11kv cables
TRANSCRIPT
ANNEXURE-F PART 3 DISTRIBUTION 390
TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B
46. TECHNICAL SPECIFICATION FOR 11 KV AERIAL BUNCHED XLPE INSULATED CABLES FOR
OVERHEAD LINES (CROSSED LINKED POLYETHYLENE DRY GAS CURED)
1. SCOPE
This specification covers requirements of 11 KV Aerial Bunched XLPE insulated Aluminium Cables
for use in overhead lines under PSPCL. The sizes are as under:-
Sr. No. Size mm2
1 3Cx50+35
2 3Cx95+70
3 3Cx120+70
4 3Cx150+150
2. COMPOSITION OF THE CABLE
The composite cable shall comprise three single-core cables twisted around a bare aluminium alloy
messenger wire, which will carry the weight of the cable.
3. RATED VOLTAGE
The rated voltage of the cables shall be 6.35KV/11KV and the maximum operating voltage shall be
12 KV.
4. APPLICABLE STANDARDS
Unless otherwise stipulated in this Specification, the following Standards with the latest
amendments shall be applicable. Any deviation from the standards should be indicated specifically
and with recorded reasons.
Sr.No. Applicable IS Description
1 IS:7098(Part-II)-1985 Cross linked Polyethylene Insulated PVC Sheathed Cables.
2 IS:8130-1984 Conductors for Insulated Cables
3 IS:10810/1984 (series) Methods for tests for cables
4 IS:10418/1982 Drums for electric cables
5 IS:398 (Part-4) 1994 Aluminium Alloy conductors
6 IS:5831/1984 PVC Insulation and sheath of electric cable
7 IS:14255 : 1995 Aerial Bunched Cables for working voltage upto& including
1100 V
8 IEC-60502(Part-II) Polyethylene Outer Sheath
5. CLIMATIC CONDITIONS :
The service / climatic conditions are given in 1.2 of part-A. The material shall be for use in
moderately hot and humid tropical climate, conducive to rust and fungus growth .
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6. DETAILS OF SINGLE CORE CABLE:-
6.1 CONDUCTORS :
The cable conductors shall be of round, stranded and compacted aluminium conductors of
minimum cross sectional area 50mm2/95mm2/120mm2/150mm2. The aluminium
conductors shall comply with the requirements as specified in IS. 8130-1984 with up to
date amendments. The standard conductor shall be clean and reasonably uniform in size
and shape and its surface shall be free from sharp edges. Not more than two joins shall be
allowed in any of the wires form and every complete length of conductor and no joint shall
be within 300 mm of any other joint in the same layer. Joints shall be blazed, silver soldered
or electric or gas welded. No joint shall be made in the conductor once, it has been
stranded.
6.2 CONDUCTOR SCREENING :
Conductor screening shall be non-metallic and shall consist of a layer of extruded-semi-
conducting cross linked polyethylene (XLPE) compound of thickness not less than 0.5mm.
6.3 INSULATION :
The insulation shall be chemically cross linked polyethylene (XLPE) applied by extrusion
conforming to IS : 7098 (Part-II) / 1985 and as required in the specification, Cross-linking
may be done by exposure to organize peroxide with nitrogen curing CCV line method with
the intention to ensure lowest free formation. Only natural unfilled compound shall be
used for insulation of cables. The average thickness of insulation when measured in
accordance with relevant clause of the specification shall not be less than the standard
thickness value specified. The smallest of the measured values of thickness shall not fall
below the standard thickness values as specified in IS : 7098 (Part-II) / 1985 by more than
0.1+0.1 standard thickness in mm. The thickness of insulation shall be as under:-
Sr. No. Nominal Area of Phase
Conductor (mm2)
Nominal Thickness
(mm)
Minimum Thickness
(mm)
1 50 3.6 3.14
2 95 3.6 3.14
3 120 3.6 3.14
4 150 3.6 3.14
6.4 INSULATION SCREENING :
The insulation screening shall consist of non-metallic semi-conducting part in combination
with a metallic part. Non- metallic part shall be applied directly over the insulation of each
core and shall consist of a layer of extruded semi-conducting compound. The minimum
thickness of non-metallic screening should be 0.6 mm.
6.5 METALLIC SCREENING :
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The metallic part shall be applied over the individual core. Metallic screening shall consist of
copper tape sheath and shall be non-magnetic. The thickness of metallic screening should
not be less than 0.2mm.
6.6 OUTER SHEATH :
Over the metallic screen the cable shall be provided with extruded PVC outer sheath. The
composition of the PVC compound for outer sheath shall be Pre-Type ST2 of IS-5831-1984.
The colour of the outer sheath shall be grey. The average thickness of the sheath shall not
be less than the standard values specified in the IS when measured as laid in IS-7098
(Part-II)/ 1985. The smallest thickness of the measured values of sheath shall not fall below
the standard value (s) specified, by more than 0.2+0.2 (ts) mm.
6.7 CORE IDENTIFICATION :
The Core identification shall be done by providing coloured strip under Copper Tape.
7. MESSENGER WIRE :
The bare messenger wire shall be of 35mm2/70mm
2/150mm
2 (nominal area). Messenger wire,
shall consist of Aluminium alloy wires generally confirming to IS : 398 ( Part-IV)/ 1979and wire
shall be tested as per relevant IS. Strands shall be suitably compacted and have smooth round
surface to avoid damage to the outer insulating sheath of single-core phase cables twisted
around the messenger. There shall be no joints in any wire of the stranded messenger
conductor except those made in the base rod or wires before finally drawing.
8. LAYING UP :
Three Power Cores shall be twisted over bare messenger wire with right hand direction of lay.
This will form the Aerial Bunched Cable.
9. TESTS:
9.1 TYPE TESTS:-
The material offered, shall be fully type tested as per relevant standard of specification of
IS:7098 (Part-II/1985) amended up to date. The bidder must furnish type test reports of similar
rating & design of tendered material within 1 month of allotment of order. The following shall
constitute type tests:
a) Tests of Conductor:
i. Annealing test (for copper) not applicable
ii. Tensile test (for aluminium)
iii. Wrapping test (for aluminium)
iv. Resistance Test
b) Test on Messenger Conductor: (as per IS: 14255/1995)
i. Breaking load test for messenger conductor.
ii. Elongation test for messenger conductor.
iii. Conductor resistance test
c) Tests for thickness of insulation and sheath.
d) Physical tests for insulation:
i. Tensile strength and elongation at break.
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ii. Ageing in air oven.
iii. Hot test.
iv. Shrinkage test.
v. Water absorption (gravimetric).
e) Physical test for outer sheath: (as per IS: 14255/1995)
i. Tensile strength and elongation at break.
ii. Melt Flow Index
iii. Vicat softening test.
iv. Carbon Black:
a) Contents.
b) Dispersion
v. Environmental Stress Cracking
f) Partial discharge test.
g) Bending test.
h) Dielectric power factor test:
a. As a function of voltage.
b. As a function of temperature.
c. Insulation resistance (volume resistivity test).
i) Insulation resistance (volume resistivity test)
j) Heating cycle test.
k) Impulse withstand test.
l) High voltage test.
m) Flammability test.
n) Any other test as per relevant IS.
9.2 ACCEPTANCE TESTS
i. a) Tensile test
ii. Wrapping test
iii. Conductor Resistance Test
iv. Test for thickness of insulation and sheath
v. Hot set test for insulation
vi Tensile strength and elongation at break test for insulation and sheath
vii Partial discharge test
viii High voltage test
ix Insulation resistance (volume resistivity test)
9.3 ROUTINE TESTS
i Conductor Resistance Test
ii Partial discharge test
iii High voltage test
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The following tests shall be carried out on the bare messenger wire in accordance with
IS:398 (part –IV).
i Breaking load Test (on finished wire).
ii Elongation test
iii Resistance test
9.2 However, the PSPCL reserves the right to demand repetition of same or all the type tests in
presence of PSPCL’s representative.
9.3 The bidder must also clearly indicate various testing facilities available at their works for testing
the material as per relevant standards. In case of otherwise particulars of the place where such
testing is proposed to be conducted during the course of inspection shall be indicated .
