MADHYA PRADESH POWER TRANSMISSION CO. LTD.

SHAKTI BHAWAN RAMPUR: JABALPUR

VOLUME-II (Part-4)

Technical Specification for XLPE EHV Cable for 132kV

Transmission Lines

O/o CHIEF ENGINEER (PROCUREMENT)

TR-21/2021 1 Vol.-II Part-4

 INDEX
S. No. Page
PARTICULARS
No.
(A) SECTION-I
1 TECHNICAL SPECIFICATION FOR 132 KV CROSS LINKED 4
POLYETHYLENE INSULATED POWER CABLE
2 14
ANNEXURE – I (OF SECTION-I)
(B) SECTION- II
1 TECHNICAL SPECIFICATION FOR 132 KV CABLE 17
TERMINATION & JOINTING KITS FOR 1 X 800 SQ.MM XLPE
CABLE
2 ANNEXURE- I (OF SECTION-II) 27

(C) SECTION – III TECHNICAL SPECIFICATION FOR

INSTALLATION OF CABLE
1 SECTION-III (A): SCOPE, ROUTE SURVEY, WORKS 30
REQUIREMENT AND STATUTORY CLEARANCES
2 SECTION-III (B): LAYING AND INSTALLATION OF CABLE 39
3 SECTION-III (C): DETAILS OF JOINTING AND TERMINATION 44
WORKS OF CABLE
4 SECTION-III (D): CIVIL AND STRUCTURAL WORKS 49
5 SECTION-III (E): EARTHING, SITE TESTING, COMMISSIONING 55
OF COMPLETE CABLE SYSTEM
(D) GENERAL DRAWINGS
1 132KV CABLE ROUTE MARKER (RCC)/JOINT MARKER 58
2 CABLE LAYING AT NORMAL EXCAVATION FOR 2 X S/C 59
3 JOINT PIT FOR 132KV LUG 60
4 TYPICAL ARRANGEMENT FOR MAINTENANCE FREE TREATED 61
EARTH PIT FOR NORMAL SOIL
5 TYPICAL ARRANGEMENT FOR MAINTENANCE FREE TREATED 62
EARTH PIT FOR ROCKY SOIL
6 132KV CABLE RCC SLAB 63
7 132KV CABLE PRE WARNING TAPE 64
8 TREFOIL CLAMP & CLEAT FOR EHV CABLE 65
9 CABLE LAYING AT ROAD / NALA CROSSING 66
10 CABLE LAYING FOR ROAD CROSSING BY TRENCH 67
LESS BY HDD METHOD
11 WARNING BOARD FOR 132KV U/G CABLE 68
12 CABLE LAYING AT NORMAL EXCAVATION FOR S/C 69
13 CABLE LAYING AT NORMAL EXCAVATION FOR 3 X S/C 70

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 SECTION-I

132 kV CROSS LINKED POLYETHYLENE

INSULATED POWER CABLE

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 SECTION-I
TECHNICAL SPECIFICATION FOR
132 kV CROSS LINKED POLYETHYLENE
INSULATED POWER CABLE

1.0 SCOPE :

1.1 The scope under this section covers design, engineering, manufacture, testing, packing
and supply of 132 kV, 800 sq. mm, XLPE insulated power cable and its accessories.
The XLPE cable and its accessories shall be complete with all fittings and components
necessary for the satisfactory performance and ease of maintenance.

2.0 STANDARDS: The cable covered by the specification shall be designed, engineered,
manufactured, tested and commissioned in accordance with the Standards as specified in
the table below.
Other internationally accepted standards which ensure equivalent or better
performance than that specified in the standards referred shall also be accepted. Copies
of such standards shall be submitted by the bidder along with the bid.

IS 7098 : Part 3 : Cross-linked polyethylene insulated thermoplastic sheathed

1993 cables:
IS 8130 : 1984 Conductors
For workingfor insulated
voltage fromelectric
66KV up cables andincluding
to and flexible cords
220KV.
IS 5831 : 1984 PVC insulation and sheath of electric cables.
IS 1255 : 1983 Code of practice for installation and maintenance of power
cables
IS 3975 : 1999 Mild steelincluding
upto and wires, formed
33KVwires and tapes for armouring of
rating.
cables.
IS 6380 : 1984 Elastomeric insulation and sheath of electric cables.
IS10418 : 1982 Drums for electric cables
IS 5 : 1994 Colours for ready mixed paints and enamels.
IS 617 : 1994 Aluminium and aluminium alloy ingots and castings for
general
IS 3043 : 1987 Code of practice
engineering for earthing.
purposes (Superseded IS 20 : 1977)
IS 5578 : 1984 Guide for marking of insulated conductors.
IS 11353 : 1985 Guide for Uniform System of Marking and
Identification of Conductors and Apparatus Terminals.
IS 5216 : Part I : Recommendations on Safety Procedures and Practices in
1982 Electrical Work.
IS 2071 : 1993 High voltage test techniques.
IEC-60540 Power cables with extruded insulation and their accessories
and cords
IEC 60060 : 1989 High Voltage Test Techniques
IEC-60502 Extruded solid dielectric insulated power cables for rated
voltages
IEC-60754 : 1991 from 1KV
Tests up toevolved
on gases 30KV during combustion of electric cables
IEC-60183 : 1990 Guide to the Selection of High Voltage Cables.
IEC-60230 : 1996 Impulse tests on cables and their accessories.
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 IEC-60840 Tests for power cables with extruded insulation for rated voltage
up to 132 kV
IEC-60287 : 1995 Calculation of the continuous current rating of cables (100% load
factor).
IEC-60304 : 1982 Standard colours for insulation for low-frequency cable and
wires.
IEC-60331 : 1970 Fire resisting characteristics of Electric cables.
IEC-60332 : 1992 Tests on electric cables under fire conditions.
BS-5468 Cross-linked polyethylene insulation of electric cables
IEC-60228 : 1978 Conductors of insulated cables
IEC-60066 Environmental Test
IEC-60117 Graphical Symbols
IEC-60270 : 2000 Partial Discharge Measurements
3.0 CLIMATIC CONDITIONS:
3 . 1 The climatic conditions under which the cable shall operate satisfactorily are as follows:-

1. Location in the state of MADHYA PRADESH

2. Max. ambient air temp. (deg.C) 50
3. Min ambient air temp (deg.C) 1
4. Average daily ambient air temperature(deg.C) 40
5. Maximum Relative humidity (%) 95, sometimes reaches
saturation.
6. Average annual rainfall (mm) 1250
7. Max. Wind pressure (Kg/sq.m.) 150
8. Max. Altitude above mean (Metres) sea level 1000
9. Isoceraunic level (days/year) 50
(Average number of thunderstorm days)
10. Seismic level (horizontal acceleration) 0.3 g

4.0 SYSTEM PARAMETERS:

SL TECHNICAL PARAMETERS 132 KV SYSTEM

NO
1 Rated Max. Voltage 145 kV (rms)
2 Rated Frequency 50 Hz
3 Grounding Effectively Earthed
4 Rated Power Frequency Withstand Voltage (1 min) 275 KV (rms)
5 Impulse withstand BIL (1.2/50/micro Sec) Line to ±650 kVp
earth
6 Rated short time withstand current (1 sec) 40 kA (rms)for 1 sec
7 Rated peak withstand current (1 sec) 100 kA (peak)
Rated normal current 800 Amp.
8 (at 50 degree C design ambient temperature)
9 Seismic level Zone- II

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5.0 PRINCIPAL PARAMETERS:
5.1 The detailed specification of 132 kV (E) grade 800 sq.mm XLPE single core power cable
is given in Clause 6.0. The cable shall conform to IEC-60502 for construction, IEC-
60840 for testing and in line with IS: 7098 (Part-III) /1993 or any latest amendments
thereof. Outer sheathing should be designed to afford high degree of mechanical protection
and should also be heat, oil, chemicals and weather resistant. Common acids, alkalis and
saline solution should not have adverse effect on the Thermoplastic HDPE sheathing
material used. The construction of cable shall generally conform to the description
mentioned in Clause 6.0 and desired technical particulars in Annexure-I enclosed. Bidder
may offer necessary layers such as separation tape, binder tapes etc. additionally as per
their manufacturing practices for meeting required performance of the offered cable.
The bidder shall enclose the drawing showing cross section of the cable with the bid.

5.2 The cable shall be suitable for laying underground considering uncontrolled back fill and
chances of flooding by water and suitably designed by the addition of chemicals in the
outer sheath for protection against rodent and termite attack.

5.3 The cables shall be designed to withstand all mechanical, electrical and thermal
stresses under steady state and transient operating conditions.

5.4 Progressive sequential marking of the length of cable in meters at every one meter shall be
provided on the outer sheath of the cable.

5.5 Allowable tolerance on the overall diameter of the cables shall be plus or minus 2 mm.

6.0 GENERAL TECHNICAL REQUIREMENTS:

6.1 CONDUCTOR: The cable conductor shall be made from stranded H.D. aluminium to
form compacted circular shaped conductor having resistance within limits specified in IS:
8130 / 1984 and any amendment thereof. The conductor shall conform to IEC: 228.
6.2 CONDUCTOR SCREEN: 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. The screen shall be firmly bonded to XLPE insulation. The minimum
thickness of extruded conductor screen shall be 1.0 mm. The outer surface of the
conductor screen shall be circular and free from irregularities. A non- hygroscopic semi-
conducting tape, if required, shall be applied to the conductor under extruded layer to
prevent penetration of compound into the conductor interstices.
6.3 INSULATION: The insulation material shall be extruded cross-linked polyethylene
(XLPE). In order to ensure that the screen and insulation are intimately bonded together
and free from all possibilities of voids between layers, the conductor screen, the insulation
and the insulation screen should be extruded simultaneously in one process. The
extrusion process should be carried out under strictly controlled atmospheric conditions.
The thickness of the insulation layer should be maintained as the maximum value
figured out from the design of the impulse voltage and A.C. voltage. The cross-linking
process by N2 gas shall be preferred instead of conventional cross-linking process by
saturated steam. The insulation of the cable shall be of standard quality, generally
confirming to IEC-60840 and I.S. 7098 Part-III / 1993 (latest edition). The eccentricity of
insulation should not be more than 10%.
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6.4 INSULATION SCREEN:
The insulation screening shall consist of non-metallic part (extruded & taped) and metallic
part.
i. Non-Metallic Part (extrusion):-
A non-metallic insulation screen of semi-conducting compound similar to conductor
screen (clause 6.2) for similar purpose shall be applied directly over the
insulation core by extrusion and shall be continuous and cover whole surface area of
insulation. It shall be firmly bonded to the insulation. The minimum thickness of
extruded insulation screen layer shall be 0.8 mm. The ovality of the core shall be not
more than 5%.

ii. Non-metallic part (taped)-Longitudinal water barrier:-

Under-sheath water barrier shall consist of a synthetic semi-conducting moisture
swellable layer (non-woven synthetic tape with suitable water swellable absorbent
with suitable overlap) covering the whole surface area of the insulation screen. The
barrier shall restrict longitudinal water penetration under the metallic sheath. The
nominal thickness of water swellable tape shall be 0.3 mm. The semi conducting
compound and the semi conducting tape shall be compatible with the insulating
material and suitable for the operating temperature of the cable.

iii. Metallic Part - Radial Water Barrier:-

The metallic screen of Lead Alloy E sheath/ Corrugated Aluminium sheath OR Poly
Aluminium Laminate sheath (as specified in BoQ) shall be provided over the non-
metallic part of the insulation screening. The details of various types of metallic
screen (sheath) are as under:-

A. Lead Alloy E Sheath : The lead alloy sheath shall have composition as per IS: 692.
The lead alloy 'E' Sheath shall be extruded using a continuous screw press and
shall be free from all extrusion defects. The nominal thickness of lead alloy E
sheath shall be as per IEC-60502-2/ IS: 7098 (Part-3). The bedding over the metallic
sheath shall be of semiconducting tape(s). Copper wire screen of annealed plain
copper wires with gap shall be helically applied over the Radial Water Barrier lead
alloy metallic sheath. The diameter of copper wire in the screen shall not be less
than 0.8 mm. The perpendicular gap between two adjacent wires shall not be more
than 4.0 mm. An open helix copper tape binder shall be applied over the copper
wire screen. The nominal thickness of the tape shall not be less than 0.1 mm. The
minimum thickness shall not fall below the nominal value by more than 10%.
Suitable non-metallic binder tape may also be applied over the copper screen to
prevent the penetration of the outer sheath into the screen. Metallic screen, together
with copper screen shall be able to withstand short circuit current of 40 kA for
duration of one second.
B . Corrugated Aluminium Sheath: The metallic screen shall comprise of a
corrugated seam welded/ seamless (extruded) aluminium sheath of suitable radial
thickness for 800 sq.mm. cable. A suitable anti-corrosive treatment should be given
to outer surface of Aluminium sheath. It should be of adequate thickness, consistent
quality and free from all defects. Aluminium sheath shall be suitable to carry 40
kA earth fault current for one second. Detailed calculation with support documents

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 shall be submitted with technical bid. For seam welded sheath, the welding shall be
of high quality and shall have strength not less than that of Aluminium with no
porosity.

