SPECIFICATION FOR FRLS POWER CABLES

1.0 SCOPE
This specification cover the technical requirements of design,
manufacture, testing and delivery to site of Power Cables of 1100V grade
with FRLS PVC Sheathed, HR PVC insulated, Copper conductors for use in
Madras Atomic Power Station, Kalpakkam, Tamil Nadu.

2.0 CODES AND STANDARDS

Details are as given in Annexure-I

3.0 GENERAL DESIGN REQUIREMENTS

a) Cables shall be designed and manufactured so that damage will not
result from transportation, installation and operation under all the
climatic and operating conditions to which they may be subjected.
b) Cables shall be suitable for laying conduits, vertical installation, ducts,
trenches and trays or for direct burial in ground in both wet and dry
locations.
c) All materials used shall be new and shall conform to this specification
and relevant Indian Standards.
d) The cables shall be suitable for continuous and reliable service at
maximum voltage of 1100 V and at a max. conductor temp of 85
degree.

4.0 SPECIFICATION OF CABLES

4.1 The conductors shall be annealed, stranded high conductivity Copper

high grade, HRPVC insulated, laid up extruded PVC (FRLS) inner
sheathed, single galvanized round steel wire armoured and overall
jacketed with PVC (FRLS)

4.2 FRLS PVC PROPERTIES

FRLS PVC shall be following properties / Characteristics.

a) The Oxygen index of cables shall be more than 30 % at 270C + 20C
When tested in accordance with ASTM-D-2863.
b) Temperature index shall be more than 2500C
c) Cables shall have smoke density of less than 50 % Max.
d) The Hydrochloric acid evolution shall be less than 17.5 %
e) Flammability test on finished cable.
The bidder shall furnish the relationship between oxygen index and the
temperature if any along with necessary relevant data about these
properties with the offer.
4.3 CORE IDENTIFICATION
For 1 C cable : Red, for 2 C cables: Red and Black, for 3 C cable : Red,
Yellow, Blue, for 4 C cables; Red, Yellow, Blue and Black .For cables more
than 4 C, as per NEMA-WC-5 meant for thermoplastic insulated wires and
cables for transmission and distribution of electrical energy.

4.4 CABLE SIZE AND LENGTHS

The size and quantity of cables are as given in Annexure-2

5.0 CONSTRUCTIONAL FEATURES

5.1 CONDUCTOR

The conductors shall be as per latest IS:8130 and shall be circular shaped.
The conductor strands shall be solid and free from any inequalities or
defects. Copper conductor shall be composed of high conductivity H2
copper smooth uniform in quality, free from scales, splits and any defect.

5.2 INSULATION

Insulation shall be of extruded HR PVC material conforming to the latest

IS-5831.

5.3 SHEATH

a) INNER SHEATH
The inner sheath of cable shall be FRLS ST-2 types as per IS-5831 and
this should be extruded over the laid up core. The surface of the
sheath shall be uniform, continuous and free from defects. Inner
sheath shall be as per table-3 of latest edition of IS-1554 Part-1.

Filler material if used shall be non-hygroscopic, thermoplastic material

and over this PVC/Plastic/millar tape shall be provided for binding the
core. Thermoplastic material shall be softer than outer sheath.

b) OUTER SHEATH
The outer sheath of the cable shall be of FRLS PVC-ST-2 type and
should be extruded uniformly over the armouring of cable. Sheath
shall confirm to IS-1554 Part-I and for dimensional requirement IS-
5831. Outer Sheath shall be black in colour. All markings i.e., year of
manufacture, voltage grade shall be embossed on the outer sheath.
Sequential no. marking shall be given in printed form at every meter
of the cable.
5.4 ARMOUR

The Armour used shall be galvanized round steel wire and shall conform
the latest IS-3975.

6.0 INSPECTION AND TESTING

QA plan of suppliers shall be approved by purchaser. Manufacturing and

quality control of procedure, record shall be properly maintained which
shall be offered for review to purchaser’s representative.
.

7.0 STAGE INSPECTION

Supplier should carry out stage wise inspection as per approved quality
control plan and the records shall be shown to NPC, QS Engineer for
review in case desired by QS Engineer.
Note: The length of cable consumed during testing is under the
scope of supplier and shall not be accounted for billing.