10 INSPECTION (TEST BEFORE DISPATCH):
10.1 No material will be allowed to be dispatched without prior inspection and approval. In case,
inspection of the consignment is waived off by the PSPCL, the bidder will be required to
furnish the test certificate of the material, in triplicate for approval. The material
consumed/destroyed during testing will be to the account of the bidder. 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. The following Acceptance tests as per Clause No.18.2 of IS:7098
(Part.II)/1985 & IS: 14255/1995 shall be conducted in presence of the PSPCL 's authorized
representative / agency on each lot of offered cables:
i) Tensile Test (If applicable).
ii) Wrapping Test (If applicable).
iii) Conductor Resistance Test (Phase Conductor & Messenger).
iv) Breaking load test for messenger conductor.
v) Elongation test for messenger conductor.
vi) Test for thickness of insulation & sheath.
vii) Hot Set Test for XLPE Insulation.
viii) Tensile strength & elongation at break test for insulation and sheath.
ix) Carbon Black:
a. Contents.
b. Dispersion
x) Partial Discharge Test (for screened cables only).
xi) High voltage test and
xii) Insulation resistance (Volume resistivity) Test.
In addition to above following type tests shall also be considered as acceptance tests and shall be
conducted on any two samples drawn from the lot offered for pre-despatch inspection:-
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i) Shrinkage Test For XLPE insulation
i) Shrinkage Test (For outer sheath as per IS: 5831/1984
with latest amendments/revision if any) ii) Heat shock Test
iii) Hot deformation Test
iv) Thermal Stability Test
v) Flammability Test
The lot shall be considered as passed if the test results of both the samples for above tests conform
to relevant clauses of IS.
The following shall constitute optional test:-
Bending test on complete cable:
The test shall be performed on a sample of complete cable. The sample shall be bent
around a test mandrel at room temperature for at least one complete turn. It shall then be
unwound and the process shall be repeated after turning the sample around its axis by 180
degrees.
The cycle of these operations shall then be repeated twice. The diameter of the mandrel
shall be: 10(D+d)
Where: D= actual diameter of the cable, for example, minimum circumscribing diameter in
mm ;
And d= actual diameter of the phase conductor in mm.
Requirement: No cracks visible to the naked eye are allowed.
10.2 ROUTINE TEST: - The following shall constitute routine tests. The tests shall be done as per
relevant ISS:
a) Conductor resistance test
b) Partial discharge test
c) High voltage test.
d) Messenger Resistance
11. SEQUENTIAL MARKING.
Supplier shall provide non erasable sequential marking on one core of AB Cable at every one
meter distance before assembly of different cores to form the cable. However, the length of
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cable for acceptance shall be based on length of finished cable and not on the basis of
sequential marks. The cores shall be identified as per relevant IS.
12. PACKING & MARKING
The cable shall be supplied in suitable non-returnable wooden drums of suitable size in
standard lengths subject to a tolerance of +/-5%. The cable shall be wrapped with polythene under
wooden covering. Each meter length shall be embossed with the trade name of manufacturer, Size
in mm2, word ELECTRIC, Voltage rating, year of manufacture and the word “PSPCL CABLE”. The
wooden drums should be provided with cast iron bushing & painted form outside with suitable
paint of any colour. The drums should be such that the cable wound on the same is transported
without any damage. The cable shall be supplied in standard length of 1000 mtr./500 Mtr.
depending upon the size.
The ends of the cable shall be sealed by means of non-hygroscopic sealing material. In addition to
this each drum shall carry the following information either stenciled on flange or label attached to it.
a) Manufacturer’s name.
b) Trade mark, if any.
c) A reference to IS i.e. IS -7098 (Part-II)/1985.
d) Length of the cable on the drum & no. of lengths.
e) Position of outer end of cable
f) Voltage grade and type of the cable.
g) Colour of outer sheath.
h) Nominal cross-sectional area of the cable conductor.
i) Work order No. & Date.
j) Name and address of consignee.
k) Number of cores.
l) Gross weight of packed and net weight of the power cable.
m) Drum No. & its direction of rotation (with an arrow)
n) Year of manufacture.
o) Property of PSPCL
13. TOLERANCE
13.1 TOLERANCE ON PACKING
The standard drum length may have tolerance of + 5%.
13.2 NON-STANDARD LENGTH
Non-standard lengths not less than 50% of the standard length of cable to the extent of 5% of the
total ordered quantity (size wise) will be acceptable.
14. CHECKING OF LENGTHS/ WEIGHTS DURING INSPECTION
The bidder shall at his own cost provide the necessary arrangements for the purpose of physical
and accurate checking of lengths and weights of the cables in drum(s) at the time of inspection by
the Inspecting Officer of the PSPCL. Out of total quantity of drums offered for inspection, the
Inspecting Officer of the PSPCL shall carry out inspection as under:-
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i) He will carry out 100% checking of all the drums offered for inspection by weight.
ii) For check measurement of length, minimum 5% drums of the offered lot shall be
considered subject to minimum of 2 numbers.
iii) The drums for length measurement shall be selected either by keeping in view the
maximum difference in weight as recorded on the drums/packing list and actually measured, or
at random. Normally half of drums to be checked for length/weight shall be selected at random
and the remaining half by difference in observed/declared weight method.
iv) Maximum shortage observed in length in any of the drums check measured shall be
applied on all the drums offered in a particular lot, by the Inspecting Officer and declared
quantity will be reduced accordingly. The verification of length to be done by the consignee; as
in para-13 above of this specification shall be over and above the results obtained in this
checking.
15. SCHEDULE OF GUARANTEED AND GUIDING TECHNICAL PARTICULARS:-
The bidders must supply the detailed guaranteed and other technical particulars as
detailed in Annexure. alongwith the tender.
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ANNEXURE
SCHEDULE OF GUARANTEED PARTICULARS
GUARANTEED TECHNICL PARTICULARS FOR HT AERIAL BUNCHED CABLE WITH CROSS-LINKED POLYETHYLENE
(XLPE) INSULATION & BARE MESSENGER WIRE (FOR NEUTRAL & EARTHING)
Sr.
No.
Particulars HT Aerial Bunched Cables
Size (sq. mm.) 3Cx50+35 3Cx95+70 3Cx120+70 3Cx150+150
1 Maker's Name & Address
2. Rated Voltage
3 Phase conductor details
i) No. of Phase conductors
ii) Nominal cross-sectional area of each
conductor-mm2
iii) No. & Size of strands (mm) (Before
Stranding)
iv) Minimum tensile strength of each strand-
N/mm2
v) Diameter of compacted conductor along
with tolerance (mm).
vi) Approximate mass per phase (Kg/Km)
vii) Maximum DC resistance at 200 C
(Ohm/Km)
viii) Insulation thickness (mm)
ix) Standard to which this material conforms
4. Messenger (Neutral conductor)
i) Nominal sectional area of each conductor
in mm2
ii) No. & size of strands (mm) (Before
Stranding)
iii) Diameter of compact conductors along
with tolerance (in mm)
iv) Approx. mass (Kg/Km)
v) Minimum Tensile strength in KN
vi) Max. DC resistance at 200 C (Ohm/Km)
vii) Standard specification to which this
material conform
5. i) Insulation of phase conductor
a. Conductor Screening
Material
Nominal Thickness (in mm)
b. Insulation
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Material
Nominal Thickness (in mm)
c. Insulation Screening
Material
Non Metallic
Metallic
Thickness
Non Metallic (Nominal) (in mm)
Metallic (Nominal) (in mm)
d. Sheathing of Core
Material
Colour
Nominal Thickness (in mm)
e. Identification of power cores
ii) Whether all properties as mentioned in
the technical Specifications are
guaranteed if not indicate deviations in
properties .
iii) Standared specification to which this
material shall conform
6. Finished cable (Complete bunched cable)
i) Overall diameter (approx.) in mm
ii) Total mass (approx.) in Kg/Km
7. Drum
i) Total weight of drum(Kg)
ii) Whether drum is wheel mounted
iii) Standard specification to which drum
shall conform
8. Standard length of each cable and its
tolerance(Mtrs.)
