Technical Specifications for LT/HT, XLPE insulated ... · PDF fileTechnical Specifications for LT/HT, XLPE insulated Aluminium/Copper Cables This technical specification intends to

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ANNEXURE TO TENDER NO. DPS/MRPU/CWMF/ELE/8320/PT-2157

Technical Specifications for LT/HT, XLPE insulated Aluminium/Copper Cables

This technical specification intends to cover the following:

1. Technical specifications for design, engineering, manufacturing, inspection, testing at manufacturer’s works, packaging and delivery by road (properly packed in non-returnable steel drums), various sizes of aluminium/copper conductor, XLPE insulated, voltage upto and including 1100 Volts, extruded PVC inner sheathed, extruded FRLS PVC outer sheathed, GI round wire armoured cables, suitable for solidly grounded system. The cables shall confirm to IS 7098-Part 1 with latest amendments. For cable list refer Table-1 (Sl. no. 1.1 to 1.19).

2. Technical specifications for design, engineering, manufacturing, inspection, testing at manufacturer’s works, packaging and delivery by road (properly packed in non-returnable steel drums), 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm Stranded Compacted Circular Shaped Aluminium Conductor of H4 Grade, Shielded with extruded Semi-conducting compound, XLPE insulated, PVC sheathed, GI Round wire armoured Power Cables for effectively grounded system. The cable shall confirm to the latest revisions of IS: 7098 (Part –2). For cable list refer Table-1 (Sl. no. 2.0).

Note:

1. Tenders will only be considered from the cable manufacturers and any one supplier to whom manufacturer can authorize. The bidder shall have adequate experience of at least 5 years in manufacturing of LT/MV & HT cables.

2. Copper & Aluminium samples from the finished cable drums shall be tested at any 3rd party NABL accredited lab to ensure its purity.

3. The following document shall be attached with technical part of the bid: i. Duly filled & Signed copy of Annexure-I, II, III & IV

ii. Deviation sheet, if any

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Contents

CABLE QUANTITY ........................................................................................................................ 3

SECTION-A General Terms & Conditions ............................................................................................................. 5

SECTION-B Technical Specifications for 1.1KV, Aluminium/Copper Conductor, Power cable .............................. 8

SECTION-C Technical Specification for 6.35/11 kV (Uo/U), 3-Core, 185 Sq. mm Aluminium Cable .................. 17

ANNEXURE-I Technical data Format for 1.1KV, Power Cable ............................................................................... 30

ANNEXURE-II Technical data Format for 6.35/11 kV (Uo/U), 3-Core, 185 Sq. mm Aluminium Cable .................... 34

ANNEXURE-III Vendor Evaluation Criteria .............................................................................................................. 38

ANNEXURE-IV Check List ....................................................................................................................................... 42

DEVIATION SHEET ...................................................................................................................... 45

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CABLE QUANTITY

TABLE-1

Sl.No. Cable Specification Quantity (in meters)

No. of Drums

1.0 Power cable of 1.1 kV grade, Multi-stranded Aluminium/Copper conductor, XLPE insulated, extruded PVC inner sheathed, GI round-wire armoured, extruded FRLS PVC ST2 outer sheathed, conforming to IS: 7098 (Part-I), 1988 ad as per the technical specifications listed in Section-A of the tender document.

1.1. 3.5C X 95 Sq.mm, Aluminium Conductor

Power Cable Type:A2XWY

1000 500 Mtr x 2



500 500 Mtr x 1



500 500 Mtr x 1

1.4. 3C X 35 Sq.mm, Aluminium Conductor


500 500 Mtr x 1



1000 500 Mtr x 2



500 500 Mtr x 1



1000 500 Mtr x 2



1000 500 Mtr x 2



1000 500 Mtr x 2

1.10. 4C X 4 Sq.mm, Aluminium Conductor 1000 500 Mtr x 2

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1.11. 3C X 2.5 Sq.mm, Copper Power Cable Type: 2XWY

1000 500 Mtr x 2


1000 500 Mtr x 2

1.13. 3C X 4 Sq.mm, Copper Power Cable Type: 2XWY

1000 500 Mtr x 2

1.14. 4C X 4 Sq.mm, Copper Power Cable Type: 2XWY 1000 500 Mtr x 2



500 500 Mtr x 1


500 500 Mtr x 1


500 500 Mtr x 1


2.0 6.35KV/11KV (U0/U) Voltage grade, 3-core, 185 Sq.mm, Stranded, compact circular shaped Aluminium Conductor of H4 grade, Water Tree free XLPE Insulated, PVC sheathed, GI round wire armoured, Longitudinal and radial water tight power cables, confirming to IS: 7098 (Part-II), and as per the technical specifications listed in Section-B of the tender document.

2500 500 Mtr x 1

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SECTION-A

General Terms & Conditions

1. PROJECT DATA These cables are required for CWMF/NRB/BARC, Government of India, Kalpakkam. The site is accessible by Road from Chennai via Chengalpattu, Thirukkazhukundram and also via Mamallapuram. The nearest Broad Gauge railway station is at Chengalpattu.

a. Purchaser : Centralized Waste Management Facility, Kalpakkam

b. Climatic Condition : The site is located about 500 meters from the seacoast and the atmosphere is laden with salt spray. The climate is tropical with high humidity, heavy rainfall and prone to rust and fungus growth.

c. Ambient Air Temperature

: i. Maximum 450C ii. Maximum Daily Average 400C iii. Max. Weighted Yearly

Average 320C

iv. Max. Relative Humidity 90%

The maximum temperature and relative humidity likely to occur simultaneously are 420C and 80% respectively.

d. Installation Location : The cables may be laid/buried directly in ground, covered cable trenches, cable racks/ladders in open air

2. SCOPE OF THE TENDER

The scope includes the jobs to be performed for all equipment and materials furnished under this specification. The scope is however not limited to the items detailed below:

• Design, manufacture, testing at manufacturers works packing and dispatch.

• Transportation to site and insurance.

• Receiving at site, unloading, handling, opening, inspecting, reporting and submitting claims in case of damages and short supply items.

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• Arranging to repair and/or reordering all damaged and short supply items.

3. GENERAL CONDITIONS FOR TENDERING

Please refer to the commercial bidding document for complementary information. Tenders will only be considered from the cable manufacturers or supplier to whom manufacturer can authorize. The bidder shall have adequate experience (at least 5 years) of manufacturing LT/MV & HT cables.

If the bidder finds that any part of this Technical Specification is difficult, or very costly to meet, he is free to propose an alternative solution, provided that the deviations from technical Specification, together with the reasons and advantages, are clearly indicated in the deviation sheet. Such alternative solution shall always be made in addition to the basic offer, which must comply fully with this Technical Specification. BARC/CWMF reserves the right to accept or reject the proposed alternative solutions without any justification.

Test Equipment The bidder shall have the necessary arrangement of test equipment for type tests, acceptance tests and routine tests as specified in the tender. In case, test is required to be done at other lab, the tenderer shall clearly specify in the deviation sheet.

Subcontractors The bidder shall declare in the tender document any subcontractors whose service is intended to be used in the event of the contract. If the contract is awarded, the bidder shall restrict to the subcontractors as mentioned in the tender document.