C. Poly Aluminium Laminate Sheath (Tape):

The metallic screen shall comprise of annealed plain concentric copper wires
helically applied with gap followed by open helix of copper tape binder. The
copper screen along with aluminium armour shall be able to withstand short
circuit current of 40 kA for duration of one second. To prevent entry / propagation of
longitudinal ingress of moisture, semiconducting non-woven water swellable tapes
shall be provided above and below the metallic screen. The nominal thickness of
water swellable tape shall be 0.3 mm. The semi conducting tape shall be compatible
with the insulating material and suitable for the operating temperature of the cable.
Poly aluminium laminate tape shall be applied longitudinally over water swellable
tape (provided over the metallic screen), with suitable overlap for water tightness.
Inner sheath and Armouring shall also be provided as under:-

(a) Inner Sheath : The sheath shall be suitable to withstand the site conditions and the
desired temperature. It should be of adequate thickness, having consistent quality
and free from all defects. The sheath shall be extruded and of black Thermoplastic
H.D.P.E. (Poly-ethylene).
(b) Armour: Single H.D. Aluminium wire armouring shall be provided. The dimension
of H.D. Aluminium wire armouring shall be as per latest IS:3975/1988. The armour
together with copper screen shall have fault current capacity of 40 kA for 1 sec.

6.5 OUTER SHEATH: Extruded HDPE type ST7 outer sheath conforming to IEC:
502/1983, with suitable additives to prevent attack by rodents and termites, shall be
provided. The outer sheath shall be coated with graphite throughout the length of cable.

6.6 Each cable length shall be provided with a pulling socket/eye which shall be fitted to
pulling end on conductor. The pulling socket/eye shall be able to take pulling tension as
per recommended for cable conductor size along with reasonable factor of safety. The
pulling socket/eye shall be fitted in such a fashion to avoid moisture/water ingress during
storage/transit.

7.0 MANUFACTURING PROCESS:

7.1 XLPE cable should be processed in modern triple head extrusion manufacturing line. The
extrusion and curing shall be done to ensure circularity and concentricity of the extruded
layers around the conductor meeting the relevant IEC standards and successful valid type
tests.

7.2 The conductor screen, insulation and insulation screen shall be extruded in one
simultaneous triple extrusion process (Clause 14.2.1 of IS: 7098-3) through common triple
crosshead. The extruders and triple crosshead shall be designed to prevent stagnation of
materials to eliminate hot spots and ensure smoothness of the conductor screen and screen
surfaces. Insulation thickness should be controlled on-line using X- ray monitoring system.

7.3 The cross linking, curing and cooling shall be carried out in one operation and shall be a
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 dry curing process under high pressure to eliminate the formation of voids in the
insulation and contaminations in the dielectric.

7.4 Process conditions such as curing and cooling temperature, production speed etc.
shall be closely monitored during manufacture to ensure a good degree of cross- linking
through the whole insulation.

7.5 The manufacturing process shall eliminate irregularities like protrusions, voids and
contamination etc. to ensure the long-term reliability of the cable.

7.6 Loading of the extruder in the manufacturing plant shall be performed in an entirely closed
and dust proof enclosure. The entire line of processing should be controlled from a
computerized central control console. Contamination shall be avoided by use of a fully
enclosed material handling system. To avoid contamination XLPE Granules must be
transported using gravitational material feeding system.

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

8.1 The one-second short circuit current rating values each for conductor & metallic
screen shall be furnished with detailed calculations along with support documents and
shall be subject to the purchaser's approval.

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.
9.0 OPERATION:
9.1 Cables shall be capable of satisfactory operation under a power supply system frequency
variation of ±5% voltage variation of ±10 % and combined frequency voltage variation
shall be +10 % & - 15%.
9.2 Cable shall be suitable for
a. Laying directly on ground /metalled road.
b. Installing outdoor in free air in vertical position.
c. Drawing into underground ducts/trenches below metalled road/nalas.
d. Laying directly in open trench.
9.3 Cable shall have heat and moisture resistant properties. These shall be of type and
design with proven record on transmission network service.

10.0 LENGTHS: The cable shall be supplied in standard drum lengths as below:

Size of cable Standard Drum length

132 kV single core , 800 sq.mm. 500 metres ±5% tolerance and ±2 %
overall tolerance in total quantity of
cable.

11.0 INDENTIFICATION MARKING: The following particulars shall be marked on cable

outer sheath:
i. Manufacturer's name/ trade name
ii. Voltage grade (132 kV)
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 iii. Cable size ( no. of core x conductor cross section)
iv. Month and Year of manufacture.
v. Purchaser's name i.e. MPPTCL
11.1 The spacing between one set of marking and the beginning of the next on the legend shall
not exceed 150 mm.

11.2 Besides above, progressive sequential marking of length shall also be provided at every
one meter, which shall be clear and legible. Sequential length marking by embossing in
same colour as that of outer sheath is permitted.

12.0 TESTS:
12.1 GENERAL

12.1.1 This schedule gives tests to be carried out on 132 kV, single core XLPE type cables
and associated accessories being supplied under these specifications. The schedule of
tests to be followed shall be generally as per IS-7098 (Part-3) / IEC 60840.
12.1.2 The facilities available for site tests shall be clearly and implicitly brought out in the
tender. The site tests shall be carried out during and after laying/installation by
the supplier.
12.2 TYPE TESTS:
12.2.1 The cable & accessories offered shall be fully type tested as per the relevant standards
i.e. IS-7098 (Part-3)/ IEC-60840. In case the cable & accessories of the type and design
offered has already been type tested in a Govt. approved/ NABL laboratory, the
Bidder shall furnish one set of type test reports along with the offer. Type test reports
shall not be older than TEN years and shall be valid up to the expiry of the validity of
the offer. The purchaser reserves the right to demand repetition of some or all the type
tests in the presence of purchaser's representative. In case of non-submission of some of
the type test reports, the bidder shall have to undertake to submit the same without
affecting delivery schedule at no extra cost to MPPTCL.
Type test reports for cable of construction other than specified in tender will be
considered for evaluation purpose, but in the event of order, the bidder shall have to
carry out all type tests on cable of construction as per specification at Govt. approved /
NABL laboratory without affecting delivery schedule and at no extra cost to MPPTCL,
for which necessary confirmation shall be submitted with technical bid.
12.2.2 The electrical tests shall be carried out on cable system (cable & accessories)
in accordance with clause 12 of IEC 60840 and in accordance with the sequence
prescribed in clause 12.3 of IEC 60840/IS-7098 (Part-3) with relevant clauses
before the dispatch of cable from contractor's works in any Govt. approved/
NABL laboratory.

12.3 ROUTINE TESTS:

The manufactured cable shall be subjected to tests as prescribed in the different IS/
IECs for routine, acceptance and type test and any other test mandatory under relevant
IS/IEC.

The following routine tests shall be carried out on each manufactured length :-
a) Conductor resistance test
b) Voltage test
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 c) DC voltage test on outer sheath
d) Partial discharge test

12.4 ACCEPTANCE TESTS:

The following tests shall be carried out on samples taken to represent a batch:-
a) Measurement of electrical resistance of conductor and metal screen
b) Measurement of thickness of insulation and oversheath
c) Measurement of thickness of metal sheath
d) Hot set test for insulation
e) Void and contaminants test
f) Measurement of diameters
g) Partial discharge test
h) High voltage test
i) Measurement of capacitance & tan delta

Note: High voltage test shall be conducted as per IEC 60840 on a fresh sample, with
magnitude of test voltage 190kV. Time duration shall be 30 minutes.
12.5 FREQUENCY OF TESTS:
The above acceptance tests shall be made on one length from each manufacturing series
of the same type and size of cable, but shall be limited to not more than 10% of the
number of lengths in any contract, rounded to upper unity.

12.6 NON-ELECTRICAL TYPE TESTS

a) All non-electrical type tests shall be performed in accordance with the
provisions laid in clause 12.5 of IEC 60840, IS-7098 (Part-3) with relevant
clauses.
b) Insulation resistance after laying each cable length shall withstand a voltage of
10kV DC between each reinforcement and external conducting surface and for
one minute as per clause no. 16 of IEC -60840. In addition, the serving
insulation resistance shall be measured and checked with the values obtained in
the routine factory test.
c) On completion of the cable laying and jointing work the complete installation
shall be tested as per clause 16 of IEC 60840. The testing kit required for the
tests shall be arranged by the tenderer.
12.7 TESTS AT SITE AFTER INSTALLATION:
Pre-commissioning tests on site, which shall be performed by the successful bidder,
shall include the following:-
a) DC voltage test on outer sheath at 10 kV for one minute between metallic
sheath/screen and external conducting surface.
b) Conductor resistance of each complete circuit.
c) AC system voltage (U0) for 24 Hrs to keep the cable on idle charge with minimum
protection setting to protect the cable in 24 Hrs.

13.0 INSPECTION:
The inspection may be carried out by the purchaser at any stage of manufacture. The
successful Bidder shall grant free access to the purchaser's representative at any reasonable
time when the work is in progress. Inspection and acceptance of any equipment/items
under this specification by the Purchaser shall not relieve the supplier, of his obligation of
furnishing equipment in accordance with the specification and shall not prevent
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 subsequent rejection, if the equipment/items is found to be defective. The supplier shall
keep the purchaser informed in advance, about the manufacturing progamme, so that
arrangement can be made for inspection, without delay. The purchaser reserves the right to
insist for witnessing the acceptance/routine testing of the bought out items.

14.0 DOCUMENTATION:
14.1 LIST OF DRAWINGS AND DOCUMENTS:
The Bidder shall furnish two sets of following documents along with the offer. The offer
without documents shall be considered incomplete.
a) The sectional view drawing showing general constructional features of power cable
with details of materials / conductor / conductor screen / XLPE insulation / water
swellable tape/ insulation screen/ outer HDPE sheath etc. with offered dimensions.
b) Literature for offered items.
c) Type test reports for the offered items in case the items have already been type tested
for specified type of cable.
15.0 PACKING AND FORWARDING:
15.1 The cable shall be packed returnable steel drums suitable for vertical/horizontal transport
as the case may be, and suitable to withstand handling during transport and
outdoor storage during transit. The supplier shall be responsible for any damage to the
items during transit, due to improper and inadequate packing. Wherever necessary,
proper arrangement for lifting shall be provided. Any item found short shall be
replenished by supplier without any extra cost.
15.2 Each consignment shall be accompanied by a detailed packing list containing the
following information:
a) Name of the consignee
b) Details of consignment
c) Destination
d) Total weight of consignment
e) Handling and unpacking instructions
f) Bill of material indicating contents of package

16.0 SEALING AND DRUMMING

16.1 Immediately after the works tests, both ends of every length of cable shall be sealed by
means of heat shrinkable end caps.

16.2 Cables shall be wound on returnable metallic drums. All the drums shall be arranged to
take a round spindle and be legged with strong closely fitting wooden battens so as to
prevent damage to the cable. Each drum shall bear an identification number permanently
stencilled or branded on the outside of the flange.

16.3 Cable reels shall be of rugged construction, with a drum diameter of ample dimensions
to accommodate the single conductor. Manufacturer shall be responsible for any damage
to the cables during transit. Changes in the shape of the cable during transit shall not result
in deformation in metallic drum. A detail of Steel Drum/reel is to be furnished by bidder
in their bid.
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16.4 The cable drum/ reel shall carry the following information clearly marked on one flange of
the drum:-
a) Manufacturer's name, Brand or trade mark.
b) Conductor of cable.
c) Type of cable and voltage grade.
d) Size of cable.
e) Length of cable on the drum.
f) Direction of rotation of drum (by means of an arrow).
g) Net weight
h) Gross weight.
i) Year of manufacture.
j) Confirming to IEC/ IS No.
k) Purchase order details.
1) Name of owner.
m) Name of consignee.

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 Annexure – I (of Section-I)
Principal Parameters of XLPE Cable
SNo. Particulars Technical Details
Single core, aluminium conductor
1 Type of Cable
XLPE cable
IEC 60840/ IS 7098 (part-3) amended
2 Applicable Standard
up to date
3 System voltage & frequency 132 ± 10% kV, 50 Hz ± 3%
4 Highest System Voltage 145 kV
5 Suitable for earthed system Yes
6 CONDUCTOR
i) Material as per IEC 60228/IS:8130 Stranded hard drawn aluminium
ii) Nominal cross sectional area 800 sq.mm
Construction of conductor/ flexibility
iii) Class-2 IEC 228/ IS:8130
class
iv) Shape and formation of conductor Stranded very well compacted circular
7 CONDUCTOR SCREENING
Extruded, semi conducting compound
i) Material & type
layer
ii) Grade As per IEC/IS
iii) Thickness 1.0 mm
8 INSULATION
Special super clean grade cross linked
i) Material
polyethylene (XLPE)
ii) Nominal thickness of insulation As per IEC-60840/7098 (Part-3)
9 INSULATION SCREENING
A Non-metallic part (extruded)
Extruded semi conducting compound
i) Material
layer
ii) Grade As per IEC/IS:7098 (Part-3)
iii) Min. Thickness 0.8 mm
Non-metallic part (taped) longitudinal
B
water barrier over insulation screen
Synthetic, non-woven, semi-
i) Material
conducting water swellable tape
ii) Min. thickness(mm) As per standard
C METALLIC SCREEN
a) Lead Alloy Sheathed Cable

Lead Alloy E Sheath conforming to IS

i) Material
692/IEC 60502/ IS 7098 (part-3)

Annealed plain copper wires applied

ii) Metallic Screen helically with gap followed by open
helix of copper tape binder