9 i) Total length of cable in a drum and its
tolerance(Mtrs.)
ii) Mass of finished cable in a drum and its
tolerance(Kg)
10. Whether material bears ISI certification
mark
11. Serial number of ISI license and its
validity
12. Max. Continuous current carrying
capacity (Amp.)
13 Max. Continuous conductor temperature
due to load
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14 Embossing
15. Any other particulars
Note:- Notwithstanding any error and omission in GTP shall conform to PSPCL’s Technical
Specification/relevant ISS.
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47. TECHNICAL SPECIFICATIONS FOR 11KV THREE CORE XLPE CABLES
1. SCOPE
This specification covers the design, manufacture, testing at manufacturer’s works, packing, supply and
delivery of ISI marked three core, 11KV, stranded Aluminum conductor, XLPE insulated, PVC sheathed,
screened, armoured cable suitable for earthed system manufactured with CCV (Dry Cure) OR SIOPLAS
Technology . The cable shall be used underground in distribution system.
2. STANDARD
The cable shall comply with IS: 7098(Part-II)/1985 (with latest amendments/revisions if any). The Aluminum
conductor shall be of H2 Grade as per IS: 8130/1984(with latest amendments/revisions if any). The XLPE
insulation shall conform to IS: 7098 (Part –2) /1985(with latest amendments /revisions if any) and PVC
sheathing will be of PVC compound conforming to the requirements of type ST-II of IS-5831/1984(with latest
amendments/revisions if any).
SIZE OF CABLE
Design, manufacture, testing at manufacturer’s works, packing ,supply and delivery of ISI marked, 11 KV,
Three Core, stranded Aluminum conductor, XLPE insulated, PVC sheathed, screened, armoured cable
manufactured with CCV/SIOPLAS technology (Dry Cure) and confirming to IS-7098(Part-2) /1985 & the
specification No.QQ-1241/2010 –11 /PO/C&S. The size are as under: -
MATERIALS
a. CONDUCTOR
The conductor shall be of stranded construction and of high conductivity H2 grade aluminum of plain wires,
conforming to flexibility class as mentioned in Table-2 of IS-8130/1984 (with latest amendments/ revisions if
any).
b. CONDUCTOR SCREENING
The cable shall be provided with conductor screening by applying non-metallic semi conducting tape or by
extrusion of semi conducting compound or combination of two as per IS-7098 (Part 2)/1985(with latest
amendments/ revisions if any).
c. INSULATION
The Aluminum conductor shall be insulated with cross-linked polyethylene insulating compound conforming
to relevant clause of IS-7098(Part-2)/1985 (with latest amendments/revisions .if any) in such a way that it fits
closely on the conductor screening and it shall be possible to remove it without damaging the conductor. The
conductor shall be insulated by CCV/SIOPLAS technology. The thickness of insulation shall not be less than
the nominal value as specified in relevant IS.
d. INSULATION SCREENING
The insulation screening shall consist of two parts, namely metallic and non-metallic part as specified in the
relevant clauses of IS: 7098 (Part-2)/1985 (with latest amendments/revisions if any).
e. FILLERS & INNER SHEATH
Fillers & inner sheath shall be of vulcanised or unvulcanised rubber or thermoplastic materials. These materials
shall not be harder than XLPE/PVC used for insulation & outer sheath respectively and these shall be so chosen
Sr. No. Size
1 3C x 35mm²
2 3C x 150mm²
3 3C x 300mm²
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to be compatible with temperature rating of the cable and shall have no adverse effect on any other component
of the cable.
The inner sheath on the laid up cores shall be applied either by extrusion or by wrapping and the method
actually adopted should be clearly defined in the tender. It shall be ensured that the shape is as circular as
possible. Further it should be possible to remove inner sheath without damage to insulation. The thickness of
the inner sheath shall be as per the relevant clause of IS-7098 (Part-2)/1985 (with latest
amendments/revisions if any).
f. ARMOURING
The cables shall be armoured as per IS:7098 (Part-2) /1985 (with latest amendments/revision if any).
g. OUTER SHEATH
The cables shall be provided with outer sheath by Pressure Extrusion Process, of PVC compound confirming
to type ST-2 of IS-5831/1984 (with latest amendment/revisions if any). The colour of outer sheath shall be
grey & thickness will be as per provisions of relevant IS.
5. IMPULSE LEVEL
The impulse level shall be 75KVp ( to be certified by the manufacturer).
6. TESTS
a. ACCEPTANCE TESTS
All the acceptance tests as specified under relevant clause of IS-7098(Part-2)/1985(with latest
amendment/revision if any) shall be carried out by the inspecting officer on the samples drawn as per
sampling plan stated in IS, from the lot offered for pre-despatch inspection.
In addition to above following type tests shall also be considered as acceptance tests and shall be
conducted on any two samples drawn from the lot offered for pre-despatch inspection:-
i) Shrinkage Test For XLPE insulation
i) Shrinkage Test ) (For outer sheath as per IS: 5831/1984
ii) Heat shock Test ) with latest amendments/revision if any)
iii) Hot deformation Test )
iv) Thermal Stability Test )
v) Flammability Test )
The lot shall be considered as passed if the test results of both the samples for above tests conform to
relevant clauses of IS.
Measurement of Weights of Various Parts of Cables.
The number of samples to be taken for the measurement of weights of various parts ,as per GTPs, shall be
50 % of the total no. of samples
b. TYPE TESTS
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The cables shall comply with Type Tests as classified under clause-18.1 of IS: 7098(Part-2)-1985 (with
latest amendments/revisions if any). Complete Type Tests Certificates from a Govt.
approved/Recognized Test House indicating the results of Type tests conducted, in respect of each size
of cable offered, should be sbmitted within 1 month of allotment of order to the respective office of
PSPCL. Type Tests should be conducted on the tendered item manufactured only at works from where
material is to be supplied. PSPCL, however , reserve its right to carryout the Type Tests wherever felt
necessary at bidder’s cost.
Complete Type Tests as per IS: 7098 (Part-2)-1985(with latest amendments/revisions if any. will
be conducted on one number sample in the first lot of each sizse (only one time for full ordered
quantity of each size) at the works of the manufacturer during pre-despatch inspection at the cost of
the bidder.
c. ROUTINE TESTS
The manufacturer shall carry out/conduct routine tests as specified in relevant IS on the cables
manufactured before pre-despatch inspection.
d. OTHER TESTS
Any other tests becoming necessary with the amendment in relevant IS or otherwise agreed
between the manufacturer/ bidder & PSPCL shall also be carried out without any extra financial burden
upon the PSPCL.
7. IDENTIFICATION
The word ‘PSPCL` and manufacturer’s trade mark or name, size in mm², voltage rating and word
‘ELECTRIC` in English shall be embossed on the outer sheath of the cable at regular intervals of not
more than 1.5 metres, as may be convenient. The cable should also be sequentially marked to display
the length at a distance not more than 1 m.
The cores shall be identified as per relevant IS.
8. PACKING & MARKING
8.1 PACKING
The cable is required to be supplied in standard lengths of 500 mtrs up to 70 mm² and 250 mtrs
for other sizes. The length shall be supplied in non-returnable standard wooden drums provided with
cast iron bushing painted form outside with suitable paint of any colour. The drums should be such that
the cable wound on the same is transported without any damage.
8.2 MARKING
The following particulars shall be specified clearly with indelible ink or paint on each drum :-
Length of drum
Name of manufacturer, Brand Name & Trade Mark
Gross weight of drum
Size of cable in mm²
No. of cores.
Type of cable and voltage rating
ISI certification mark
Cable code
No. of lengths in drum (if more than one)
Direction of rotation of drum
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Year of manufacturing
9. TOLERANCE
9.1 TOLERANCE ON PACKING
The standard drum length may have tolerance of + 5%.
9.2 NON-STANDARD LENGTH
Non-standard lengths not less than 100 M each to the extent of 5% of the total ordered quantity (size
wise) will be acceptable.
