working of cable. Sheath shall be solidly
grounded at suitable location with or without SVL. Bidder must indicate details of
configuration proposed along with sufficiency calculation with the bid so as to limit induced
voltage of sheath within 65V.
1.4.5 CABLE PARAMETERS
Sr. No. Description 66 KV
i) Voltage Grade (Uo/U) 38/66
ii) No. of cores Single
iii) Size (mm​2​) 400mm​2​,630mm​2​,
800mm​2​,1000mm​2​, 1200 mm​2
iv) Nominal system voltage KV 66

v) Highest system voltage KV 72.5

vi) System Frequency Hz 50
vii) Variation in Frequency + ​3%
viii) Fault level individually for
i) Conductor 31.5 KA for1sec
ii) Cu.Screen/Armour 31.5 KA for 1sec
ix) Maximum allowable temperature

a) Design continuous operation at rated full load 90

current, the max, temp. of conductor shall not
0​
exceed. C
b) The conductor temperature after a short 250
circuit for 1.0 sec shall not exceed. 0​​ C

x) Basic insulation level (1.2/50 Micro Second 325 KVP

Wave)
xi) 1-min. power frequency withstand voltage (rms) 140 KV

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xii) System earthing Effectively earthed

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1.5 GENERAL TECHNICAL REQUIREMENTS​:

1.5.1 CONDUCTOR: The cable conductor shall be made from electrolytic grade copper with
formation as stranded compacted circular conductor for size upto 800mm​2 and segmental
type as per IEC-60228 for the size above 800mm​2​.The conductor shall confirm to
IS:8130/1984.
1.5.2 CONDUCOTR SHIELD: The conductor having a semi-conducting screen shall ensure
perfectly smooth profile and avoid stress concentration. The conductor screen shall be
extruded in the same operation as the insulation; the semi-conducting polymer shall be
cross-linked.

1.5.3 INSULATION: The XLPE insulation should be suitable for specified 66 kV system voltage.
The manufacturing process shall ensure that insulations shall be free from voids. The
insulation shall withstand mechanical and thermal stressed under steady state and
transient operating conditions. The extrusion method should give very smooth interface
between semi-conducting screen and insulation.

1.5.4 INSULATION SHIELD: To confine electrical field to the insulation, non-magnetic

semi-conducting shield shall be put over the insulation. The insulation shield shall be
extruded in the same operation as the conductor shield and the insulation by suitable
extrusion process. The XLPE insulation shield should be bonded type. Metallic screening
shall be provided. The metallic screen shall be of copper wire having fault current capacity
same as the conductor (31.5KA for 1-sec).

1.5.5 INNER SHEATH/ARMOUR: The inner sheath shall comprise of a combination of

semi-conducting water swell able and extruded aluminium sheath with anti-corrosive layer.
The sheath shall be suitable to withstand the site conditions and the desired temperature.
It should be of adequate thickness, consistent quality and free from all defects.
The armour shall be having fault current capacity same as conductor (31.5KA for 1 sec.)

1.5.6 OUTER SHEATH: Extruded HDPE outer sheath confirming to IEC: 60840, shall be
applied over armouring with suitable additives to prevent attack by rodents and termites.

1.5.7 CONSTRUCTION:
1.5.7.1 All materials used in the manufacture of cable shall be new unused and of finest quality.
All materials should comply with the applicable provision of the tests of the specification.
IS, IEC, Indian Electricity Rules, Indian Electricity Act and any other applicable statutory
provisions rules and regulations.

1.5.8 CURRENT RATING: The cable will have current ratings and derating factors as per
relevant standard IEC.

1.5.8.1 The one-second short circuit rating values each for conductor, screen & armour shall be
furnished and shall be subject to the purchaser’s approval.

1.5.8.2 The current ratings shall be based on maximum conductor temperature of 90 deg. C with
ambient site condition specified for continuous operation at the rated current.

1.5.8.3 SIZE:

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 The different sizes of cable shall be 66 KV Single Core

a) 400mm​2
b) 630mm​2
c) 800mm​2
d) 1000mm​2
e) 1200mm​2
1.5.9 OPERATION:
1.5.10.1Cables shall be capable of satisfactory operation under a power supply system frequency
variation of plus minus 3% voltage variation of plus, minus 10% and combined frequency
voltage variation of 10% (absolute sum).

1.5.10.2 Cable shall be suitable for laying in ducts or buried under ground.

1.5.10.3 Cable shall have heat and moisture resistance properties. These shall be of type and
design with proven record on transmission network service.

1.5.11 LENGHTS: The cable shall be supplied in standard drum lengths as below:

Size of cable Standard Drum Length

a) 1c x 400mm​2​, 630mm​2​,800mm​2​, 750 meters ​+ ​5% tolerance and

1000mm​2​, 1200 mm​2 ​+ ​2% overall tolerance in total quantity of cable.

