SECTION: POWER & CONTROL CABLES

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

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SECTION: POWER & CONTROL CABLES

1.
1.1. 1.1.1.

1.1 KV GRADE POWER & CONTROL CABLES

CRITERIA FOR SELECTION OF POWER & CONTROL CABLES Aluminium conductor XLPE insulated armoured cables shall be used for main power supply purpose from LT Aux. Transformers to control room, between distribution boards and for supply for colony lighting from control room. Aluminium conductor PVC insulated armoured power cables shall be used for various other applications in switchyard area/control room except for control/protection purposes. For all control/protection/instrumentation purposes PVC insulated armoured control cables of minimum 2.5 sq.mm. size with stranded Copper conductors shall be used. MEW has standardised the sizes of power cables for various feeders. Bidders are to estimate the quantity of cables and quote accordingly. The sizes of power cables to be used per feeder in different application shall be as follows: S.No. From 1. Main Board To Switch LT Transformer Cable size 2-1C X mm2 per phase 1-1C X mm2 for neutral Switch AC Distribution 2-3C X Board mm2 Switch Air Conditioning 1-3C X Board mm2 Switch Oil Filtration Unit 1-3C X mm2 Switch Colony Lighting 1-3C X mm2 Switch HVW pump LCP 1-3C X mm2 Switch Lighting 1-3C X transformer mm2 Cable type 630 XLPE

1.1.2

1.1.3

1.1.4

630

2. Main Board 3. Main Board 4. Main Board 5. Main Board 6. Main Board 7. Main Board

300 XLPE 300 XLPE 300 XLPE 300 XLPE 300 XLPE 300 XLPE

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

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8. Lighting transformer 9. AC Distribution Board 10. AC Distribution Board 11. Emergency Lighting transformer 12. AC Distribution Board 13. AC Distribution Board 14. AC Distribution Board 15. DCDB 16. DCDB 17. DCDB 18. Main Lighting DB 19. Main Lighting DB 20. Main Lighting DB 21. Main Lighting DB 22. Lighting Panel 23. Lighting Panel

Main Lighting Distribution Board D.G. Set AMF Panel Emergency Lighting transformer Emergency Lighting DB ICT MB Bay MB Battery Charger Battery Battery Charger Protection/PLCC panel Lighting panels(Indoor) Lighting panels (outdoor) Receptacles (Indoor) Receptacles (Outdoor) Sub lighting panels Street Lighting Poles Lighting Fixtures (Outdoor)

1-3C X 300 XLPE mm2 2-3C X 300 XLPE mm2 1-3C X 70 PVC mm2 1-3C mm2 X 70 PVC

1-3C X 70 mm2 1-3C X 35 mm2 1--3C X 70 mm2 2-1C X 150 mm2 2-1C X 150 mm2 1-2C X 6 mm2 1-3C X 35 mm2 1-3C X 70 mm2 1-3C X 35 mm2 1-3C X 70 mm2 1-4C X 16 mm2 1-4C X 16 mm2 1-2C X 6 mm2

PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC

24. Lighting Panel/ Sub lighting panels 25. Bay MB Equipments

26. Air Conditioning A/C Unit Panel Board 27. Air Conditioning AHU Board
Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

1-4C X 16 mm2 PVC /1-4C X 6 mm2 /1-2C X 6 mm2 1-3C X 70 PVC mm2 1-3C X 35 PVC mm2
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28. Air Conditioning Heater Board 29. Air Conditioning Chiller Pump Board 1.1.5

