TECHNICAL SPECIFICATION FOR

11KV 3-C 300mm² XLPE POWER CABLE

(CROSS LINKED POLYETHYLENE DRY CURED)

SECTION-1

1.1 SCOPE

1.1.1 This specification covers design, manufacturing, testing, packing,

supply & delivery of 11KV XLPE insulated power cables for
effectively earthed specification system.

1.2 STANDARDS

1.2.1 Unless otherwise specified, the cable shall confirm in all respect
to IS:7098 (Part2)-1985,latest amendments till date.

1.3 INSTALLATION CONDITIONS:

1.3.1 The climatic conditions under which are cables shall operate
satisfactory are as follows:

a. Maximum ambient temperature of air Deg. C : 400C

b. Maximum relative humidity : 96%

c. Depth of laying. : 0.9 M

d. Maximum soil temperature at cable depth : 30° C

e. Maximum soil thermal resistively :150 ° C cm/ Watt

pg. 3
1.4 PRINCIPAL PARAMETERS:

1.4.1 11kV (E) Grade XLPE,3-Core 300mm², power cable shall be of

high conductivity, stranded & compacted, Hard Drawn aluminum
circular shaped conductor, conductor screen with extruded semi
conducting compound XLPE (cross linked Poly Ethylene ) Dry/
Gas cured insulation provided with shielding of extruded semi
conducting materials over conductors and XLPE insulation. Each
insulated core shall have one layer of copper tape screen and
provided with phase markers. The cores shall be laid together and
gaps filled with solid PVC round fillers and provided with a
common covering of extruded PVC inner sheath. Overall
galvanized steel wire armour and yellow coloured HDPE outer
sheath to be provided.
The specification for manufacturer of cable shall be confirming to
IS: 7098(Part2) with latest amendments.

The cable shall be suitable for laying in ducts and/or buried

underground and /or horizontal direction drilling.

The HDPE outer sheath shall be designed as per requirements
of IEC-60502-2 for PE-(type-ST7) sheathing compound.

1.4.2 Cable Parameters :

• Voltage Grade (Uo/U) KV : 6.35 / 11

• Cores (Nos) : 3

• Nominal System voltage KV : 11

• Highest System Voltage KV : 12

• System Frequency HZ : 50

• Maximum allowable temp. of conductor during continuous normal

operation at rated full load current. Deg. C : 90

• Maximum allowable temp. under short circuit condition Deg. C : 250

pg. 4
 • 1.2/50 Microsecond lighting impulse withstand voltage wave value
kVp : 75

• 5 min. power frequency withstand voltage KV rms : 21(IEC : 60502-

2, Clause 16.4.4 )

• System Earthing : Effectively earthed.

1.5 GENERAL TECHNCAL REQUIREMENTS:

1.5.1 CONDUCTOR

The cable conductor shall be made from high conductivity stranded

High Density aluminum to form compacted circular shaped
conductor having resistance with in limits specified in IS 8130/1984
and any latest amendments.

1.5.2 CONDUCTOR SHIELD:

The conductor having semi conducting screen shall ensure perfectly

smooth profile & avoid concentration of stress shall be extruded in
the same operation as the insulation. The semi-conducting polymer
shall be cross linked.

pg. 5
1.5.3 INSULATION:

The XLPE insulation shall be suitable for 11 KV system voltages and

should be manufactured with dry curing process. The bidder shall
submit the description of dry curing process, with clear inclusion of
equipments / parameters involved. The manufacturing process shall
ensure that the insulation shall be free of voids. The insulation shall
withstand mechanical and thermal stress under steady state and
transient operating conditions. The extrusion method should give very
smooth interface between semi-conducting screen and insulation .The
insulation of the cable shall be of high standard quality and the
thickness of the insulation should be conforming to IS:7098 (Part-II)
1985 and latest amendments to it.

1.5.4 INSULATION SHIELD:

Non-metallic semi-conducting shield shall be provided over the

insulation to confine the electrical field radial within the insulation.
The insulation shield shall be extruded in the same operation as the
conductor shield and the insulation by Triple Extrusion Process. The
XLPE insulation shield shall be of bonded type and made of
semiconducting XLPE compound. The metallic portion of insulation
shield shall be provided with Copper Tape applied over individual
cores with 20% overlap. The minimum area of Copper Tape should
not be less than 2.5 mm² (i.e: Width-50mm and thickness 0.05mm).