Short Circuit Current Withstand of

iii) 40 kA for one second
metallic sheath and metallic screen
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 SNo. Particulars Technical Details
b) Corrugated Aluminium Sheathed
Cable
Corrugated seam welded/ seamless
i)
Material (extruded) aluminium sheath
Short Circuit Current Withstand of
ii) 40 kA for one second
metallic sheath
Cable with Poly Aluminium
c)
Laminate tape
Poly Aluminium Laminate Tape of
i) Material minimum thickness conforming to IS-
60502-2/ IS: 7098 (Part 3)
Annealed plain copper wires applied
helically with gap followed by open
ii) Metallic Screen
helix of copper tape binder & poly
aluminium laminate tape
Short Circuit Current Withstand of
iii) 40 kA for one second
metallic screen and Armour
iv) Inner Sheath
(a) Material Extruded black thermoplastic HDPE
Conforming to IS-60502-2/ IS: 7098
(b) Min. thickness of inner sheath
(Part 3)
v) Armouring
Single hard drawn aluminium wire
(a) Material
conforming to IS-3975/1988
Fault Current Capacity together with
(b) 40 kA for 1 sec.
metallic screen
10 OUTER SHEATH
Extruded Layer of Black PE type ST-7
i) Material
as per IS:7098 (Part-3)
ii) Min. thickness of outer sheath As per standard
11 Conducting layer over outer sheath Graphite coating
Maximum D.C. Resistance of
12 As per standard
conductor at 90 deg C in ohm/km
Maximum allowable temperature for
13
cable and accessories
At rated full load and at site
i) 90°C
conditions
The conductor temperature after a
short circuit for one second shall not
ii) 250°C
exceed (with conductor temperature at
start of short circuit as 90°C)
Symmetrical Short circuit rating for
14 one second duration for copper screen 40 kA for one second
and tape.
15 Standard Drum Length 500 mtr
16 Expected cable life 35 years

TR-21/2021 15 Vol.-II Part-4

 SECTION- II

132 kV CABLE TERMINATION

&

JOINTING KITS FOR

1 x 800 SQ.MM XLPE CABLE

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 SECTION- II

TECHNICAL SPECIFICATION FOR

132 kV CABLE TERMINATION & JOINTING KITS
FOR 1 x 800 sq.mm XLPE CABLE

1.0 SCOPE
1.1 The scope includes supply, testing at manufacturer's works before dispatch and
delivery of internationally reputed make of following types of cable sealing ends, (end
terminals), and straight through joints conforming to relevant IEC, unless otherwise
stipulated in the Section-II and all other accessories as well as consumables etc. suitable
for XLPE cable (Section-I). These kits and accessories shall be an integral part of 132 kV
cable system.
i. 132 kV rated outdoor cable sealing ends conforming to IEC 60840 for terminating the
single circuit highest voltage 145 kV XLPE cables along with all the necessary
supporting structure, fittings & mountings.
ii. 132 kV rated outdoor straight through joints conforming to IEC 60840 for jointing of
highest voltage 145 kV XLPE buried underground cables.

1.2 Single/ Three phase Earth Link boxes with all associated accessories (for the
connection of the cable sheath of 132 kV rated XLPE cable) suitable for cross
bonding arrangement of the complete cabling system.

1.3 All the testing devices and instruments etc. including HV Generator required for final
acceptance testing and commissioning shall be the responsibility of the contractor and no
separate cost/ rental is payable. The testing devices etc. shall be taken back by the
contractor after successful testing & commissioning. List of special tools and equipment
required for installation, commissioning and testing of the cable system by contractor (on
returnable basis) shall be enclosed with the bid.

1.4 It is not the intent to specify completely herein all details of design and construction of
the equipment/ system and accessories required. However, the cable system and its
installation shall be complete with all accessories, conform in all respects to high
standards of engineering, design and workmanship and be capable of performing the
continuous commercial operation up to guarantee in a manner acceptable to MPPTCL.

2.0 STANDARDS
Unless otherwise stated hereafter, rating, characteristics, test and procedures etc.
concerning the 132 kV XLPE cable accessories shall preferably be as per IEC standards
wherever existing and shall be in compliance with the latest editions or revisions thereof.
Although a few preferred IEC standards are mentioned below but the list is not
exhaustive and may be improved.

IEC-60840 Tests for power cables with extruded insulation for rated
voltage up to 132 kV.
IEC : IS 60859 Cable connection for Gas insulated metal enclosed
switchgear for rated voltages of 72.5 kV and above.
IEC: 62271-203 Gas-insulated metal- enclosed switchgear for rated
TR-21/2021 17 Vol.-II Part-4
 voltages of 72.5 kV and above.
IEC: 60228 Conductor for insulated cable
IEC: 60229 Tests on cable over sheaths
IEC: 60230 Impulse tests on cables and their accessories
IEC: 60270 Partial discharge measurements
IEC: 60287 Calculation of continuous current carrying capacity
IEC: 60502 Power Cables with extruded insulation and their
accessories.
BIS: 7098 (Part- XLPE cable specification-for working voltages from 66
3) kV up to and including 220 kV.
IEEE 48-1990 IEEE Standard Test, Procedure & requirement for high
voltage alternating current cable terminations

3.0 SYSTEM CONFIGURATION

3.1 The 132 kV systems will be solidly grounded. Cables will be protected from over-
voltages caused by lightning strikes or switching surges by means of 120 kV Class 3
station type lightning arresters located at terminal points.

4.0 GENERAL DETAILS OF CABLE KITS

4.1 All the cable sealing ends/ termination kits and straight through joints rated for 132 kV
shall be of pre-moulded type from one of internationally reputed manufacturers of
proven design which has already been extensively used and fully type tested.

4.2 The offered kits shall be easy in handling, simple to install without much skill with
minimum tools at site.

4.3 All cable sealing ends and straight through joints shall be suitable for connecting
single core, Aluminium Conductor XLPE cables for a maximum continuous voltage
of 145 kV and core cross section of 800 sq. mm. as per details in Section-I.

4.4 The kits shall be suitable for storage without deterioration at a temperature up to 55° C.

4.5 The offered XLPE cable termination and straight through jointing kits for 132 kV
earthed system shall meet the technical particulars indicated in Annexure–I of Section-II.

4.6 Field tests of sealing end terminals shall be made in conjunction with the 132 kV cables
after installation of the cables and terminals.

5.0 TYPE OF CABLE KITS

5.1 OUTDOOR TYPE SEALING END

5.1.1 The cable sealing end conforming to IEC-60840 of termination for maximum
continuous voltage of 145 kV cables shall be supplied by the cable manufacturer. The
contractor shall be responsible for correct termination of each cable to sealing ends,
installation of the cable sealing end and providing of terminal connectors for connecting to
terminal conductor. The requisite interconnection between line end & sealing end is
required to be designed (as per safety and statutory provision aspects) and executed (after

TR-21/2021 18 Vol.-II Part-4

 approval of MPPTCL) by the successful bidder.

5.1.2 The silicone rubber /composite bushing termination of rated capacity, suitable for
outdoor installation in moderately polluted atmosphere shall be used. It should be resistant
to UV exposure. The termination stress control shall be means of stress cone.

5.1.3 The stress cone made of silicone rubber shall inhibit possible mechanical stress and
deformation of the cable insulation surface during operation and also shall be capable of
accommodating minor radial and longitudinal movement without determent to the
dielectric stress in the insulation shield.
5.2 STRAIGHT THROUGH JOINTS
5.2.1 The straight through joints for XLPE cable (Section I), conforming to IEC-60840 shall be
suitable for underground buried installation with incorporated back fill and chances
of flooding by water. The straight through joints should be absolutely impervious to the
entry of water. The manufacturer shall use the proven technology and design to prevent
entry of water or any other liquid inside the straight through joints and cables.

5.3 MAKE OF CABLE KITS

All cable sealing ends and straight through joints shall be of reputed make. New
technology is to be used/ adopted while manufacturing and latest technology kits are
essential requirement. The successful valid type test reports (not older than 10 years from
the bid opening date) for cable sealing ends and straight through joints are to be
submitted by the bidder at the time of bid submission.

6.0 ELECTRICAL CHARACTERISTICS OF CABLE KITS

6.1 The cable termination and straight through jointing kits and accessories shall be capable
of carrying the specified rated current continuously without exceeding the specified
temperature limits.
6.2 The cable termination and straight through jointing kits and accessories to be supplied
against this specification shall be rated for 40 kA for 1 second.

6.3 The sheath voltage under full load conditions shall not exceed 65 volts specified in
relevant standards for safety of personnel as well as satisfactory working of cable. The
sheath shall be solidly grounded at the terminations.

6.4 The fault level withstand capacity of end termination and straight through jointing kits
should strictly match with the parameters of cables for which the kits are intended to be
used.
6.5 After jointing by straight through joints and connecting the cable with terminal ends, the
cable sheath/ screen bonding system shall provide a continuous current path through the
cable sheath/ screen and shall be bonded and earthed at both ends.
6.6 The XLPE cable termination and straight through jointing kits shall be suitable for use
where combined ambient temperature and temperature rise due to load result in conductor
temperature not exceeding 90 deg C under normal operation and 250 deg C under short
circuit conditions.

TR-21/2021 19 Vol.-II Part-4

6.7 132 kV XLPE cable termination and straight through jointing kits shall be designed to
withstand the mechanical, electrical and thermal stresses under the steady state and
transient/ fault conditions and shall be suitable for proposed method of installation.

7.0 DESIGN & COMPONENT FEATURES OF CABLE KITS

The following considerations shall be taken into account in the design of the product,
material properties & components of cable kits.
7.1. The most important part of cable accessories is the stress grading device, the stress
cone. The pre-moulded cone shall be made of insulating and conducting silicone
rubber moulded together in the shape of geometric stress control unit. The synthetic
insulating compound shall be used together with stress cone to improve the electrical
properties inside the termination. The compound should swell the insulation of the cone
and the cable to some extent so as to improve the electrical strength along with interface.
7.2 For XLPE cable, the critical part of the operation is making an electrical connection
between the stress relief device and insulation screen. If any air pocket is created,
discharge and breakdown can occur. As such, connection method and material should be
such that no risk of cable damage arises and that the jointer can check the result of his
work at every stage. The installation instructions should be easy to follow and should be
well illustrated.
7.3 The design shall be such that when the cone is supplied, the diameter of hole in the cone
shall be smaller than the diameter over cable insulation. After the cone is pushed on, the
elasticity of silicone rubber should guarantee an active pressure on the cable insulation to
ensure that no voids appear between the cone and the cable even after years of load
cycling.

7.4 The straight through joints shall be of pre-moulded construction. This design shall
comprise a factory tested synthetic rubber joint, with all stress management elements
provided during the moulding process in the factory. The dielectric design of the straight
through joints shall be optimized. The electric stress distribution along the interface
between the insulator and the cable shall take into account the dimensions of the joint
and the dielectric permittivity of the cable insulation. The material of insulator shall have
good thermo-mechanical behaviour.

7.5 The materials used in the assembly of the straight through joints shall be compatible with
the material of the insulator and the cable insulation. The conductor shall be connected by
means of an approved arrangement. The tensile strength of the connector shall meet the
requirements of the aluminium conductor.
7.6 Every single stress cone & stress grading device shall be tested electrically prior to
delivery in presence of Purchaser’s representative. Each stress cone shall be marked with
an individual number and a certificate containing detailed specification of tests shall be
included with every delivery.
7.7 The different accessories shall be type tested according to IEC- 60840 and IEEE
standards which include tests for impulse, AC, load cycling and partial discharge. Before
delivery, every stress cone shall be installed on cable and carefully checked to establish
that it is PF free in presence of owner's representative(s).
7.8 Details of proper stress control, stress grading and non-tracking arrangement in the

TR-21/2021 20 Vol.-II Part-4

 terminations & joints shall be elaborated in the offer. Detailed sectional view of assemblies
shall be submitted along with the offer. The application of stress control system shall be
safe, fool-proof & independent of cable jointers’ skills. The stress control method
should withstand expansion & contraction of cable during load cycling.

7.9 The jointing kits offered shall be so designed so as to prevent discharge/ leakage at the cut
back, nicks and scratches on XLPE insulations. Full details of method of discharge
prevention shall be indicated by the bidder.

7.10 The cable end termination and straight through joints shall be designed in such a way so
as to give track resistant, erosion & weather resistant protection to the cable insulation.
The outdoor end termination & straight through joints shall be totally sealed against
ingress of moisture of environment.

7.11 All end outdoor terminations shall be provided with rain sheds/ creepage petticoats. The
weather sheds shall be non-tracking, weather resistant, hydrophobic and have smooth
surface to collect any water/ dirt etc. The design of rain skirts shall avoid any skirt to skirt
conducting path under heavy rain conditions.

7.12 For XLPE cables, the lugs should withstand thermal short circuit of 250 degrees
centigrade. For XLPE cables, the ferrule should be suitable for compacted conductor
and should withstand thermal short circuit of 250 degrees centigrade.

7.13 Design features may be highlighted in the bid and the mouldings of rubber
components should be aimed to achieve a smooth finish on interior and exterior of the
components.

7.14 The kits shall be provided with protection against rodent & termite attack.

7.15 The kits offered shall provide for total environment sealing of the cable crutch and at the
lugs end, details of which shall be offered along with the offer. Provision for effective
screening over each core shall be made and bidder shall categorically confirm this aspect
in their offer.

7.16 The materials & components of kits not specifically stated in the specification, but which
are essential for satisfactory operation of cable shall be deemed to be included in
scope of suppl y without any extra cost.

7.17 The earthing arrangement shall form part of the termination joints and shall be protected
from erosion either by suitable tape or tube.

7.18 The word "MPPTCL" along with trade name of the manufacturer, month/ year
of manufacture, size etc. shall be embossed/ engraved for the purpose of identification.

7.19 Adequate provision for eliminating the chances of entrapment of air at steps formed by
semiconductor screen shall be made.

7.20 The terminations/ joints shall be supplied in kit form. All insulation and sealing materials,
consumable items, conductor fittings, earthing arrangements & lugs etc. should be
provided. Requisite No. and size of lugs & ferrules depending upon the type of the cable
TR-21/2021 21 Vol.-II Part-4
 shall be provided in the kit. Lugs & Ferrules shall be of crimping type and shall conform
to the relevant standards applicable to XLPE cables.

