Detail Technical Specification
Detail Technical Specification
Detail Technical Specification
Technical Specifications
For
Laying of underground cable network
with terminations
INDEX
1. HEAT SHRINKABLE TYPE INDOOR & OUTDOOR TERMINATIONS KIT FOR 11kV CABLE
2. HEAT SHRINKABLE STRAIGHT THROUGH JOINT KIT FOR 11kV CABLE
3. TECHNICAL SPECIFICATION FOR 22 KV XLPE POWER CABLE TERMINATION KIT
4. DWC HDPE PIPES
5. TECHNICAL SPECIFICATION FOR RCC HALF ROUND HUME PIPE
1. Scope:
5.1 This Section of the Specification covers design, manufacturing, testing, packing, supply
& commissioning of heat shrinkable type indoor and outdoor termination kit suitable for
11 kV XLPE cable.
5.2 The equipment offered shall be complete with all parts necessary for their effective
and trouble-free operation. Such parts will be deemed to be within the scope of the
supply irrespective of whether they are specifically indicated in the commercial order
or not.
5.3 It is not the intent to specify herein complete details of design and construction. The
equipment offered shall conform to the relevant standards and be of high quality,
sturdy, robust and of good design and workmanship complete in all respects and
capable to perform continuous and satisfactory operations in the actual service
conditions at site and shall have sufficiently long life in service as per statutory
requirements.
5.4 In these specifications, the design and constructional aspects, including materials and
dimensions, will be subject to good engineering practice in conformity with the
required quality of the product, and to such tolerances, allowances and requirements
for clearances etc. as are necessary by virtue of various stipulations in that respect in
the relevant IEC, IS standards and other statutory provisions.
5.5 Tolerances on all the dimensions shall be in accordance with provisions made in the
relevant standards. Otherwise the same will be governed by good engineering practice
in conformity with required quality of the product.
2. Service Conditions:
System details:
4. Application Standards: -
Power cables with extruded insulation and their IS 7098 (Part-II) IEC 60502
accessories for rated voltages from 1 kV (Um = 1,2 IS 13573,1992
kV) up to 30 kV (Um = 36 kV) - ALL PARTS
6.1 The termination kits offered shall be fully type tested as per the relevant standards and
the test certificates are to be provided.
6.2 The supplier shall carry out all routine tests as stipulated in the relevant standards.
6.3 The termination kits offered shall be fully type tested at CPRI as per the relevant
standards. The vendor shall furnish four sets of the type test reports along with the MQP
for getting approval on material before placing purchase order to the manufacturer.
1. Scope:
1.1 This Section of the Specification covers design, manufacturing, testing, packing, supply
& commissioning of heat shrinkable type straight through joint kit suitable for 11 kV
XLPE cable.
1.2 The equipment offered shall be complete with all parts necessary for their effective
and trouble-free operation. Such parts will be deemed to be within the scope of the
supply irrespective of whether they are specifically indicated in the commercial order
or not.
1.3 It is not the intent to specify herein complete details of design and construction. The
equipment offered shall conform to the relevant standards and be of high quality,
sturdy, robust and of good design and workmanship complete in all respects and
capable to perform continuous and satisfactory operations in the actual service
conditions at site and shall have sufficiently long life in service as per statutory
requirements.
1.4 In these specifications, the design and constructional aspects, including materials and
dimensions, will be subject to good engineering practice in conformity with the
required quality of the product, and to such tolerances, allowances and requirements
for clearances etc. as are necessary by virtue of various stipulations in that respect in
the relevant IEC, IS standards and other statutory provisions.
1.5 Tolerances on all the dimensions shall be in accordance with provisions made in the
relevant standards. Otherwise the same will be governed by good engineering practice
in conformity with required quality of the product.
2. Service Conditions:
System details:
Application Standards: -
Power cables with extruded insulation and their IS 7098 (Part-II) IEC 60502
accessories for rated voltages from 1 kV (Um = 1,2 IS 13573,1992
kV) up to 30 kV (Um = 36 kV) - ALL PARTS
4.1 The straight jointing kits shall be as per defined as per IS 13573-1992 with latest
amendment no. 2 1998, IEEE 48-1990 and shall be Class-1, ESI-09-13 performance
specification for high voltage cable accessories.