Deviations from Technical Specification: No deviations to this specification shall be acceptable unless specifically indicated in the offer in the relevant schedule. All deviations shall be clearly spelt out by the Bidder and the price implications thereof if any. Bidder must furnish List of Technical Deviations mentioning the specification clause nos. against which deviations have been sought for. Compliance with this specification will be taken for granted in absence of any specific mention of deviations in the said list of deviations. Any implied deviation or any deviation mentioned elsewhere in the offer shall not be considered. The engineer-in-charge at their discretion will decide regarding acceptance of deviation looking to standard and project requirement.

Technical Questionnaire: The technical questionnaire attached to this technical specification shall be completely filled and submitted. The bidder shall also submit in written a detail plan for the manufacturing & testing schedule.

Factory Access BARC/CWMF and its representative shall have free access during normal working hours to the manufacturing or testing sites, including any subcontractor’s premises, during the contract period.

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• 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 a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specifications and shall not prevent subsequent rejection if the equipment is found to be defective.

• The supplier shall keep the purchaser informed well in advance, about the manufacturing programme so that the arrangement can be made for inspection.

• No equipments shall be dispatched before all tests and inspection have been carried out unless otherwise instructed by the purchaser.

Evaluation criteria: • The cable manufacturer shall have minimum annual turnover of 7 Crores in

the last three years. The company shall not have incurred loss during last 3 consecutive years. This shall be substantiated by submitting relevant documents.

• The bidder shall be Original Equipment Manufacturer (OEM) of XLPE cable up to 11 kV for the past 5 years.

• Manufacturer shall have completed all the type tests at CPRI / ERDA / NABL accredited lab. Type test certificates for longitudinal and water tight cables of 11kV or higher voltage rating as per IEC shall be furnished along with the offer.

• The manufacturer shall have ISO 9001 & 14001 certification for quality management system and environmental management system.

• The company shall have valid IS certification for production of the specified cable.

• The manufacturer shall have a single point triple extrusion process with gas curing.

• The vendor shall carry out copper & aluminium (samples will be selected from finished lot of cables) 3rd party lab test to confirm its purity.

Tender Evaluation • Item wise L1 will be considered for placing purchase order. • All prices quoted by the TENDERER shall be firm.

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SECTION-B

Technical Specifications for 1.1 kV grade, Aluminium/Copper conductor, Power cables

This section covers the technical specifications for design, engineering, manufacturing, inspection, testing at manufacturer’s works, packaging and delivery by road (properly packed in non-returnable steel drums), 1.1KV grade, Multi-stranded Aluminium/Copper conductor, XLPE insulated, extruded PVC inner sheathed, GI round-wire armoured, extruded FRLS PVC ST2 outer sheathed. Power Cables for effectively grounded system, conforming to the latest revisions of IS: 7098 (Part –I), 1988 & as per the technical specifications attached herewith.

1. STANDARDS The design, manufacture and testing of the cable shall comply with the latest editions/amendments of the following Indian Standards, unless otherwise specified. Equipments complying with equivalent standards shall also be acceptable.

a. IS-7098, 1998 (Part-I) : Cross linked polyethylene insulated

PVC sheathed cables for working voltages upto 1100V.

b. IS-3961 : Recommended current ratings for cables

c. IS 8130-1984 : Specification for conductors for insulated electric cables and flexible cords.

d. IS-3975, 1999 : Low Carbon galvanized steel wires, formed wires & tapes for armouring of cables

e. IS-4759 : Specifications for Hot dipped galvanized coating on round steel wires

f. IS-5831 : PVC insulation and sheath of electric cables.

g. IS-10418 : Drums for electric cables. h. IS-10810

(Part 0 to 64) : Method of test for cables.

2. SERVICE CONDITION The cable shall be designed with the following service conditions into consideration:

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a. Cables shall be capable of satisfactory operation under a power supply system frequency variation of +3% and voltage variation of ±10%.

b. Cables shall be suitable for laying in conduits, ducts, trenches, channels, trays, racks or for direct buried in ground in both dry and wet locations with chances of flooding by water.

c. The cables shall be suitable for the following ambient condition: Ambient Air temperature: 400C Ambient ground temperature: 300C

d. The current rating shall be based on maximum conductor temperature depending on the type of insulation for continuous at the rated current.

e. The one second short circuit current rating values shall be furnished and shall be subjected to the purchaser’s approval.

f. The cables will have current ratings and de-rating factors as per relevant Indian Standards.

Full technical details and descriptive literature shall be furnished indicating the construction details, standard applicable for the components of the cable and current ratings of the cables in air and ground. De-rating factors to be considered for the ambient temperature, ground temperature, de-rating due to cable location in air and ground shall also be furnished. The certificates for the type tests conducted on cables similar to the cables covered herein shall be submitted along with the tender.

3. DESIGN AND CONSTRUCTION PERTICULARS

3.1. General The cables supplied under this specification shall be adequate insulated to operate continuously at the specified voltage with a high degree of safety and reliability throughout the life of the cables. The sheathing material shall be high quality PVC based compound. The construction of cable shall be as per IS: 7098 (Part I) – 1988.

Cable shall be designed and manufactured to prevent damage during transportation, installation & operation under all climatic & operating conditions to which cable may be subjected to.

3.2. Technical parameters i. Quantity : Refer Table-1, Sl. No: 1.1 to

1.19 ii. Packaging : Steel drum packaging, each

having single length cable ≥ 500 metres.

iii. Cable Type : A2XWY/ 2XWY (refer Table-1 for details)

iv. No. of Cores : 3/3.5/4 (refer Table-1 for details)

v. Voltage Level : 1.1kV vi. System Grounding : Solidly Grounded

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vii. Nominal System voltage : 400V ±10% viii. Nominal System Frequency : 50Hz ±3%

ix. Maximum conductor temperature at rated current

: 90oC

x. Maximum conductor temperature at Short-circuit

: 250oC

xi. Conductor Conductor Material : H4-Grade Aluminium of

purity > 99.6% Electrolytic grade Copper, Purity > 99.97%

Conductor type : Stranded with number of strands as per IS 8130 (Part-I) 1984

xii. Insulating material : Cross-Linked-Polyethylene (XLPE) Compound

xiii. Core Identification Strips : Red, Yellow, Blue & Black (for neutral)

xiv. Material of Inner Sheath : FRLS, PVC ST-2 Compound xv. Armour : Single layer of Galvanized

Steel Round Wire according to IS-3975

xvi. Outer Sheath : FRLS, PVC ST-2 Compound according to IS-5831

3.3. Conductor ALUMINIUM The Aluminium conductor used shall be of H-4 grade (Tensile strength above 150 N/mm2). High conductive aluminium, stranded (Class-II, stranded circular shaped), uniform in quality and free from scale, inequalities, spills, splits and other defects. The aluminium used shall have purity meeting the criteria for maximum resistance allowed. Two sample conductor randomly selected from finished lot of cables, shall be tested for its purity at any 3rd party NABL accredited lab.

COPPER The conductors shall be made from high conductivity copper rods complying with IS: 613-1964. The conductor material used shall be electrolytic grade with high purity. Two sample conductor randomly selected from finished lot of cables, shall be tested for its purity at any 3rd party NABL accredited lab.

Cable Joints: Joints shall be permitted in the individual wires of which the conductor is formed, but no joint shall be within 300 mm of any other joint within the same layer. The joints shall be made by resistance butt welding, fusion welding, cold pressure welding,

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electric welding, gas welding, brazing or silver soldering. No joint is allowed in the conductor after stranding. A maximum of two joint shall be allowed in any strand forming complete length of the cable. The conductors shall conform to appropriate dimensions, resistance and number of wire in the conductor (number of strands) as given in IS 8130 (Part I): 1984.

