WAPDA

NATIONAL TRANSMISSION AND DESPATCH COMPANY

SPECIFICATION P-100:2005

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CONTROL CABLES
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DESIGN DEPARTMENT

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 CONTENTS

0. Foreword
1. Scope
2. Service Conditions
3. Types and Sizes of Cable
4. Cable Construction
5. Dimensions and Tolerances
6. Conductor

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7. Insulation

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8. Sheath

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9. Filler
10. Test Methods
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11. Tests
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12. Test Samples, Acceptance and Rejection

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13. Packing and Marking

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PRINTING HISTORY
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First approved on 21st October, 1975

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Reprinted on May, 1983

Third revised edition in April, 2005
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This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 SPECIFICATION NO. P-100:2005
FOR
CONTROL CABLES

0. FOREWORD

0.1 This specification has been prepared by the Design Department (NTDC),
WAPDA.

0.2 This specification is intended for the procurement of material and does not
include all the necessary provisions of a contract.

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0.3 This specification is subject to revision as and when required.

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0.4 The control cables shall be tested in accordance with IEC-330:70,
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IEC-227:67 and ISO/R 402, 1964 (E).
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0.5 In case the requirements laid down herein differ from those given in IEC
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publications in any particular, the control cables shall comply with the
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requirements listed herein.

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1. SCOPE
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1.1 This specification covers single and multi core PVC insulated control
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cables. Single core cables shall be used for internal wiring of panels.
Multicore cables shall be used in ducts, conduits, trenches or trays on
different type of services e.g. connection of protective devices, monitoring,
data recording, conveyance of information, connection of circuits with
heavy magnetic trip or break devices, connection DC circuits etc.

2. SERVICE CONDITIONS

2.1 The cables shall be suitable for installation in ducts or conduits or trenches.
The duct conditions vary from dry to wet. The ambient temperature may
range from minus 100C to 500C.

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 2.2 The cable shall be suitable for 600/1000 volts grade.

2.3 The PVC cable shall be suitable for conductor temperature 750C for
continuous operation.

3. TYPES AND SIZES OF CABLE

3.1 The following types and sizes of control cable are standardised:
a) Single core cables 1.5, 2.5, 4.0 & 6.0 sq mm
b) Four core cables 2.5 & 6.0 sq mm
c) Eight, twelve & sixteen core cable 2.5 sq mm

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4. CABLE CONSTRUCTION

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4.1 Single Core Cables
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4.1.1 The conductor shall consist of circular solid or strand uncoated annealed
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copper.
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4.1.2 The insulation shall be made of polyvinyl chloride.

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4.1.3 The colour of insulation shall be as per clause 4.3.1.

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4.2 Multicore Cables

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4.2.1 The construction of the individual cores or Multicore cables having 4, 8, 12

& 16 cores shall be the same as for single core cable stated in clause 4.1
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above. The colour of the insulation shall be in accordance with clause

4.3.2.

4.2.2 In Multicore cable, the outer layer shall have a left hand lay. The length of
lay of the individual cores in the outer layer of any cable shall not exceed
the value calculated from the factors given in Table-I:

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 TABLE-I
Lengths of Lay of Individual Core

Number of Cores Factors for

in Cable Maximum Length of Lay
4 40 times individual core diameter
5 or more 15 times the dia over the assembled cores

A left hand lay is defined as a counter clockwise twist away from the
observer.

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4.2.3 Where necessary, the intersections shall be filled with non-hygroscopic

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fillers to give the completed cable a substantially circular cross section.

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4.2.4 An overall black PVC sheath shall then be applied over the assembled
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cores.
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4.3 Core Identification

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4.3.1 Single Core Cables

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The conductor insulation in single core cables shall be coloured as follows:

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a) 1.5 & 2.5 sq mm …………red colour

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b) 4.0 & 6.0 sq mm …………black colour

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4.3.2 Multicore Cables

The insulation shall be coloured in accordance with Table-II. In addition
the cores of each colour shall be serially marked. These numbers shall be
marked every 15 mm throughout the length:

4.4 Metallic Screen

A metallic screen of copper shall be provided which shall be superposed on
the conductor assembly. Its resistance shall not be greater than 2 ohms/km
at 20 C.