4.2 Proper stress control, stress grading and non-tracking arrangement in the joint shall be
offered by means of proven methods, details of which shall be elaborated in the offer.
Detailed sectional views of the assemblies shall be submitted along with the offer. In
case of heat shrinkable cable accessories, stress control tubing, shall have volume
resistively of minimum 1, 00, 00,000 Ohms- meter for straight through joints. Also
relative permittivity shall be minimum 15.
4.3 Impedance of stress control tubing shall not change over a range of temperature from
0 C to 125C. The impedance also remains constant in spite of the difference in stress,
which will exist within the sleeve due to hearting effect within the conductors and the
temperature of the environment. Bidder must submit graph-showing effect on the
impedance value of stress control humbling due to temperature variations and thermal
ageing with his offer.
4.4 The jointing kit shall be with aluminum crimping type ferrules, semi-conductor self-
bonding tape, the self-amalgamating tape [or EPR or equivalent] stress grading pad
etc. The straight through joints should be absolutely impervious to the entry or water.
The manufacturer shall use the proven technologies and design to ensure a
construction, which will prevent entry of water or any other liquid inside the straight
through joint and cable. Proven technologies such as resin injection, hydrophobic
sealants etc. shall be deployed in the critical areas.
4.5 In all type of jointing kits offered, the external leakage insulation between high
voltage conductor and ground as specified in I.E.E.E. –48, 1975 amended up to date,
shall be of non-tracking erosion resistant and weather resistant flexible sleeve.
4.6 The kit offered shall provide for total environmental sealing of the cable crutch and at
the lug end.
4.7 Jointing system shall be suitable for use with standard aluminum conductor fittings
[cable lugs and ferrules] of compressed crimping type.
4.8 For straight through joint the kit shall also include tubular sleeve in line connectors for
solder less crimping of cable connector. The connector shall be of aluminum alloy A 6
drop forged type or other equivalent or better material.
4.9 Material used for construction of a joint shall perfectly match with the dielectric,
chemical and physical characteristics of the associated cable. The material and design
concepts shall incorporate a high degree of operating compatibility between the cable
and the joints. The tenderer shall indicate the required net dimensions of the indoor
cable, joints for various cable sizes, in the form of Length X Breadth X Depth in mm.
4.10 The kit which requires lesser skill for the cable jointing which can be done in shorter
time and guarantee a reliable and long operating life and reduced or no waiting time
for erection shall be given preference.
5.1 The jointing kits offered, shall be fully type tested as per the relevant standards and
the test certificates are to be provided.
5.2 The supplier shall carry out all routine tests as stipulated in the relevant standards.
5.3 The jointing kits offered, shall be fully type tested at CPRI as per the relevant
standards. The vendor shall furnish four sets of the type test reports along with the
MQP for getting approval on material before placing purchase order to the
manufacturer.
5.4 Type tests shall be carried out as per the test sequence given in I.S.:13573 or VDE-0278
at C.P.R.I. Laboratory as amended from time to time. The test report will have to be
submitted for the test carried out.
5.5 Test details for Termination Kit should be as follow:
GUARANTEED PARTICULARS
For the nominal (phase to phase) System KV 11KV
3.
voltages
Maximum system voltage 12KV
KV
A.C. withstand voltage Dry (ph./ground) KV 35KV
3.1
Time duration Mins 1Min.
A.C. withstand voltage Wet(ph./ground) 28KV
KV
Mins
Time duration 1Min.
3.2 PartialDischargeat2Uo pC <5pC
3.3 Impulsewithstand,1.2/50/Us kV 75KV
1. Termination:
The 22 kV cable termination/joints shall be done by skilled and experienced
jointers duly approved by the Engineer in charge. Termination including supply of
jointing kit is included in the contractor’s scope unless specified otherwise.
Heat shrink type of approved make of DGVCL as mentioned in approved make list
in section 5.0(Technical specification) using factory molded silicone rubber
insulators. For outdoor installations weather shields, shielding ends and any other
accessories required should form part of the kit.