3.4. Insulation The insulating material for power cables shall be extruded cross linked polyethylene (XLPE) compound as per IS-7098(Part-I)-1988. The minimum thickness of insulation shall not be less than the values specified in Table-2 of IS-7098 (Part-I)-1988. No negative tolerance shall be applicable for the thickness. The insulation of the cable shall be designed and manufactured for the specified system voltage. The manufacturing process shall ensure that insulation shall be free from voids. The insulation shall withstand mechanical and thermal stress under steady state and transient operating conditions. The cores shall be identified as per the following colour scheme: 3-Core - Red, Yellow & Blue 3 ½ or 4-Core - Red, Yellow, Blue & Black

3.5. Inner Sheath The inner sheath shall be extruded FRLS PVC, Type ST2, compatible with thermal rating of insulation conforming to IS-6380-1984. The sheath shall have adequate thickness, mechanical strength and elasticity, as specified in IS 5831. The material shall be soft thermoplastic type, applied by extrusion method. The thickness of the inner sheath shall be as per IS: 7098 (Part I) and the color of the inner sheath shall be Grey. The inner sheath shall be so formed that it fits closely on the laid up cores and could be easily removed without damaging insulation. One or more layer of proofed plastic tape shall be provided over the laid up core before extrusion.

3.6. Armouring The armouring arranged over the inner sheath shall consist of one layer of galvanized round steel wires for all sizes of cable. The armour round wire used on the cable shall conform to IS: 3975 for all requirements. The direction of lay of armour shall be opposite to that of the cores. The zinc coating on the galvanized steel strip shall comply with relevant standards.

The joints in armour wires/strips shall be made by brazing or welding and the surface irregularities shall be removed. A joint in any wire/strip shall be at least 300 mm away from the nearest joint in any other wire/strip in the completed cable.

3.7. Outer Sheath Extruded outer sheath shall be provided over the armouring. The material used for sheathing shall be FRLS PVC sheath, Type ST-2 base compound conforming to IS 1554/ IS 5831 for power cable. The outer sheath shall be so formed that it fits closely on the laid up armour and could be easily removed without damaging the intermediate sheath and insulation. The colour of the outer sheath shall be black. The thickness of

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outer sheath shall be in accordance with the IS 1554 (Part-I)-1988. Suitable additives shall be added to prevent attack by rodents and termites. All serving must be given anti-termite treatment.

Cables shall have suitable fillers laid up with the conductor to provide a substantially circular cross section before the sheath is applied. Fillers shall be suitable for the temperature of the cable and compatible with the insulating material. The material shall be of the best quality and workmanship. The fillers and sheath material shall be non-hygroscopic. All materials shall be new, unused and of the finest quality.

4. TESTS All the tests specified below shall be carried out in accordance with the Indian Standards by the manufacturer in the presence of Purchaser’s representative. If the cable fails to pass the test specified, the Purchaser shall have the option to reject it. Shipping release shall be obtained from the Purchaser's representative. The Purchaser, however reserves the right to waive off the inspection. The tests at works shall include electrical, mechanical and hydraulic tests in accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards, in addition any test called for by the Purchaser or his representative to ensure that the equipment being supplied fulfils the requirement of the specification. For test not covered by any code or specifically mentioned in this specification, the test procedures are to be agreed with the Purchaser.

Pre Dispatch Inspection The manufacturer shall be given at least 15 days advance notice prior to the commencement of testing, so that Purchaser’s representative can plan to witness the tests.

All the tests indicated in the test clause of this specification shall be carried out in the presence of Purchaser’s representative by the manufacturer and shall provide all the facilities and equipment for testing.

Six copies of the Test Certificate shall be furnished to the Purchaser for approval prior to dispatch of cables from factory.

Visual check to conform the details given in this specification is to be done. In addition to the above, the general workmanship of the cable drums and cables laid in drums shall be checked.

Manufacturer shall have proper test set up for testing all the routine tests & type tests on finished cables as per IEC.

List of type tests mentioned in the tender specifications shall be conducted on four drum irrespective of type test certificates given or not.

4.1. Type Test

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Type tests on four randomly selected cable drums will have to be conducted in the presence of the department’s representative. The test samples will be taken from finished cables. This test shall be in accordance to IS: 7098, Part-1,1988.

a. Test on Conductor • Annealing test for copper conductors • Tensile test for aluminium conductor • Wrapping test for aluminium conductor • Conductor Resistance Test

b. Test on Insulation • Physical dimension measurement • Tensile strength and elongation at break • Hot set test • Shrinkage test • Ageing in air oven • Water absorption test

c. Test on round Armour • Physical dimension measurement • Tensile strength • Elongation at break • Torsion test for round wires • Winding test for firmed wire • Mass of zinc coating. • Uniformity of zinc coating • Resistivity measurement, Resistance test for armour

d. Test on Sheath • Physical dimension measurement • Tensile strength & Elongation at break test • Ageing in air oven • Loss of mass in air oven • Shrinkage test • Hot deformation test • Heat shock test • Thermal stability test

e. Insulation Resistance Test f. High Voltage Test at room temperature g. Volume resistivity at room temperature & at 90o C. (IS-10810-Part 43) h. Flammability test i. Test requirement of FRLS inner and outer sheath

The inner and outer sheath of cables shall meet the following test requirements related to flame retardant, low smoke emission, low acid and toxic gas emission. The BIDDERs shall have proper test apparatus to conduct all the relevant tests as per the applicable standards:

• Flame retardant test on single cable

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• Oxygen Index Test The critical oxygen index value shall be minimum 29 when tested at 27+2ºC as per ASTMD-2863

• Temperature index test Temperature index value shall be minimum 250ºC at oxygen index of 21 when tested as per NES 715.

• Flammability test Cables shall pass test under fire conditions as per IS-10810- Part-53. Cables shall also pass tests as per IS-10810 Part- 61 & Part-62. Flammability shall be as per IEC 332-1 and IS 694: 1990.

• Smoke Density Test The cables shall satisfy the tests conducted to evaluate the percentage obscuration by smoke in an optical system placed in the path of the smoke. The maximum smoke density rating shall not be more than 60% when tested as per ASTM-D-2843.

• Acid Gas Generation test (halogen acid gas evolution) The hydrochloric acid generation when tested as per IEC 754-1 shall be less than 20% by weight.

• Test for specific optical density of smoke • Anti termite and rodent property test

The sequence of electric tests shall be as per the relevant Indian/International standards. The Bidder shall submit the sequence of tests for the approval of the purchaser before conducting the tests. A copy of the adopted standard shall also be supplied.

4.2. Routine Test (On each drum) The following routine tests shall be carried out by the Manufacturer on each and every length of the cable in the presence of Purchaser’s representative at manufacturer’s works.

a. Resistance test for conductors b. Insulation resistance test c. High voltage test

4.3. Conductor purity test Two samples of aluminium and copper shall be taken from any of the finished set of cables at random and the sample shall be tested for its purity at a NABL accredited lab.

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Qualifying Criteria: The test results should be within limits as per IS 7098. All the routine tests as per IS 7098 / IEC shall be conducted and passed as per the limits given in the standards. All the bought out certificates will be verified and the test results shall be as per respective standards.