8.0 FINAL TESTS

The supplier shall conduct the final tests in the presence of purchaser’s
representative. Details of the entire test are given below:

Acceptance Test.

a. Conductor Resistance Test (IS :8130)

b. Test for armour wires (IS:3975)
c. Test for thickness of insulation and sheath (IS:5381)
d. Physical test for insulation and outer sheath (IS: 5831)
e. Insulation Resistance Test (IS : 5831)
f. High voltage Test (Water Immersion Test) (IS:1554)
g. Critical Oxygen Index Test (ASTM-D 2863)
h. Temperature Index Test (ASTM-D-2863)
i. Acid Gas Generation Test (To determine percentage of
hydrochloric acid released from the PVC jacket over the cable)
(IEC-754-1)
j. Smoke generation test (ASTM-D-2843/77)
k. Flammablity test for finished cables-IEC-60332
l. Annealing test (IS-8130)

Information and data based on the previous test conducted on the similar
type of cables of tests ‘g” to “k” shall be submitted with the offer
 ROUTINE TEST
a. Conductor Resistance Test (IS-8130)
b. High Voltage Test (IS-1554)
c. Measurement of insulation resistance on the complete supplied
length of cable in all the drums.

9.0 CABLE SUPPLY LENGTH & DRUM

9.1 DRUM LENGTH

Cables shall be supplied in specified non-returnable wooden drums.
The bidder shall offer the cables in drum lengths specified in
Annexure-2 with allowable tolerance of +5% to -1%. The bidder
shall indicate in the offer the maximum length of each size of cable
that can be furnished in one drum.

9.2 CABLE DRUMS

The drums shall be of heavy construction made up of good quality
wood. Ferrous parts used shall be treated with suitable rust
preventive finish or coating to avoid rusting during transit or
storage. The drums shall be suitable for outdoor storage for long
periods without deterioration.

9.3 CABLES LENGTHS

Cable lengths as specified in this specification are approximate.
Actual requirements will be confirmed to the successful bidder at
the time of placing the order. The total cable length tolerance shall
be only on +ve side upto a limit of 5% as specified in Annexure-2.

10.0 PACKING AND TRANSPORT

The cable shall be placed on drums in such a manner that it will be

protected from damage during transit. Each end of the cable shall be
firmly and properly secured to the drum. The end of each length shall be
sealed before shipment. The drums shall be secured firmly in position so
that they will not shift during transit. All details shall be marked legibly to
each end of the drum indicating the purchaser’s order number, length of
cable, size of conductor, number or cores, type of cables and voltage for
which it is suitable, reference I.S., manufacturer’s name, weight and the
year of manufacture. A tag containing the same information shall be
attached to the leading end of the cable. An arrow and suitable
accompanying wording shall be marked on one end of the drum indicating
the direction in which it should be rolled.
 The number of each drum shall be either branded at the end of the drum
or stamped on metal discs to an end of the drum.

11.0 DOCUMENTATION

2 copies of documentation in bound volume shall be supplied prior to the

transportation of the cables. The volume shall include amongst others,
the following particulars:

a) General Information
b) Principal Technical Data
c) Description of Insulation and Sheathing
d) Installation and Termination instructions
e) Test Reports/Certificates
f) P.O. Copy
g) Shipping Release

12.0 DELIVERY SCHEDULE

The cable shall be supplied within 8 weeks from the date of placement of
the purchase order.

13.0 The bidder shall submit technical data as per annexure-3 and price
schedule as per annexure-4 of this tender specification, without which
tender shall not be considered for evaluation.
 ANNEXURE-I
CODES AND STANDARS

1. IS-1554 Part-I PVC insulated cable for working voltage up to

and including 1100 V
2. IS-3961 Part-II & V Recommended current ratings for cables
3. IS-3975 Mild steel wires and tapes for armouring of
cables
4. IS-4826 Hot dipped galvanized coatings on round
steel wires
5. IS-5831 PVC insulation and sheath of electric cables
6. IS-6380 Specification for Elastomeric insulation and
sheathing of electrical cables.
7. IS-8130 Conductors for insulated electric cables and
flexible chords
8. IS-10418 Drum for electric cables
9. IS-10810 Methods of test for cables
10. IEC-287 Calculation of the continuous current rating
of cables (100 % load factor).
11. IEC 332-1 & 3 Tests of Electric cables under fire conditions
12. IEC-331 Fire resistance characteristics of electrical
cables
13. IEC-754-1 Tests on gases evolved during combustion of
electrical cables.
14. ASTM-D-2843 Test method of density of smoke from the
burning or decomposition of plastics
15. ASTM-D-2863 Test method for measuring the minimum
oxygen Concentration to support candle like
combustion of plastics (oxygen Index)
16. IEEE: 383 Standard for type test of Class-1E
Electric cables, field splices and connections
for Nuclear power generating stations.
17. SS-4241475 Swedish standard for cables testing of flame
propagation characteristics
18. IEC-189 Low frequency cables and wires with PVC
insulation and PVC sheath.
Part-I General test and measuring methods.
19. NEMA-WC-5 Thermoplastic insulated wires and
distribution of electrical energy.
 Annexure-II

S.No Cable Size Quantity in Drum Lengths in Remarks

Meters Meters
1. 4C x 2.5 sq mm 2000 1000 1) Drum length
copper tolerance shall
conductor be 5% on +ve
side and 1% on
-ve side
2) Total Cable
length tolerance
shall only be on
+ve side
3) Upper limit of
cable length at
+ve tolerance
shall be 5 %
 Annexure-III

The following data to be furnished by the TENDERER Alongwith the Tender for
each cable.