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 TABLE-II
Core Identification of Cables

No. of Cores Size of Cable Colour of Colour of

Insulation Number on
Insulation
4 2.5 Red White
4 6 Green White
8 2.5 Blue White
12 2.5 Yellow Black
16 2.5 White Black

5 DIMENSIONS AND TOLERANCES

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5.1 The dimensions of the conductors, insulation and sheath shall be in

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accordance with Table-III.

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5.2
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The cross sectional area of the stranded conductor shall be the sum of the
areas of its components wires at any point. It shall not be less then 98% of
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the value given in Table-III.

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5.3 The average thickness of the insulation and sheath shall be given in
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Table-III. The minimum thickness at any point shall not be less than 90%
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and 80% of the specified values in Table-III for insulation and sheath
respectively:
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Table-II
Dimensions of Cables
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Sr. Item 1.5 mm² 2.5 mm² 4 mm² 6 mm²

No. Cable Cable Cable Cable
1. Cross section area of 1.5 2.5 4 6
conductor (sq mm)
2. Stranding (No. of wire/ 1/1.38 1/1.78 1/2.25 7/1.04
dia mm)
3. Conductor dia (mm) 1.38 1.78 2.25 3.12
4. Thickness of insulation 1.0 1.0 1.0 1.0
(mm)
5. Thickness of overall - 1.8 - 1.8
sheath (mm)
6. Maximum conductor DC
resistance at 20ºC
(ohms/km),
Single Core 11.9 7.14 4.47 2.97
Multi Core - 7.28 - 3.03

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
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6 CONDUCTOR

6.1 1.5, 2.5 & 4.0 sq mm conductor shall be solid and 6 sq mm conductor shall
consist of stranded conductor as per Table-III.
6.2 Resistance

The DC resistance of the conductor at 20ºC shall neither exceed the value
given in the Table-III above nor shall be less than 87% of the value.

6.3 Elongation

The min elongation of the copper wire at break shall be 25%.

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6.4 Joints in Conductors

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Joints are permitted in the individual wires of which the conductor is
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formed but no joint shall be within 300 mm of any other joint in the same
layer. No joint shall be made in a stranded conductor after stranding. Joint
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shall be brazed, silver soldered or welded.

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7 INSULATION
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7.1 Polyvinyl Chloride

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75ºC grade PVC shall be used. It shall meet the following requirements.

7.2 Original Physical Properties

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a) Tensile strength, min: MN/m²…………………13.5

b) Elongation at rupture, Min percent……………150

7.3 Physical Properties After Aging

After aging in air oven at 121ºC for 168 hours.

a) Tensile strength, percent of unaged value

Max: 120
Min: 80
b) Elongation at rupture, min, percent of unaged value 85

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 7.4 Heat Distortion

At 121ºC, max. percent distortion ………….25

7.5 Heat Shock

At 121ºC …….….. No cracks

7.6 Cold Bend

At -15ºC ……….. No cracks

7.7 Accelerated Water Absorption

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Water absorption, max 1.5 mg/cm²

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7.8 Resistance to Burning
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Self extinguishing
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7.9 Colour Fastness

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The colour of insulation and of printed numbers shall be fast to both water
and to sunlight.
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7.10 High Voltage AC Test

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Each length of cable shall withstand the AC test voltage of 4kV (RMS) for
5 minutes.
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7.11 High Voltage DC Test

Each length of cable shall withstand the DC test voltage of 12kV for
4 minutes.