5. IDENTIFICATION The following details shall be marked sequentially for each meter run length of the cable by non-erasable embossing on the outer sheath:

a. Reference to Indian Standard b. Name of the manufacturer/ Trade Name c. Name of the project: CWMF, BARC (K) d. Configuration of the cable: viz. Voltage grade, no. of Core, Sq. mm,

A2XWY/2XWY/YWY / YY as applicable e. Year of manufacturing f. Sequential marking of running meter length

The running length of the cable shall be identified at regular intervals of one meter (Increasing order from inner end to outer end of the cable)

6. PACKAGING • Each drum shall consist of single length cable ≥ 500 metres. • The cable shall be wound on non-returnable steel drums of suitable size,

packed and marked. • Packing shall be sturdy to protect the cable from any injury during

transportation, handling and storage. The cut ends of the cable shall be sealed by means of non hygroscopic sealing material preferably Heat shrinkable end caps.

• One end of the cable shall be brought out of the drum and suitably clamped to the drum flange with proper mechanical protection. Location of the other end may be marked on the drum.

• The cable shall be placed on drums in such a manner that it will be protected from injury during transit. Each end of the cable shall be firmly and properly secured to the drum. No undue stress shall appear on cables when laid on drums.

• The cable drum shall carry the following information stencilled on a metallic label, securely attached to each end of the drum:

i. Reference to the Indian standard ii. Manufacturer’s name, brand or trade mark

iii. Type of cable and voltage grade iv. No. of cores v. Nominal cross-sectional area of conductor

vi. Cable code vii. Length of cable on drum

viii. No. of lengths on reel, drum or coil (if more than one)

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ix. Gross weight x. Country of manufacture

xi. Year of manufacture xii. Direction of rotation of drum (an arrow)

xiii. ISI certification mark

7. PREFERRED MAKE FINOLEX/POLYCAB/KEI/RRKable or reputed brand possessing system certification of ISO 9001:2008, ISO14001:2004, OHSAS18001:2007 & EN 16001-2009 and product certifications IS: 7098 (Part-I), CE, UL etc. Quotations without these certification details will not be considered for technical evaluation.

Preferred make of bought out material: a. Aluminium for Conductor : Hindalco/Balco/Nalco b. Copper for Conductor : Hindustan Copper/Hindalco c. XLPE compound of

Insulator : Dow/Borealis

d. Armour Steel : TATA/Jindal.

8. GUARANTEE All the cables shall be guaranteed against faulty material, defective design & poor workmanship for a period of 18 months from the date of supply. The materials becoming defective during the guarantee period shall be replaced free of cost and the defects arising out of the works shall be rectified free of charge without delay.

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SECTION-C

Technical Specifications for 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm Aluminium Cable

This section covers the technical specifications for design, engineering, manufacturing, inspection, testing at manufacturer’s works, packaging and delivery by road (properly packed in non-returnable steel drums), 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm Stranded Compacted Circular Shaped Aluminium Conductor of H4 Grade, Shielded with extruded Semi-conducting compound, XLPE insulated, PVC sheathed, GI Round wire armoured, longitudinal and radial water tight Power Cables for effectively grounded system, conforming to the latest revisions of IS: 7098 (Part –2) & as per the technical specifications attached herewith.

1. STANDARDS

The design, manufacture, inspection, testing & performance of the 11KV (E), HV power cable shall comply with the latest editions/amendments of the following standards, unless otherwise specified. Where no standards are available, the supply items shall be of good quality and workmanship, backed by test results. Other National Standards are acceptable if they are established as equivalent or superior to the standards (listed below) and subject to approval by the purchaser.

a. IS-7098 (Part –2) : Specification for cross linked polyethylene insulated PVC sheathed cables for working voltages from 3.3.kV up to and including 33 kV

b. IEC-60502-2 1998 : Power Cables with extruded insulation and their accessories for rated voltages from 1 kV up to 30 kV

c. IS-5819 : Recommended Short circuit Current ratings for High voltage cables

d. IS-3961 : Recommended current ratings for cables

e. IS-8130 : Specification for conductors for insulated electric cables and flexible cords.

f. IS-3975 : Low Carbon galvanized steel wires, formed wires & tapes for armouring of cables

g. IS-4759 : Specifications for Hot dipped galvanized coating on round steel wires

h. IS-5831 : PVC insulation and sheath of electric cables.

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i. IS-10418 : Drums for electric cables.

2. SERVICE CONDITION The cable shall be designed with the following service conditions into consideration:

a. Cables shall be capable of satisfactory operation under a power supply system frequency variation of +5% and voltage variation of ±10%.

b. Cables shall be suitable for laying in vertical installation, built in trench, conduits, ducts, cable tray or for direct burial in ground in both dry and wet locations with chances of flooding by water.

c. The cables shall be suitable for the following ambient condition: Ambient Air temperature: 400C Ambient ground temperature: 300C

d. The material used for cable construction shall be suitable for specified limits of temperature rise.

e. The current rating shall be based on maximum conductor temperature depending on the type of insulation for continuous operation at the rated current.

f. The one second short circuit current rating values shall be furnished and shall be subjected to the purchaser’s approval.

g. The cables will have current ratings and de-rating factors as per relevant Indian Standards.

Full technical details and descriptive literature shall be furnished indicating the construction details, standard applicable for the components of the cable and current ratings of the cables in air and ground. De-rating factors to be considered for the ambient temperature, ground temperature, de-rating due to cable location in air and ground shall also be furnished. The certificates for the type tests conducted on cables similar to the cables covered herein shall be submitted along with the tender.

3. DESIGN AND CONSTRUCTION PERTICULARS

3.1. General The cables supplied under this specification shall be adequate insulation to operate continuously at the specified voltage with a high degree of safety and reliability throughout the life of the cables. The sheathing material shall be high quality PVC based compound. The construction of cable shall be as per IS: 7098 (Part-2). No hygroscopic material/paper shall be used in cable construction.

Cable shall be designed and manufactured to prevent damage during transportation, installation & operation under all climatic & operating conditions to which cable may be subjected to.

3.2. Technical parameters

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a. Quantity : 2.5KM b. Packaging : 5 steel drums, each having

single length cable ≥ 500 metres.

c. Cable Type : A2XWY d. No. of Cores : 3 e. Voltage Grade (U0/U) : 6.35kV / 11kV f. System Grounding : Effectively Grounded g. Nominal System voltage : 11kV ±10% h. Nominal System Frequency : 50Hz ±5% i. Maximum conductor temperature at

rated current : 90oC

j. Maximum conductor temperature at Short-circuit

: 250oC

k. Maximum continuous rated current in Air

: 325

l. Maximum continuous rated current in Ground

: 270

m. 1.2/50 microsecond lightning impulse withstand voltage wave value

: 75 kVp

n. Short circuit current for 1 sec with initial conductor temperature of 90oC and final temperature after short-circuit 250oC

: 17.5 kA

o. Conductor Nominal Cross-section area : 185 mm2 Conductor Material : H4-Grade Aluminium Conductor type : Class-2 Stranded Compacted

Circular shaped p. Conductor Screening Material : Extruded semiconducting

compound q. Insulating material : Water-Tree-resistant Cross-

Linked-Polyethylene (XLPE) r. Insulator Screening : Extruded Semiconducting

compound followed by a water swell-able semiconducting tape, metallic screening of a layer of plain copper tape, followed by water swell-able semiconducting tape

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s. Core Identification Strips : Red, Yellow and Blue colored strips

t. Material of Inner Sheath : Pressure Extruded PVC Type ST-2 conforming to IS-5831 followed by a layer of water swell-able non-conducting tape over inner sheath, followed by Poly-Aluminium Laminated Tape & HDPE Type ST-7 according to IEC-60502-2

u. Armour : Single layer of Galvanized Steel Round Wire according to IS-3975

v. Outer Sheath : PVC Type ST-2 according to IS-5831

Cable Voltage Rating The cables shall be suitable for Voltage grade (Uo/U) 6.35/11 kV, 3 phase, 50 Hz frequency, effectively grounded system and capable of continuous operation at their rated currents.