1-3C mm2 1-3C mm2

X X

35 PVC 35 PVC

Bidder may offer sizes other than the sizes specified in clause 1.1.4. In such case and for other application where sizes of cables have not been indicated in the specification, sizing of power cables shall be done keeping in view continuous current, voltage drop & short-circuit consideration of the system. Relevant calculations shall be submitted by bidder during detailed engineering for purchasers approval. Cables shall be laid conforming to relevant international standard. While preparing cable schedules for control/protection purpose following shall be ensured: Separate cables shall be used for AC & DC. Separate cables shall be used for DC1 & DC2. For different cores of CT & CVT separate cable shall be used Atleast one (1) cores shall be kept as spare in each copper control cable of 4C, 5C or 7C size whereas minimum no. of spare cores shall be two (2) for control cables of 10 core or higher size. For control cabling, including CT/VT circuits, 2.5 sq.mm. size copper cables shall be used per connection. However, if required from voltage drop/VA burden consideration additional cores shall be used. Further for potential circuits of energy meters separate connections by 2 cores of 2.5 sq.mm. size shall be provided. TECHNICAL REQUIREMENTS General The cables shall be suitable for laying in racks, ducts, trenches, conduits and underground buried installation with uncontrolled back fill and chances of flooding by water. They shall be designed to withstand all mechanical, electrical and thermal stresses under steady state and transient operating conditions. The XLPE /PVC insulated L.T. power cables of sizes 240 sq. mm. and above shall withstand without damage a 3 phase fault current of at least 45 kA for at least 0.12 second, with an initial
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1.1.6 1.1.7

1.1.7.1 1.1.7.2 1.1.8 1.1.9

1.1.10

1.2. 1.2.1. 1.2.1.1.

1.2.1.2.

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

peak of 105 kA in one of the phases. The armour for these power cables shall be capable of carrying 45 kA for at least 0.12 seconds without exceeding the maximum allowable temperature of PVC outer sheath. 1.2.1.3. The XLPE insulated cables shall be capable of withstanding a conductor temperature of 250C during a short circuit without any damage. The PVC insulated cables shall be capable of withstanding a conductor temperature of 160C during a short circuit. The Aluminium/Copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be uniformly good quality, free from defects. All aluminium used in the cables shall be of H2 grade. The fillers and inner sheath shall be of non-hygroscopic, fire retardant material, shall be softer than insulation and outer sheath shall be suitable for the operating temperature of the cable. Progressive sequential marking of the length of cable in metres at every one metre shall be provided on the outer sheath of all cables. Strip wire armouring method (a) mentioned in relevant international standard shall not be accepted for any of the cables. For control cables only round wire armouring shall be used. The cables shall have outer sheath of a material with an oxygen index of not less than 29 and a temperature index of not less than 250C. All the cables shall pass fire resistance test as per relevant international standard The normal current rating of all PVC insulated cables shall be as per relevant international standard. Repaired cables shall not be accepted. Allowable tolerance on the overall diameter of the cables shall be plus or minus 2 mm. XLPE Power Cables The XLPE insulated cables shall be of FR type, C1 category conforming to relevant international standard and its amendments read alongwith this specification. The conductor shall be stranded aluminium circular/sector shaped and compacted. In multicore cables, the core shall be identified by red, yellow, blue and black coloured strips or colouring of insulation. A distinct inner sheath shall be provided in all multicore cables. For XLPE cables, the inner sheath shall
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1.2.1.4.

1.2.1.5.

1.2.1.6.

1.2.1.7.

1.2.1.8.

1.2.1.9. 1.2.1.10.

1.2.1.11. 1.2.1.12.

1.2.2. 1.2.2.1.

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

be of extruded PVC to type ST-2 of relevant international standard. When armouring is specified for single core cables, the same shall consist of aluminium wires/strips. The outer sheath shall be extruded PVC to Type ST-2 of relevant international standard for all XLPE cables. 1.2.3. 1.2.3.1. PVC Power Cables The PVC (70C) insulated 1100V grade power cables shall be of FR type, C1 category, conforming to relevant international standard and its amendments, read alongwith this specification and shall be suitable for a steady conductor temperature of 70C. The conductor shall be stranded aluminium. The Insulation shall be extruded PVC to type-A of relevant international standard. A distinct inner sheath shall be provided in all multicore cables. For multicore armoured cables, the inner sheath shall be of extruded PVC. The outer sheath shall be extruded PVC to Type ST-1 of relevant international standard for all cables.

1.2.4. 1.2.4.1.

PVC Control Cables The 1100V grade control cables shall be of FR type C1 category conforming to relevant international standard and its amendments, read alongwith this specification. The conductor shall be stranded copper. The insulation shall be extruded PVC to type A of relevant international standard. A distinct inner sheath shall be provided in all cables whether armoured or not. The over sheath shall be extruded PVC to type ST-1 of relevant international standard and shall be grey in colour except where specifically advised by the Owner to be black. Cores shall be identified as per relevant international standard for the cables up to five (5) cores and for cables with more than five (5) cores the identification of cores shall be done by printing legible Hindu Arabic Numerals on all cores as per clause 10.3 of relevant international standard.