10. INSPECTION
The material offered for supply will be inspected by a fully authorised representative of the PSPCL or an
outside Agency nominated by PSPCL within two weeks from the date of receipt of intimation regarding
readiness of the material . No material will be allowed to be despatched without prior inspection and
approval. In case, inspection of any consignment is waived off by the PSPCL /Agency, the bidder will be
required to furnish routine & acceptance test certificates in triplicate, of the same for approval. It will
be the responsibility of the bidder to make adequate arrangement for testing of material at their works.
All testing instruments and appliances duly calibrated from Govt. Recognised test house will be made
available and material consumed/ destroyed during testing will be to the account of the supplier. The
PSPCL has the right to have the tests carried out by independent test house/laboratory/agency
whenever there is a dispute regarding the quality of material, cost of which shall be borne by the
bidder.
The material shall be sealed with lead seals and lash wire to be provided by the manufacturer / bidder.
Random testing of material on receipt in the stores irrespective of fact whether or not it was inspected
before despatch, shall be carried out by PSPCL and in case of failure, entire lot shall be rejected at the
cost and risk of supplier.
10. SCHEDULE OF GURANTEED TECHNICAL PARTICULARS
Bidder / Bidder must supply the detailed guaranteed technical alongwith the tender
11. ISI MARK
The bidders must supply photocopy of valid ISI licence, indicating item for which it has been issued
(valid on original date of opening of tender) along with their tender failing which their price bid will not
be opened. The above license should preferably be valid during the validity of the offer also. In case, the
license is expiring within the validity period of the offer, it will be the responsibility of the bidder to get
the same re-validated from time to time.
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48. TECHNICAL SPECIFICATION FOR LT AERIAL BUNCHED CABLES
1. SCOPE:
1.1 This specification covers the requirements of LT Ariel Bunched cross linked polyethylene insulated cables
with aluminium conductors twisted over a central bare/insulated aluminium alloy messenger wire for use as
overhead distribution feeders of the following sizes:
Sr. No. Size mm2
1 3Cx16+25
2 3Cx25+25
3 3Cx35+25
4 3Cx 50+35
5 3Cx 95+70
6 3Cx 120+70
1.2 The cables covered in this standard are suitable for use on three-phase ac (earthed or unearthed) system
for rated voltage up to and including 1100 V.
Note: The cables conforming to this standard may be operated continuously at a power frequency voltage to
percent higher than the rated voltage.
1.3 The cables covered in this standard are suitable for use where the combination of ambient temperature
and temperature rise due to load, including temperature on exposure to direct sunlight results in conductor
temperature not exceeding the following:
Type of Insulation Normal Continuous
Operation
Short Circuit Operation
Polyethylene 700 C 160
0 C
Cross linked Polyethylene 900 C 250
0 C
2 COMPOSITION OF THE CABLE
The composite cable shall comprise three single-core cables twisted around a bare/insulated
aluminium alloy messenger wire, which will carry the weight of the cable.
3. RATED VOLTAGE
The rated voltage of the cables shall be 1100 volts.
4. APLICABLE STANDARDS:
The following standards with latest amendments shall be applicable.
1. IS: 1596 1984: Polyethylene insulated cable 1100 volts
2. IS: 8130 - 1984: Conductors for insulated cables
3. IS: 6474 - 1984: Polyethylene insulation of cables.
4. IS: 398 - 1994: (Part IV) Aluminium alloy conductor.
5. IS: 398 1996: (part II) For ACSR conductor.
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6. IS: 14255 1995: Arial Bunched Cable Specification
7. IS: 7098 (PI) 1988 with latest version.
5. TERMINOLOGY
For the purpose of this standard the following definition to those given in IS 1885 (Part 32): 1993 shall
apply.
6. TESTS:
6.1 Routine Tests
Tests made by the manufacturers on all finished cable lengths to Demonstrate the integrity of
the cables.
6.2 Type Tests
Tests required to be supplied within 1 month of allotment of order.
Note: These tests are of such a nature that after they have been made, they need not be
repeated unless changes are made in
the cable materials of design, which might change the performance characteristics.
6.3 Acceptance Tests
Tests carried out on samples taken from a lot for the purpose of acceptance of the lot.
6.4 Optional Tests
Special tests to be carried out, when required by agreement between the PSPCL and the
supplier.
6.5 Earthed System
All electric system, which fulfills any of the following conditions:
a) The neutral point or midpoint connection is earthed in such a manner that even fault
conditions, the maximum voltage that can between any conductor and earth docs not
exceed 80 percent of the nominal system voltage;
b) The neutral point or midpoint connection is not earthed but a protective device is installed
which automatically cuts out part of the system which accidentally becomes earthed; or
c) In case of ac system only, the neutral point is earthed through an ARC suppression coil with
arrangement for isolation within 1 hour of occurrence of the fault provided that total of
such periods in a year does not exceed 125 hours.
6.6 Unearthed System
An electric system which does not fulfill the requirements of earthed system (see 3.5 (a), (b),
(c).
MATERIALS
7. CONDUCTOR
7.1 The power/outer insulated neutral/street lighting conductors shall conform to flexibility class
2 of IS 8130: 1984.
7.2 The messenger (Neutral conductor) or otherwise shall be either stranded circular or
compacted circular type and shall have minimum 7 strands. The surface of the conductor shall
be smooth.
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7.3 A protective barrier may be applied between the conductor and insulation, if required. Such
barrier, when used, shall be compatible with insulating material and suitable for the operating
temperature of the cable.
7.4 The size of street lighting conductor shall be (16 sq mm)
7.5 The size of messenger conductor and its breaking load shall be as under:
SIZE AND REQUIREMENTS OF MESSENGER CONDUCTOR
Sr.
No.
Nominal Cross
Sectional
Area of phase
conductor
Messenger Conductor
Nominal Cross
Sectional Area
Maximum de
Resistance at 20 O
C
Minimum
Breaking
Load
mm2
mm2 Ohm/km KN
1 16 25 1.38 7.0
2 25 25 1.38 7.0c
3 35 25 1.38 7.0
4 50 35 0.986 9.8
5 70 50 0.689 14.0
6 95 70 0.492 19.7
7 120 70 0.492 19.7
7.6 There shall be no joints in any wire of the messenger conductor. The direction of outer layer
of wires in messenger conductors shall be right hand.
7.7 CORE IDENTIFICATION:
The phase conductors shall be provided with one, two or three 'ridges' and Outer neutral
insulated conductor, if provided, shall have four 'ridges' as shown in Fig. I for quick
identification. The street lighting conductor and messenger conductor (if insulated) shall not
have any identification mark.
Identification by other means, as agreed between the supplier and PSPCL, is also permissible.
7.8 ASSEMBLY (LAYING UP):
Three insulated phase conductors, one insulated neutral conductor (if required) and a street
lighting conductor (if required) shall be twisted around the bare (or insulated) as required
messenger conductor without fillers with a lay not exceeding 35 times the diameter of the
insulated phase conductor.
The direction of lay shall be right hand.
PHASE CONDUCTOR & NEUTRAL CONDUCTOR
Phase Conductors
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Neutral Conductor
Fig. 1, Core Identification
7.9 Phase/Street Lighting Conductor
The conductor shall be of H2 or H4 grade aluminium complying with the Requirements of IS
8130: 1984.
PHASE CONDUCTOR
1. The phase conductor and street lighting conductors shall be insulate with black weather
resistant, polyethylene suitable for1100 v insulation, the insulated Conductors shall
generally confirm to the standards, applicable standards.
2. The phase conductors shall be suitable compacted and the outer diameter shall be within
the limits specified.
3. The phase conductors shall be provided with one, two and three 'ridges' for quick
identification.
4. The tensile strength of aluminium wire used in the conductors shall not be less the 90 N/
sqmm.
5. The standard sizes and technical characteristics of the phase and street lighting conductors
shall be as shown as under:
Nominal
sectional
area (mm2)
No. of
strands
Dia. Of
compacted
Conductor (mm)
Approx.
mass
(Kg/km)
Max.D.C.
resistance NCE
at 20 OC
Insulation
Thickness
(mm)
16 1 4.4 42 1.91 1.0
25 7 5.8 65 1.20 1.0
35 7 6.8 95 0.868 1.0
50 7 7.9 127 0.641 1.2
70 12 9.7 191 0.443
95 19 259 0.320
120 19 329 0.253
Note: The resistance value given in Col. 5 are the max, permissible Tolerance of +/- 5% is
allowable on diameters shown in col.3
7.10 Messenger (Neutral Conductor or Otherwise)
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TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B
The conductor shall be of heat-treated aluminium magnesium-silicon alloy wires containing
approximate 0.5% magnesium and approximately 0.5% silicon conforming to IS 398 (Part-4):
1979. Customers can opt for ACSR as messenger wire. Messenger wire can be either bare OR
insulated as per requirement.