Cable Insulation Level The power cables shall withstand power frequency voltage, impulse voltage and partial discharge extinction level as per IS: 7098 part – 2.

Cable Current Carrying capacity The cable shall be suitable for use where combination of ambient temperature and temperature rise due to load, results in conductor temperature not exceeding 90oC under normal operation. The cables shall have the following continuous current ratings when laid in ground 1100 mm below ground level and in air with the ground temperature being 30oC and air temperature being 40° C and assuming that thermal resistivity of soil is 150°C.cm/W and a maximum operating temperature of 90o C.

11 KV, XLPE, 3C X 185 Sq. mm – 270 Amps (in ground), 325 Amps (in air)

Cable Short Circuit withstand capacity The cable shall withstand the short-circuit current of 17.5KA for 1 second, assuming the initial conductor temperature of 90° C and final temperature of 250° C.

3.3. Conductor Aluminium Conductor: The Aluminium conductor used shall be of H-4 grade (Tensile strength above 150 N/mm2). High conductive aluminium, stranded (Class-II, stranded circular shaped), uniform in quality and free from scale, inequalities, spills, splits and other defects. The

21

aluminium used shall have purity meeting the criteria for maximum allowable resistance. Number of strands and strand diameter for the cable shall be indicated.

Cable Joints: Joints are permitted for individual wires of which the conductor is formed, but no joint shall be within 300 mm of any other joint within the same layer. The joints shall be made by resistance butt welding, fusion welding, cold pressure welding, electric welding, gas welding, brazing or silver soldering. No joint is allowed in the conductor after stranding. A maximum of two joint shall be allowed in any strand forming complete length of the cable.

The conductors shall conform to appropriate dimensions, resistance and number of wire in the conductor (number of strands) as given in IS 8130 (Part I).

One sample conductor randomly selected from finished lot of cables, shall be tested for its purity at any 3rd party NABL accredited lab.

3.4. Conductor Screening The Conductor screening shall be provided over the conductor by extrusion of semi-conducting compound and shall be so applied that it fits closely on the conductor and it shall be possible to remove it without damaging the conductor. Strippable screening shall be provided. The screening material shall be non-metallic semi-conducting compound.

3.5. Insulator The conductor insulation shall be of extruded layer of water tree free cross-linked polyethylene (XLPE), meeting the requirements of IS: 7098 (part–2). The method of cross-linking of polyethylene shall be indicated in the offer. Cross linking will be by Dry Gas Curing process.

The average thickness and tolerance of insulation when measured in accordance with IS shall not be less than the values specified in IS: 7098- Part -2.

3.6. Insulator Screening Insulation screening shall be by means of extruded bonded strippable semi-conducting layer followed by a semi-conduction-water swell able tape and metallic screening by means of wrapped copper tape.

The cable core shall be triple extruded and cross-linked in fully enclosed process such that the inner semi-conducting screen, XLPE insulation and outer semi-conducting screen are applied simultaneously on the pre heated cable conductor. In-line inspection mechanism shall continuously monitor the dimensional accuracy of the extruded core.

The cable will be tested for partial discharges after application of the copper tape screen as part of the Quality Control Procedure.

22

3.7. Core Layout The core identification for the 3-core cable shall be done by using coloured strips of Red, Yellow & Blue colours respectively for each phase. The three cores shall be laid up together with a suitable right hand lay as per IS: 7098 (Part-2).

The interstices shall be filled with Non-hygroscopic material. The filler at the centre of the three cores shall be of vulcanised rubber. The filler shall be fresh material, recycled PVC material is not acceptable. The filling material shall be suitable for the operating temperature of the cable and compatible with the insulating material. The filler material should be non-hygroscopic, fire retardant and compatible with sheath.

3.8. Inner Sheath The inner sheath shall be PVC Type ST2 as specified in Latest IS: 5831, soft thermoplastic material applied by pressure extrusion. Over the inner sheath, non conducting water swell able tape shall be provided, followed by poly-aluminium-laminate tape and extruded type HDPE-ST-7 intermediate sheath.

The colour of the inner sheath shall be gray. The inner sheath shall be so applied that it fits closely on the laid up cores, circular in shape and easy to remove without damaging the insulation.

The thickness and tolerance of the inner sheath shall be as per table-3 of latest IS: 7098, Part-2.

3.9. Armouring Armouring shall be applied over the inner sheath and shall consist of one layer of galvanised steel round wire. The armour wire being put on the cable shall conform to latest revisions of IS: 3975 for all requirements. The armour wires shall be applied as closely as practicable & the direction of lay of armour shall be opposite to that of the cores lay. The zinc coating on the galvanised steel wires shall comply with relevant Standards. The dimensions of galvanised steel wires shall be as specified in Table - 4 of IS: 7098 (Part 2).

The joints in armour wires/strips shall be made by brazing or welding and the surface irregularities shall be removed. A joint in any wire/strip shall be at least 300 mm away from the nearest joint in any other wire/strip in the completed cable.

3.10. Outer Sheath Extruded outer sheath shall be provided over the armouring. The material used for sheathing shall be PVC Type ST2 as specified in Latest IS 5831. The colour of the outer sheath shall be BLACK. The thickness of outer sheath shall be as per Table 5 of Latest IS: 7098 (Part 2). The outer sheath shall be so applied that it fits closely over the armouring. It shall be possible to remove it without damage to the inner sheath and insulation.

The PVC compound used shall be abrasion proof, chemical resistant, provide protection against ants, termites, rodent and fungal growth.

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3.11. End Sealing, Joining and Joining Material

End Sealing Materials: The two ends of the cable shall be sealed by means of non-hygroscopic sealing materials preferably by Heat shrinkable end caps. Each drum shall be supplied with two numbers additional heat shrinkable end caps.

Jointing & Jointing Materials: Supplier shall indicate jointing procedures for terminal joints / straight joints of XLPE cables at motors, transformers and in switchgear. Detailed write-up shall be given along with the bid detailing the procedure for jointing along with drawings.

4. INSPECTION & TESTING

All the tests specified below shall be carried out in accordance with the Indian Standards by the manufacturer in the presence of Purchaser’s representative. If the cable fails to pass the test specified, the Purchaser shall have the option to reject it. Shipping release shall be obtained from the Purchaser's representative. The Purchaser, however reserves the right to waive off the inspection.

The tests at works shall include electrical, mechanical and hydraulic tests in accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards, in addition any test called for by the Purchaser or his representative to ensure that the equipment being supplied fulfils the requirement of the specification.

For test not covered by any code or specifically mentioned in this specification, the test procedures are to be agreed with the Purchaser.

