UltraTech TECHNICAL SPECIFICATIONS Dept

Project Cell 1.1KV, XLPE, AL, LT Cables E&I

TABLE OF CONTENTS

SL PARTICULARS PAGE

1 INTRODUCTION

2 STANDARDS

3 SCOPE OF SUPPLY

4 DESIGN DATA AND TECHNICAL SPECIFICATIONS

5 INSPECTION AND TESTING SCHEDULE

6 SUBMITTAL & APPROVAL OF DRAWINGS / DOCUMENTS

7 PERFORMANCE GUARANTEE & LIQUIDATED DAMAGES

8 GENERAL REQUIREMENT

9 TECHNICAL DATA SHEET

10 PRICE SCHEDULE, VALIDITY AND QUANTITY VARIATION

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

1.0 INTRODUCTION
M/s Ultratech Cement Limited is under expansion of its cement
manufacturing capacity at various locations:

The specification covers design, testing at works, supply and

commissioning of 1.1KV LT CABLES as mentioned above.

2.0 STANDARDS
All materials in cables shall comply with applicable provisions of the latest
editions of relevant Indian Standards, Indian Electricity Rules, Indian
Electricity Act and other applicable statutory provisions, rules and
regulations such as IEC, IEEE and other relevant International Standards.
Equipment meeting the requirements of IEC/ANSI or any other
internationally recognized standard which ensure a quality equal to or better
than as per the standards indicated below shall also be acceptable. When
the equipment conforms to any other standards, salient points of difference
between the standards adopted and those prescribed in this specification
shall be clearly brought out in the tender and a copy of the applicable
standards(s) in English language shall also be enclosed by the supplier with
the tender.
Unless otherwise specified, the design, manufacture and performance of all
the equipment and material provided under this specification shall generally
conform to the latest issues of the following standards:-
The design, manufacture and testing of the cables shall be carried out as
per the latest applicable Indian Standards, Indian Electricity Rules and
Code of Practices. However, for ready reference, some of the salient
Standards and Code of Practices are given below:

1. IS-694 PVC insulated cables for working

voltages up to and including 1100V.
2. IS-1554 (Part-I) PVC insulated (heavy duty) electric
cables for working voltages up to and
including 1100V.
3. IS-1554 (Part-II) PVC insulated (heavy duty) electric
cables for working voltages from
3.3kV up to and including 11kV.
4. IS-3961 Recommended current ratings for
cables
5. IS-8130 Conductors for insulated electric
cables and flexible cords.
6. IS-5831 PVC insulation and sheath of electric
cables.

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

7. IS-6380 Specification of Elastomeric

Insulation & Sheath of Electric
Cables.
8. IS-7098 (Part-I & II) Cross linked polyethylene insulated
PVC sheathed cables for working
voltages up to 33kV.
9. IS-3975 Mild steel wires, strips and tapes for
armouring cables.
10. IS-1753 Aluminium conductors for insulated
cables.
11. IS-1255 Code of practice for installation and
maintenance of power cables up to
and including 33kV rating.
12. IS-12943 Brass glands for PVC cables.

13. IS-10418 Drums for electric cables.

14. IS-10810 (Part 0 to 63) Method of test for cables.

15. IS-6474 Polyethylene insulation and sheath of

electric cables.
16. IS-5819 Recommended short circuit ratings of
high voltage PVC cables.
17. IEC-60502 Power Cables with extruded
insulation & their accessories for
rated voltages 1kV to 30 kV
18. IEC-540 & 540A Test methods for insulation and
sheaths of electric cables and cord.
19. IEC-60332 Test on electric cables under fire
conditions.
20. IEC-60754 Test on gases evolved during
combustion of electric cables.
21. IEC Hand Book for Cable in fire regarding temperature
Temperature Index Index Chapter-6.
22. IEC-10333 Cable joints and terminations
23. Any other applicable standards:
Indian Electricity Rules 1956 and Relevant Code of Practices or
International Electricity Rules and Relevant Code of Practices.

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

3.0 SCOPE OF SUPPLY

The scope of supply shall include design, manufacturing, testing and supply
are as per annexure enclosed attached. The cable quantity shall be as per
tender
There may be cable quantity variation approximate of (+/-) 25% from
ordered value subject to requirement of the project which may happed
during detailed engineering of the project.