1. Name of the Manufacturer

2. Voltage grade
3. No. of Cores
4. Armoured / Unarmoured
5. Whether suitable for unearthed / earthed system
6. Maximum permissible voltage variation
7. Maximum permissible frequency variation
8. Whether cable will carry ISI mark
9. Whether the list of supplies of similar cables enclosed
10. Continuous current rating with single cable laid in air in an ambient
temperature of 450C and max. Conductor temperature 700C
11. Continuous current rating with single cable laid directly in ground
temperature of 350C and max. Conductor temperature 700C
12. De rating factors for the following shall be indicated:
Variation in ambient air temperature (for cables laid in air) from 350C to
500C in step of 50C.
Variation in ambient air temperature (for cables laid directly in ground from
150C to 500C in step of 50C
13. Grouping :
Furnish chart showing de rating factors for different spacing of cables
connecting multi core cables installed in horizontal formation in single row
as well as in different tiers under the following methods of laying
Cables laid in formed concrete cable trenches with removable covers.
Cables laid in cable trays side by side without spacing in groups both for
vertical and horizontal runs.
Cable laid in ground.
Cables laid in pipes or unventilated ducts duty.
14. Short Circuit capacity
Short Circuit current for different duration of short circuit from 0.1 to 1 sec.
(Preferably attach) for curves that apply to various cables covered by this
specification Amp/sec.
Conductor temperature allowed for short circuit duty (0C)
15. Loss tangent at normal frequency.
16. Dielectric constant at normal frequency.
17. Conductor.
Material and its hardness
No. of stands.
Diameter of stands.
 Overall diameter of conductor

18. Normal cross section area

19. Temperature coefficient of resistance at 200C / 0C
20. Strands tinned ( Yes / No).
21. No. of twists / unit length
22. Insulation
Composition of Insulation
Thickness of Insulation
Tolerance of the Insulation
Colour Scheme for identification of cores
Electrical properties at 200C
23. Conductor resistance to loop.
24. Minimum insulation resistance
25. High voltage test
Conductor to Conductor
Conductor to Shield
Mutual capacitance
26. Power frequency withstand voltage
Dry
Wet
27. Conductor resistance test.
28. High voltage test.
29. Temperature rise tests on power circuit
30. Short time current tests on power circuits
31. Annealing Tests
32. Test for insulation and sheath
33. Test for inner and outer sheaths of cables
34. Test for acid gas generation
35. Inner Sheath
Material
Whether extruded
Calculated diameter over stranded cores
Thickness of inner sheaths
Tolerance on thickness of sheath
36. Outer Sheath
Material
Calculated diameter over stranded cores
Tolerances of thickness of sheath
Colour of Sheath.
37. FRLS PVC inner and outer Sheath properties
Minimum critical oxygen index value at room temperature of 35 0 C
Minimum temperature index (0C)
 Maximum Halogen content by weight (%)
Maximum smoke density rating (%)
Density of FRLS sheath material (g/cm3)
Tensile strength of sheath material (N/mm2)
Elongation of break of sheath material (%)
Volume resistivity (Ohm/cm)
Dielectric strength at a temperature of 200C (kv/mm)
Cold bend temp. (0C)
Hot pressure deformation at a temperature of 1000C (%)
Typical aging behaviour of FRLS PVC sheath material.

Temp Duration % of Original Property

(0C) (Days) Oxygen Tensile Elongation Oxygen
Index Strength at break Index

38. Armour
a) Type of Armour
b) Nominal diameter of cable over inner sheath (min.)
c) Nominal dimensions of round wire
d) Tolerance on round wire +mm
e) D.C resistance of galvanized steel wire /Alu. Wire at 200C ohm/km
39. Finished cables
Overall diameter of the cable (mm)
Weight per 1000 meter cable (Kg)
Insulation resistance at 200C per 1000 meters
Conductor resistance at 200C per 1000 meters
Recommended minimum installation radius (mm)
Safe pulling force when pulled by pulling eye.
Will the cable offered against this specification pass the flammability test as
per
IS:10810 Part-53.
IEC-322-1 &II
SS-4241475
40. Cable drums (wood)
a) Material used
b) The dimensions and weights of cable drum
c) Relevant IS reference
d) Drums assignments
e) Maximum length per drum for each size of cable (m)
41. Cables are tropicalised and rodent resistant