4.1. Stage Inspection

i. The Purchaser’s representative shall have access to the Supplier’s works for the purpose of witnessing the tests and to ascertain that the cable being manufactured conforms to the requirements of this specification.

ii. The Purchaser’s representative shall have a stage inspection during the following, important stages of production processes at manufacturer’s works.

a. During Triple Extrusion process. b. The cables will be tested for partial discharges after application of the

copper tape screen as part of the stage inspection.

iii. During stage inspection the following tests shall be carried out. a. Tensile strength b. Elongation at break c. Hot set test d. Permanent set e. Partial discharge test f. IR before and after HV test

24

g. High voltage test h. Conductor resistance test.

iv. Purchaser will witness triple extrusion process. Advance intimation shall be given to the Purchaser before starting of triple extrusion process. Ensure that online thickness monitoring unit (SIKORA) is in working condition. If online thickness monitoring unit is not working at triple extrusion point then production and as well as stage inspection shall not be carried out.

v. The customer will see the stabilizing point during triple extrusion process. Bubbles and other uneven surfaces shall not appear on the cable coming out of CCV line. If any bubbles or any other abnormality observed on the triple extruded single core cable at the end of the triple extrusion process then upto that point cable shall be cut and shall not become part of supply.

vi. After completion of water cooling of triple extruded line, residual moisture on the cable shall be removed with sufficient number of heaters. At the end of the CCV line, heaters in all the angles shall be placed to remove the residual moisture on the cable.

vii. Hot air blower shall be provided at the end of the CCV line, so that moisture on surface of the triple extruded core will get evaporated. It has to be ensured that there shall not be any water on surface of the core of the cable before winding it on to a cable drum. Sufficient delay (1 day) shall be given between end of triple extrusion process and winding of water swellable tape. & copper foil. (To avoid trapped moisture in copper foil).

4.2. Pre-dispatch Inspection

i. The manufacturer shall be given at least 15 days advance notice prior to the commencement of testing, so that Purchaser’s representative can plan to witness the tests.

ii. All the tests indicated in the test clause of this specification shall be carried out in the presence of Purchaser’s representative by the manufacturer and shall provide all the facilities and equipment for testing.

iii. Six copies of the Test Certificate shall be furnished to the Purchaser for approval prior to dispatch of cables from factory.

iv. Visual check to conform the details given in this specification is to be done. In addition to the above, the general workmanship of the cable drums and cables laid in drums shall be checked.

v. Manufacturer shall have proper test set up for testing all the routine tests, type tests and longitudinal water tightness test on finished cables as per IEC.

vi. List of type tests mentioned in the tender specifications shall be conducted in one drum irrespective of type test certificates given or not.

25

vii. Longitudinal water immersion test shall be conducted on the sample on which bending test is conducted. Test procedure shall be as per IEC 60502.The test shall be conducted on first day of final inspection.

viii. Six Copies of test reports shall be submitted after approval of preliminary copy is received from the Purchaser

4.3. Type Test Type tests on one randomly selected cable drums will have to be conducted in the presence of the department’s representative. The test samples will be taken from finished cables.

The sequence of tests shall be as follows on one particular cable sample: a. Bending tests b. Water tightness tests c. Remaining type tests (as listed below) d. Routine tests mentioned in the routine test clause shall be conducted on this

particular sample which underwent bending tests, water tightness tests and type tests.

The following tests will be conducted on selected samples from the lot for acceptance of the material. This test shall be in accordance to IS: 7098, Part-2, 1985.

a. Test on Conductor • Tensile test for aluminium conductor • Wrapping test for aluminium conductor

• Conductor Resistance Test b. Test on Insulation & Sheath

• Physical dimension measurement/Test for thickness of insulation & sheath

• Tensile strength and elongation at break • Hot set test • Shrinkage test • Ageing in air oven

• Water absorption test c. Test on round Armour

• Physical dimension measurement

• Tensile strength • Elongation at break • Torsion test for round wires • Winding test for firmed wire

26

• Mass of zinc coating. • Uniformity of zinc coating • Resistivity measurement, Resistance test for armour

d. Test on Outer Sheath • Physical dimension measurement • Tensile strength & Elongation at break test

• Ageing in air oven • Loss of mass in air oven • Shrinkage test • Hot deformation test • Heat shock test

• Thermal stability test e. Partial discharge test

f. Dielectric power factor test

• As a function of voltage • As a function of temperature

g. Insulation resistance (volume resistivity test)

h. Heating cycle test

i. Impulse withstand test

j. High voltage test

k. Flammability test

l. Water tightness test in longitudinal and radial direction (Manufacturer shall submit detailed procedure for this test and shall take prior approval of the engineer-in-charge).

m. Conductor purity test One sample of aluminium shall be taken from any of the finished set of cables at random and the sample shall be tested for its purity at a NABL accredited lab.

4.4. Routine Test The following routine tests shall be carried out by the Manufacturer on each and every length of the cable in the presence of Purchaser’s representative at manufacturer’s works.

a. Resistance test for conductors b. Insulation resistance (Dry) test c. High voltage test d. Partial discharge test.

27

Qualifying Criteria: The test results should be within limits as per IS 7098. All the routine tests as per IS 7098 / IEC shall be conducted and passed as per the limits given in the standards. All the bought out certificates will be verified and the test results shall be as per respective standards.

5. IDENTIFICATION The following details shall be marked sequentially for each meter run length of the cable by non-erasable embossing on the outer sheath:

a. Reference to Indian Standard b. Name of the manufacturer/ Trade Name c. Name of the project: CWMF, BARC (K) d. Configuration of the cable: viz. Voltage grade, no. of Core, Sq. mm e. Year of manufacturing f. Sequential marking of running meter length

The running length of the cable shall be identified at regular intervals of one meter (Increasing order from inner end to outer end of the cable)

6. PACKAGING

i. Cables shall be supplied in non-returnable steel drums. The cable drums shall comply to relevant Indian standards.

ii. Cable drums shall be so constructed as to have required mechanical strength so that the drum flanges and other components do not break during transport, in actual use or in storage.

iii. The flanges and the outside surface of the barrel shall be free from protruding materials or projections or unevenness capable of damaging the cable or hands of operator during rotation of drums.

iv. A metal preservation shall be applied to the entire drum. All ferrous parts used shall be treated with a suitable rust free finish or coating to avoid rusting during transit or storage.

v. The barrel diameter of the drum shall be greater than 15 times of OD of the cable.

vi. 3 rounds of black colour high density plastic sheet shall be wrapped on cable on cable drum.

vii. Wrapping of plastic cover is required for storing the cable for longer time at site.

viii. Name plate on Painted 2 mm thick MS plate on cable drum for identification shall be provided.

ix. Proper drum rotation mark shall be marked on the finished cable drums.

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x. Each drum shall consist of single length cable ≥ 500 metres.

xi. Packing shall be sturdy to protect the cable from any injury during transportation, handling and storage. The cut ends of the cable shall be sealed by means of non hygroscopic sealing material preferably Heat shrinkable end caps.

xii. One end of the cable shall be brought out of the drum and suitably clamped to the drum flange with proper mechanical protection. Location of the other end may be marked on the drum.

xiii. The cable shall be placed on drums in such a manner that it will be protected from injury during transit. Each end of the cable shall be firmly and properly secured to the drum. The drums shall be secured firmly in position so that they will not shift during transit. No undue stress shall appear on cables when laid on drums.

xiv. The cable drum shall carry the following information stencilled on a metallic label, securely attached to each end of the drum:

a. Reference to the Indian standard b. Manufacturer’s name, brand or trade mark c. Type of cable and voltage grade d. No. of cores e. Nominal cross-sectional area of conductor f. Cable code g. Length of cable on drum h. Gross weight i. Country of manufacture j. Year of manufacture k. Direction of rotation of drum (an arrow) l. ISI certification mark

7. PREFERRED MAKE FINOLEX/POLYCAB/KEI/RRKable or reputed brand possessing system certification of ISO 9001:2008, ISO14001:2004, OHSAS18001:2007 & EN 16001-2009 and product certifications IS: 7098 (Part-I), CE, UL etc. Quotations without these certification details will not be considered for technical evaluation.