Straight through jointing kits shall be suitable for underground installation with
uncontrolled backfill and possibility of flooding by water. The jointing kit shall be
preferably of PUSH ON/Heat shrink type as per technical specifications mentioned
in tender and as per IS-13753-1992 and its latest amendments.
I) Contractor should clarify the make of cable end termination and straight through
joint. The heat & shrink type end termination & straight through joints shall be
utilized for the job.
II) Dual wall molded type should be available in straight through joint.
III) After completing work of cable laying end termination straight through joints,
following test shall be carried out jointly by engineer in charge of DGVCL and
contractor.
IV) Insulation resistance test before & after with 5 KV insulation tester. (A) Hypo test
V) Contractor has to furnish Guaranteed Technical Parameters (GTP) type test
certificate of various tests conducted at any Govt./ NABL approved laboratory for
the joints they intend to supply for this job. The test certificate should not be
prior to 7 years from the date of tender. The contractor shall have to submit the
same with technical bid and failure in which technical bid will be disqualified &
the price bid of that party will not be opened.
VI) One competent skilled supervisor shall have to co-ordinate the site authority and
he has to do all communication with engineer in charge of DGVCL.
VII) It is essential to have suppliers certificate of training for cable jointing of cable
jointer.
VIII) Jointer has to ensure safety while making joints so that other nearby cables will
not damage.
IX) Before using Termination Kit & Jointing Kit should be got verified at Corporate
office level. The bidder has to get verification certificate from A.C.E. (S.D.&P.),
Corporate office, DGVCL, Surat.
The Bidder shall have to supply cable end joint / straight joint kit as per IS 13573-
1992 with latest amendment No. 2- 1998, IEEE 48-1990 and shall be Class -1, ESI-
09-13 performance specification for high voltage cable accessories.
CLASS OF TERMINATION:
The XLPE 11/22 KV Link Line shall be class 1 termination as per appropriate ISI code
nos. i.e. IEEE-48-1990.
3. APPLICABLE STANDARDS:
IS 13573-1992 with latest amendment – Latest amendment No.2- 1998, IEEE 48-
1990. The termination shall be Class 1. ESI-09-13 performance specification for
high voltage cable accessories. The cable accessories being supplied in the form
of kit which has different components to be assembled at site.
4. MATERIALS:
The termination of 22 kV XLPE Cable refers to extruded or Molded Polymeric.
Polymeric material which are cross linked by gamma radiation to develop elastic
memory and supplied in an expanded or otherwise deformed size and shape.
Bidders should submit the proof that the tubes are cross linked by gamma
radiations. However chemically cross linked, crotch seal and lug seals are
permitted.
For straight joints, the insulation over the ferrules should be reinsulated by dual
wall tubing. This should have an inner insulating layer vulcanized to an outer
semi-conducting layer. This is required to ensure reconnection of cable insulation
screen of the core from one end of the joint to the other. The dual wall tubing
ensures that there is no entrapment of air pockets between the insulating and
semi-conducting layers.
5. FOR JOINTS:
22 kV XLPE underground flexible polymeric tubing, preferably black colored pre
coated with adhesive shall be provided for sealing the exposed metallic sheaths
and sheath/earth connections.
10. Tests:
Before energizing the insulation resistance of every circuit shall be measured
from phase to phase and from phase to ground with 5 KV Megger both before
and after backfilling.
a) Type tests are to be carried out at manufacturer’s works for quality approval of
termination/jointing kits. Following tests confirming to the latest IS 13573 and or
IEC 502.2, 466 and VDE 0278 and C 81 specifications. The report of last seven years
type tests result shall be submitted for approval of the Kits. Terminations shall be
kept open so that switchgears, transformers etc are not subjected to test voltage.