8.0 LINK BOX FOR EARTHING & EARTHING CABLE WITH PVC INSULATION

8.1 Bidder shall carry out the earthing of sheath/ screen in the cross bonding configuration.
The successful bidder shall submit the complete sheath voltage calculation along with
identification of major/ minor sections for cross bonding. The 3 Phase link boxes with
SVLs shall be installed at cross bonding points and three/ single Phase link boxes with
direct grounding at cable termination ends. The bonding lead/ grounding cable of suitable
sizes (as per sufficiency/ adequacy calculation submitted by successful bidder) shall be
used for connecting cable sheath to earth.

9.0 SUPPORTING STRUCTURE & ANGLE BRACKET SUPPORTS FOR CABLE

9.1 Any support structures and cable clamps required to support the cables between the trays
and the sealing end supports will be supplied and installed by the bidder.

9.2 Fabricated structure of suitable height, to be approved by Purchaser, shall be provided and
installed by manufacturer of cable for supporting the outdoor cable sealing ends. The
height of the structure shall be suitable for the terminal connection to receive the
Purchaser's ACSR Zebra conductor maintaining phase to phase and phase to earth
and ground clearances. Exact height shall be intimated/ confirmed to the successful bidder
at the time of approval of drawings. The structures shall be of galvanized steel structural
sections. Anchor bolts, washers etc will be supplied and installed by successful bidder.

9.3 The supporting structure shall be suitable to withstand the wind pressure, seismic
forces and the short circuit forces; etc., and the design shall have an adequate factor of
safety as specified in I.E. rules 1956.

9.4 The bidder shall furnish the design and fabrication drawings of these structures &
foundation anchor bolts and design calculations etc.

9.5 The bidder shall quote for unit prices for support structures for each single core cable to
suit the end terminations supplied by them.

10.0 CABLE END TERMINALS (OUT DOOR TYPE) CONNECTORS

10.1 Clamps shall be pressure die cast aluminium (LM-6) or Nylon-6 or fibre glass and shall
include neoprene rubber lining wherever the cable touches the clamps and below the clamp
base and necessary fixing nonmagnetic nuts, bolts, washer etc. The thickness of neoprene
rubber shall not be less than 10 mm inside the inner surface of the trefoil clamp and
minimum 20 mm thick below the base of trefoil clamp. The neoprene shall be tested as per
IS 11149 – 1984. Trefoil clamps shall be provided at every five meter of cable run for
maintaining perfect trefoil. The contractor shall submit drawings of trefoil clamps and
arrangements for employer’s approval.
10.2 The terminal connector/clamps shall be suitable for connection to Zebra ACSR conductor.
10.3 The type and size of the conductor will be confirmed to the successful bidder.
10.4 The connector/clamp shall be designed to overcome:
i) Galvanic Corrosion.
TR-21/2021 22 Vol.-II Part-4
 ii) Thermal Cycling.
10.5 The current carrying capacity of the connector/ clamps shall be greater than the
maximum capacity of the power cable. The terminal clamp shall be free from burrs, voids,
and blow holes.

10.5 The terminals clamps shall have passed the tests for short circuit current capability and
temperature rise.

11.0 TESTING INSTRUMENTS & DEVICES

11.1 The contractor shall arrange for all testing devices, instruments etc. required during
assembly, erection, testing and commissioning of 132 kV XLPE cable.

11.2 Arrangement of all the testing devices and instruments etc. including HV Generator
required for final acceptance testing and commissioning shall be the responsibility of the
contractor and no separate cost/ rental is payable. The testing devices etc. shall be taken
back by the contractor after successful testing & commissioning.

12.0 EARTHING

12.1 Bidder shall carry out the earthing of sheath/screen at cross bonding points as well as at
both termination ends of 132 kV cable using insulation sheath bonding (earthing) cable of
required size through Link box with/ without surge voltage limiter at cross bonding points.
The Link box should preferably be of stainless steel. It should be provided with IP 65 or
better weather protection.
12.2 Earthing shall be as per relevant standards and the details of the earthing arrangement
offered for the cable accessories shall be submitted along with the offer.

12.3 The sheath/screen shall bound in the earth station through disconnecting type link boxes.

12.4 Screen continuity by using tinned copper mesh and earth continuity by tinned copper
braids of appropriate size shall be provided for transfer of screen earth in straight through
joints.
12.5 The earth conductor shall be of GI flat and shall be protected against mechanical damage
and corrosion. The connection of the earth continuity conductors to earth bus and earth
electrodes shall be strong, secure and sound and shall be easily accessible.

13.0 TESTS
13.1 The testing of cable termination for outdoor type sealing end and straight through
jointing kits for XLPE Cable shall be as per IEC: 60840. All the acceptance tests and
routine tests shall be carried out on the cable kits (referred as accessories in IEC) as per
Clause 12 (Tests), Section-I.

13.2 The acceptance tests shall be carried out in presence of Purchaser's representative as
per relevant standard IEC: 60840 at bidder's cost and the sampling plan shall be 1 percent
subject to minimum of one number.

13.3 The contractor shall make available to the MPPTCL Engineer a complete set of detailed
data required for inspection and tests.
TR-21/2021 23 Vol.-II Part-4
13.4 Details of Tests: The bidder must specify the details of the type, acceptance and routine
tests to be conducted on offered cable kits at their works along with the standards
applicable in their offer.

14.0 QUALITY ASSURANCE

14.1 Raw materials used for manufacture of cable shall be of highest quality and material
received by manufacturer should be checked/ tested to ensure that it meets manufacturer's
material specification. The materials shall be clean and packed in moisture and dust proof
packing.
14.2 As the quality control of EHV XLPE cables termination & jointing kits and
accessories while manufacturing is very critical, expert supervision is required for raw
material testing, in process checks and also for final testing. A specially trained quality
assurance team should be in place for maintenance of the quality at an optimum level at
the plant. Complete details of manufacturing process along with details of automatic
manufacturing plant, list of officers /staff to supervise the manufacturing and other details
desired shall be furnished by bidder in the bid.

14.3 Quality assurance plan indicating test /checks of raw material, process of
manufacturer and final inspection with customer hold points shall be submitted to the
Purchaser for approval.

15.0 TEST CERTIFICATES

The latest complete type test certificates' (conducted during last 10 years from date of
tender along with attested drawing) in duplicate for all types of terminations &joints of
offered design/material conducted at International repute test house confirming to IEC:
60840 must be enclosed with the offer. The offer without type tests results shall be
ignored.

16.0 INSPECTION & TRAINING AT MANUFACTURER'S WORKS

16.1 The 132 kV XLPE cable termination for outdoor type sealing end and straight
through jointing kits and other accessories should be manufactured and tested while
manufacturing as per approved Quality Assurance plan and foregoing specification.
Supplier shall intimate the programme of manufacturing of the cable termination &
jointing kits and accessories in advance. The inspection during manufacturing shall be
carried out by the MPPTCL engineers at various stages of manufacture. The
successful bidder shall grant free access to the purchaser's representative at a reasonable
time when the work is in progress.

16.2 Inspection and acceptance of any equipment/material under this specification by the
purchaser shall not relieve the supplier of his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection if the
equipment/material is found to be defective.

16.3 The supplier shall present the latest Calibration Certificate(s) of testing instruments /
equipment to be used for the testing of the material covered in the Purchase Order to the
TR-21/2021 24 Vol.-II Part-4
 authorized inspecting officer/ inspecting agency of the purchaser. The testing instruments
/meters/apparatus etc should be got calibrated by the supplier from time to time from
independent test laboratory/house having valid accreditation from NABL for the
testing equipment/ original manufacturer having credibility to NABL/ NPL or equivalent.

16.4 The calibration certificate(s) should not in any case be older than one year at the time of
presenting the same to the inspecting officer/ inspecting agency of the purchaser. The
testing instruments/ equipment should be duly sealed by the Calibrating Agency and
mention thereof shall be indicated in the calibration certificate( s).

16.5 The Purchaser reserves the right to insist for witnessing the sample/routine tests of the
bought out raw material/items used in manufacturing of cable end terminations/ joints.

17.0 FIRE RESISTANCE

The cable terminations shall be fire resistant. The components of kits shall have flame
retardant property.

18.0 INTERCHANGEABILITY

The components of different number of the kits shall be inter-changeable in case the need
arises.

19.0 COMPLETENESS OF CABLE KIT FOR EASY INSTALLATION

19.1 The bidder shall offer complete material and components for each kit so as to meet one
termination complete in all respects. The bidder shall indicate the list of the material/
components with quantities of each or cable end termination.

19.2 An instruction manual in English, indicating the complete method/ proceedings adopted
for installations of kits, preferably with more diagrams/ pictorial presentation shall be
supplied with each kit. Various items, quantity thereof against each kit must be indicated
in the instruction manual.

19.3 The detailed bill of material and installation instructions shall be provided with each kit
for verification by purchaser's inspecting officer & at MPPTCL's stores/ site.

19.4 All components shall be sealed separately and marked clearly for the purpose of
identification of each component. All components shall be supplied in single package as a
complete kit for one termination joints and shall bear manufacturer's name & cable
size of kit size for which it can be used.

19.5 The Bidder shall also indicate shelf life & ideal life of kit contents.

20.0 GUARANTEE

The cable termination & straight through joints shall be guaranteed for satisfactory
performance as stipulated in Volume –I of Bidding Document. Any defect noticed in the kit
shall be attended by the successful bidder at the earliest on getting the complaint and if
required shall be replaced and installed free of cost, otherwise the same will be arranged
TR-21/2021 25 Vol.-II Part-4
 at the successful bidder's risk and cost.

21.0 SPECIAL TOOLS & TACKLES

Complete outfit of tools, special tools, spanners and other lifting devices, instrument and
appliance necessary for the complete assembly, erection at site, dismantling and
maintenance of Power Cable including all accessories (kits) covered by the contract
together with suitable racks for holding them shall be supplied by the contractor.

22.0 MANUALS AND LITERATURE ON CABLE & CABLE KITS

The following documents should be furnished along with the bid:-

i) Dimensioned cross sectional details of the cable.
ii) Current carrying capacities "with supporting calculated data" of the cable and de-
rated factors.
iii) Instructions Manual on cable laying installation, storage, handling, maintenance,
fault finding, repairs, preventive maintenance, etc.,
iv) Type, acceptance and routine test certificates on the cable as per relevant IS, IEC or
other International standards.
v) Dimensioned cross sectional details of the straight through Joint kit along with bill of
materials.
vi) Instruction Manual on the method and formation on cable joining techniques of the
straight through joint.
vii) Type, acceptance and routine test certificate on the straight through joints.
viii) OGA drawing of the cable end termination.
ix) Dimensioned cross sectional details of cable end terminations with bill of materials.
x) Instructions Manual on the method and formation on cable joining techniques of the
cable end terminations.
xi) Type, acceptance and routine test certificate on the cable end terminations. xii)
OGA drawing of the cable termination structure along with the bill of materials.
xiii) Literature on special Tools & Plant.
xiv) Literature on sheath bonding, maintenance of link boxes.
xv) Any other relevant literature/ manual.
xvi) Drawing showing additional details if any.

23.0 TRAINING DURING ERECTION

At the time of erection the successful bidder shall arrange demonstration of use of kits
(ordered by purchaser) for giving the training to three or more personnel of MPPTCL for
getting acquainted with the cable jointing method/ procedure.

TR-21/2021 26 Vol.-II Part-4

 Annexure- I (of Section-II)
PRINCIPAL PARAMETERS OF
XLPE CABLE KITS & ACCESSORIES

A. OUTDOOR CABLE END TERMINATION

1 Nominal System Voltage U 132 kV( rms)
2 Rated/Highest System Voltage Urn 145 kV (rms)
3 Rated frequency & No. of phase 50 Hz±3%, Three (3)
4 Installation Outdoor
5 Type of Kit Pre-molded
6 Suitable for Single Core Copper Conductor XLPE Yes
cable Conforming to IEC 60840 /IS 7098(part-3)
amended upto date and as per Section -1 of the
specification.
7 Rated continuous current Maximum current of the
cable
8 Applicable standard for testing IEC 60840
9 Maximum allowable Pd-level As per IEC
10 Type ofInsulator. Silicone/ Composite.
11 Creepage distance 25 mm/kV
12 Colour Brown
13 Maximum allowable temperature for cable and
accessories
i) At rated full load and at site condition 90°C

ii) The conductor temperature after a short circuit for 250°C

one second shall not exceed (with conductor
temperature at start of short circuits as 90°C).
14 Basic impulse insulation level 650 kV
(1.2/50 micro second wave)
15 Power frequency withstand voltage As per Standard
16 Stress relief cone made of Silicone rubber
17 Whether provision made for: Yes
a. Stress relief
b. Track Resistance
c. Sealing
18 Sectional Drawing Showing constructional details along To be furnished
with material and description of each item
19 Expected life of Cable joint and cable: 35 years
20 Guarantee of kit. Five (5) years from date of
commissioning

TR-21/2021 27 Vol.-II Part-4

 B STRAIGHT THROUGH JOINTS
1 Nominal System Voltage U 132 kV( rms)
2 Rated/Highest System Voltage Urn 145 kV (rms)
3 Rated frequency & No. of phase 50 Hz±3%, Three ( 3)
4 Installation Underground buried
installation
5 Name and address of manufacturer of end termination Refer clause no 5, Section-2
6 Type of Kit Pre-moulded
7 Suitable for Single Core Copper Conductor XLPE Yes
cable Conforming to IEC 60840 /IS 7098 (Part-3)
amended upto date and as per Section – I of the
specification
8 Rated continuous current Maximum current of the
cable
9 Applicable standard for testing IEC 60840
10 Maximum allowable Pd-level As per IEC
11 Guarantee of kit. Five (5) years from date of
commissioning
12 Proven technology and design to prevent entry of Yes
water
13 Sectional Drawing Showing constructional details Yes.
along with each item material, description enclosed.
14 Maximum allowable temperature for cable and
accessones
i) At rated full load and at site condition
ii) The conductor temperature after a short circuit for 90° C
one second shall not exceed (with conductor 250°C
temperature at start of short circuits as 90° C).
15 Basic impulse insulation level (1.2/50 micro second 650 kV
wave)
16 Power frequency withstand voltage As per Standard.
17 Power frequency withstand voltage As per IEC
(a) Dry (KV rms.)
(b) Wet (KV rms.)
18 Stress relief cone made of Silicone rubber
19 Whether provision made for: Yes
a) Stress relief.
b) Track resistance.
c) Sealing.