Preferred make of bought out material: a. Aluminium for Conductor : Hindalco/Balco/Nalco b. XLPE compound of

Insulator : Dow/Borealis

c. Armour Steel : TATA/Jindal. d. Semiconducting Compound : Dow/Borealis

29

for screening e. Semiconducting water

swell-able tape : Lantor/Scapa Cable Solution

f. Heat Shrinkable End cap : Raychem

8. GUARANTEE All the cables shall be guaranteed against faulty material, defective design & poor workmanship for a period of 18 months from the date of supply. The materials becoming defective during the guarantee period shall be replaced free of cost and the defects arising out of the works shall be rectified free of charge without delay.

30

ANNEXURE-I

Technical Data Format for 1.1KV, XLPE Insulated, Aluminium/Copper Cable

The tenderer shall furnish all technical details as called for in the following format for all sizes of cables (Refer: 1.1 to 1.19, Table-1) failing which the tender shall be considered as incomplete. The details shall be furnished separately for all the cables.

31

Cable Type & Sl.No. as per Table-1 :

Sl.No. Particulars Details

a. Cores

a. No. of cores :

b. Nom. Area of conductor in Sq. mm :

c. Voltage grade :

b. Conductor

a. Standard applicable :

b. Material copper/aluminium/grade :

c. Purity :

d. Nominal cross-sectional area :

e. Form of conductor circular/shaped :

f. No. of strands :

g. Nominal dia of each strand :

h. Temperature co-efficient of resistance at 20 deg.C.

:

c. Insulation


b. Material (mention type) :

c. XLPE is cured by steam process or gas process?

:

d. Minimum average thickness :

e. Tolerance on the smallest of the measured values of thickness of insulation

:

f. Minimum volume resistivity at 27 deg. C

:

g. Minimum volume resistivity at 70 deg.C.

:

h. Color scheme for identification of cores

:

i. Average dielectric strength :

d. Inner Sheath

32


b. Material for inner sheath :

c. Minimum thickness of inner sheath :

d. Whether extruded :

e. Armour

1. Standard applicable :

2. Shape :

3. Size :

4. Material for Armour :

f. Outer Sheath/Overall Covering


b. Material (mention type if any) :

c. Whether extruded :

d. Minimum average thickness :

e. Whether anti-termite treatment has been given in the outer sheath

:

f. Whether flame retardant low smoke compound added in outer sheath

:

g. Electrical Properties

1. Maximum DC resistance of conductor at 20°C in ohms/km

:

2. Maximum DC resistance of armour at 20°C in ohms/km

:

3. Maximum permissible conductor temperature

Under continuous full load :

Under transient conditions :

4. Loss tangent at normal frequency :

5. Reactance at maximum operating temperature, 50 Hz (Ώ/km.)

:

6. Capacitance at maximum operating temperature, 50 Hz (Ώ/km.)

:

7. Total impedance at maximum operating temperature, 50 Hz (Ώ/km.)

:

8. Recommended continuous current rating

33

In Ground at 30°C Ground Temperature (Amps)

:

In Trench/Ducts at 40 °C (Amps) :

In Air at 40°C ambient Temperature (Amps)

:

9. Short circuit current rating for 1 sec. duration (in kA)

Conductor :

Armour :

10. Minimum volume Resistivity of insulation

At 27 °C in Ohm cm :

At Max operating temperature in Ohm-cm

:

11. Approximate AC resistance at max. Operating temperature

Phase :

Neutral :

h. Mechanical Data

a. Overall dia of the cable :

b. Dia of the cable under the sheath :

c. Diameter under armour :

d. Diameter over the stranded cores :

e. Wight of cable per km. :

f. Drum length :

g. Tolerance on drum length :

h. Total weight of the drum :

i. Dimension of the drum :

j. Recommended minimum installation radius/ bending radius

:

k. Maximum safe pulling force :

l. Whether identification as per clause of the specification is being provided

:

m. Whether packing has been done as per clause of the specification

:

(Seal & Signature of the supplier)

34

ANNEXURE-II

Technical Data Format for 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm Aluminium Cable

The tenderer shall furnish all technical details as called for in the following format for 6.35/11 kV (Uo/U) Voltage Grade, 3-Core, 185 Sq. mm Aluminium Cable (Refer: 2.0, Table-1) failing which the tender shall be considered as incomplete.

35


1. Voltage grade :

2. Reference Standard :

3. No of cores :

4. Conductor

a. Material as per IS : 8130 :

b. Nominal cross section area (Sq.mm) :

c. No. of Strands :

d. Nominal dia. of each strand :

e. Flexibility Class (as per IS:8130) :

f. Shape of conductor :

g. Purity of Aluminium :

h. Density of Aluminium :

i. Tensile strength :

j. Make of Conductor :

k. Material & Thickness of Water swellable compound material between each layer except outermost layer of conductor

:

l. Material & Thickness of Water swellable compound at the outermost layer of the conductor

:

5. Conductor Screening

a. Material :

b. Min. thickness (mm) :

c. Make, grade & brand name of the semi-conducting compound

:

6. Insulation

a. Material as per IS : 7098/II/2011 :

b. Nominal thickness (mm) :

c. Make, grade & brand name of the insulation compound

:

7. Insulation Screening

a. Material :

b. Nominal thickness (mm) :

c. Make, grade & brand name of semiconducting compound

:

36

d. Water swellable compound material :

e. Water swellable compound thickness :

f. Approx. thickness of Copper tape (mm) :

g. Core identification :

h. Filler material :

i. Laying Up :

8. Inner Sheath

a. Material as per IS : 5831/84 :

b. Min. thickness (mm) :

c. Color of inner sheath :

d. water swellable tape over inner sheath material :

e. water swellable tape over inner sheath thickness

:

f. Poly Al tape over inner sheath thickness :

g. Intermediate sheath Material Min. thickness (mm)

:

9. Armouring

a. Material as per IS : 3975 :

b. Nom. dimension of armour :

c. Short circuit current carrying capacity :

10. Outer Sheath

a. Material as per IS : 5831/84 :

b. Min. thickness of outer sheath (mm) :

c. Color of outer sheath :

11. End Cap material :

12. Recommended continuous current ratings under standard IS conditions

:

a. In ground, at 30 deg C Ground temp :

b. In Air, at 40 deg C ambient temp. :

13. Short circuit current carrying capacity of conductor for one second duration (KA)

:

14. Cable type designation :

15. Mechanical Data

a. Overall dia of the cable :

b. Dia of the shaped conductor :

c. Dia. over conductor screening :

37

d. Dia. over Insulation :

e. Dia. over Insulation Screen :

f. Dia. over armour :

g. Wight of cable per km. :

h. Dimension of the drum :

i. Recommended minimum installation radius/ bending radius

:

j. Maximum safe pulling force :

16. Electrical Properties

a. Loss tangent at normal frequency :

b. AC resistance at maximum operating temperature, 50 Hz (Ώ/km.)

:

c. Reactance at maximum operating temperature, 50 Hz (Ώ/km.)

:

d. Capacitance at maximum operating temperature, 50 Hz (Ώ/km.)

:

e. Total impedance at maximum operating temperature, 50 Hz (Ώ/km.)