1.5.5 FILLER & INNER-SHEATH:

The sheath shall be suitable to withstand the site conditions and the
desired temperature. It shall be of adequate thickness, consistent
quality and free from defects. The PVC sheath shall be extruded. The
material of fillers and inner-sheath shall be compatible with the
temperature ratings of the cable and shall have no detritus effect on
any other component of the cable. Central PVC filler shall also, be
provided with other peripheral PVC fillers to have proper circular
shape. The cable shall have suitable round PVC filers laid up with
insulation cores to have subsequent circular cross section.
PVC Inner Sheath thickness should be less than 1.0 mm.

pg. 6
1.5.6 ARMOUR:

• Armouring of galvanized steel wire shall be provided. The armour

wire should completely cover the PVC inner sheath, leaving no gaps.
The nominal diameter of armour wire must be 3.15mm and minimum
no of wire should not be less than 62 nos. Armour wire should be
provided in such a manner that full coverage over inner sheath is
ensured, so that cumulative gap between the wires does not exceed the
diameter of one wire. The mass of zinc oxide coating on armour wires
of finished cables should not be less than 120 gm/sqm as per IS;
4826 of 1979.

1.5.7 OUTER SHEATH:

Extruded type ST-7 PE, yellow colour outer sheath, confirming to

IEC-60502-2.The minimum thickness of outer sheath should not fall
below 2.84 mm.

1.5.8 CONSTRUCTION:

All materials used in manufacturing of cable shall be new, unused and

of finest quality. All materials should comply with the requirements /
test as per applicable IS / IEC specification, Indian Electricity Rules
and other statutory provision of rules & regulations.

The PVC material used in the manufacturing of cable shall be of

reputed manufacturer. No recycling of PVC is permitted. The
purchaser reserves the right to ask for documentary evidence of the
purchase of various materials, (to be used for manufacture of cable) as
per Quality Assurance plans submitted.

pg. 7
1.5.9 CURRENT RATING:

• The current rating shall be based on the maximum conductor

temperature of 90° C with ambient site condition as specified
for continuous operation. The de-rating factors should be
clearly specified in a tabular form.
• The cable should have a short circuit rating of 28 KA for 1 Sec
for the conductor and 24 KA for 1 Sec. for the metallic tape &
armour wire combine.

1.5.10 OPERATION:

• Cable shall be suitable for operation under frequency variation

of +/-3% and voltage variation +10% to -15% and combined
frequency-voltage variation of 10% (absolute sum).
• Cable shall be suitable for laying in duct or buried underground.
• Cable shall have heat & moisture resistance properties. These
shall be type & design with proven record on distribution
network service.

1.5.11 LENGTH:

The cable shall be supplied in standard drum length of 250

meters. With 5% tolerance. Overall tolerance in total quantity
of ordered cables shall be +/- 2%

1.5.12 IDENTIFICATION MARK:

• The cable drum shall be printed with information as per Cl 21.2

of IS 7098 Part-II and ISI Certification mark. Bidder shall
submit Xerox copy of valid ISI License with technical bid.
• For identification of cores, coloured strip of Red, Yellow and
Blue colours shall be used for identification of phases.
Following details of identification shall be embossed in yellow
colour at intervals of length of three meter of cable outer
sheath.

pg. 8
 • Name of manufacturer/year of manufacture/voltage grade/cable
code/size (300 sq. mm-3 core) /name of purchaser.
• Sequential cable length after each meter of cable just
diametrically opposite side of the above.

1.6 TEST:

1.6.1 Type Test:

All cables sizes i.e. items offered should have been fully type tested as
per the relevant standards at any Govt. recognized Laboratory .The
bidder shall furnish three sets of type test reports along with the offer.
The type test reports shall not be older than FIVE years and shall be
valid up to the expire of validity of offer. For any changes in
design/type offered against this specification, the purchaser reserves
the right to demand repetition of type test without any extra cost.
The purchaser also reserve the right to have tests carried out at his
own cost by an independent agency, whenever there is a dispute
regarding the quality of supply.

1.6.2 The following type test reports shall be furnished with the offer:

a. Test on conductor:
• Tensile test.
• Resistance test.
• Wrapping test (to be done before stranding )
b. Test for armouring wires:
• Dimensions test.
• Physical tests :

Tensile strength

Elongation at break

Torsion test(for round wires only)

Winding test for formed wires

Uniformity of zinc coating

Mass of zinc coating

Resistivity

pg. 9
c. Test for thickness of insulation and sheath:

d. Physical tests for insulation:

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

e. Physical tests on outer sheath as per IEC- 60502-2 and 60229

• Tensile strength and elongation at break
• Ageing in air oven
• Hot deformation
• Shrinkage test
• Abrasion Test as per Clause 4.1 of IEC 60229.

f. Partial discharge test

g. Bending test

h. Dielectric power factor test

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

i. Insulation resistance (volume resistivity) test

j. Heating cycle test

k. Impulse withstand test

l. High voltage test

pg. 10
1.6.3 Acceptance Test:

The selection of samples pieces for acceptance test shall be from 10%
drums of each lot offered for inspection or part thereof. The minimum
shall be one drum. The purchaser reserves the right to conduct
acceptance test on more no of sample if he so desires.