TR-21/2021 28 Vol.-II Part-4

 SECTION – III

TECHNICAL SPECIFICATION FOR INSTALLATION OF CABLE

CONSISTING OF

Section-III (A): Scope, Route Survey, Works requirement and statutory

clearances

Section-III (B): Laying and Installation of cable

Section-III (C): Details of Jointing and Termination works of Cable

Section-III (D): Civil and Structural Works

Section-III (E): Earthing, Site Testing, commissioning of complete cable

system

TR-21/2021 29 Vol.-II Part-4

 SECTION-III (A)

SCOPE, ROUTE SURVEY, WORKS REQUIREMENT AND

STATUTORY CLEARANCES

1.0 SCOPE

1.1 The 132 kV XLPE cable (Section-I) is to be laid underground along with jointing with
straight through joints in route run and termination kits (Section II) detailed hereunder in
the Section-III. Earthing of the cable screens/ sheath bonding at cross bonding points and
terminal ends of cable is to be done. After erection of complete cable system, site testing
is to be conducted in presence of owner and after successful commissioning, complete
cable system is to be handed over along with completion report.

1.2 The scope includes detailed route survey, evaluation of soil thermal resistivity along the
cable route, laying and erection of the XLPE cable in ground, under bitumen road, under
roadside lane, under road crossing under open drains/ closed drains, sewer line and
water pipe line and other crossings etc., in cable trench & jointing of straight through
joints in between cable lengths as well as jointing of end terminals at ends of cable by
expert cable jointer, as per respective approved drawings etc.

1.3 The scope also includes the inspection of cable on receipt, handling of cables,
providing of cable end sealing caps whenever required, paying out, flaking and providing/
fixing of joint markers, route indicators, precaution indicators for joint hole & sump holes
& all necessary precautions required in conformation with IS 1255-1983 or its equivalent.
Supply & providing of warning tape, cable laying i n cable trenches with covers up to
cable termination.

1.4 The scope of civil works includes digging of road, earth excavation, removal of excavated
earth, design, supply and providing plain and reinforced cement concrete slabs etc. paying
out, flaking, cushioning of cable with sand or sieved compacted soil, back-filling, removal
of excavated earth, dewatering of trenches, dressing of road surfaces as per requirement of
the field conditions, design, supply and construction of cable jointing bays, design of
cable duct/ pipe ducts for crossing drains, roads, bridges and other obstacles as per site
condition and their construction as per approved drawings.

1.5 The scope of civil works also includes foundations of end terminations support
structures etc, back filling, erection of galvanized steel structure for cable end
terminations, mounting of earthing link boxes, providing of earth continuity cable and
OFC clamping/ fixing in cable trench.

1.6 The scope also includes supply of all requisite materials, labour, tools and plant like sand,
brick, stones, steel, cement/ aggregate for all civil works for works detailed in above paras
including reinforcement, trenches, pipes, fabrication of joint and route markers, materials
like wall brackets, anchor bolts etc and all other consumables required for the completion
of the work.

1.7 Supply of all consumable and sundry materials not included in the specification in detail
but which are necessary to meet the intent of the project.

TR-21/2021 30 Vol.-II Part-4

1.8 The successful bidder shall carry out all activities connected with the laying and
installation of power cables & arrange for security till commissioning and handing over to
MPPTCL and completion of the work, for which the project is intended, to the full
satisfaction of the owner.

1.9 However, alternate installation arrangements offered by the bidders with clear
justification for these alternatives will be considered by the owner, if they prove to be of
a better and economical design.

2.0 CABLE LENGTHS AND ROUTE SURVEY

2.1 Bidder shall conduct detailed survey of cable route and accordingly finalize the route
plan. The final total quantity, the number of drums, the length of cable on each drum
etc. shall be ascertained by the successful bidder after detailed survey and identifying
locations of jointing bays preferably within two months from the date of letter of award.
The route plan and actual lengths of 132 kV XLPE cables required shall be submitted to
Purchaser for approval.

2.2 The route plan of the cable is enclosed with bid documents for reference only to
enable the bidder to assess the work involved in a broad way. The bidder is advised to
visit the site and acquaint themselves with the topography, infrastructure and
requirements etc. The contractor shall be fully responsible for providing all equipment,
materials, T&P and services specified or otherwise which are required to complete the
erection and successful commissioning of 132 kV cable system in all respects.

2.3 The arrangement of laying the cable under road, road side lane, under the road crossing
etc are indicated in enclosed drawing section of bid documents for reference of
bidders The bidder should furnish the drawings of arrangement of laying in above
cases along with others to meet site condition.

2.4 RIGHT OF WAY:

2.4.1 Any right of way, which may be required by the contractor for execution of cable line,
shall be arranged by him. The approval from civil authorities, P&T authorities and other
agencies / Government as required shall be arranged by the contractor. Statutory signature
of MPPTCL officers for PTCC and other clearance shall have to be obtained by the
contractor at appropriate time. Obtaining approval of the above proposal is the contractor’s
responsibility.

2.4.2 For PTCC clearance, the contractor shall prepare all drawings including route map, obtain
soil resistivity data as per requirement of PTCC and submit PTCC proposal to PTCC
authority at appropriate time. The cost of compensation, if required for strengthening,
protection of telecom lines from inductive interference from power lines will however be
paid by MPPTCL to appropriate authorities at actual.
2.4.3 Compensation of land for tower footing shall be paid by the contractor.
2.4.4 Access road to the work site shall be arranged by the contractor at his own cost. Any
compensation if needed to be paid for this purpose will be to the contractors account.
2.4.5 The compensation for trees, crops etc. (except Govt. forest) if required to be paid to
TR-21/2021 31 Vol.-II Part-4
 execute the erection of the line and for getting corridor clearance shall be paid by the
contractor.

2.4.6 Identification and demarcation of forest land, plotting, preparation of necessary drawings /
schedules is the responsibility of the contractor. Submission of the proposal to the state
Govt. authorities will be sole responsibility of the purchaser. The felling down of trees in
the forest will also be done by the contractor at his own cost. However, the necessary
charges i.r.o forest land / forest clearance will be paid directly by the Employer to the
concerned authorities.

2.5 SOIL DATA :

2.5.1 The bidder shall be responsible for carrying out the required survey and should fully
satisfy himself about the nature of soil expected to be encountered prior to the submission
of bid. The unit rate quoted by the Bidder shall be irrespective of soil type such as normal
soil, soft rock, hard rock and crossings such as pavements, all types of roads, rivers,
canals, drains, culverts, rail track etc. encountered during the actual installation. The
bidders are required to make their own estimates and offer a single uniform rate applicable
for all kinds of soil strata and crossings. The Employer shall not entertain any additional
claims for payment for any type of soil/crossings encountered during installation.
Employer strongly recommends site visits/investigation by the Bidders (at their own cost)
before submission of the bid for proper estimation. The contractor shall be required to
carry out excavation and back filling in accordance with this specification and provide all
additional items required at its own cost for proper installation not limited to those
described in this specification. Unit rate for construction of buried cable trench and Back
filling shall interalia include all related work/activities such as excavation, blasting of
rocks and backfilling of trenches, fixing of gradient of trench, excavation of trial pits if
required, clearing of bushes, roots of trees along the trenches, cutting of bushes, trees,
shoring, dewatering, excavation and backfilling of any temporary manhole, support of the
existing facilities/plant, removal of let out materials, breaking of pavement, clearing of
obstacles, temporary reinstatement of footpath wherever required, providing all types of
markers, cover slab and tapes etc., suitable structure/techniques, material for crossings
(road, rail, culvert, river, canal etc.) for installation of HDPE pipe and other installation
materials etc. A unit rate of laying of cable will be considered in all type of trenches,
trench less laying, through air, through hangers while negotiating existing overhead road
bridges etc. No separate rate for specified type of laying of cable will be considered. The
BOQ in the bid proposal sheets indicates the total route length to be implemented under
subject package.

2.5.2 Map Study: The Contractor shall arrange topographical maps and other maps of the
concerned area in proper scale. All links shall then carefully be studied using maps.
Various feasible alternative routes shall be identified on the maps and the Contractor shall
shortlist most suitable route.

2.5.3 Collection of details of other utilities: Contractor shall arrange information about existing
underground facilities for the proposed routes. To do so as built drawing or route index
diagram for various services viz. water works, electric supply utilities, telecom services
providers, public health, gas/oil authorities etc. may be collected from the concerned
authorities. In case details are not available, the Contractor shall assess suitably by
conducting enquiries and surveys with help of cable locator or similar type of instrument.
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2.5.4 Identification of underground cable route: The Contractor shall propose most suitable
route for cable laying keeping in view the following broad criteria:
1) The route shall be as straight and as short as possible.
2) The route shall have minimum obstacles in order to minimize reinstatement cost.
3) Minimum clearances shall be required from other authorities/ bodies and that the
clearances can be obtained expeditiously.
4) Wet or unstable ground shall be avoided to the extent possible.
5) The route for the cables shall be away from the carriage way of the road to the
extent possible.
6) The route shall be suitable for placing manholes wherever required.
7) Future expansion of roads shall be taken into consideration.
8) Road/ rail/ canal/ drain/ culvert crossing and trenchless digging shall be minimum.
9) As far as possible underground cable route shall be on the opposite side of the
existing cables laid by DOT/BSNL or other utilities. Wherever both routes fall on
the same side of the road, a spacing of about 2.0 mtr .horizontal and 1 mtr vertical
spacing is to be maintained to the extent possible.
10) Care must be taken to avoid choosing routes, roads and areas that are prone to
floods etc.
11) Cable crossing of HV, LT, communication cable or Gas, water, sewage line etc
shall be at a suitable distance according to guidelines available
(Indian/International or guide line of the concerned utilities).

2.5.5 After finalizing the best alternative route, some trial pits shall be dug at suitably selected
locations to assess the obstacles. It is necessary to locate the trial pits at proposed manhole
locations. They shall be dug carefully keeping watch over the existing underground
facilities. The presence of each type of facilities shall be recorded in the inspection note of
the trial pit along with their sites sketch are kept in record for future reference. These
details shall be enclosed along with the survey report. The Contractor shall submit the
survey report with the most suitable route for cable link along with details above.
Contractor shall submit the final survey report for approval before implementation. The
final survey report shall include at least the following:-
1) A drawing of the proposed route indicating all details of the route including
relevant details of soil strata, bridges, culverts, causeways, rail over under bridges,
canal, defense area, underground gas/oil/water pipe line, power and communication
cable routes, other important landmarks etc.
2) The distance of the cable route from the centre of the road/ rail/ canal/ river/ bridge/
culvert etc. shall be indicated on the route maps as well as documented in table.
3) Coverage Area of city/ town/ village/ forest/ defence etc.
4) Sections of the links where trenchless digging may be required.
5) Location and number of permanent and temporary manholes.
6) Location of all turns, bends and major landmarks.
7) List of authorities from which clearance shall be required to be obtained from each
relevant section.

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 The final survey report shall have to be approved by the Employer and requisite
clearances need to be obtained before the cable installation work is commenced. The
contractor shall prepare and submit for approval by the Employer, specific
construction drawings for all types of soil strata/ crossings taking into consideration
the guidelines given in this specification. The construction/implementation shall be
carried out as per the approved drawings. The construction drawings shall inter-alia
include the longitudinal sectional diagram of the trench for different soil strata and
detail arrangement of crossings, number of pipes, size of pipes, location and position
of manholes, other details as per the technical specification. Any other items not
specifically mentioned in the specification but which are required for installation,
testing, commissioning and satisfactory operation of the cable as per Indian
Standards/IE Rules/IE Act and concerned authority regulations are deemed to be
included in the scope of the specification and no deviation in this regard shall be
accepted. The contractor shall also be responsible for the overall co-ordination with
internal/external agencies, project management, manpower, loading, unloading,
handling, moving to final destination for successful erection, testing and
commissioning of the 132 kV cable.

3.0 CODES AND STANDARDS

3.1 Cable installation shall be carried out generally as per following applicable standards
and other relevant applicable standards unless otherwise stated:-

IS 1255 Installation and maintenance of power Cable Specification for pre-

IS: 5820 cast concrete cable covers
IS: 209 Quality of zinc for galvanizing.
IS: 226 Structural steel
IS : 456 Plain and reinforced cement concrete
IS: 800 Use of structural steel in general building construction. Plain
IS: 2016 Washers
IS: 2633 Zinc coating on galvanized steel. Spring washers
IS : 3063 & 5358 Hot Dip Galvanized coating on fasteners.
IS: 6639 Hexagonal bolts for steel structures.
IEC-62067 Tests for power cables with extruded insulation for rated voltage
above 150 kV upto 500 kV.
BIS: 7098 (Part-3) XLPE cable specification for working voltage from 66 kV up to and
including 220 kV.
IEC: 60229 Tests on cable over sheaths

Any other equivalent International/National standard referred in the sections-I, II& III
or otherwise.

4.0 INSPECTION, STORAGE AND HANDLING

4.1 The cable drums shall be mounted and transported only on approved type cable drum
TR-21/2021 34 Vol.-II Part-4
 conveyors.