1.5.10 INDENTIFICATION MARKING: ​Identification of cables shall be provided externally at

three meters’ intervals to identify as under:-
i) ‘Name of Manufacture’
ii) ‘Year of manufacture’
iii) ‘Voltage grade’ to be printed/embossed at the interval of one meter-length. The
identification, by printing or embossing shall be done only on the outer sheath.
Name of purchaser shall also be embossed.
1.6.0 TESTS
1.6.1 Type Tests
The equipment offered should be type tested. Type test report should not be more than
seven years old, reckoned from the date of bid opening, in respect of the following tests,
carried out in accordance with ISS-7098/IEC-871, from Govt./Govt. approved test house,
shall be submitted along with bid:
i) Physical tests for insulation and outer sheath.
ii) Bending test.
iii) Di-electrical power factor test.
iv) Heating cycle test followed by di-electrical power factor as a function of voltage and
partial discharge test.
v) Impulse withstand test.

The remaining type test report as per clause 3 of ISS-7098/IEC-871/IEC-60840 shall be

submitted by the successful bidder within three months from the date of placement of
order. These type test reports shall be from Govt./Govt. approved test house and shall not
be more than seven years old, reckoned from the date of placement of order. The failure
to do so will be considered as a breach of contract.

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1.6.2 ROUTINE TESTS AND ACCEPTANCE TESTS
All routine and acceptance tests shall be carried as per relevant ISS in the presence of
Nigam’s representative.

1.7 INSPECTION
The material shall be inspected and tested before dispatch by an authorised
representative of the Nigam in respect of quality.
The inspecting officer shall also satisfy himself about the correctness of length of cables
as provided in Instruction No. 208 of E.B. Manual of Instruction 1963 Edition amended
vide O/O No. G/BD-33(57) 75 dt. 18.04.75 now HVPNL. In case the supplier is not in a
position to get these tests carried out at his works, such tests may be got carried out by
him at any Govt. recognized test agency at his own expense.

1.8 TEST CERTIFICATES

The supplier shall supply test certificates from a Govt. agency in respect of quality as per
IS:7098(part-II) 1985 with latest amendments thereof for approval of the purchaser.

1.9 PACKING
The cable shall be supplied in non-returnable wooden drum as per IS:10418:1982 so
constructed, as to enable the cable to be transported on each drum. The cable wound on
such drum shall be one continuous length. The ends of cables shall be sealed by means
of non-hygroscopic sealing material.

1.10 MARKING
The marking on the drum shall have the following information: -

a) Reference to Indian Standard & cable code.

b) Name of the manufacturer & trade name.
c) Nominal cross section area of conductor for the cables.
d) Number of core.
e) Sequential No. at each meter.
f) Type of the cable & voltage for which it is suitable.
g) Length of cable on the drum.
h) Approximate gross weight.
i) Net weight of the cable.
j) Drum identification number.
k) P.O. No. and date.
l) Consignee’s name with designation.
m) Year of manufacture.

1.11 DRAWINGS & INSTRUCTION MANUAL

The tenderer shall supply the following drawings with the tender: -
i) Detailed drawing of the cable showing conductor, screening insulation, Armoring, outer
sheath etc.
ii) Detailed drawing showing jointing of cable and sealing of end boxes.

Copies of instruction manuals for testing, installation jointing operation and maintenance of
cables shall also be submitted with the offer for reference of the purchaser.

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1.12 TECHNICAL & GUARANTEED PARTICULARS: The tenderer shall furnish guaranteed
technical particulars as called for in appendix-I (Schedule-A) of this specification.
Particulars, which are subject to guarantee, shall be clearly marked. Offer not containing
this information will not be considered.

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 PART-II
TECHNICAL SPECIFICATION FOR LAYING, TESTING AND COMMISSIONING OF 66kV XLPE
UNDERGROUND POWER CABLE

SECTION-1
SPECIFICATION FOR LAYING OF CABLE

1.1 LAYING OF POWER CABLE:

1.1.1 The 66kV(E) XLPE cable shall be installed underground and normally buried directly in the
ground complying with all applicable standards and IS:1255 & their amendments.

1.1.2 The sealing of power cable ends should be made during the storage; execution &
completion of jointing works shall be in the scope of successful tenderer. In no
circumstances, the cable ends shall be kept open.

1.1.3 Three single core cables shall be laid in trefoil formation.

1.1.4 The power cable shall be laid generally at a depth of 1500mm and can vary, if obstacles
like power cable of other rating/telephone cable/water pipe line etc, come in the way of
installation. At least minimum Depth of 1000 mm shall be maintained from nearest road
level.