1. The bare messenger wire shall be generally made of aluminium alloy wire/ACSR confirming
to IS: 398 (Part IV) 1994/398 (Part-II) 1996 with latest amendment composed of 7 strands
and shall be suitably competed to have smooth surface to avoid damage to the
polyethylene insulation of the phase conductors twisted around the messenger.
2. There shall be no joints in any wire of the stranded messenger conductor and other
technical characteristics of the messenger wire (bare) shall be given as under:
Normal
Sectional
area
No. of
strands
Dia (min)
of
compacted
cond. (mm)
Approx.
Mass
(kg/km)
Max.
D.C.
resistance
NCE at 20%
ohm /km
Min. Tensile
Strength (KN)
25 7 5.8 65 1.380 7.4
35 7 6.8 95 0.986 10.3
50 7 7.9 127 0.689 14.7
70 12 9.7 191 0.492 20.6
Note: While the limiting values in col.5 & 6 are to be guaranteed and 5% plus tolerance will be
permissible on values in col.3.
The number of the insulated Phase Conductor in an ABC cable will vary depending on the
specifications and requirement of customer. Whereas, the ABC Cable with a single Insulated
conductor is called Duplex, the one with two insulated Conductors is called Triplex, and the
one with three insulated Conductors is called Quadruple. In addition to this, a street lighting
or an emergency service conductor may also be provided public amenities such as street
lighting.
COMPOSITION AND DESIGNATION OF FINISHED CABLES
7.11 The composition and designation of finished cables are given as under.
Sr. no. Designation Complete Bunched
Cables overall Dia in
mm
Total Mass approx in
Kg/km
1 3X16+25 19 250
2 3X16+16+25 19 310
3 3X25+25 22 330
4 3X25+16+25 22 390
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5 3X35+25 24 430
6 3X35+16+25 24 490
7 3X50+35 32 580
8 3X50+16+35 32 640
Note: The first part of the designation refers to the number and size of the phase conductor,
the middle to the street lighting conductor(were provided) and the last to the bare
messenger wire. The sixes shown are the nominal sectional areas.
1. Polyethylene insulation will generally confirming to IS1596 1984 and IS-6474-1984 and XLPE
insulation confirming IS 7098 (P.I)/ IS 14255.
2. Cable Phase or street Lightening will confirm to IS-8130/1984 duly compacted.
3. The messenger (neutral conductor) will generally confirm to IS-398 (Part 4) 1994/ IS 398
Part II /1996 for Aluminium Alloy Conductors or ACSR Conductors duly compacted.
8. INSULATION:
8.1 The insulation shall be either of cross-liked polyethylene compound or of polyethylene
insulation applied by extrusion. Confirming to requirement given in Tables 1 and 2
respectively.
Sr. No.
(1)
Tests
(2)
Requirements
(3)
1 Tensile strength 12.5 N/ mm2,Min
2 Elongation at break 200 percent, Min
3 Ageing in air oven:
a) Treatment: Temperature
Duration
b) Tensile strength variation
c) Elongation variation
135 oC, +/- 3
oC
7 days
25 percent, Max
25 percent, Max
4 Hot set:
a) Treatment: Temperature
Time under load
Mechanical Stress
b) Elongation under load
c) Permanent elongation (set) after cooling
200 o
C, +/- 3oC
15 Min
20 N/cm2
175 percent, Max
15 percent, Max
5 Shrinkage:
a) Treatment: Temperature
Duration
130 o
C,+/- 3oC
1 hour
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b) Shrinkage: 4 percent, Max
6 Water absorption (Gravimetric):
a) Treatment: Temperature
Duration
b) Water absorbed
85 oC,+/- 2
oC
14 days
1 mg/cm2, Max
7 Volume resistively:
a) at 27 o
C
b) at 90 o
C
1X1013ohm-cm, Min
1X1011ohm-cm, Min
PROPERTIES OF PE INSULATION
(CLAUSE 5.1)
Sr.No. Property Requirements
1 Volume /resistively:
a) at 27 o
C
b) at 70 o
C
1 X 1014 ohm-cm, Min
1 X 1012 ohm-cm, Min
2 Tensile Strength 10 N/mm2, Min
3 Elongation at break 300 percent Min
4 Melt flow index 3, Max
5 Vacant softening point 85 o
C,Min
6 Carbon black:
a) Content
b) Dispersion
Under consideration
7 Environmental stress cracking No cracks shall be visible to
marked eye
The conductor (with protective barrier, wherever applied) shall be provided with cross-linked
polyethylene or polyethylene insulation applied by extrusion.
Thickness of Insulation This average thickness of insulation shall be not less than the nominal value (t)
specified as under.
THICKNESS OF INSULATION
Nominal Area of Conductor Nominal Thickness (ti)
(mm2) (mm)
16 1.2
25 1.2
35 1.2
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50 1.5
70 1.5
95 1.5
Tolerance on Thickness of Insulation
The smallest of measured values of thickness of insulation shall not fall below the nominal value (ti)
specified above by more than 0.1 mm + 0.1 (ti).
Application of Insulation
The insulation shall be so applied that it this closely on the conductor (or barrier, if any) and it shall be
possible to remove it without damaging the conductor.
The color of insulation shall be GREY.
POLYETHYLENE INSULATION
The Polyethylene insulation shall generally confirm to IS: 6474-1971.The following properties shall be
guaranteed:
Melt Flow Index: 0.5 or less
Yield Stress: Not less than 8n/mm2
Percentage Elongation: Not less than 350
Carbon Black Content: Between 2 &3
Vicat Softening Point: Not less than 850 C
Volume
At 270 C 1 X 10
15 Ohm Cm (min)
At 700 C : 1 X 1013 Ohm Cm (min)
9. CLASSIFICATION OF TESTS:
9.1 TYPE TESTS
THE FOLLOWING SHALL CONSITITUTE TYPE TEST
Sr.
No.
Tests Requirement Test method
(Ref to part IS
10801)
a. Tests on phase/street light conductor
i) Tensile test
ii) Wrapping test
iii) Resistance test
See IS 8130: 1984
See IS 8130: 1984
See IS 8130: 1984
2
3
b. Test on messenger conductor:
i) Breaking load
Section table 1
2
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TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B
ii) Elongation test
iii) Resistance test
Sec 11.3
Sec Table 1
11.3
5
c. Physical tests for XLPE Insulation:
i) Tensile strength and elongation at
break
ii) Ageing in air oven
iii) Hot set test
iv) Shrinkage test
v) Water absorption (Gravimetric)
vi) Carbon Black:
1) Content:
2) Dispersion
See Table 2
See Table 2
See Table 2
See Table 2
See Table 2
Under Consideration
See Table 2
See Table 2
See Table 2
See Table 2
See Table 2
Under
Consideration
d. Physical test for PE Insulation:
i) Tensile strength and elongation at
break
ii) Melt flow index
iii) Carbon black:
1) Content
2) Dispersion
iv) Vicat softening Point
v) Environmental stress cracking
See Table 3
See Table 3
See Table 3
See Table 3
See Table 3
See Table 3
7
23
32
Under
Consideration
22
2
e. Test for thickness insulation See Table 4 8
f. Insulation resistance (Volume
receptivity)
See Table 2 & 3 43
g. High voltage test See 6.2 45
9.2 Acceptance Test
The following shall constitute acceptance tests:
a) Tensile test (for phase/street light conductor).
b) Wrapping test (for phase/streetlight conductor).
c) Breaking load test for messenger conductor.
d) Elongation test for messenger conductor.
e) Conductor resistance test,
f) Test for thickness of insulation,
g) Tensile strength and elongation at break test.
i) Insulation resistance test, and
h) Hot set test for XLPE insulation,
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TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B
j) High voltage test,
INSPECTION:
All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed
upon by the manufacturer and PSPCL at the time of PSPCL at the time of purchase. The manufacturer
shall afford the inspector representing the PSPCL all reasonable facilities, without charge, to satisfy
him that the material is being furnished in accordance with this specification.