4.2 The contractor should take all necessary precautions for inspection of cables on
receipt and for the proper handling and storage. The contractor shall have his own
arrangement for transporting the cables, materials and equipment to site and back to
store.

4.3 While laying cable, cable drum shall be unloaded, handled and stored in an approved
manner. In no case the drum shall be stored flat i.e. with flankage horizontal. Rolling
of drums shall be avoided as far as possible.

4.4 The cables shall be stored on hard packed surfaces and protected from harmful
weather conditions.

4.5 For unreeling of cables, the drum shall be mounted on suitable jacks or wheels. All
possible care shall be taken during unreeling and laying to avoid damage due to twist,
kink or sharp bends.

4.6 Bending radii for cables shall be as per manufacturer's recommendations. The cable
should not be bent beyond permissible limits of the bending radius while laying and
jointing.

4.7 Manufacturer's instructions shall be strictly adhered to.

5.0 EXECUTION OF WORK

5.1 This specification is intended for general description of quality of materials and
workmanship of finished work. They are not intended to cover the minute details. The
work shall be executed in accordance with the best modem practices, Indian standards
(I.S.) and other relevant codes.

5.2 The specification shall be read in conjunction with the other parts of the bid
documents.
5.3 The Purchaser's decision shall be final on any issue in respect of installation.

5.4 The bidder shall prepare the drawings for applicable field conditions of cable
installation like cables directly buried, below metalled road, in ducts, in road
crossing, on drainage crossings, cable jointing bays, man holes and other drawings
referred in foregoing paras etc. and furnish 3 copies of each to the owner for approval
and 6 sets of final approved drawings for execution of work.

5.5 All works are to be executed by bidder only after due approval of the MPPTCL
engineer and under his supervision.

TR-21/2021 35 Vol.-II Part-4

6.0 STATUTORY CLEARANCES
6.1 The installation of cables shall be as per established code or practice and fulfill the
requirements of status. All clearances as per statute shall be maintained from other
utility services, like telephones, water supply, power supply etc.

6.2 The civic highways/traffic authorities etc. charge as per their standard schedules for
grant of permission for trenching. These charges are towards restoration of the surface
to its original condition. These charges shall be paid by the owner as per actual, on
production of bills/demand notices.

7.0 EXPERTISE OF UNIT TO HANDLE WORK

7.1 Cable laying/erection unit shall be having good experience (at least 5-7 years) of
similar work of 66 kV and above class cables and have at least completed 5 such jobs
of 66 kV and above class cables but at least conducted 2 jobs of 132 kV and above
cables. Unit in-charge should have at least 15 years of experience of EHV class cable
laying /erection.

7.2 The cables jointing and termination work shall be carried out by experienced cable
jointer who shall have more than 15 years experience in jointing and termination of
33 kV or higher voltage grade XLPE cables and have at least completed 2 such Job
of 132 kV and above class cables.

7.3 The bidder should give the bio data of team in-charge and other engineers/
supervision/experts along with the bid to assess the capability of bidder in this
respect. Bidder should also enclose the list of such work conducted along with bid.

8.0 PREVENTION FROM TRAFFIC ACCIDENTS WHILE WORK IS IN

PROGRESS.

8.1 Suitable barriers should be erected between the cable trench and pedestrian/
motorway to prevent accidents. The barriers shall be painted with yellow and black or
red and white coloured cross stripes. Warning and caution boards should be
consciously displayed. Red lights as warning signal should be placed along the trench
during the nights.

8.2 The excavated material shall be properly stored to avoid obstruction to public and
traffic movement.

9.0 DAMAGE TO PUBLIC PROPERTY WHILE WORK IS IN PROGRESS.

9.1 The contractor shall take all precautions during excavation of trench, trial pits etc., to
protect the public and private properties and to avoid accidental damage. Any damage
so caused shall be immediately repaired and brought to the notice of the concerned
and MPPTCL Engineer/ Purchaser
TR-21/2021 36 Vol.-II Part-4
9.2 The contractor shall bear all responsibilities and liabilities and shall bear all costs of
the damages so caused by him or by his workman or agents.

9.3 At places where the cables cross private roads, gates of residential houses or
buildings, the cables shall be laid in PVC pipes of adequate strength.

10.0 DOCUMENTATION

10.1 Bidder should enclose complete literature of following with bid:-

i) Laying method and precautions to be taken.

ii) Method and detailed description of joints through straight through terminals.
iii) Method and detailed description of cable end terminations

10.2 The contractor shall prepare the route layout plan indicating the road crossing,
crossing across drains, nallahs, etc., and location of the straight through joints and
relevant and associated drawings.

11.0 INSPECTION AND SITE TESTING WHILE WORK IS IN PROGRESS

11.1 The material and equipment covered under this contract are subject to strict codes of
owner approved Q.A.P. inspection and tests.

11.2 Approval or passing of any such testing/inspection by the owner shall not however
prejudice the right of the owner to reject the material/ equipment if it does not
comply with the specification when installed and or fails to give the intended
service.
11.3 A complete test schedule/ program shall be furnished by the contractor.

11.4 The bidder shall provide test pieces in required quantity, to determine the quality of
material supplied under this contract. If any test piece fails to comply with the
requirement the Engineer may reject the whole material represented by the test
pieces.

11.5 In the case of stage inspection during erection work, the bidder shall proceed from
one stage to another only after the component is inspected by the Engineer and
permission given to proceed further. The same procedure shall apply for any
rectification or repairs suggested by the Engineer.

11.6 The contractor shall give the owner 3/5 days written notice for inspection/site tests.
The Engineer shall within 3 days of the inspection give notice in writing to the bidder
of any defects noticed during inspection site tests. The bidder shall take corrective
measures and shall confirm in writing, of the compliance or otherwise with due
reason.

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11.7 The purchaser or the Engineer shall have the right to inspect any machinery, material,
structure, equipment, plant or workmanship furnished or used by the contractor and
may reject any or all which is defective or unsuitable for the use and purpose intended
or which is not in accordance with the specification.

11.8 The contractor on demand by the owner shall remedy or replace at his expense such
defective material/plant equipment. In the event of the failure of the contractor to
correct the defect or replace the material/equipment/plant, the owner may take such
remedial measures necessary at the expense of the contractor.
11.9 In the event of inspection by the engineer and the inspection revealing
that the Goods/ materials are not in conformity with the standard/specification, the
owner shall specify additional tests/inspection procedures, if required to ascertain
compliance with specifications.
11.10 A set of latest relevant approved drawings/data shall be made available to the
Engineer during inspection.

11.11 The Engineer shall issue a certificate for having inspected the material/equipment
within seven days of inspection. The issue of the certificate does not bind the
purchaser to accept the material should further tests on installation be found not to
comply with the contract specification.

11.12 The bidder shall conduct all tests or repeat the tests already conducted, for the
satisfaction of the purchaser.

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 SECTION-III (B)

LAYING AND INSTALLATION OF CABLE

1.0 LAYING OF CABLE :

132 kV XLPE Power Cable ( as per specification in Section-I) shall be laid throughout
the route as under:
Four No. cable lengths (@3 No. per Ckt. + 1 No. spare) in trefoil formation.
However, the cables shall also have to be laid as per approved drawings, as per
requirement of the field conditions:
1. In ducts
2. In HDPE Pipes at road crossings (pipes to be filled with sand / suitable material
after cabling)
3. In HDPE pipes at crossings of private roads and gates of residential houses /
buildings.
4. In open air / over steel rack (for end termination).
5. At varying depths due to obstructions.

2.0 LAYING OF POWER AND OPTICAL FIBRE CABLES

2.1 One / Two circuits of the 132 kV XLPE cable shall be laid in the same trench/duct
along with 1 No. earth continuity cable (@1 No. per Ckt) and 1 No. optical fibre cable
in HDPE pipe (@1 No. per Ckt.) as indicated in drawing enclosed for reference. The
contractor shall furnish detailed drawing complying with all applicable standards
for approval by the owner.

2.2 The 132 kV XLPE power cable shall be laid wherever required in 0.6 Mpa class
HDPE pipes of ISI approved quality as indicated in drawing enclosed for reference.

3.0 TRENCHING & TRENCHLESS DIGGING

3.1 TRENCHING :
3.1.1 The cable trench work involves earth excavation for cable trench, back filling and
removal of excess earth from site. The work site shall be left as clean as possible.

3.1.2 The trench shall be excavated using manual/mechanical modes as per field
conditions. Most main roads are of asphalt surface and some of the roads with cement
concrete surface. At road / nallah crossing with open excavated trench, the cable shall
be laid in 0.6 Mpa HDPE pipe of min. 200 mm dia @ 1 No. per phase and all phases
per circuit simultaneously in trefoil formation in NP4 RCC hume pipe of min 600 mm
dia, 0.6 Mpa class, @ 1 No. per ckt.

3.1.3 Where paved footpaths are encountered, the pavement slabs shall be properly stored
and reinstated. Identification markers of other services shall be properly stored and

TR-21/2021 39 Vol.-II Part-4

 restored. The excavated material shall be properly stored to avoid obstruction to
public and traffic movement.

3.1.4 The sides of the excavated trenches shall be well shored up wherever required.

3.1.5 The bottom of the excavated trench should be levelled flat and free from any object
which would damage the cables. Any gradient encountered shall be gradual.

3.1.6 Suitable barriers should be erected between the cable trench and pedestrian/
motorway to prevent accidents. The barriers shall be painted with yellow and black or
red and white coloured cross stripes. Warning and caution boards should be
consciously displayed. Red lights as warning signal should be placed along the trench
during the nights.

3.1.7 The bottom of the excavated trench should be levelled flat and free from any object
which would damage the cables. Any gradient encountered shall be gradual.

3.2 TRENCHLESS DIGGING:

3.2.1 It is envisaged that trench less digging shall be used for crossing national highways,
rail line and canal / nallah and this shall be in the scope of bidder. The cable shall
be laid in 0.6 Mpa HDPE pipe of min. 200 mm dia @ 1 No. per phase and all phases
per circuit simultaneously in trefoil formation in one HDPE pipe of min 600 mm dia,
0.6 Mpa class. Trenchless digging shall also be used where the concerned authorities
do not permit open cut method and it is essentially required to be carried out for
installation of underground cables. The trenchless digging methods shall generally
conform to ITU-T 1.38. The various methods of trenchless digging such as
hand/manual auguring (up to 15m.) impact moulding (from 16m to about 40-50m.)
and HDD (above 40-50m) shall be adopted based on the soil/site conditions and the
requirement and exact method for trenchless digging shall be finalized during detail
engineering as per actual site/soil condition. The equipment used for HDD shall be
capable of drilling at least 100m at one go. The contractor shall propose the exact
methods and procedures for implementation of trench less digging at various
crossings taking into consideration the following guidelines, for approval by the
Employer.

a) Excavation and backfilling of trial pits and verification of soil condition.

b) Excavation of entry and exit pits.
c) Erection of drill machine. Drilling of pilot hole.
d) Placement and driving hand augur.
e) Placement and carrying out impact moulding.
f) Reaming and widening of bore holes in steps (if required).
g) Pulling of product pipe.

4.0 DEPTH OF LAYING OF CABLES

Depth of laying shall be 1.5 m. During detailed engineering, depth proposed for more
TR-21/2021 40 Vol.-II Part-4
 than 1.5 m at typical location (s) shall be accepted subject to approval of MPPTCL.

5.0 PAYING OUT THE CABLE

The excavated cable trench shall be drained of all water and the bed surface shall be
smooth, uniform and fairly hard before paying out the cable. The cable shall be rolled
in the trench on cable rollers, spaced out at uniform intervals. The paying out process
must be smooth and steady without subjecting the cable to abnormal tension.
The cable on being paid out shall be smoothly and evenly transferred to the ground
after providing the cushion. The cables shall never be dropped. All snake bends shall
be straightened. Suitable size cable stocking pulling eye shall be used for pulling the
cable. While pulling the cable by winches or machines, the tension loading shall be
by tension indicator and shall not exceed the permissible value for the cable. The
cable laying shall be performed continuously at a speed not exceeding 200 to
300 meters per hour.

6.0 CABLE END SEALS

The cable end seals shall be checked after laying and if found damaged shall
immediately be resealed. Sufficient number of heat shrinkable cable end sealing
caps shall be stocked at site stores for testing and jointing work. The integrity of the
outer sheath shall be checked after the cable is laid in position.

7.0 FLAKING
The cables shall be flaked and left with slight extra lengths at jointing bays for
expansion and flexibility. This shall have prior approval of Engineer.

8.0 SAND CUSHION

The sand cushion for the cables shall be provided as per the drawings. Sand
covering shall be done by hand and in such a manner as to provide complete
envelope for the cables.

9.0 SAND BEDDING

The cable shall be completely surrounded by well compacted cable sand having low
thermal resistivity (selected sand) about 250 mm above and below the cable surface
so that the cable is protected against damage.

10.0 THERMAL BACKFILL

Based on the evaluation of soil thermal resistivity along the cable route and after
approval from the MPPTCL the contractor shall design, specify, supply, lay and
monitor the installation of thermal backfill surrounding the cables.

11.1 IMMEDIATE ENVELOPE TO CABLE

The option on the use of the material that immediately envelopes the cable viz.,
thermal backfill or sand or sieved native soil rests with the MPPTCL. The contractor
shall seek prior approval on the use of the envelop material from the MPPTCL before
execution of the works.

TR-21/2021 41 Vol.-II Part-4

12.0 BACK FILLING
Normally back filling shall consist of the material earlier excavated. However, bigger
stones or pieces of rock should be removed.

13.0 PREVENTION OF DAMAGE DUE TO SHARP EDGES

13.1 After the cables have been laid in the trench and until the cables are covered with
protective covering, no sharp metal tool shall be used in the trench or placed in such a
position that may fall into the trench.