4.0 DESIGN DATA AND TECHNICAL SPECIFICATION

4.1 SYSTEM DETAILS
4.1.1 Rated System Voltage:
4.1.1.1 0.433 KV + 10%
4.1.2 Highest System Voltage
4.1.2.1 1.1 KV + 10%
4.1.3 System Frequency:
4.1.3.1 50 Hz +3%
4.1.4 Combined Voltage and Frequency
4.1.4.1 (+/-) 10%
4.1.5 Type of Earthing System:
4.1.5.1 Solidly Earthed
4.1.6 System Fault Level of Conductor:
4.1.6.1 Isc=KA/(Squire Root of T) where:
Isc= Fault Current in Kilo Ampere
K=constant i.e. 0.093 for aluminium and 0.143
for copper conductor
A=Cross Section Area of the Conductor
T= Withstand time of fault current
4.1.7 Maximum ambient temperature:
4.1.7.1 50 deg C
4.2 TECHNICAL SPECIFICATIONS:
Cable shall be of following construction and composition:
4.2.1 Type of Cable: The cable shall be multi-core, XLPE
insulated, GI steel strip armoured and outer sheath should
have high resistance to flame propagation.
4.2.2 Conductor Material: The material for conductor for power
cables shall consist of plain aluminum of H4 grade having
tensile strength above 150 N/sqmm. The cable conductor

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

shall be made from stranded aluminum wire to form

compacted sector shapped conductor having resistance
within the limits specified in relevant IEC/Indian Standard.
The minimum number of strands in the conductor shall not be
less than the appropriate minimum numbers specified in the
relevant standard. Electrical purity of aluminium wires shall be
as per material IS: 8130.
4.2.3 Conductor Insulation: The insulation of the cable shall be
designed and manufactured for the specified system voltage.
The cable shall be manufactured using cross linked
polyethylene insulating material with added colours for core
identification in the extrusion process.
The manufacturing process shall ensure that insulation shall
be free from voids. The insulation shall withstand mechanical
and thermal stress under steady state and transient operating
conditions.
The insulation of the cables shall be of high standard quality.
The thickness of the insulation shall not be less than that
specified in the relevant standards.
4.2.4 Core Identification: The individual core shall be provided
identification mark by coloured insulation. It shall be in vector
sequence i.e. RED, YELLOW & BLUE for 3 core cables and
BLACK for Neutral for 3.5/4 core cables. The core
identification shall be provided over conductor with extruded
XLPE insulation over cable conductor.
4.2.5 Filler Material: Cables shall have suitable fillers laid up with
the conductor to provide a substantially circular cross section
before the sheath is applied. Fillers shall be suitable for the
temperature of the cable and compatible with the insulating
material. The material shall be of the best quality and
workmanship should be neat and clean and of highest grade.
The fillers and sheath material be non-hygroscopic. All
materials shall be new, unused and of the finest quality
The insulating filler material shall be provided in air pockets of
the cable to form circulatory of the cable. It shall be lighter in
weight and will able to provide cushion between cores to the
cable during external mechanical impacts.
4.2.6 Inner Sheath: In case of cables consisting of two or more
cores inner sheath suitable to withstand the site conditions
and the desired temperature shall be provided on the
individual core and then surrounded by common covering
applied either by extrusion of a filling material containing
thermoplastic material. It shall be of adequate thickness and
applied by continuous process to produce a sheath of
consistent quality free from all defects.

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

PVC sheath shall be extruded to hold filler material and

conductor cores together.. The circularity of the cable should
be maintained. Thickness of the inner sheath shall be as per
IS/IEC confirming to requirement of type ST2 compound.
4.2.7 Armouring: Cable shall be protected from external
mechanical impacts by providing hot dipped galvanised steel
strip. The GI strips shall be wrapped over inner PVC extrusion
in over lapped manner to achieve more than 95% surface
coverage of the cable.
4.2.8 Outer Sheath: The outer sheath shall be extruded over the
armouring for armoured cable. It shall be specially formulated
heat resistant black PVC compound conforming to the
requirement of type ST2 of IS: 5831-1984, extruded to form
the outer sheath. The colour of outer sheath shall be BLACK
unless otherwise specifically asked
The cables for CAPTIVE POWER PLANT AND COAL
GRINDING SYSTEM shall be offer with a specially
formulated Flame Retardant Low Smoke compound
(FRLS) for outer sheath. Suitable additives may be added
to prevent attack by rodents and termites. All serving
must be given anti-termite treatment. The thickness of the
sheaths shall be as per relevant standards.