9.2.1 A probable sampling plan for acceptance tests is given in Annex”A”
ANNEX A
(Clause 9.2.1)
SAMPLING OF CABLES
A-1 LOT
A-1.1 In any consignment the cables of the same size manufactured under essentially similar
conditions of production shall be grouped together to constitute a lot.
A-2 SCALE OF SAMPLING
A-2.1 Sample shall be taken and tested from each lot for ascertaining the Conformity of the lot to the
requirements of the specification.
A-2.2 The number of drums (n) to be selected from the lot of drums (N) of Consignment of cable shall
be in accordance with col 2 and 1 of Table 5 respectively. These samples shall be taken at
random.
In order to ensure the randomness of selection, random number labels shall be used (see IS 4905:
1968 Methods of random sampling).
A-3 NUMBER OF TESTS AND CRITERION FOR CONFORMITY
A-3.1 Suitable length of test sample shall be taken from each of the drums selected. These test
samples shall be subjected to each of the acceptance to each of the acceptance tests (see
12.2) A. test sample is called defective if it fails in any of the acceptance tests.
If the number of defectives is less than or equal to the corresponding permissible number (a)
given in col 3 of following Table the lot shall be declared as conforming to the requirements of
acceptance test, otherwise not.
NUMBER OF DRUMS TO BE SELECTED FOR
SAMPLING AND PERMISSIBLE NUMBER OF DEFECTIVES.
Number of Drums in
The Lot
Number of Drums
to be Taken
as Sample
Permissible Number of
Defectives
N N a
Up to 50 2 0
51 to 100 5 0
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101 to 300 13 0
301 to 500 20 1
501 and above 32 2
9.3 Routine Tests
The following shall constitute routine tests:
a) Conductor resistance test, and
b) High voltage test.
9.4 Optional Test
The following shall constitute optional test:
Bending test
10. DETAILS OF TEST:
10.1 General
Unless otherwise stated in this standard, the tests shall be carried out in accordance with
appropriate parts of IS 10810 taking into account additional information given in this standard.
10.2 High Voltage Test
High voltage at room temperature (Type, Acceptance and Routine Test): The cable shall
withstand a voltage of (3kvac (rms) at a frequency of 40 to 60 Hz or a dc voltage of 7.2 kV
between conductor for 5 minutes.
10.3 Elongation Test on Messenger Conductor
Test shall be carried out on wires before stranding. The specimen shall be straightened by
hand and an original gauge length of 200 mm shall be marked on the wire. A tensile load shall
be applied by means of a suitable tensile testing machine. The load shall be applied gradually
and the rate of separation of the jaws of the testing machine shall be not less than 25, per
minute and not greater than 100 mm per minute. The elongation shall be measured after the
fractured ends have been fitted together. If the fractured occurs outside the gauge marks, of
within 25 mm of either mark, or the required elongation is not obtained, the test shall be
disregarded and another test made. The elongation of the specimen shall be not less than 4
percent on a gauge length of 200 mm. The test shall be performed on a sample of complete
cable. The sample shall be bent around a test mandrel at room temperature for at least one
complete turn. It shall then be unwound and the process shall be repeated after turning the
sample around its axis by 180 degrees. The cycle of these operations shall then be repeated
twice. The diameter of the manderel shall be 10 (D + d) Where D = actual diameter of the
cable, for example, Minimum circumscribing diameter, mm; and
d = actual diameter of the phase conductor, mm.
Requirement: No cracks visible to the naked eye are allowed.
SECTIONS IDENTIFICATION, PACKING AND MARKING
11. IDENTIFICATION:
11.1 Manufactures, Identification
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TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B
The manufacturer shall be identified throughout the length of the cable by means of a tape
bearing the manufacturers name or trademark and year of manufacture. In case the above
method cannot be employed, or if the PSPCL so desires, colour identification threads in
accordance with a scheme to be approved by the Bureau of Indian Standards (BIS) shall be
employed.
11.2 Cable Identification
Cables with cross-linked polyethylene insulation shall be identified throughout the length of
the cable by the legend 'XLPE 90' and year of manufacture by a printed tape. No identification
is required for polyethylene insulation.
NOTES:
1 Single tape bearing manufacturer's name or trademark and the cable identification, that is,
XLPE 90, if provided shall be acceptable against the requirement of 11.1 and 11.2.
2. Identification required in 11.1 and 11.2 shall be given on any one of the insulated conductor
of cables.
12. PACKING AND MARKING:
12.1 The cable shall be wound on a drum (see IS 10418: 1982) of suitable size and packed. The ends
of the cable shall be sealed by non-hygroscopic material.
12.2 The cable shall carry the following information either stenciled on the drum or contained in a
label attached to it:
a) Reference to this Indian Standard, for example, Ref IS14255:
b) Manufacturer's name or trade-mark:
c) Type of cable and voltage grade:
d) Nominal cross-sectional area of phase conductor:
e) Length of cable on the drum:
f) Number of lengths on the drum (if more than one):
g) Direction of rotation of drum (by means of an arrow):
h) Gross mass;
i) Country of manufacture; and
j) Year of manufacture.
12.2.1 The cable (drum or label) may also be marked with the Standard Mark.
Note: The use of the Standard Mark is governed by the provision of Bureau of Indian
Standards Act, 1986 and the Rules and Regulations made there under. The details of
conditions under which the license for the use of Standard Mark may be granted to
manufacturers of producers may be obtained from the Bureau of Indian Standards.
12.3 Standard Length:
The standard length of 500 with +5% and longer length shall be acceptable.
12.4 Non Standard Length:
Non Standard Length not less than 50% of the standard length shall be accepted to the extent
of 10% of the ordered quantity.
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TECHNICAL SPECIFICATIONS FOR R-APDRP PART-B
TECHNICAL PARTICULARS
LT Aerial Bunched Cable 1100 Volts (4 core). Reference standard: Generally to IS: 7098(1)88.
Sl
No.
Description 3x25
+
1x25
+
1x35
3x35
+
1x35
+
1x35
3x50
+
1x50
+
1x35
3x70
+
1x70
+
1x55
3x95
+
1x95
+
1x55
1.
1.1
1.2
Power/Neutral core:
Conductors
a) Nom. cross sectional area
(i) Power cores (mm2)
(ii) Neutral core (mm2)
b) Max. D.C. resistance of conductor at
200
C
(i) Power cores (Ohm/Km)
(ii) Neutral core (Ohm/Km)
c) Approx. diameter of Conductor
(i) Power cores (mm)
(ii) Neutral core (mm)
Insulation:
Minimum thickness:
(i) Power cores (mm)
(ii) Neutral core (mm)
25
25
1.20
1.20
6.2
6.2
0.9
0.9
35
35
0.868
0.868
7.3
7.3
0.9
0.9
50
50
0.641
0.641
8.35
8.35
1.0
1.0
70
70
0.443
0.443
10.1
10.1
1.1
1.1
95
95
0.320
0.320
12.0
12.0
1.1
1.1
2 Messenger Wire (Bare):
(i) Nom. cross sectional area (Sq. mm)
(ii) Approx. breaking load (KN)
35
41
35
41
35
41
55
62
55
62
3 Current ratings:
Continuous current carrying capacity of
cable in Air at Ambient temp. 400
C
(Amp.)
99
122
149
190
235
4 Approx. weight (kg./km.) 610 725 880 1270 1570
5 Number of cores:
(i) Power cores
(ii) Neutral core
(iii) Bare messenger
(No.) : 3
(No.) : 1
(No.) : 1
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6 Derating factor:
Derating factors for variation In air Temp.
Air Tedmprature in (0C)
Rating factor
30 35 40 45 50 55
1.12 1.06 1.0 0.94 0.88 0.83
7 (a) Identification of Power core:
(b) Laying
By providing ridges on the insulation Three power cores
and one neutral core shall be suitably twisted around
bare H.T. Steel Messenger. /AAAC.