7.12 Insulation Resistance

Each length of cable following the AC test shall show an insulation

resistance corrected to 15.6ºC not less than the value calculated from the
following formula:

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 R = 600 log10 D/d
Where R Insulation resistance in meg Ohms – km

D = Dia over insulation

d = Dia under insulation

8 SHEATH

8.1 Polyvinyl chloride

PVC sheaths shall be made from a polyvinyl chloride compound suitable

for the service conditions described in clause 2. It shall meet the following
requirements:

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8.2 Original Physical Properties

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a) Tensile strength, min. MN/m²……………..10
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b) Elongation at rupture, min. percent………. 150
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8.3 Physical Properties After Aging

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After aging in air oven at 100ºC for 120 hours.

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a) Tensile strength, percent of unaged value

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Max: 120
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Min: 80
b) Elongation at rupture, min, percent of unaged value 85
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Max: 120
Min: 80

8.4 Heat Distortion

At 70ºC, max. percent distortion 50

8.5 Heat Shock

At 121ºC …….….. No cracks

8.6 Elongation Test

Min percentage elongation 20

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 8.7 Resistance to Burning

Self extinguishing

8.8 Colour Fastness

The colour of sheath shall be fast to both water and to sunlight.

9 FILLERS

9.1 Polyvinyl chloride

The PVC fillers shall meet the requirements laid down in clause 7 of this

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specification.

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10 TEST METHODS 19
10.1 Tests on Conductor
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10.1.1 Elongation Test

The test shall be made in accordance with ISO/R402-1964(E).
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10.1.2 Electrical Resistance Test

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The test shall be carried out either by measuring the resistance of each
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conductor at least one meter long and by measuring the length of sample
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or by similar measurement made on a complete length of cable. The

resistance shall than be corrected to 20oC by applying the following
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formula:
R 20 = Rt x 254.5/(234.5+t) X 1000/L
t = Temperature of conductor at the time of
measurements, in oC
R 20 = Resistance at 20oC in ohm/km
Rt = Resistance of L meters cable at
t oC, in ohm/km
L = Length of the sample of cable in meters.
10.2 Tests on Insulation
10.2.1 Measurement of Thickness of Insulation
The test shall be made in accordance with IEC-227:67 clause 8.

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 10.2.2 Tensile Test
The test shall be made in accordance with IEC-330 clause 3.
10.2.3 Accelerated Aging Test
The test shall be made in accordance with IEC-330 clause 3.
10.2.4 Heat Distortion Test
The test shall be made in accordance with IEC-330 clause 8.
10.2.5 Cold Bend Test
This test shall be made in accordance with IEC-330 clause 7.2.
10.2.6 Heat Shock Test
This test shall be made in accordance with IEC-330 clause 6.

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10.2.7 Resistance to Burning Test

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This test shall be made in accordance with IEC-227-1967 clause 16.
10.2.8 Accelerated water Absorption Test
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10.2.8.1 Gravimetric Method
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10.2.8.1.1 Test Specimen

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A 275mm test specimen of the insulated conductor shall be taken if the

weight of the specimen is less than 100 grams. For heavier specimens, a
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segment of the insulation 100 mm long and 25 mm wide shall be cut from
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the insulated conductor and smoothed to remove all corrugations.

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10.2.8.1.2 Preparation of Test Specimen

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The surface of the test specimen shall be cleaned by scrubbing with lintless
cloth moistened with water. The specimen shall be dried for 48 hours at
70˚C and then weighed to the nearest milligram, Weight, A. The area, S,
shall be the number of square centimeter in a 254 mm length of the
insulated wire or the total area in square centimeter of the segment. The
insulated wire specimen shall be bent in the shape of a U around a mandrel
having a diameter not less than three times in a tightly fitting holes in the
cover of a 1-point glass jar so that 254 mm of the specimen will be
immersed when the jar is completely filled with water and the cover
applied.

