CABLEItem:-Checklist for 3.3kV Cu XLPE single core Cables FRLSChecklist of FAT AS PER STANDARD IEC 60502-2(2005) & GTPSr. no.Type of test Description Acceptance normsProcedureSample on which test conducted

Remarks

1.PhysicalCross section area of metallic screenNom.8 sq.mmN*0.78548*d2 Where N = no. of wire & d=nom. Dia of wire, Physical measurement of diameter to calculate the areapara of 10 of IEC60502-2& GTP

2.PhysicalThickness of insulationNom.2.0 mmPhysical measurement of thickness of Insulationpara of 17.5. of IEC60502-2& GTP

3.PhysicalThickness of outer sheathMin. 1.9 mmPhysical measurement of thickness of Insulationpara of 14.3. of IEC 60502-2& GTP

4.PhysicalMeasurement of overall dia. of cable

Approx. 34 mm Physical measurement of diameter of cablepara of 17.8 of IEC 60502-2& GTP

5.Physical

(a)Conductor material

(b)conductor shapeAnnealed Plane Copper.

Stranded Compacted Circular

Could not be measured directly as conductors were compacted. The test report for the time of manufacturing taken from the quality department

IEC 60228& GTP

6.PhysicalLength check Rewinding MethodThe cable length should not be vary from the offered length of the drum -There should be finish of the cable i.e. no joint ,no puncture etc. in the cableOne complete drum taken from the offered lot. The full drum to be rewind into another empty drum with the help of measuring roller. The cable to be rolled by passing from the hand

7.PhysicalOxygen index test on outer sheathMin. 30 at room temperatureThe test sample positioned vertically in a glass chimney and an oxygen environment is established with a flow from the bottom of the chimney the top edgeof the test sample is ignited and the oxygen concentration in the flow is decreased until the flame is no longer supported.

ASTM D-2863&GTP

8.PhysicalTemperature index test on outer sheathMin.260CASTM D-2863

9.PhysicalAcid gas generation test on outer sheathMax.20%The test Sample inserted into quartz glass tube and put on a combustion boat and 200 ML of the solution measured into a conical flask and chemical liquids is used to conglomeration and coating of the silver halide that is formed by the reaction.

IEC 60754 part-1

10.PhysicalSmoke emission testMax. smoke density rating 50%(After vendor approval)Turn on the all apparatus the pressure of propane adjust 276Kpa. Warning-do not fail to light the burner immediately set the temp. composition adjust the lamp control to 0% light absorption lay the test specimen flat on the screen set the time is zero .shut off the exhaust blower close the smoke chamber door .if in a hood shutoff the hood fan close the hood door within 50mm.of the bottom of the hood. Record the % light absorbed at 15 second interval continue 4 min.

ASTM D-2843

11.PhysicalFlammability test on finished cableThe length of specimen is 600mm.position for IEC 60332-1 of the specimen is vertical & position of the flame 45 to vertical specimen the test. Duration of flaming is 480 second.For IEC 60332-3 Cat A the length of the specimen is 3.5 m and the number of samples is 4 and the charred portion should not have reached a height exceeding 2.5 m above the bottom edge of the burner.

IEC 60332-1IEC 60332-3 Cat-A

12.PhysicalConductor screening

(a) material

Semi-conducting tape followed by extruded semi-conducting compound Visual examination and physical measurement.7.1 Para of IEC 60502-2

13.PhysicalArmouring

Material

Nominal thickness

Double Aluminium Tape

0.5mmVisual examination and physical measurement.As per Para 12.7 of IEC60502-1 &GTP

14.PhysicalMetallic screen

Helically applied plain copper wires (with gap) followed by an open helix plain copper tape.Visual examination and physical measurement.As per GTP

15.ElectricalDC resistance test of conductor at 20CMax. 0.0754/kmThis test is done at 20C. Temperature maintains 20C at least 12h before the test in case of doubt as to whether the conductor temperature is the same as the room temp. the resistance shall be measured after the cable has been in the test room for 24h Req-the DC resistance of the each conductor at 20C shall be not exceeding the given max value.Para 16.2 of IEC60502 part(II)

16.ElectricalPartial Discharge testSensitivity should be less than 5 PCTest voltage shall be raised gradually to and held at 2u0 for 10 second and than gradually reduced to 1.73 u0

Para of 18.1.4 of IEC 60502-2

17.

ElectricalCapacitance TestMax. 0.76 mF/KmThe capacitance should be measured between conductor and metallic sheath.Para of 10.10 of IEC 60840 &GTP

18.ElectricalHigh Voltage Test 4 HrsTest voltage shall be raised gradually to and held at 2u0 for 10 second and than gradually reduced to 1.73 u0para of17.9 of IEC-60502-2

2) Type Test reports(I) Electrical Type Test Reports as per QAP and IEC 60502-2 on (II)Physical and Mechanical Type Test report as per QAP and IEC 60502-2 on3) Stage Inspection CertificatesI) Copper RodII) Semiconducting TapeIII) Semiconducting CompoundIV) XLPE CompoundV) Copper TapeVI) Glass Fibre TapeVII) Aluminium TapeVIII) FRLS PVC compound4) Raw Material Test Certificates (I)Conductor(II)Semi conducting tape(III)Inner Semiconducting tape(IV) Insulation(V)Outer Semiconducting tape(VI)Copper wire(VII)Copper Tape(VIII)Inner Sheath(IX)Glass Fibre Tape(X)Aluminium Tape(XI)Outer Sheath5) Calibration status and Calibration certificates:Physical and Chemical EquipmentsName of Instrument 1 Dial Vernire Caliper2 Micrometer Pointed 3 Dial Thickness Gauge 4 Tensile Tester 5 Tensile Tester 6 Profile projector 7 Hot set oven Digital Temp. Controller Digital Timer Digital Timer Weight Box8 Profile Projector 9 Oxygen Index/Temperature Index test apparatus as per ASTM D 286310 Halogen Acid gas Test11 Smoke density Chamber ASTM D284312 Flammability Test (IEC-60332-3 Cat. A)Air Flow meter Range 100 to 1500 L.P.H.Air Flow meter Range 0 to 150 L.P.M.Electrical Instruments1 Digital kV Meter (AC) Q0036592 Digital Micro OHM Meter Q0048053 P D Calibrator Q0008034 Digital kV Meter (AC) Q003656 & 36575 Glass Thermometer Q-002745

*All test, otherwise mentioned should be above 5C to 35C As per para15.1 of IEC60502-2These are above the guiding list and not complete.Other parameters should be check as per approved GTP & IEC specification