13.2 Straight and curved rollers used shall have no sharp projecting parts liable to damage
the cable.

13.3 While pulling through pipes and ducts, the cable shall be protected to avoid damage
due to sharp edges.

13 4 The cables shall never be bent, beyond the specified bending radius.

14.0 WARNING TAPE

A pre-warning, yellow colour plastic/ PVC tape, 250 mm wide 100 microns
thick, shall be laid at approx. 0.4 m above the cable specified depth, throughout the
cable route. The tape shall carry the legend printed in red continuously as under;
CAUTION:132000 V CABLE MPPTCL.

15.0 IDENTIFICATION
An identification marker/ tag of lead of size 50 mm x 25 mm x 2 mm shall be
provided at 2.5 metres interval throughout the route length of the cable and
fastened with a suitable nylon string. The marker shall be embossed/ bunched on both
sides with the letters MPPTCL 132 kV Cable Ckt-I; MPPTCL OFC; MPPTCL
132 kV Cable Ckt-II respectively. In case of double circuit, phase identification by
coloured PVC tape shall be at 1 M interval. Alternatively plastic tags may be used.
These tags should also be fixed at the cable inlet and outlets of a duct, tunnel,
manhole and joint bays.

16.0 CABLE OVER BRIDGES

16.1 Wherever the cable route crosses the bridges, the cables shall be laid in ducts by
removing and replacing the R.C.C. covers and properly back filled.

16.2 Cable Crossing Open Drains With Long Span

a) Wherever the cable route has to cross an open drain, with a long span, the
cable shall be laid in suitable size ducts or pipes, suitably jointed with collars.
The entire duct system shall be designed as per civil engineering practice and
shall be got approved by the concerned authorities and owner.

b) At places where the cables cross private roads, gates of residential houses or
buildings, the cables shall be laid in HDPE pipes.

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17.0 ROAD CUTTING
The road cutting, whether of cement concrete/ asphalt or macadam road surface
shall be taken after obtaining approval for cutting from the civic authorities, traffic
police, telephone authorities and work should be planned to be completed in the
shortest possible time. Where necessary the work shall be planned during night or
light traffic periods.

18.0 ROAD CROSSING

Cables shall be laid in 0.6 MPa HDPE pipes of min. 200 mm outer diameter at road
/nallah crossings.

19.0 FOOTPATH CUTTING

The slabs/ kerb-stones on the roads shall be removed and reinstated without damage.

20.0 REINSTATEMENT

20.1 After the cables and pipes have been laid and before the trench is backfilled all
joints and cable positions should be carefully plotted and preserved till such time
the cable is energized and taken over by the Engineer. The protective covers shall
then be provided, the excavated soil riddled, sieved and replaced. It is advisable to
leave a crown of earth not less than 50 mm and not more than 100 mm in the centre
and tapering towards the sides of the trench.

20.2 The temporary reinstatement of roadways should be inspected at regular intervals,

more frequently in rainy season and immediately after overnight rain for checking
settlement and if required the temporary reinstatement should be done.

20.3 After the subsidence has ceased the trench may be permanently reinstated and the
surface restored to the best possible condition.

20.4 The road surface being cement concrete, asphalt or tarred macadam, resurfacing
will be done by the civic authorities at owner's cost. The fixing of markers etc. shall
be co-ordinated by bidder.

20.5 All works shall be carried out under supervision of the engineer in charge or his
representative.

21.0 CABLE ROUTE MARKERS/ CABLE JOINT MARKERS

21.1 Permanent means of indicating the position of joints and cable route shall be
fabricated, supplied and erected by successful bidder as per approved drawings. Pre-
cast RCC markers shall be placed as per the field requirement, if the route passes
through open fields, markers should be conspicuously visible and above ground
surface.
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21.2 The marker should incorporate the relevant information viz. the name of purchaser
(MPPTCL), voltage, circuit and distance of cable from the marker. The minimum size
shall be 600 (L) x 30 (Thk) x 100 (W) mm and it shall be embedded in ground up to at
least 500 mm.
21.3 The exposed portions shall be painted with non-washable paints (preferably yellow
paint). Letters shall be painted in red colour.
21.4 The interval should be maximum 50 meters between two markers. It should be put a
bends, curves, road crossing, etc. of cable route.

22.0 TOOLS AND PLANTS

22.1 The successful bidder shall have all necessary tools, plant and equipment to carry out
the survey and cable installation work.

22.2 The bidders are instructed to give all the details of equipment at their disposal to carry
out the work successfully and speedily.

23.0 MAINTENANCE OF SITE CONDITIONS

The contractor shall clean the completed cable route and shall remove all surplus and
waste materials, empty cable reels etc. preferably the same day but not later than the
next day after the particular work is completed.

24.0 BENDING RADIUS

The minimum bending radius of XLPE insulated cables are as follows:

Cable Bending radius

Single Core 25 x Overall diameter of cable

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 SECTION-III(C)

DETAILS OF JOINTING AND

TERMINATION WORKS OF CABLES

1.0 GENERAL

1.1 The cable jointing personnel and his crew shall have good experience in the type of
joints and terminations that are used. The jointing work shall commence as soon as
two or three lengths of cables have been laid. All care should be taken to protect the
factory-plumbed caps/ seals on the cable ends, and the cable end shall be sealed
whenever the end is exposed for tests.

1.2 Jointing of cables in carriage ways, drive ways under costly paving, under concrete
or asphalt surfaces and in proximity to telephone cables and water mains should be
avoided whenever possible.

1.3 Sufficient overlap of cables shall be allowed for making the joints.

1.4 The joint bay should be of sufficient dimensions to allow the jointers to work with
as much freedom of movement and comfort as possible. Sufficient space should be
kept below the cable to be jointed.

1.5 The joints of different phases shall be staggered in the jointing bay.

1.6 During the cable jointing works, the overlapping cable portions are cut for suitable
positioning of cable joints. In this process, lot of cable pieces gets accumulated as
wastage/ scrap. Such wastage of cable for jointing shall be kept to a minimum by the
contractor.

1.7 All accessories and consumables used in the termination should be of good quality
and compatible with the cable.

2.0 JOINTING BAYS / MANHOLES:

2.1 The bidder shall identify the location of the joint bays after carrying out detailed
survey of the cable route and excavation of the trial pits. The delivery lengths of the
cables shall match the location.

2.2 In case of underground portion, 'the joint bay should have a flat and level surface
lined with bricks and properly plastered. The retaining walls on all sides, to the
required height shall be of brick/stone masonry. The top of the wall shall have a
cement concrete bed 1:2:4 with 20 mm size aggregate all-round. The top shall be
covered with pre-fabricated RCC slabs of adequate strength and shall be provided with
an inspection cover. At the bottom in a corner, a sump pit shall be made for bailing
out water.

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2.3 The contractor shall submit design and drawing of joint bay for both underground and
bridge portion for approval of the MPPTCL.

2.4 Manholes shall be provided at every proposed joint location for jointing bays. The
Contractor shall get inspected all manholes by a representative of the Employer,
before carrying out the backfilling. Pipe and cable sealing, installation of joint bus and
cable service loops as per approved drawings shall be visually inspected and checked
for tightness. The contractor shall submit design and drawing of Jointing bay
including manholes in the buried cable trench portion for withstanding a live load of
20 tons vehicle plus 30% for impact from moving vehicle. The Contractor shall
propose a suitable procedure for testing the manhole for approval by the Employer.
Manholes of the type approved by the Employer only shall be acceptable. The
manhole shall include sufficient number of suitable entries. All works shall be
carried out under supervision of the engineer in charge or his
representative.

3.0 SUMP HOLES

When jointing cables in water logged ground or under unforeseen rainy conditions, a
sump hole should be made at one end of the joint bay, in such a position so that the
accumulated water can be pumped or bailed out by buckets, without causing
interference to the jointing operation.

4.0 TENTS/COVERS
An enclosure or suitable protection cover shall be used in all circumstances
wherever jointing work is carried out in the open irrespective of the weather
conditions. The joint shall be made in dust free, moisture free and clean
atmosphere. The full details of the cover and how it will be provided at site so as to
ensure full compliance to the requirements of this clause should be furnished by the
bidder along with the offer.

5.0 PRECAUTIONS BEFORE MAKING A JOINT

The cable end seals should not be opened until all necessary precautions have been
taken to prevent circumstances arising out of rainy/ inclement weather conditions
which might become uncontrollable. If the cable end seals or cable ends are found to
have suffered damage, the cables should not be jointed without tests and rectification.

6.0 MEASUREMENT OF INSULATION RESISTANCE

Before jointing, the insulation resistance of both sections of cables shall be checked.

7.0 IDENTIFICATION OF PHASES AT JOINT BAYS

The identification of each phase shall be clearly and properly marked. The cables
shall be jointed as per the approved design. Each cable shall have identification for
phase at joint bays.

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8.0 MAKING A STRAIGHT THROUGH JOINT

8.1 Comprehensive jointing instructions of the straight through joints detailed in Section-
II of this specification shall be supplied by the manufacturer of jointing kits and same
shall be meticulously followed by bidders' jointers.
8.2 The materials used in the joints like ferrules, screen/ sheath continuity bonds, lugs
etc., shall be of good quality and conform to standards.

8.3 The jointing tools shall be appropriate and as per the requirement of jointing HV
XLPE cables.

9.0 MAKING A CABLE END TERMINATION

9.1 The cable end terminations and its supporting structures shall be as per Section-II of
this specification. The preparation of the cable end for installing the terminations
and the precautions to be taken before fixing the terminations shall be followed as
in the case of the cable jointing procedures.

9.2 The instructions furnished by the manufacturer of cable terminals ends shall be strictly
followed.
9.3 At cable terminating end, the following provisions for supply and erection are to be
included:-

(i) A sufficient length of spare cable shall be left in the ground for future needs.
(ii) The rise of the cable immediately from the ground shall be enclosed in
PVC/ PE pipe of suitable diameter to protect against direct exposure to the
sun.
(iii) The cable shall be properly fastened using non-metallic clamps.
(iv) Appropriate labels shall be fixed identifying the phase circuit, voltage and date
of commissioning etc. on the cable supporting structure.
(v) The sealing end shall be mounted on pedestal insulators to isolate them from their
supporting steel work.
(vi) Protection from contact with the exposed metal work at the termination shall be
provided by resin bonded glass fiber shroud.
(vii) Providing earth stations with all required materials, like leads, connectors etc.

10.0 BONDING OF SCREEN/ SHEATH

The screens at both ends/ cross bonded points en-route, shall be brought out and
bonded to the earth station through disconnecting type link boxes and through SVL
wherever applicable.

The sheath bonding as per relevant standards shall be done to effectively reduce
sheath voltage below the acceptable level of 65 Volts. Bidders shall give complete
details of the type of the bonding offered and its effect with the designed current

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11.0 CONNECTION OF RADIAL WATER BARRIER AND CABLE SCREEN
If the metallic radial water barrier is insulated from the metallic wire screen a
connection suitable to carry the currents occurring during operation must be
installed between metallic radial water barrier of the cable and metallic wire screen in
joints and sealing ends.

12.0 CABLE TERMINATING STRUCTURES.

12.1 The cable terminating structure (Section-II) shall be fixed on the cement concrete
foundation, the design and drawings of which shall be submitted to MPPTCL for their
approval during the course of detailed engineering

12.2 After fixing the end termination, the cable shall be fixed to the support, with non-
magnetic material clamps to the required height securely

12.3 The mounting structure includes the supports for cable end boxes, link boxes and any
other structure required for the intent of the contract.

12.4 All steel sections used shall be free from all imperfections, mill scales, slag intrusions,
laminations, fillings, rust etc., which may impair their strength, durability and
appearance. All materials shall be of tested quality only unless otherwise permitted by
the MPPTCL.

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 SECTION -III (D)
SPECIFICATION FOR CIVIL AND
STRUCTURAL WORKS

1.0 EXCAVATION

1.1 The specification covers excavation for cable trenches, ducts, structural foundation
and jointing bays.

1.2 The contractor shall control the grading in the vicinity of all excavations so that the
surface of the ground will be properly sloped or diked to prevent surface water from
running into the excavated area during construction.

1.3 The excavation shall include the removal of all materials required to execute the
work properly and shall be made with sufficient clearance to permit the placing,
inspection and setting of forms and completion of all works for which the
excavation was done.

1.4 The sides and bottoms of excavation shall be cut sharp and true. Undercutting shall
not be permitted. Earth sides of excavation shall not be used in lieu of form work
for replacement of concrete unless authorized by the Engineer where the limitations
of space for large excavation necessitate such decision.

1.5 When machines are used for excavation, the last 300 mm before reaching the
required level shall be excavated by hand or by such equipment that will leave the
soil at required final level in its natural condition.

1.6 The bottom of the excavation shall be trimmed to the required level and when
carried below such level by error, shall be brought to level by filling with lean
concrete of 1:4:8 mix at contractor’s cost.

1.7 All excavation for installation of underground facilities shall be open cuts.

1.8 The excavation for foundation where specified shall be carried out at least 75 mm or
as specified in relevant drawing below the bottom of the structure concrete and then
be brought to the required level by placing lean concrete of 1:4:8 mix or as specified
with aggregate of 40 mm nominal size.

1.9 When the excavation requires tracing, sheeting, shoring, strutting etc. the contractor
shall submit to the Engineer in charge drawings showing arrangement and details of
proposed installation and shall obtain the approval from the Engineer in charge before
proceeding with the work.

1.10 The contractor shall have to constantly pump out the water collected in the pits
and trenches due to rain, sub-soil springs etc. and maintain dry working conditions
at no extra cost to the owner.
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2.0 DISPOSAL OF EXCAVATED EARTH

2.1 The contractor shall arrange to transport the surplus excavated earth by mechanical
transport. It shall however be ensured that stacking /disposal shall be as directed by
the Engineer-in-charge.