1.2.4.2.

2.
2.1.

HT CABLE FOR AUXILIARY POWER SUPPLY

(a) The HT cable of 1Cx185 mm2 (Aluminium Conductor) or 1Cx120mm2 (Copper Conductor) of voltage class as specified for 630kVA LT transformer for interconnecting 630kVA LT transformer to the SEB feeder shall be, XLPE insulated, armoured cable conforming to relevant international standard and IEC 60502-2 1998. Terminating accessories shall conform to IEC 61442 1997/IEC 60502-4 1998. The HT cable of 3Cx95 mm2 (Aluminium Conductor) or 3Cx70mm2 (Copper Conductor) of voltage class as specified for 250kVA LT transformer for interconnecting 250kVA LT transformer to the SEB feeder
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(b)

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

shall be, XLPE insulated, armoured cable conforming to relevant international standard and IEC 60502-2 1998. Terminating accessories shall conform to IEC 61442 1997/IEC 60502-4 1998. 2.2. Only overhead connection has been foreseen for interconnecting 800 kVA, LT transformer to the tertiary of the ICT. However, HT cable connections in place of overhead connection, if necessary shall also be in the scope of contractor. In this case contractor shall provide 1C x 185 mm2 (Aluminium Conductor) or 1Cx120mm2 (Copper Conductor), 38/66kV HT cable alongwith necessary terminating accessories. The construction of XLPE insulated, armoured HT cable shall be generally conforming to relevant international standard. Terminating accessories shall conform to IEC 60840 1999. Bidder may offer sizes other than the sizes specified in clause 2.1 and 2.2. In such case sizing of power cables shall be done keeping in view continuous current, voltage drop & short-circuit consideration of the system. Relevant calculations shall be submitted by bidder during detailed engineering for purchasers approval. CABLE DRUMS Cables shall be supplied non-returnable wooden or steel drums of heavy construction. Wooden drum shall be properly seasoned sound and free from defects. Wood preservative shall be applied to the entire drum. Standard lengths for each size of power and control cables shall be 500/1000 meters. The cable length per drum shall be subject to a tolerance of plus or minus 5% of the standard drum length. The owner shall have the option of rejecting cable drums with shorter lengths. However, the total quantity of cables after taking into consideration of all cable drums for each size shall be within the tolerance of 2%. A layer of water proof paper shall be applied to the surface of the drums and over the outer most cable layer. A clear space of at least 40 mm shall be left between the cables and the lagging. Each drums shall carry the manufacturer's name, the purchaser's name, address and contract number and type, size and length of the cable, net and gross weight stencilled on both sides of drum. A tag containing the same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. Packing shall be sturdy and adequate to protect the cables, from any injury due to mishandling or other conditions encountered during transportation, handling and
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2.3.

3. 3.1.

3.2.

3.3.

3.4. 3.5.

3.6.

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

storage. Both cable ends shall be sealed with PVC/Rubber caps so as to eliminate ingress of water during transportation and erection.

4.
4.1.

TYPE TESTS
All cables shall conform to all type, routine and acceptance tests listed in the relevant IS. The type tests on cables shall be conducted on each type and size of cables offered. Following type tests as per relevant international standard including its amendments and additional type tests shall be carried out on 1.1 kV grade XLPE insulated cables: a) Tests on conductor i) Annealing test (for Copper) ii) Tensile test (for aluminium) iii) Wrapping test (for aluminium) iv) Resistance test b) Test for armouring wires/strips c) Test for thickness of insulation and sheath d) Physical tests for insulation i) Tensile strength and elongation at break ii) Ageing in air oven iii) Hot set test iv) Shrinkage test e) Physical tests for outer sheath i) Tensile strength and elongation at break ii) Ageing in air oven iii) Loss of mass in air oven iv) Shrinkage test v) Hot deformation vi) Heat shock test vii) Thermal stability f) Insulation resistance (volume resistivity test) g) High voltage test h) Flammability test i) Oxygen index and temperature index test on outer sheath j) Short time current test on power cables of sizes 240 sq.mm and above. 1) On conductor(s). 2) On armours. Following type tests as per relevant international standard including its amendments and additional type tests shall be carried out on 1.1 kV grade PVC insulated cables:
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4.2.