5.0 INSPECTION AND TESTING SCHEDULE

After completion of manufacture of cables, type, routine and acceptance tests
shall be performed strictly as per applicable standard specifications and copies
of tests certificates shall be furnished. The tests reports on the cables shall be
got approved from the purchaser before dispatch of the cables.
The seller shall confirm the above items for following inspection and testing,
which may be witnessed by the purchaser's representatives. The seller shall also
confirm that the purchaser’s representatives will be allowed to inspect and test
any of the items at any manufacturing process / stage.
The tests on the cables that will be conducted by the supplier shall be mentioned
in the schedule of tests.
The purchaser reserves the right to witness all tests and the supplier shall
provide all facilities, to the purchaser in this regard and shall inform the
purchaser sufficiently in advance to enable the purchaser to depute his
representative to witness the same.
5.1 ROUTINE TEST on all the cable drums shall be as follows:
5.1.1 Conductor resistance test,
5.1.2 High voltage test,
5.1.3 Partial discharge test,
5.1.4 Insulation resistance test,

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

The above test shall be as per relevant Indian/International standards. The test
method, condition of test and test requirement shall comply with those given
under the type tests. Apart from these conductor examination, check of
dimensions etc. shall also be carried out as routine tests.
5.2 The following TYPE TEST shall be conducted as per applicable
standards on XLPE insulated power cables:
5.2.1 Tensile test
5.2.2 Wrapping test
5.2.3 Conductor resistance
5.2.4 Partial discharge test
5.2.5 Dielectric power factor test
5.2.6 Bending test followed by partial discharge test
5.2.7 Heating cycle test followed by partial discharge test
5.2.8 Test for thickness of insulation and sheath
5.2.9 Tensile strength and elongation test for insulation and sheath
5.2.10 Ageing test for insulation and sheath
5.2.11 Loss of mass tests for insulation and sheath
5.2.12 Shrinkage Test for Insulation and Sheath
5.2.13 Hot Deformation Test for Insulation and Sheath
5.2.14 Cold Bend Test (up to 6mm.sq.) size
5.2.15 Cold Impact Test for Insulation and Sheath
5.2.16 Heat Shock Test for Insulation and Sheath
5.2.17 Thermal Stability Test for Insulation and Sheath
5.2.18 Test for Bleeding and Blooming of pigments for PVC
Insulation & Sheath
5.2.19 Fire Resistance Test
5.2.20 Measurement of Insulation Resistance
5.2.21 Impulse withstands Test.
Sequence of electric tests shall be as per the relevant Indian/International
standards. The Bidder shall submit the sequence of tests for the approval of the
purchaser before conducting the tests. A copy of the adopted standard shall also
be supplied.
The cables covered under this specification shall be subject to above mentioned
tests along with any other test specifically required for the material. The cables
other than PVC insulation shall be subjected to tests as per the respective
IS/International Standards.
5.3 The following TEST shall also be performed on the cables
wherever applicable, as per relevant standard. Copies of the

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

test certificate along with English version of the standard

adopted shall also be furnished along with bid:
5.3.1 Accelerated water absorption test for insulation
5.3.2 Di-electric Test,
5.3.3 Oxygen Index Test,
5.3.4 Temperature Index Test,
5.3.5 Flammability Test,
5.3.6 Acid Gas Generation Test,
5.3.7 Smoke Generation Test,
5.3.8 Test for Rodent and Termite Repulsion
Test details are to be given by the manufacturer. The numbering of cores of the
cables shall be prominent and indelible and shall be checked after the various
physical tests such as ageing test, heating cycle test, bleeding and blooming test
etc. The test method is to be given by the manufacturer.
Test certificates for the above type tests, conducted by the manufacturer on
cables similar to the cables covered herein by an Independent Agency approved
by Govt./NABL (National Accreditation Board for Laboratories) shall be
acceptable in lieu of the type tests. However, type test certificates from the
collaborators shall not be acceptable.
5.4 Acceptance Test:
5.4.1 Tensile Test
5.4.2 Wrapping Test
5.4.3 Conductor Resistance Test
5.4.4 Test for thickness of Insulation and Sheath
5.4.5 Partial discharge test
5.4.6 HV Test
5.4.7 Insulation resistance test
5.5 Optional Test: The purchaser reserves the right to conduct the
following tests at an additional cost, if considered necessary. The
supplier shall furnish the price for conducting these tests separately.
5.5.1 Fire Resistance Test
5.5.2 Flammability Test
5.5.3 Cold Bend Test
5.5.4 Cold Impact Test
5.6 Cable Particulars:
Full technical details and descriptive literature shall be furnished indicating
the construction details, standard applicable for the components of the
cable and current ratings of the cables in air and ground. De-rating factors
to be considered for the ambient temperature, ground temperature and