8 Details of the Power/Neutral core:
(i) Conductor:
(a) Material
(b) Flexibility class as per IS: 8130/84
(c) Form of conductor
(ii) Insulation:
(a) Material
(b) Colour of Insulation
Aluminium to IS: 8130/84
Class-2
Compacted circular
Cross linked Polyethylene to IS: 7098(I)88
Black
9 Details of the Messenger wire (Bare)
(i) Material
(ii) Form of conductor
ACSR/AAAC. Conductor to IS: 398 (II) & (IV) respectively
Stranded circular/compacted circular.
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TECHNICAL PARTICULARS
LT Aerial Bunched Cable 1100 Volts (5 core) with Street Lighting Conductor. Reference Standard: Generally
to IS: 6474-71
Sl
No.
Description 3x16
+
1x16
+
1x25
3x25
+
1x16
+
1x25
3x35
+
1x16
+
1x25
3x50
+
1x16
+
1x35
3x70
+
1x16
+
1x50
3x95
+
1x16
+
1x70
3x120
+
1x16
+
1x70
1.
1.1
1.2
Power/Neutral core:
Conductors
a) Nom. cross sectional area
(i) Phase conductor (mm2)
(ii) Street lighting conductor (mm2)
b) Max. D.C. resistance of conductor at
200
C
(i) Phase conductor (Ohm/Km)
(ii) Street lighting conductor (Ohm/Km)
c) Approx. diameter of Conductor
(i) Phase conductor (mm)
(ii) Street lighting conductor (mm)
Insulation:
Minimum thickness:
(i) Phase conductor (mm)
(ii) Street lighting conductor (mm)
16
16
1.91
1.91
6.2
6.2
1.0
1.0
25
16
1.20
1.91
6.2
6.2
1.0
1.0
35
16
0.868
1.91
7.3
7.3
1.0
1.0
50
16
0.641
1.91
8.35
8.35
1.2
1.0
70
16
0.443
1.91
10.1
10.1
1.4
1.0
95
16
0.320
1.91
12.0
12.0
1.4
1.0
120
16
0.253
1.91
12.0
12.0
1.6
1.0
2 Messenger Wire (Bare):
(i) Nom. cross sectional area (Sq. mm)
(ii) Approx. breaking load (KN)
25
7.4
25
7.4
25
7.4
35
10.3
50
14.7
70
20.6
70
20.6
3 Current ratings:
Continuous current carrying capacity of
cable in Air at Ambient temp. 400
C
(Amp.)
51
70
86
105
130
155
180
4 Approx. weight (kg./km.) 310 390 490 640 890 1180 1430
5 Number of cores:
(i) Power cores
(ii) street lighting core
(iii) Bare messenger
(No.) : 3
(No.) : 1
(No.) : 1
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6 De-rating factor:
De-rating factors for variation In air
Temp. Air Temperature in (0C)
Rating factor
30 35 40 45 50 55
1.12 1.06 1.0 0.94 0.88 0.83
7 (a) Identification of Power core:
(b) Laying
By providing ridges on the insulation Three power cores
and one neutral core shall be suitably twisted around bare
H.T. Steel Messenger. /AAAC.
8 Details of the Power/Neutral core:
(i) Conductor:
(a) Material
(b) Flexibility class as per IS: 8130/84
(c) Form of conductor
(ii) Insulation:
(a) Material
(b) Colour of Insulation
Aluminium to IS: 8130/84
Class-2
Compacted circular
Cross linked Polyethylene to IS: 7098(I)88
Black
9 Details of the Messenger wire (Bare)
(i) Material
(ii) Form of conductor
ACSR/AAAC. Conductor to IS: 398 (IV) respectively
Stranded circular/compacted circular.
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TECHNICAL PARTICULARS
LT Aerial Bunched Cable 1100 Volts (4 core). Reference standard: Generally to IS: 6474-71.
Sl
No.
Description 3x16
+
1x25
3x25
+
1x25
3x35
+
1x25
3x50
+
1x35
1.
1.1
1.2
Power/Neutral core:
Conductors
a) Nom. cross sectional area
(i) Phase conductor (mm2)
(ii) Neutral conductor (mm2)
b) Max. D.C. resistance of conductor at 200
C
(i) Phase conductor (Ohm/Km)
(ii) Neutral conductor (Ohm/Km)
c) Approx. diameter of Conductor
(i) Phase conductor (mm)
(ii) Neutral conductor (mm)
Insulation:
Minimum thickness:
(i) Phase conductor (mm)
16
25
1.91
1.38
4.4
5.8
1.0
25
25
1.20
1.38
5.5
5.8
1.0
35
25
0.868
1.38
6.8
5.8
1.0
50
35
0.641
0.968
7.9
6.8
1.2
2 Messenger Wire (Bare):
(i) Nom. cross sectional area (Sq. mm)
(ii) Approx. breaking load (KN)
25
7.4
25
7.4
25
7.4
35
10.3
3 Current ratings:
Continuous current carrying capacity of cable in Air
at Ambient temp. 400
C (Amp.)
60
76
92
110
4 Approx. weight (kg./km.) 250 330 430 580
5 Number of cores:
(i) Power cores
(ii) Neutral messenger core
(No.) : 3
(No.) : 1
6 De-rating factor:
De-rating factors for variation In air Temp. Air
Temperature in (0C)
Rating factor
30 35 40 45 50 55
1.12 1.06 1.0 0.94 0.88 0.83
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7 (a) Identification of Power core:
(b) Laying
By providing ridges on the insulation
Three power cores and one neutral core shall be
suitably twisted around bare AAAC Messenger.
8 Details of the Power/Neutral core:
(i) Conductor:
(a) Material
(b) Flexibility class as per IS: 8130/84
(c) Form of conductor
(ii) Insulation:
(a) Material
(b) Colour of Insulation
Aluminium to IS: 8130/84
Class-2
Compacted circular
Cross linked Polyethylene to IS: 7098(I)88
Black
9 Details of the Messenger wire (Bare)
(i) Material
(ii) Form of conductor
ACSR/AAAC. Conductor to IS: 398 (IV)
respectively
Stranded circular/compacted circular.
FINISHED AERIAL BUNCHED CABLE TESTING
Prior to dispatch, cable is subjected to rigorous testing. Test procedures followed at manufacturer’s works are
according to various national & International specifications and are covered in this paper.
Following tests are performed on Aerial Bunched Cables:-
1. Test on Phase/Street lighting conductor
TESTS METHOD OF TESTING
a) Tensile test IS: 10810 pt - 2
b) Wrapping test IS: 10810 pt - 3
c) Conductor Resistant Test IS: 10810 pt - 5
d) Test for thickness of insulation IS: 10810 pt - 6
e) Physical test for polyethylene insulation
(i) Tensile strength & Elong. Test IS: 10810 pt - 7
(ii) Melt flow Index IS: 10810 pt - 23
(iii) Vicat softening Point IS: 10810 pt - 22
(iv) Carbon Black Content & dispersion IS: 10810 pt - 32
(v) Colour factness IS: 10810 pt - 18
(vi) Environmental stress cracking IS: 10810 pt - 29
(vii) Bleeding & Blooming IS: 10810 pt - 19
(viii) Volume Resistivity test IS: 10810 pt - 43
(f) High Voltage test including water immersion test. IS: 1596
2. Test for messenger conductor: -
(a) Breaking load test IS: 398 (pt-IV)
(b) Elongation test IS: 398 (pt-IV)
(c) Resistance test IS: 398 (pt-IV)
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3. Dimensional test as per the parameters specified in the technical particulars.
4. Bending test on completed cable shall also as performed. The diameter of mandrel shall be 10 (D+d),
Where D = Overall diameter of the cable
d = Dia over conductor
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49. TECHNICAL SPECIFICATION FOR LT & HT AB (ARIAL
BUNCHED) CABLE ACCESSORIES
CONNECTORS AND FITTINGS (C&F)
1. LOW VOLTAGE AERIAL BUNDLED CABLE (LTABC)& HIGH VOLTAGE AERIAL BUNDLED CABLE
ACCESSORIES
Scope
This specification covers the design, manufacture and testing of Accessories for Low Voltage Aerial
Bundled Conductor (LT ABC) with Bare/ insulated Messenger & Service cables.