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 10.2.8.1.3 Immersion of Specimen

The test specimen shall be immersed in freshly boiled distilled water at

70˚C for 168 hours. The level of the water shall be maintained flush with
the under surface of the cover during the soaking period. The segment-
shaped specimen shall be completely immersed. After the specimen has
been immersed for 168 hours, the water shall be cooled to room
temperature. The specimen shall be removed and the adhering water
shaken off. The specimen shall be bolted lightly with lintless cloth and
weighed within 3 minutes to the nearest milligram, weight B. The

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specimen shall be dried in a vacuum of 5 millimeters of mercury or less

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over calcium chloride at 70˚C for 48 hours and then weighted to the nearest

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milligram, weight C.
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10.2.8.1.4 Calculation
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The water absorption shall be calculated in terms of milligrams per square

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centimeter of surface as follows:

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(If C is less than A) = B-C

S
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Water absorption
(If C is greater than A) = B-A
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S
Where: -
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A = Weight of the specimen in milligrams before immersion.

B = Weight of the specimen in milligrams after immersion.
C = Weight of the specimen in milligrams after drying in vacuum.
D = Total area in square centimeter of the test specimen.

10.2.9 Colour Fastness Test

10.2.9.1 Colour Fastness to Water

A piece of core about 100mm long, from which the conductor has been
removed (or a piece of sheath about 100mm long, from which the core
have been removed) shall be cut into small pieces and then immersed in

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 about 10 times its own volume of distilled water for 48 hours at a
temperature of 70˚C. At the end of this period the water shall be examined.

10.2.9.2 Colour Fastness to Day Light

This test shall be made in accordance with method 507A, in

BS 2782:part 5.

10.2.10 Voltage Tests

These tests shall be made on each entire length of completed cable.

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10.2.10.1 Alternating Current Voltage Test

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This test shall be made with alternating potential from a transformer and

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generator of ample capacity but in no case, less than 5 kilovolt-amperes.
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The frequency of the test voltage shall be normally, between 25 and 60
hertz and shall have a wave shape approximating a sine wave as closely as
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possible.
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10.2.10.2 Direct Current Voltage Test

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This test shall be made after the insulation resistance test described in
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clause 10.2.11 of this specification.

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10.2.10.3 Application of Test Voltage

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The voltage shall be applied between the conductor or conductors and the
water in which the cables have been immersed for at least 6 hours. In
addition, each conductor of multiple-conductor cable shall be tested against
all other conductors.

The initially applied alternating current test voltage shall be not greater
than the rated alternating current voltage of the cable under test and
initially applied direct current voltage shall be not greater than 3.0 times
the rated alternating voltage of the cable. In all cases, the rate of increase
from the initially applied voltage to the specified test voltages in clauses
7.10 & 7.11 shall be approximately uniform and shall not be over 100
percent in 10 seconds not less than 100 percent in 60 seconds.

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 The duration of the alternating current voltage test shall be 5 minutes. The
duration of the direct current voltages, test shall also be 4 minutes.

10.2.10 Insulation Resistance Test

The insulation resistance shall be measured after the completed cable

alternating current voltage tests. Where the voltage tests are made on wire
or cable immersed in water, the insulation resistance shall be measured
while the cable is still immersed. Single conductor cables shall be tested
between the conductor and water. Multiple conductor cables shall be tested

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between each conductor and all other conductors and water. The conductor

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under test shall be connected to the negative terminal of the test equipment

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and reading shall be taken after an electrification of 1 minute. Each coil,
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reel or length of wire or cable shall have an insulation resistance in mega
ohms/km at a temperature of 70˚C of not less than the calculated value of
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clause 7.11 of this specification.

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10.3 Tests on Sheath

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10.3.1 Measurement of Thickness of Sheath

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The test shall be made in accordance with IEC-277:67 clause 12.

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10.3.2 Tensile Test

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The test shall be made in accordance with IEC-330:70 clause 4.

10.3.3 Accelerated Aging Test

The test shall be made in accordance with IEC-330:70 clause 4.

10.3.4 Heat Distortion Test

This test shall be made in accordance with IEC-330:70 clause 8.