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

grounding of cable in air and ground shall be furnished. The certificates

for the type tests conducted on cables similar to the cables covered
herein shall be submitted along with the tender.
5.7 Current Ratings:
5.7.1 The cables will have current ratings and de-rating factors as
per relevant Indian Standards.
5.7.2 The one second short circuit current rating values shall be
furnished and shall be subjected to the purchaser’s approval.
5.7.3 The current rating shall be based on maximum conductor
temperature depending on the type of insulation for
continuous at the rated current.
5.8 Normal Service Conditions:
The cables shall be used in the sub-station having an ambient
temperature of –5 deg C to 50 deg C.
5.9 Operating Conditions:
5.9.1 Cables shall be capable of satisfactory operation under a
power supply system frequency variation of +3%, -5% voltage
variation of ±10%.
5.9.2 Cables shall be suitable for lying in conduits, ducts, trenches,
channels, trays, racks or for direct buried in ground in both dry
and wet locations with chances of flooding by water.
5.9.3 Cables shall have heat and moisture resistance properties.
These shall be of type and design with proven record of
underground Sub-Station.
5.10 Quantity and Variation:
5.10.1 The various sizes and quantities of cables required are given
in the Annexure-I i.e. Schedule of Requirement.
5.10.2 The quantity is approximate and can be changed at the time
of manufacturing clearance up to ±25%.
5.10.3 The cable quantity varies i.e. increase or decrease by 25% of
the total order value (project wise). However, this quantity
variation may be 100% for individual each type of cable
5.11 Drum Length and Cable Drum:
5.11.1 The length of the cable on each drum shall be as per IS:
10418-1972 but minimum of 1000 meter.
5.11.2 Cable shall be supplied in non-returnable steel/ wooden
drums of heavy construction. The wood used for construction
of the drum shall be properly seasoned, sound and free from
defects and wood preservative shall be applied to the entire
drum.

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

5.11.3 The 80% cables (each type) shall be dispatched in wooden

drums and balance 20% cable shall be dispatched in steel
drums.
5.11.4 The successful bidder shall obtain owner’s approval for the
drum lengths, before packing the cables on drums.
5.12 Packing:
5.12.1 Packing shall be sturdy to protect the cable from any injury
during transportation, handling and storage. The cut ends of
the cable shall be sealed by means of non hygroscopic
sealing material.
5.12.2 The cable shall carry the following information either stenciled
on the drum or contained in a label attached to it:-
5.12.2.1 Reference to this Indian standard
5.12.2.2 Manufacturer’s name, brand or trade mark
5.12.2.3 Type of cable and voltage grade
5.12.2.4 No. of cores
5.12.2.5 Nominal cross-sectional area of conductor
5.12.2.6 Cable code
5.12.2.7 Length of cable on drum
5.12.2.8 No. of lengths on reel, drum or coil (if more than
one)
5.12.2.9 Gross weight
5.12.2.10 Country of manufacture
5.12.2.11 Year of manufacture
5.12.2.12 Direction of rotation of drum (an arrow)
5.13 Core Identification:
5.13.1 The conductor cores shall be identified with codes as per
relevant Indian Standards.
5.13.2 The cables shall carry the manufacturer’s name or trade mark
and the word identified throughout its length. The
manufacturer’s data shall include the name, the cable size,
and voltage rating together with any other information which
the manufacturer considers appropriate. This identification
endorsed or print shall be done only on the outer sheath.
5.13.2.1 Tensile test for aluminium
5.13.2.2 Wrapping test for aluminium
5.13.2.3 Test for thickness of insulation and sheath
5.13.2.4 Physical test for insulation and sheath
5.13.2.5 Flammability test as per IS

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

5.13.2.6 Test for bleeding and blooming of pigments

5.13.2.7 High voltage test (water immersion test)
5.13.2.8 AC High voltage test for 4 hours on HT XLPE
cables as per Clause 19.7.1 of IS: 7098 (Part-II).
5.13.2.9 Partial discharge test.