1. General conditions
2. Standard References
3. Technical Specifications of ABC Accessories
a. Dead End Clamps (DEC)
b. Suspension Clamps (SC)
c. Service Anchoring Clamps (SAC)
d. Insulation Piercing Connectors (IPC)
e. Distribution Box (DB)
f. Hardware: Eye Hooks & Pole Clamps
1. General Conditions
The products shall be in accordance with Indian standards and most of the European recognised
standards used in LT ABC (NFC for example) or with any relevant standard.
• Marking: Each product shall be clearly identified with Manufacturer name or trade mark, reference
and capacity of the item and batch No.
• Packaging: Manufacturer shall mention the packaging of each item. Installation instruction should be
included in the packaging.
• Type tests: Each supplier should provide type test reports with, carried out in accordance with one of
the referenced standards in NABL or any govt test house / accredited laboratory.
• Routine tests: Suppliers shall provide a control plan, which will be implemented on each item. Routine
Test reports should be submitted by the manufacturer with the Inspection Call.
• Anchoring and Suspension clamps should be installable on existing poles using appropriate devices
(hooks, brackets etc.)
• All crimped connectors should be installed with mechanical or hydraulic hand crimping tools.
2. Standard References
i) REC Construction Standard E-34: For Suspension Clamp & Eye Hook
ii) REC Construction Standard E-35: For Dead End Clamp & Eye Hook
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iii) REC Construction Standard E-36: For LT Cable Tapping Connections
iv) NFC 33-040:1998 "Suspension Equipments for Overhead distribution with Bundle assembled
cores, of rated voltage 0,6/1 kV
v) NFC 33-041:1998 "Anchoring devices for Overhead Distribution with bundle assembled cores,
of rated voltage 0,6/1 kV"
vi) NFC 33-042:1998 "Service Anchoring devices for overhead and underground services with
insulated cables, of rated voltage 0,6/1 kV"
vii) NFC 33-020:1998 "Insulation piercing connectors for overhead distributions and services with
bundle assembled cores, of rated voltage 0,6/1 kV".
viii) NFC 33-021:1998 "Pre-insulated compression type connecting equipment for Overhead
Distributions and Services with bundle assembled cores, of rated voltage 0.6/1 kV"
ix) NFC 33-004:1998 "Electrical ageing test"
x) NFC 33-003:1998 "Corrosion test"
xi) NFC 20-540:1998 "Climatic ageing test"
3. Technical Specifications of ABC Accessories
a) Dead End Clamp for Bare / Insulated Messenger (DEC)
The clamps should be designed to Anchor Bare / Insulator Messenger of LT ABC. The clamp
should consist of an Aluminium alloy corrosion resistant body with bolted / self-adjusting
plastic wedges clamping.
• The clamp should be installed properly with no losable part.
• The clamp should not damage the conductor/ insulation of conductor
• For insulated messenger, it shall conform to the standard NFC 33-041 or equivalent I.S., if
any.
• The clamp body should be made of corrosion resistant Aluminium alloy.
• It should be fixed with pole by eye hook / bracket.
• Ultimate Tensile Strength of the clamp should not be less than 15 KN for 25-70 sq.mm
messenger wire.
• Slip load of the clamp should not be less than 5KN for 50/70 sq.mm bare messenger & 3KN
for 25/35 sq.mm bare messenger wire.
• Detailed design/ drawing to be furnished by the bidder / manufacturer. REC construction
standard drawing mentioned below are indicative drawing, may be followed.
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b) Suspension clamp for Bare / Insulator neutral messenger(SC)
The clamp should be designed to hang LT-ABC with bare / insulated neutral messengers. The
neutral messengers should be fixed by an adjustable grip device /1 or 2 bolted.
• The suspension clamp range to accommodate messenger shall be 25-70mm2 and shall be as per similar design of REC E-34.
• For insulated messenger, it shall conform to the standard NFC 33-040 or equivalent I.S., if any. • The clamp shall be made up of Aluminium Alloy. • Clamps should be fixed with pole by eye hook/bracket. The Suspension Clamp & the eye
hook/bracket will be preferably delivered together in order to minimize abrasion between two materials.
• Ultimate Tensile Strength of the clamp should not be less than 12 KN for 25-70 sq.mm bare / insulated messenger wire.
• Slip load of the clamp should not be less than 300N for 25-70 sq.mm bare messenger wire
• The clamp should sustain to maximum angle of deviation of 60 degrees of the conductors.
• Detailed design/ drawing to be furnished by the bidder/manufacturer. REC construction standard drawing mentioned below are indicative drawing, may be followed.
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c) Service Anchoring Clamp (SAC)
The clamps should be designed to anchor insulated service lines (armoured or un-
armoured) with 2/4 conductors.
• The clamps should be made of weather and UV resistant polymer & should be of wedge /
bolted type design.
• The clamp should be installed properly.
• No losable parts & should have a rigid bail.
• The clamp shall conform to the standard NFC33-042 or equivalent I.S., if any.
• Breaking load of the clamp should not be less than 1 KN.
• Detailed design/ drawing to be furnished by the bidder/manufacturer.
• Reference standard: NFC 33 021 or equivalent I.S., if any.
• Detailed design/ drawing to be furnished by the bidder/manufacturer.
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d) Insulation Piercing Connectors (IPC)
Scope For proper method of providing service connection from AB Cables to our consumers without damaging the cable, the Insulating Piercing Connectors are required
a) for providing 1-2 service connections from 8 / 9 mtr. PCC LT pole,
b) for providing supply to Junction/ Distribution Box from AB Cable
c) for establishing Tee connection from LT ABC to LT ABC.
It must have Shear Head type mechanism to control the effective Torque during
connection and to ensure perfect installation. Connectors should not have any
losable parts, which may drop and then lost while installation at overhead
conditions. Torque required for Proper Installation should be mentioned on IPC,
should be 10-12 N-m.
Standards As per NF C 33-020 & NFC33-003, or equivalent I.S., if any.
Construction: The connectors should be totally insulated with no loose parts. The connectors
should be totally Weather & Moisture proof so that no water or moisture can
enter through the pierced holes on the cable insulation.
The maximum voltage withstand capacity should be 6 KV.
Moisture
Ingress:
The connectors should work at 30 cm under water bath for 30 min. & voltage
applied of 6KV for 1 min in underwater condition. No flashover/ failure should
occur during voltage application.
Working
Temp.:
Designed for installation from -10˚C upto +60˚C & operation experience with
temperature from -20˚C upto +75˚C.
Materials: Material used in the manufacturing process of the components of this product
should be specified in the respective product drawings & can be summarized as
follows:
• All the metallic part of the connector should be Corrosion resistance & should be proven in Corrosion Test.
• The contact plates should be made of tinned Copper / Aluminium Alloy as per IPC current rating.
• Connector teeth should be factory greased & sealed to retard water or moisture ingress & corrosion.
• The insulation material should be made of weather & UV resistance, reinforced polymer.
• The outer metallic part should have potential free tightening bolts to allow safe Live-Line installation.
• The bolts should be of Metallic Shear Head type so that it controls the effective applied Torque during installation & break off at a specified torque after establishing proper connection.
• The connector should not have any losable component. The cable end cap should be attached to the body.
• Should have attached flexible end caps without Grease in order to seal the open end of tap cable or in-built type. The end of tap should be felt from outside end cap, to ensure proper installation.
• Should be designed with encapsulated bolt heads or round head in order to avoid damaging other conductor insulation during installation.
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• Should have an anti rotation device which ensures that the tap blades will not turn in front of main blades mainly in case of service application.
Testing
The Insulating Piercing Connector should conform to following std.- As per NF C 33-020, NFC33-003 & NFC33-004, or equivalent I.S., if any.
1. Corrosion Qualification Test
2. Electrical Ageing Test
3. Underwater High Voltage Test
4. Mechanical Tests
5. Voltage Test
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