The following acceptance test shall be carried out on the selected

samples as per IS: 7098 (Part 2)-1985,except for the High Voltage
Test to be conducted as per IEC: 60502-2 and Abrasion test to be
conducted as per IEC:60229.

• Tensile test for aluminum

• Wrapping test for aluminum

• Conductor resistance test

• Test for thickness of insulation and sheath

• Hot set test for insulation

• Tensile strength and elongation at break test for insulation.

• Partial discharge test for screened cables only.

• High voltage test ( as per IEC-60502 cl.17.9)

• Insulation resistance (volume resistivity) test.

• Abrasion test on outer sheath as per clause 4.1 of IEC : 60229

pg. 11
1.6.4 All the acceptance test shall be carried out by the bidder, in the
presence of purchaser’s representative at their works. The bidder shall
give at least 15 days advance notice to the purchaser to enable him to
depute the engineer for witnessing the tests. The test certificate for
acceptance tests witnessed by inspecting officer / engineer shall be
submitted for approval before dispatch of material.

1.6.5 The bidder shall have to submit, well in advance the test certificates
for the following Routine Test for approval prior to inspection of the
materials for the complete lot offered for inspection at a time.
• Conductor resistance test as per IS : 7098 Part-2 (1985)
• Partial discharge test as per IS : 7098 Part-2 (1985)
• High voltage test for 5 min (as per IEC-60502 cl.16.4.4)

1.7 STAGE INSPECTION:

The inspection may be carried out by the purchaser at any stage of

manufacture. The successful bidder shall grant free access to the
purchaser’s representative at reasonable time, when the work is in
progress. Inspection and acceptance, of any cables under this
specification by the purchaser, shall not prevent subsequent rejection,
if the cables are found defective.

The supplier shall keep the purchaser informed in advance about the
program of manufacturing of cables so that arrangement can be made
for inspection.
The purchaser reserves the right to insist for witnessing the acceptance
/ routine tests of the bought out items.

pg. 12
1.8 SAMPLING OF CABLES:

Samples shall be taken and tested from each lot for ascertaining the
conformity of the lot to the requirements of the specification. The
sampling will be done complying to the conditions as stipulated in
Appendix A (Cl. 18.2.1) of IS:7098 (Part 2)- 1985.

1.9 DOCUMENTATION:

The bidder shall furnish following documents along with his offer.

• Detailed Quality Assurance Plan related to raw materials,

manufacturing process, testing of finished products.
• Sectional views, showing the General construction feature with
conductor / conductor screen / insulation / armouring / inner
and outer sheath etc. along with a detailed GTP as per the
annexure enclosed.
• Drawing of cable with details of materials dimension and paint
etc shall be submitted.
• Bidder must submit all the documents related with all the major
items of cable, for ex: insulation, conductor etc.
• Bidder must submit all the calculation sheet regarding
1.Short circuit current rating for galvanized steel armour and
copper tape combined.
2.Continuous current rating considering usual installation
conditions.
3.Short time overloading.
• All the required type test reports for offered items tested at any
Government recognized laboratory as stated under clause No.
1.6.1
• Literature, pamphlets for record items.

pg. 13
1.10 PACKING AND FORWARDING:

• The cable shall be wound on wooden drums as per IS: 10418-

1972 and packed in drums suitable for vertical / horizontal
transport, as the case may be and shall be suitable to withstand
rough handling during transport and outer storage. The outer
surface of he drum shall be painted with white aluminum paint.
Similarly, the inside surface of drum shall have the protective
layer of varnish / paint to protect it from white ants.
• The wooden drums shall be reinforced with steel bends and
strips for better protection.
• The ends of the cables shall be sealed by means of non-
hygroscopic sealing materials in the form of putty & the sealing
should be complete by application of heat shrinkable tube
coated inside with water sealant adhesive.
• The following information may be stenciled on the drum with
either water proof ink or oil paint.
1. Reference of IS / IEC standards.
2. Manufacturer’s name or trademark.
3. Type of cable and voltage grade.
4. No of cores.
5. Nominal cross section area of conductor.
6. Cable code.
7. Length of cable on the drum.
8. Direction of rotation of drum (by means of an
arrow)
9. Position of outer end of cable.
10. Gross weight.
11. Country of manufacture
12. Year of manufacture
13. Property of CESC Ltd.
14. Name of consignee and the destination.

pg. 14
 • Over and above, name plate of aluminum of suitable size
and thickness, containing all the above information, shall be
fixed on the drum in addition to the painting.
• The bidder shall be responsible for any damage to the cables
during transit due to improper and inadequate packing.
Where ever necessary, proper arrangement of lifting hooks
shall be provided. Any cable found short inside the packing
cases shall be supplied by the supplier, without any extra
cost.