:

17. Maximum permissible conductor temperature

a. Under continuous full load :

b. Under transient conditions :

38

ANNEXURE-III

Vendor evaluation Criteria


1. Name of Manufacturer :

a. Address of firm

:

b. e-mail :

c. Telephone/fax nos. :

d. Ownership of premises with address :

e. Nature of Business (Stockiest/General order Supplier/Manufacturer/Importer/Indenter/Service Provider etc.)

:

f. Company Registration details :

g. Year of Establishment :

h. Years of Operation/ Number of year experience in the business

:

i. Type of ownership of the company (Sole Proprietor/Partnership/Private/Public)

:

j. Company ISO certificate available :

39

k. Weather finished product is ISI marked? :

2. Proof of ability

a. Capacity of works :

b. Commercial performance over last three years :

c. Anticipated performance for the present year :

d. Annual production capacity of Cables in km. :

e. Licensed production capacity :

f. Maximum capacity reached so far and period during which it was achieved

:

g. Raw Material Handling

What is your current annual consumption of major raw materials

:

Describe your company’s raw material procurement policy

:

Describe your companies ram material supplier evaluation policy

:

Do you have any long term product purchase agreement with your current supplier for raw materials?

:

Do you have any approved specifications for the incoming material?

:

Do you get certificate of analysis for all incoming material from suppliers?

:

What are the testing methods/processes for incoming material?

:

h. Quality Management

Does your company have a (documented) system to manage Quality in your organization and is this system implemented?

:

Does your company have a Quality Policy? Please provide copy of policy

:

What are the checks conducted on your finished

40

products Field feed-back on laid cable

(Supporting documents shall be attached) :

i. Details of machinery available (Machine model number & Sl.No. shall be provided)

:

j. Details of collaboration for Technology :

k. Testing Equipments available (Machine model number & Sl.No. shall be provided)

:

l. Manpower available and qualifications

Total number of permanent staff :

Total number of temporary/contract staff :

Manpower Qualification Graduates Engineers Skilled Non Skilled

:

Number of personnel in your organization responsible for quality Assurance Provide details of technical qualification & experience of key persons in quality control

:

Are employees provided with any training for performance of the job?

:

m. R&D Facilities :

41

3. Manufacturing & Delivery schedule

a. Period required for arranging the required raw material and start of production after placement of purchase order

:

b. Period required for total production of final finished product

:

c. Period required for inspection & testing at site :

d. Period required for delivery to the site after inspection and verification of finished material

:


42

ANNEXURE-IV

CHECK-LIST

Sl.No. Description Yes/No Document Attached

(Yes/No)

i. Whether the bidder is an Original Equipment Manufacturer (OEM) of XLPE cable up to 11 kV for the past 5 years.

:

ii. Whether annual turnover for last 3 years is above 7 crores and no loss has been incurred during this period.

:

iii. Whether the OEM has completed all the type tests at CPRI /ERDA / NABL accredited lab. (Attach relevant document)

:

iv. Whether OEM have their own R&D lab. :

v. Whether OEM has ISO9001 & 14001 certification. :

vi. Whether the OEM has submitted Quality Assurance plan meeting the technical requirement.

:

vii. Whether the OEM is agreeing for complete tender technical specifications.

:

viii. Whether OEM has Established ISO procedure for selecting & monitoring a sub-vendor for procurement of raw materials.

:

ix. Whether the manufacturer has a single point triple Extrusion process with dry curing. (For HT cables)

:

x. Whether the OEM has Established plant standards (Validated with IS / IEC) in process inspection for manufacturing of cable.

:

xi. Confirm that no outsourced man power is employed in manufacturing sections of triple extrusion, QA process & R&D facility.

:

xii. Confirm: Recycled PVC are not used in the cable manufacturing.

:

xiii. Confirm whether the manufacturer has proper test set up for testing all the routine & type tests

:

43

xiv. Do you agree to conduct all the tests as per the specifications?

xv. Do you have in-house facility to conduct Longitudinal water tightness test on finished cables as per IEC.

:

xvi. Do you agree to conduct copper & aluminium conductor purity test at a 3rd party NABL accredited lab? (Two copper samples from LT cable, Two Aluminium samples from LT cable & one Aluminium sample from HT cable)

:

xvii. Confirm whether the Entire testing equipments have NABL accreditation.

:

xviii. Confirm whether indoor raw material storage is available for storage of armour wire, conductor wire drums, PVC and XLPE materials.

:

xix. Confirm whether the manufacturer considered supply of two number additional heat shrinkable end covers per drum

:

xx. Confirm the vendor has duly filled “Technical particulars/specification details” for all the LT cables as listed in Annexure-I

:

xxi. Confirm the vendor has duly filled “Technical particulars/specification details” for the HT cable as listed in Annexure-II

:

xxii. Confirm the vendor has duly filled & submitted the Vendor evaluation criteria as listed in Annexure-III

:

xxiii. Deviation Sheet (Bidder must furnish List of Technical Deviations mentioning the specification clause nos. against which deviations has been sought for. Compliance with this specification will be taken for granted in absence of any specific mention of deviations in the said list of deviations)

:

xxiv. The vendor shall submit details of minimum three similar supplies to any Govt./PSU organisation. The vendor shall submit the feedback and test report details.

:

xxv. Company’s Catalogues/Leaflets to be submitted :

44

xxvi. Cable De-rating chart for LT & Ht cables to be submitted separately (Group laying, UG laying, ambient temperature, ground temperature, de-rating factors for cable laying in ground, air, cable trenches etc.)

:


45

DEVIATION SHEET Sl.No. Clause no. as per tender

document Deviation Reason


46

Sl.No. Clause no. as per tender document Deviation Reason


47

Sl.No. Clause no. as per tender document Deviation Reason


48

Price Bid for E-Tender (Rates shall be uploaded only in the online price bid)

Tender no:

Sl.No. Cable Specification Quantity

(in meters) No. of Drums

1.0 The bidder shall quote for design, manufacture, testing, delivery at site, for Power cable of 1.1 kV grade, Multi-stranded Aluminium/Copper conductor, XLPE insulated, extruded PVC inner sheathed, GI round-wire armoured, extruded FRLS PVC ST2 outer sheathed, conforming to IS: 7098 (Part-I), 1988 and as per the technical specifications listed in Section-A of the tender document.



1000 500 Mtr x 2



500 500 Mtr x 1



500 500 Mtr x 1



500 500 Mtr x 1



1000 500 Mtr x 2



500 500 Mtr x 1



1000 500 Mtr x 2



1000 500 Mtr x 2



1000 500 Mtr x 2

1.10. 4C X 4 Sq.mm, Aluminium Conductor 1000 500 Mtr x 2

49



1000 500 Mtr x 2


1000 500 Mtr x 2


1000 500 Mtr x 2




500 500 Mtr x 1


500 500 Mtr x 1


500 500 Mtr x 1


2.0 The bidder shall quote for design, manufacture, testing, delivery at site, for 6.35KV/11KV (U0/U) Voltage grade, 3-core, 185 Sq.mm, Stranded, compact circular shaped Aluminium Conductor of H4 grade, Water Tree free XLPE Insulated, PVC sheathed, GI round wire armoured, Longitudinal and radial water tight power cables, confirming to IS: 7098 (Part-II), and as per the technical specifications listed in Section-B of the tender document.

2500 500 Mtr x 1

Documents

Technical Specifications for LT/HT, XLPE insulated ... · PDF fileTechnical Specifications for LT/HT, XLPE insulated Aluminium/Copper Cables This technical specification intends to