6.0 SUBMITTAL AND APPROVAL OF DRAWINGS

The successful seller shall submit the following drawings/ documents:

Sn. Description Schedule of

Documents
(Weeks)

01 Certified outline dimensional drawing for

each type and size of cable showing three 4
cores, insulation and armour thickness,
diameters of cable- overall, under the
armour and over the armour.

02 Data furnishing DC resistance, inductance

and capacitance per KM for XLPE power
4
cables for each type and size of cables.

03 Data furnishing current carrying capacities

of each type and size of cable at 50 deg C. 4

04 Operation, maintenance and installation Before

manuals for the above items. despatch

05 Type and routine test certificates shall be During

supplied for each type and size of cable - Inspection
four sets to Purchaser and two sets to
Consultants.

7.0 PERFORMANCE GUARANTEES AND LIQUIDATED DAMAGES

7.1 The seller shall give a guarantee for trouble-free operation of the
cables offered under the stipulated operating conditions.
7.2 The seller shall be liable to the purchaser for the liquidated damages
in case the cables are found defective and do not fulfil guaranteed
technical parameters/performance.

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

7.3 The manufacturer shall be liable to manufacture the requisite cross

section of the cable conductor as mentioned in the technical
specification which shall be measured by density method instead of
resistance method (an approximation method) failing of which shall
lead to LD damages @ 1% for every 1% reduction in conductor
diameter.
7.4 Seller shall liable for temperature rise of cable for declared capacity
under asking ambient conditions. Failing of which shall lead to LD
damages @ 1% for every 1% increase of temperature at declared
current carrying capacity.

8.0 GENERAL REQUIREMENTS:

8.1 The CROSS SECTION of the conductor mentioned in the cable size
shall be GUARANTEED. The measurement of the conductor cross
section shall be followed by density method. Density of the
conductor shall be considered as per test report of the material
supplier.
8.2 All cables shall be supplied in standard drum lengths. The tolerance
in drum length shall be +3% whereas the tolerance for total length of
each cable to be supplied shall be +2%.
8.3 The cable current carrying capacity and other performance data
shall be furnished at 50 deg C ambient temperature. (Because
designer will calculate running voltage drop up to 5% and starting
voltage drop as 12% of rated voltage).
8.4 All cables shall be designed and manufactured such that no damage
occurs during transportation, installation and operation of the cables
under stipulated conditions.
8.5 The cable shall be laid partly in trays in air and partly in closed
trenches/tunnels hence performance data and de-ration factor shall
be furnished by the bidder accordingly.
8.6 The Cables shall be suitable for steady full load condition at
declared capacity with maximum temperature rise of 90 deg C.
(including ambient)
8.7 The cable manufacturer shall furnish maximum short circuit capacity
of the conductor and relevant temperature rise not exceeding above
250 deg C (including ambient) for XLPE cables.
8.8 Cables shall be properly packed in drums; transit damage shall be
seller’s responsibility.
8.9 There shall be engraved measurement marking at every meter of
cable outer sheath in ascending order.
8.10 Outer sheath colour of the cable shall be RED.
8.11 In case of failure of the cable at site within guaranteed period, seller
shall rectify the fault or replace the cable at free of cost.

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 UltraTech TECHNICAL SPECIFICATIONS Dept
Project Cell 1.1KV, XLPE, AL, LT Cables E&I

8.12 The ends of the cable shall be sealed by means of non hygroscopic
sealing material during packing.

9.0 TECHNICAL DATA SHEET:

The bidder shall submit technical data sheet in prescribed format for each
type of cable. The submitted technical data shall be guaranteed for the
performance of the cables. The technical data shall be covered into quality
assurance plan by the bidder to ascertain proper quality of the
manufactured product at every stage of manufacturing process. The critical
performance data shall be witnessed at the time of cable inspection as per
agreed terms and conditions.
10.0 PRICE SCHEDULE, VALIDITY AND QUANTITY VARIATION:
The bidder shall submit price of cable as per prescribed price schedule
format. The applicable unit rates per meter length of the cables in price
schedule shall be valid for a period of one year or till completion of the
project.

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