1.11 Each consignment shall be accompanied by a detailed packing list,

containing the following information.

• Name of consignee.
• Details of consignment.
• Destination.
• Total weight of consignment.
• Handling and unpacking instruction.
• Bill of materials, including contents of each package.

pg. 15
 Annexure-I
GUARANTEED TECHNICAL PARTICULARS
FOR 3 CORE 11 KV XLPE CABLE

1. Name of Manufacturer :

2. Country of Manufacture :

3. Type of Cable :

4. Standard according to which cable has : IS:7098 (Part 2)

been manufactured IEC: 60502 & IEC: 60229.

5. Standard according to which cable has : - Do -

been tested.
6. Voltage Grade ( Uo / U ) : kV

7. Maximum Conductor temperature

(a) Continuous : °C
(b) Short Time (for 1 Second) : °C

8. Conductor
(a) Material :
(b) Grade :
(c) Nominal Cross-Sectional Area : Sq. mm
(d) No. of Wires and Diameter of each : No / mm
Wire (before stranding)
(e) Shape :
(f) Diameter over Conductor : mm

9. Conductor Screen
(a) Material :
(b) Thickness : mm
(c) Diameter over Conductor Screen : mm

pg. 16
10. Insulation
(a) Material :
(b) Nominal Thickness : mm
(c) Minimum Thickness : mm
(d) Diameter over insulation : mm
(e) Designed Maximum Stress : kV/mm
(f) Method of curing : Dry

11. Insulation Screen

(a) Material :
(b) Thickness : mm
(c) Diameter over Insulation Screen : mm
(d) Strippable / Bonded : Bonded
(e) Extrusion Process : Triple Extrusion

12. Metallic Tape and phase marking

(a) Material :
(b) Thickness :
(c) Width :
(d) Area : 2.5mm²(minimum)

13. Solid Filler

(a) Material :
(b) Diameter over laid up core : mm

14. Extruded Inner Sheath

(a) Material and Colour :
(b) Maximum Thickness : 1.0 mm
: mm
(c) Diameter over Inner Sheath

pg. 17
15. Armour Wire
(a) Material : GI Steel Round Wire
(b) No. of Wire and Diameter of each :
wire
(c) Diameter over armour : mm

16. HDPE Outer Sheath (Type ST7)

(a) Colour : Yellow
(b) Thickness (Nom/Min) : mm

(c) Embossing
(i) At every 3 Mts. length : CESC Ltd., Manufacturer’s Name, Type
of Cable, Year of Manufacture.
(ii) At every 1 Mt. length : Sequential marking of length

17. Nominal Overall Diameter of Cable : mm

18. Nominal Weight/Metre of Cable : Kg./mt
19. Standard Drum Length with Tolerance : Mts.
20. Short Circuit Current Rating of :
Conductor with maximum conductor
temperature (90°C) at the
commencement of fault
(a) 1 Sec. Duration : KA
(b) 0.5 Sec. Duration : KA
(c) 0.1 Sec. Duration : KA

pg. 18
21. Minimum Bending Radius for Cable : m
during installation

22. Maximum Continuous Current Rating

when installed at a depth of 0.9 m, Soil
Thermal Resistivity = 150°C Cm/w at
Ground Temperature = 30°C, Ambient
Temperature = 40°C

(a) In Ground : A
(b) In Air : A
(c) In Pipe/ Ducts : A

23. Electrical Parameters at Maximum :

Operating Temperature
(a) AC Resistance : (Ω / Km)
(b) Reactance at 50 C/S : (Ω / Km)
(c) Impedance : (Ω / Km)

24. Derating factors for following Ambient :

Temperature
(a) 35°C :
(b) 40°C :
(c) 45°C :
25. Group derating factor for Cable laid
touching / 2D apart
Where D = overall diameter of cable
(i) 3 Nos. :
(ii) 4 Nos. :
(iii) 5 Nos. :

26. Test Voltages

(a) Impulse Test : kV
(b) High Voltage AC Power Frequency : kV
(c) Abrasion Test on HDPE Yes
Outer Sheath as per IEC 60229
(d) Recommended Test Voltage after :
installation

pg. 19
27. Details of Drum
(a) Material and Weight of Drum : Kg.
(b) Weight of Drum with Cable : Kg.
(c) Flange Diameter of Drum : m
(d) Barrel Width of Drum : m
(e) Spindle Hole Diameter : Mm

NOTE :

1. The Short Circuit Rating of Metallic Tape & Armour Wires (combined) of 3-Core 11 kV
XLPE Cable should be 24 kA for 01 second.

2. To submit Cross-Sectional Drawing of the Cable specifying the Dimensions in mm.

3. To submit all calculations pertaining to Continuous as well as Short Circuit Current

Ratings (for 01 second) of Conductor and Armour/Screen Wires.

pg. 20