As per C - 81
1) Impact Test
2) Insulation Resistance Test
3) A.C High Voltage Test
4) Insulation Resistance Test
5) Heat shock Test
6) Insulation Resistance Test
6) A.C High Voltage Test
7) Insulation Resistance Test
8) Electric Heat cycle Test
9) Evaluation after Electrical heat cycle Test
10) Insulation Resistance Test
11) A.C High Voltage Test
12) Insulation Resistance Test
13) After Sheath Damage Test
14) Electric Heat cycle Test
15) Evaluation after Electrical heat cycle Test & sheath damage
14) Insulation Resistance Test
15) A.C High Voltage Test
16) Insulation Resistance Test
17) Examination Of Joint
1.0 MANUFACTURER
(ph/ground) Min
1 Min
Wet conditiom
Mins
Time duration 1 Min
a) Each Cycle-Heating
Hrs 5
3
Cooling Duration Hrs
b) Number of Cycles 3
c)Continuous phase to
KV
Ground Voltage Withstand
2.5Uo
a) Each Cycle-Heating
Hrs 5
3
Cooling Duration Hrs
b) Number of Cycles 60
c)Continuous phase to
KV
Ground Voltage Withstand
2.5Uo
Manuals
TECHNICAL SPECIFICATION
1.0 MANUFACTURER
(ph/ground)
Mins
1 Min.
Time
Wet(ph/ground)
Mins
1 Min.
d) Time
a)Each Cycle-Heating
Hrs 5
Temperature
0C 100
Cooling 3
Hrs.
3
b)Number of Cycles
Technical Specification for TENDER NOTICE No:-
c)Continuous phase to kV
2.5Uo
ground
Voltage Withstand
a)Each Cycle-Heating
Hrs 5
Temperature
0C 100
Cooling 3
Hrs.
60
b)Number of Cycles -
c)Continuous phase to kV
2.5Uo
ground
Voltage Withstand
Yes
b)Allowable kit storage
Manuals
GUARANTEED TECHNICAL PARTICULARS HEATSHRINK OUT DOOR TERMINATION ON 22KV (E) XLPECABLE
1 MANUFACTURER
2. APPLICABLE STANDARDS
3. GUARANTEED PARTICULARS
3.1 For the nominal (phase to phase) KV
System voltages
Maximum system voltage KV
Temperature 0C
Cooling Duration Hrs.
b) . Number of Cycles
kV
c). Continuous phase to ground Voltage Withstand
3.7 Leak Tightness
3.8 Thermal Withstand Short circuit current 1Sec. ka
3.9 Dynamic short circuit Withstand Ka peak
3.10 DC Voltage kV
4 KIT PARTICULARS
4.1 Material of the tubing/molded parts
4.2 Method of stress control
4.3 Method of environmental seal
4.4 Allowable Kit storage Temperature 0C
4.5 Shelf life of H.S components Years
5. Cable Termination Instruction Manuals Yes/No
GUARANTEED TECHNICAL PARTICULARS HEAT SHRINK STRAIGHT THROUGH JOINT ON 22KV (E) XLPE CABLE
System voltages
Maximum system voltage KV
3.2 A.C. withstand voltage Dry (ph/ground) KV
Time duration Mins
3.3 A.C. withstand voltage Wet(ph/ground) KV
Time duration Mins
3.4 Partial Discharge at 2 Uo pC
3.5 Impulse withstand,1.2/50/Us kV
3.6 Load cycle Test
a) Each Cycle-Heating Duration Hrs
Temperature 0C
Cooling Duration Hrs.
b) Number of Cycles
c)Continuous phase to ground Voltage Withstand kV
a) For Terminations
b) Allowable kit storage temperature 0C
c) Kit shelf life Years
2 Service Conditions:
Equipment to be supplied against this specification shall be suitable for satisfactory
continuous operation under the following tropical conditions.
a) Maximum ambient temperature of air: 50˚C
b) Maximum temperature of air in shade: 4˚C
c) Maximum daily average ambient temperature: 40˚C
d) Maximum yearly average ambient temperature: 30˚C
e) Relative Humidity: up to 95%
f) Average number of thunder storm days per annum: 15
g) Maximum annual Rainfall: 150cm
h) Maximum Altitude above mean sea level: 1000Meter
i) Maximum Wind Pressure: 150 Kg/cm2 (As per IS 802 latest code)
j) Maximum soil temperature at cable depth: 30˚C
k) Maximum soil thermal resistively: 150˚C cm/watt
3 Technical Parameters:
(a) DWC high density Polyethylene pipe shall have corrugation on outer wall but inner
wall shall be plain conforming to IS – 14930 Part I and II amended from time to time.