4.3.

4.4.

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

4.5.

Tests on conductor a. Annealing test (for Copper) b. Tensile test (for aluminium) c. Wrapping test (for aluminium) d. Conductor Resistance test b) Test for armouring wires/strips c) Test for thickness of insulation and sheath d) Physical tests for insulation and outer sheath i) Tensile strength and elongation at break ii) Ageing in air oven iii) Shrinkage test iv) Hot deformation v) Loss of mass vi) Heat shock test vii) Thermal stability e) Insulation resistance f) High voltage test (water immersion test only a.c. test as per clause no. 16.3.1) g) High voltage test at room temperature h) Flammability test i) Oxygen index and temperature index test on outer sheath j) Short time current test on power cables of sizes 240 sq.mm and above. i)On conductor(s). ii)On armours. Following type tests as per relevant international standard including its amendments and additional type tests shall be carried out on XLPE insulated HT cable up to 33kV earthed system: a) Tests on conductor i) Annealing test (for Copper) ii) Tensile test (for aluminium) iii) Wrapping test (for aluminium) iv) Resistance test b) Test for armouring wires/strips c) Test for thickness of insulation and sheath d) Physical tests for insulation e) Physical tests for outer sheath Partial discharge test f) g) Bending test h) Dielectric power factor test i) Heating cycle test j) Impulse withstand test k) High voltage test l) Oxygen index and temperature index test on outer sheath

a)

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

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4.6.

Following type tests as per relevant international standard including its amendments and additional type tests and additional type tests shall be carried out on XLPE insulated HT cable from 66kV up to and including 220kV: a) Tests on conductor i) Annealing test (for Copper) ii) Resistance test iii) Tensile test (for aluminium) iv) Wrapping test (for aluminium) b) Physical tests for insulation i) Test for thickness and dimensions of insulation ii) Tensile strength and elongation at break iii) Thermal Ageing in air oven iv) Hot set test v) Shrinkage test c) Resistivity test for semi-conducting layers d) Test for concentric metallic screen: i) Test for concentric copper wire ii) Test for concentric copper tape e) Thickness of metallic sheath f) Test for armouring material: i) Dimensions h) Physical tests for outer sheath: 1. Measurement of thickness 2. PVC sheath i) Tensile strength and elongation at break ii) Ageing in air oven iii) Loss of mass in air oven only for PVC sheath iv) Heat shock test v) Hot deformation test vi) Shrinkage test vii) Thermal stability 3. PE sheath i) Carbon black content ii) Tensile strength and elongation at break before and after ageing iii) Hot-deformation i) Flammability test (for PVC outer sheathed cables only) j) Water tightness test k) 1) Thermal ageing on complete cable sample 2) Tensile strength and elongation at break for insulation and outer sheath 3) Resistivity test for semi-conducting layer l) Bending test followed by P.D. test

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

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m) n) o) p) 4.7.

Dielectric power factor and capacitance measurement at ambient temperature Dielectric power factor measurement at elevated temperature Impulse withstand test followed by HV test Oxygen index and temperature index test on outer sheath

Contractor shall submit type test reports as per clause no. 9.2 of Technical Specification, Section: GTR for which test conducted once are acceptable (i.e. The requirement of test conducted within last five years shall not be applicable) for the following: 1.1 kV grade PVC insulated cables a) High voltage test (water immersion d.c. test as per clause no. 16.3.2 of relevant international standard 1.1 kV grade XLPE insulated cables a) Water absorption (gravimetric) test as per relevant international standard XLPE insulated HT cable from 66kV up to and including 220kV a) Load cycle test followed by P.D. measurement as per relevant international standard Terminating/jointing accessories as per IEC 60840:1999 a) Partial discharge test at ambient temperature; b) Heating cycle voltage test c) Partial discharge tests -At ambient temperature -At high temperature d) Impulse voltage test followed by power frequency test e) Test of outer protection for buried joints

4.7.1.

4.7.2.

4.7.3.

4.7.4.

Technical Specification, Section: Power and Control Cable C/ENGG/ SPEC/CAB REV. NO: 4

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