2.2 However the contractor shall take all precautions at the site of excavation for
keeping the free flow of vehicular and human traffic and to avoid inconvenience in
general. The soil transported for disposal shall be stacked, levelled and dressed neatly.

3.0 BACK FILLING MATERIALS

3.1 The backfilling of excavated trenches around foundation shall consist of one of the
following materials, as the Engineer-in-charge may direct, in each location.

i) Selected sieved earth from excavated soil.

ii) Selected sieved earth brought from borough area.
iii) Sand filling (sieved).

3.2 Filling shall be done after the concrete or masonry work has fully set and its curing
completed.

3.3 The contractor shall not fill in and around any work until it has been properly
reinstated and approved by the Engineer-in-charge.

4.0 BACK FILLING FOR CABLE TRENCH

4.1 Back filling shall be done in horizontal layers of thickness not exceeding 300 mm,
free from pockets with careful watering where necessary for compaction. The
backfill shall be riddled earth free from materials likely to cause damage to the
cables.

4.2 The thermal backfill surrounding the cable shall be as per the design approved by the
owner.

5.0 SPECIFICATION FOR CEMENT CONCRETE

5.1 For the cement concrete, plain or reinforced for general use, requirement of concrete
for nominal mix, strength and quality of pouring at all levels, from works, protective
covering, finishing, add mixtures, inserts, curing etc., the provision of the latest
revision of IS: 456 shall be complied with, unless permitted otherwise by any other
Indian Standard codes and shall form the part of the specification to the extent
applicable. The cement used shall comply with IS: 12269 (OPC). The metal (Jelly)
used in PCC/RCC shall be properly graded and machine mixed.
6.0 CURING AND PROTECTION OF CONCRETE
6.1 All fresh concrete shall be covered with the layer of an absorbent material and kept
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 constantly wet for a period of seven days or more from the date of placing concrete.
The immature concrete shall be protected from damage and contamination that
would impair the strength of the concrete.

7.0 PRECAST RCC ITEMS

7.1 The concrete mix for the various types of pre-cast units shall conform to IS: 456.
The aggregate shall be mixed by weight and water cement ratio shall be controlled
to obtain the dense concrete and the strength required. The reinforcement shall be as
per the design approved. The curing shall be carried out for the period of minimum
seven days from the date of casting and the pre-cast element shall be cured by
flooding with water of minimum 25 mm depth over the element for the period
mentioned above.

7.2 All the pre-cast element shall be marked appropriately as specified.

8.0 FOUNDATION

Foundations for mounting structures in cement concrete shall be cast by bidder as

per approved drawings.

9.0 BOLTS, NUTS AND WASHERS

Standard bolts, nuts and washers shall be used in all works. These should be
galvanized in accordance with IS: 5358.

10.0 PAINTING

Outdoor kiosk for link boxes etc. shall be painted with anticorrosive paint and red
oxide as primer and two coats of enamel paint. The boxes should be appropriately
labelled as per installation at site regarding S.No., location, type etc. and provided
with caution/ danger board.

11.0 MATERIALS USED IN CABLE LAYING

Specification in brief on the materials used in installation of the 132 kV

underground cables, like RCC precast cable protection covers, precluded cement
concrete blocks for cable route/joint indication, cable and mounting structures, joint
bays, earthing and other miscellaneous materials are given below. All materials
shall conform to relevant standards and shall be approved by the Engineer.

12.0 RCC PRE CAST CABLE PROTECTION COVERS

These should be fabricated as per the design supplied by the purchaser. The
reinforced cement concrete should be in the proportion not less than 1:2:4 of 20
mm and down size aggregate and steel reinforcement of 6 / 8 mm diameter mild
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 steel rods should be used (4 No. on 300 mm side and 5 No. on 600 mm side) and
cured as per Civil Engineering standards. The covers should carry the legends
MPPTCL 132 kV CABLES, Ckt-I OR Ckt-II as the case may be The covers
should be free from burrs and projecting edges so that they may be easily laid to
butt. The average breaking load shall be 450 kg for the cover slabs.

13.0 CABLE ROUTE MARKERS/JOINT MARKERS

13.1 Permanent and durable type, cable route markers/joint indicating blocks should be
provided as per the design approved by the purchaser.

13.2 The cement concrete block should be made by wet process and the concrete
shall consists of one part cement, two parts sand, four parts aggregate of size 20 mm
and below.

13.3 The marking block should be given a smooth cover surface or cement mortar and
shall have the appropriate legends engraved 5 mm deep such as "MPPTCL
132kV CABLE Ckt- I" OR "MPPTCL 132kV CABLE Ckt- II ", "MPPTCL
132kV CABLE JOINT Ckt- I" OR "MPPTCL 132kV CABLE JOINT. Ckt- II".

14.0 PIPES

14.1 HDPE Pipes of ISI mark, of 200 mm OD (min), of good quality shall be used for
formation of cable ducts. All sundry materials like coupling, collars and caps to
cover the pipe ends before cable is pulled in, shall be provided. Bidder shall indicate
diameter and thickness of these pipes in the bid itself.

14.2 NP4 Reinforced Hume pipes of 600 mm OD and accessories conforming to IS

shall be used, if required, at Road crossing / Nallah/ bridges.

14.3 Hume pipes without steel reinforcement, stoneware pipes, PVC pipes can also be
used where the cable passes through the passage or drive ways of public and private
buildings.

15.0 SAND

15.1 Sand supplied for backfill shall be river sand, free from flakes, dust, earth, organic
matter and large pebbles and stones and should be free from any chemical
contaminants, likely to have corrosive action on the cable coverings. The sand
should be sieved through a mesh to remove all large stones and pebbles. The sand
shall be properly graded and shall conform to IS: 383 for concreting work.

15.2 The owner will decide on the requirement of the use of sand depending on the
availability of the excavated earth to be used for backfill. The sand should be used
with the approval of the owner as a backfill.

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16.0 QUANTITIES

16.1 The bidder shall indicate the ceiling volumes/quantities for excavation and RCC
works and steel structure works, wherever specifically indicated.

16.2 The bidder shall quote unit rates also for the items of works. He shall have to quote
the total price for each of the works. The quoted price shall also include supply of
all material transportation charges, taxes, duties, octroi and toll tax, labour,
construction, plant and equipment and fixtures, fittings and all temporary and
permanent works necessary for satisfactory completion in all respects.

16.3 The measurement for the payment of earth excavation will be based on volume
calculations of pit/trench. The unit of measurement shall be cubic meters. Nothing
extra would be payable for slopes, shoring, strutting, etc., irrespective of whatever is
provided. If directed by the Engineer in charge, the excavation shall be done on the
slopes from slope stability point of view at no extra cost to the owner.

16.4 If the contractor is directed by the Engineer in charge to excavate to a lower level
than that indicated in the drawing, such additional excavation shall be paid for at
the applicable unit rates.

16.5 LEAD AND LIFT

16.6 The rates quoted for all items of works shall include all lifts and leads wherever
applicable unless otherwise specified.

16.7 Payments for back filling shall be based on the volume of consolidated fill. This
volume shall be derived from the difference between the volume of excavation and
that of the structure (concrete work, sand filling), or trench as the case may be.

16.8 CARRIAGE OF EXCAVATED SOIL BEYOND A LEAD OF 50 MTRS PER

LIFT OF 1.5 MTRS.

16.8.1 BY MANUAL LABOUR :

The excavated earth for disposal purpose up to 300 mtrs. shall be carried by manual
labour. If directed by the Engineer-in-charge this earth shall be used for back filling
purpose/ filling of low laying areas with prior approval of the concerned local bodies.
The rate for disposal of earth by manual labor up to a lead of 300Mtrs shall be
included in the rate for excavation items and no extra rate for the same is admissible.

16.8.2 BY MECHANICAL TRANSPORT:

The contractor shall arrange to transport the surplus earth including hard rock and soft
rock left over after back filling the trench/ raising low laying areas by manual labor up
to a lead of 300 mtrs, by mechanical means to the disposal point of the local bodies
with all leads and lifts and as directed by the Engineer in charge.. It shall however be
ensured that no soil is stacked in excavated area. Location where the soil is to be
stacked/disposed shall be as directed by the Engineer-in-charge. However the
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 successful bidder shall take all precautions at the site of excavation, for keeping the
free flow of vehicular and human traffic and to avoid inconvenience in general. The
soil transported for disposal, shall be stacked and leveled neatly and dressed. The rate
for this item shall include loading, carriage, unloading, stacking and dressing etc.,
complete. In no case the excavated soil shall be stacked upto the distance of 1.5
Mtrs. from the edge of excavation or one third the depth of excavation whichever is
more.

16.9 The measurements of various civil works shall be jointly recorded by the contractor
and the Engineer in charge and duly certified.

16.10 The contractor shall be responsible for estimates, assumptions and conclusions
regarding the nature of the materials to be excavated and difficulty of making and
maintaining of required excavations and performing the work required as shown on
the drawing and in accordance with these specifications. Cofferdams, sheeting,
shoring, draining, dewatering etc. shall be furnished and installed as required and
the cost thereof shall be included in the rate quoted. The contractor shall be held
responsible for any damage to any part of the work and property caused by collapse
of sides of excavation. The materials can be salvaged if it can be done with safety
for the work and structure and as approved by the Engineer in charge.

16.11 However, no extra claim shall be entertained for material not salvaged or any other
damage to contractor’s property as a result of the collapse. He shall not be entitled to
any claim for redoing the excavation as a result of the same.

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 SECTION-III (E)

EARTHING, SITE TESTING AND COMMISSIONING

OF COMPLETE CABLE SYSTEM

1.0 EARTHING OF SYSTEM

1.1 The earthing system required is for:

a) Earthing of all non-current carrying metal parts and

b) Earthing system for cable screens/sheath bonding at terminations.

1.2 The latest edition of following standards and codes are applicable:-
i) IS: 3043: Code or practice for earthing.
ii) IS: 2309: Code of practice for the protection of buildings and allied structures
against lightning.
iii) Indian Electricity Rules 1956: Provision of Rules on EHV systems
iv) IEEE- 80: Guide for safety in substation grounding.

1.3 All equipment, supporting and mounting structures of the installation shall be
bonded together and connected by separate and distinct conductor to earth
electrode.

2.0 EARTH CONDUCTOR

The earth conductor shall be of G.I flat, of approved size and shall be protected
against mechanical damage and corrosion. The connection of the earth continuity
conductors to earth bus and earth electrodes shall be strong, secure and sound and
shall be easily accessible.

3.0 PIPE EARTH STATION

3.1 The pipe earth electrodes shall be in conformity with IS: 3043, buried vertically and
the pit filled with alternate layers of charcoal, salt and earth. The earth lead shall be
properly fastened with brass bolts, nuts and connections shall be enclosed in a
masonry chamber. The chamber shall be provided with RCC inspection cover.

3.2 The connection between the earthing terminal of equipment and earth electrode shall
be made by short and direct earthing lead, free from kinks and splices.

3.3 The distance between any two electrodes shall not be less than twice the length of the
electrode.

3.4 All joints shall be covered with suitable compound to protect against corrosion.
Earthing connections with equipment earthing terminals shall be of bolted type.
The contact surfaces shall be free from scale, paint, enamels, grease, rust or dirt. Two
bolts shall be provided for making earth connection. The bolted connections after
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 being checked and tested shall be painted with anticorrosive paint or compound.

3.5 Welds and brazed joints shall be treated with red lead and afterwards coated with
bitumen compound to prevent corrosion.

3.6 Steel to copper connection shall be brazed type and shall be treated to prevent
moisture ingress.

3.7 The resistance of the welded joint shall not be more than the resistance of equivalent
length of the conductor.

3.8 All welded joints shall be made by electric are welding. All welded joints shall be
allowed to cool down gradually to atmospheric temperature.

3.9 Arc welding with large diameter conductor shall be done with low hydrogen content
electrodes.

4.0 BONDING OF CABLE SCREENS/ SHEATH

4.1 Each single phase cable shall have a separate earth for the screen earthing. The
system short circuit level is 40 kA for 1 sec. The earthing lead at solid earth
position shall be single core, 300 sq.mm copper conductor PVC insulated 6.6 kV
voltage grade (or appropriate size/type supported by calculation and approved by
MPPTCL) cable.

5.0 EARTH TESTS

5.1 Tests on earths shall be carried out by the contractor in presence of MPPTCL
Engineer for testing the effectiveness of earth resistance of electrodes and the
results furnished to the owner.

6.0 ELECTRICAL TESTS AFTER INSTALLATION

6.1 The contractor shall conduct the following tests during and after installation of
complete cable system (Section-I, II and III) as per IEC 62067.

6.2 In the event of the installation failing the tests, the contractor shall at his expense
identify the cause and rectify the defects and render the installation serviceable.

6.3 D.C. TESTING

a) The insulation resistance of each cable length shall be checked after laying and
before jointing and terminating.
b) Polarization Index test.
c) After laying, jointing and terminating, the cables shall be tested with all
accessories.

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6.4 AC TESTING
8.1
[
The installation shall be tested with AC voltage at power frequency.
8.2 The installation shall withstand for 5 minutes, the phase to phase voltage applied
between the conductor and metallic screen/ sheath.

OR
8.3 Test for 24 hours with normal operative voltage of the system.

7.0 TESTS ON NON METALLIC SHEATH

The non-metallic sheath shall be subjected to test as per IEC publication 60229.
The bidder can recommend any other test for satisfactory performance of the
installed system.

8.0 Any other site installation / commissioning tests as specified in Section I & II shall be
conducted by the bidder in presence of MPPTCL Engineer.

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