10.3.5 Elongation Test

This test shall be made in accordance with IEC-330:70 clause 7.3.

10.3.6 Heat Shock Test

This test shall be made in accordance with IEC-330:70 clause 6.

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This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 10.3.7 Resistance to Burning Test

This test shall be made in accordance with IEC-227:67 clause 16.

10.3.8 Colour Fastness Test

This test shall be made in accordance with 10.2.9 of this specification.

11 TESTS

11.1 Sample Tests

11.1.1 Sample Tests on Conductor

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i) Elongation Test

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ii) Electrical Resistance Test

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11.1.2 Sample Test on Insulation and Sheath 19
i) Tensile strength test
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ii) Aging tests

iii) Heat shock test
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iv) Heat distortion test

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v) Cold bend test (for insulation only)

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vi) Elongation test (for sheath only)

vii) Resistance to burning test
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viii) Measurement of thickness of insulation and sheath

ix) Accelerated water absorption test (for insulation outer)
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x) Colour fastness test

11.2 Routine Tests

i) High voltage AC tests

ii) High voltage DC tests
iii) Insulation resistance tests

12 TEST SAMPLES, ACCEPTANCE AND REJECTION

12.1 The manufacturer shall afford to the inspector all necessary test facilities
and assistance for carrying out the tests. The facilities shall be provided
free of charge.

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 12.2 The manufacturer shall divide each consignment into lots for inspection.
These lots shall be so selected that material in a lot is of reasonably
uniform quality and as far as possible is manufactured at the same time and
under the same conditions. The manufacturer shall keep sufficient
production records to ensure that this can be done regularly. A lot may
contain any No. of lengths upto max of 15.

12.3 From each lot, regardless of its size, samples of cables shall be taken at
random from four length of cable. One sample sufficient to provide the
required No. of specimens for each test, shall be taken from each cable,

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single core or Multicore, in each of the selected lengths.

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12.4 The samples taken shall be subjected to each of the tests prescribed in
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clause 11.1. The lot shall be accepted, if for each test, the sample complies
with the requirements of clause 12.5 and 12.6.
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12.5 If in any test, at the most one specimen fails the sample shall be considered
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acceptable for the test.

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12.6 If two specimens fail in any test, a further sample in accordance with
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clause 11.3 shall be taken from the lot, and the particular test repeated. If
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there are no further failures the sample shall be considered acceptable for
the test.
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12.7 If in any test three or more specimens fail, the entire lot shall be rejected.

13 PACKING AND MARKING

13.1 Control cables shall be supplied on standard wooden reels. The reels shall
be made from high quality wood and shall be of sound construction, able to
withstand the usual rigours of transportation and field construction. The
wooden reels shall be given two brush coats of penta-chlorophenol solution
in oil before winding of cable. The cable shall be wound tightly.

13.2 Single core cable reels and Multicore cable reels shall be as per Fig.
Nos. 1 and 2 respectively.

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This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 13.3 The complete periphery of single core cable reel shall be protected by one
mm thick paper and that of the Multicore cable reel shall be protected by
heavy wooden lagging nailed at each end of the reel flanges as per Fig. 2
and shall also be bound by two steel straps.

13.4 The manufacturer shall provide the following marking on the reels in
legible and indelible letters:

i) Manufacturer’s name and designation.

ii) Address of the consignee and purchase order number.

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iii) Serial number of reel.

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13.5 The manufacturer shall stamp the following information on metallic plates
which shall be securely nailed to the reel:
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i) Size and designation of control cables e.g. 2.5 sq mm. 16 core,
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600/1000 V etc.
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ii) Weight (net gross).

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iii) Total length of control cable on the reel in meters.

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13.6 Both sides of the reel shall have an arrow mark indicating the direction of
rolling.
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13.7 All markings shall appear on both sides of the reel in the positions
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indicated in Fig. 1 & 2.

Enclosures: Fig. 1 & 2

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This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.