(b) Terminology as defined in IS: 14930shallbefollowed
(c) DWC HDPE pipe to be supplied shall be ‘ISI’ marked.
(d) Accessories like HDPE snap fit coupler with neoprene ‘O’ ring shall be part of supply
to make the joints water / damp proof.
5 General Requirement:
General:
i. The DWC HDPE pipe shall consist of two layers, the outer layer will be corrugated and
the inner layer shall be plain and smooth.
ii. DWC HDPE pipe shall be so designed and constructed that in normal use their
performance is reliable and without danger to the user or surroundings.
iii. When assembled in accordance with manufacturer’s instruction as part of a conduit
system, they shall provide mechanical protection to Signaling Cables’ on tainted
therein.
iv. Within the conduit system there shall be nos hardedge, burrs or surface projections
which are likely to damage insulated conductors or cables or inflict impure it to the
installer or user.
v. The protective properties of the joint between conduit and conduit fittings shall be
not less than that declared for the conduit system.
vi. The DWC HDPE pipe and fittings hall withstand and the stresses likely to occur during
transport, storage, recommended installed on practice and application.
vii. The DWC HDPE pipe shall be supplied in continuous length in coil for more straight
length, suitable for shipping and handling purpose.
viii. For conduit systems that areas assembled by means other than threads, the
manufacturer shall indicate whether the system can be disassembled and if, so, how
this can be achieved.
i. The following accessories are required for jointing the ducts and shall be supplied
along with the ducts against specific orders. The manufacturers shall provide
complete procedure and method for installation of the accessories. The required
quantities of accessories are to be mentioned by the purchasing authority in the
purchase order.
a. Plastic Coupler:
The coupler shall be of Push-fit type with O-ring. It is used for jointing woor more
ducts. The design of this shall be simple easy to install and shall provide air tight and
water tight joint between the two ducts. The coupler shall insure that the two ducts
are butted smoothly without any step formation in the inner surface. The coupler
may be straight, bands, T-joints type as per requirements of purchaser.
b. End Cap:
This cap made of suitable plastic material shall be fitted on the both ends of duct,
coil after manufacturing the duct. This shall avoid entry of dust, mudandra in water
in to the duct during the transit &storage.
Selection of pipe for different sizes Cables
Following guide of the pipe fill shall be used for sizing the pipe Size:
a. 1 cable in pipe - 53% full
b. 2 cable in pipe - 31% full
c. 3 or more cables - 43% full
d. 4 Multiple cables - 40% full
6 Tests
The following tests shall be carried out in accordance with IS or the latest version
thereof:
a. TYPE TESTS
i) Visual.
ii) Requirement of Colour.
iii) Dimension
iv) Standard Length
v) Compression Strength
vi) Impact Strength
vii) Bending Strength
viii) Oxidation Induction Test
ix) Resistance to Flame Propagation
x) Anti-Rodent
xi) Resistance to External influence on DWC HDPE Pipe
b. ACCEPTANCE TESTS
The following tests be carried out by the manufacturer after 240 hrs of manufacture: -
i) Visual Requirement
ii) Requirement of Colour.
iii) Dimension
iv) Standard Length
v) Compression Strength
vi) Impact Strength
vii) Bending Strength
viii) Resistance to Flame Propagation
7 Tests Procedure
a) COMPRESSION TEST
i. Conduits are subjected to a compression test as per IS: 14930 (Pt-II). The tests for
conduits shall not best rated until 240 hrs after manufacture.
ii. Samples shall be200 ±5mm long.
iii. Before the test the outside and inside diameters of the samples shall be measures
described in clause above.
iv. The samples shall be compressed between two flat steel plates having minimum
dimensions (100x200x15mm), the length 200mm being along the length of the sample.