1.1.5 The cables shall be completely surrounded by a layer of having a low thermal resistivity
(selected sand) sand about 250mm over & below of the cable surface throughout width of
the cable trench at no extra cost. (River sand shall be allowed for surrounding layer).

1.1.6 The extra protection of pre-cost flat RCC slab with proportion 1:2:4 having size 600(L)
X300(B) X 50(Thk) mm shall be provided about 250mm over the power cables for
complete route of the cable.

The RCC slab shall be with proportion not less than 1:2:4 (M-150) and also shall have
steel reinforced of 6/8 mm dia. Steel bar (4 nos. of 300mm side and 5 Nos. on 600 mm
side ) at adequate required distance. The slab shall be given curing time of minimum 15
days.

1.1.7 Normally, the back filling shall consist of the materials earlier excavated, however, bigger
stones or piece of rock should be removed OR if required new soil has to be provided and
used for back filling with no extra cost.

1.1.8 The cable drum must be handled correctly and with care during transport and laying of the
power cables, in order to avoid damage to the cables.

1.1.9 The minimum bending radius of the cable shall be 30xD where D is diameter of the cable.

1.2 CROSSINGS:

1.2.1 a) Where road crossing comes in way of laying power cable, the power cable shall be laid
through NP-4 RCC Hume Pipes.

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 b) The RCC Hume pipe inner dia-meter shall not be less than 400mm.

c) The RCC pipes to be laid shall have minimum depth in such a way that the back filling
on top surface of the pipe shall be at least 600mm in depth. The pipe joints shall be
smooth so that cables are not damaged during pulling & operation.

d) During the crossing of utilities like water line, drainage lines, telephone lines, gas lines
etc. sufficient care shall be taken & protection shall be made available so that other utilities
do not damage the cable mechanically and/or electrically or do not effect the performance
of the cable.

e) NALA CROSSINGS/CULVERT CROSSINGS: The Nala crossings are to be made with

separate fly-over bridges of adequate sizes to carry all the cables in required formation.
The bridges are to be made at the sufficient distances from the edge of Nala considering
the further expansions of roads. The strength shall be such that it should not wash away
with the flow of water during heavy rain.

1.3 IDENTIFICATOIN, MARKING AND WARNING​:

1.3.1 The identification marker shall be of adequate size fabricated from 3mm thick,
25mmx25mm aluminium strip. The marker shall be embossed with letter as stated below:

“Name of S/Stn” and “Phase R or Y or B" as the case may be .

The marker shall be tightened with nylon thread along with each cable at interval of 3
meters in such a way that it does not damage/penetrate the outer sheath of cable because
of the dead weight of back filled materials OR soil.

1.3.2 A pre-warning PVC yellow tape with size 152 mm (width) x 100 microns thick
(HDDPE)/LLDPF shall also be laid as per following clause of the specification. The
warning tape shall also contain the “WARNING” printed in black letters as under (In
English as well as Hindi).

“CAUTION: 66000 VOLTS HVPNL CABLE” and “CAUTION: 132000 VOLTS HVPNL
CABLE”

1.3.3 A pre-warning tap as per above clause shall be laid below ground level in the earth about
400/500 mm deep along the route of cable and in jointing bays.

1.3.4 The cable route marker is to be made from R.C.C. blocks duly embossed on all the side as
under:-
“HVPNL 66 KV CABLE LINE”

The minimum size shall be 600x400x50mm. It shall be at least embedded in ground upto
400mm depth. The exposed portions shall be painted with non-washable paints. The
interval should be minimum 30meters between two markers. It should be put at bends,
curves, road crossing etc. of cable route.

1.4 TEST AFTER INSTALLATION:

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1.4.1 Pre-commissioning tests on site, shall include the following:-
a) Insulation Resistance of each cable drum length after laying and before jointing.

b) Tests for detection of damage to outer sheath, if any.

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 c) Serving insulation resistance after laying each cable length shall withstand a
voltage of 10 KV DC for one minute between each reinforcement and external
conducting surface; In addition, the serving insulation resistance shall be measured
and checked with the values obtained during routine factory tests.

d) On completion of the cable laying and jointing work, the complete installation shall
be checked with a D.C. voltage of 3 Uo applied for 15 minutes between each
conductor and sheath.

e) Conductor resistance of each cable of each complete circuit.

f) Test for 5 min. with system voltage applied between the conductor and the screen.

g) Test for 24 hours with normal operating voltage of the system.

h) Continuity & phase confirmation.

Note: The pre-commissioning test at (f) or (g) at site to be undertaken as an alternative to

the test (d).

1.5 GENERAL:
1) The cable laying shall have to be done, as per actual site condition at the time of
execution, and as per the instruction of the engineer-in-charge.

2) The end of cut pieces of cables left out during executions shall be sealed to prevent
ingress of any moisture in the cable before handing over to consignee.

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