The sample shall be compressed data rate of 15±0.5mm/min and the load recorded at
the vertical deflection equivalent to 5%of the average value of the original inside
diameter of the sample.
v. When reaching the deflection of 5 %, the applied force shall be at least 450N
vi. After the test there shall be no crack allowing the ingress of light or water between
the inside and the outside.
vii. The deflection is calculated with the inner dia meter but the measurement of the
outside diameter may be sufficient. In case of doubt, itwill be necessary to measure
the inner diameter.
b) IMPACT TEST
i. Twelve samples of the duct each 200±5mm in length or fittings are subjected to an
impact test as per IS: 14930(Pt-II) by means of the apparatus shown Figure-1.
ii. The test apparatus shall be placed on a firm flat surface. The samples shall be
conditioned in a cold chamber at a temperature of–5±1°C for 2h. The samples shall be
removed from the cold chamber and placed on the vee block holder of the impact
tester as shown in figure 1.
iii. The striker shall fall once on each sample. The time between removal of the sample
from the cold chamber and completion of impact shall not exceed 10seconds.The
impact height and mass shall be as follows.
Nominal Size of Mass of Striker Fall Height Energy Joules
Conduit (+1%/-0%)kg (+0%/-1%)(mm)
Upto60 mm 5 300 15
61to90 mm 5 400 20
91to140 mm 5 570 28
Above140mm 5 800 40
iv. The test sample shall be made on the weakest part of the Duct fittings except that it
shall not be applied within 5mm of any sample entry. Samples of ducts are tested on
FIGURE- 1
IMPACT APPRATUS
FIGURE- 2
BENDINGTESTAPPARATUS
RESISTANCETOFLAMEPROPAGATIONTESTAPPARATUS
This Specification provides for the manufacture, inspection and testing, forwarding and
delivery at site/stores of R.C.C. Half Round Hume Pipe for covering HT & LT. cables as
specified hereunder:
2 Tests Procedure
The R.C.C. Half Round Hume Pipe shall have the following Parameters
Dimensions
Inner Diameter 150.00 mm
Thickness 30.00 mm
Length 1 Meter (+/- 10 mm)
3 General Requirement:
3.1 The inner & outer surface shall not have any sharp edge, which can damage the cable.
No additional cost shall be provided to smooth the surface.
3.2 The welded wire mesh shall not be exposed to surface. Also, the wire mesh shall be
properly welded type.
3.3 Grade of concrete shall be M25. The raw material shall be of standard quality. The
cement shall be 53 Grade OPC of any reputed make available in market only.
3.4 The R.C.C. Half Round Hume Pipe shall be cured in water pond for minimum 14 days.
Also, the R.C.C. Half Round Hume Pipe shall be completely dried before dispatch.
3.5 In concrete mixing, the ratio shall be maintained. The Grit shall be used instead of
Gravel with size of 12mm.
3.6 Process of manufacturing shall be rolling machine made or Table vibrator type.
4 Marking:
6.1 The R.C.C. Half Round Hume Pipe shall be indelibly marked with the following
information.
6.2 “Purchasers name or Logo” & “Manufacturer's name or Trade mark shall be embossed
or printed on outer surface.
6.3 Voltage Rating “Up to 11000 V “ OR as directed by Engineer In charge shall be
embossed / printed on outer surface.
6.4 Printing shall be with RED color in readable size & format.
6.1 The Purchaser shall have access at all reasonable times to the works and all other
places of manufacture, where the R.C.C. Half Round Hume Pipe are being
manufactured and the supplier shall provide all facilities for unrestricted inspection of
the supplier's works raw materials, manufacture of the equipment, all the accessories
and for conducting necessary tests.
6.2 The supplier shall keep the Purchaser informed in advance of the time of starting and
of the progress of manufacture of equipment in its various stages so that arrangements
could be made for inspection.
6 Test
7.1 Vendor shall be responsible for any damage to the material during transit.
7.2 Vendor is liable for free replacements of damaged items due to defective or
insufficient packing and / or protection.
8 Warranty:
The material found defective to be replaced by supplier free of cost within 7 days of
notification.