lv power cable specification_06.11.2009

LV AC/DC POWER CABLE SPECIFICATION

DOC. NO: 277------

STANDARD DOCUMENT (LH PROJECTS)

Drawn: 06.11.2009 JSC

Checked: 06.11.2009 AP

Approved: 06.11.2009 ABS

Rev. Modification Date Check Date Appd


Internal Drawing Number:

XXXXXX of 9

Rev.

0

THIS DOCUMENT IS THE PROPERTY OF ANDRITZ HYDRO Pvt. Ltd. AND MUST NEITHER BE COPEID NOR USED IN ANY OTHER WAY WIHTOUT THE WRITTEN CONSENT OF ANDRITZ HYDRO Pvt. Ltd. NEITHER IT IS TO BE HANDED OVER, NOR IN OTHER WAY COMMUNICATED TO A THIRD PARTY. INFRINGMENT WILL LEAD TO PROSECUTION.OBSERVE THE PROTECTION ISSUE ISO 16016.


DOC. NO: 277------


INDEX

1. Scope................................................................................................................................................ 3

2. Code and Standards........................................................................................................................ 3

3. General Requirement....................................................................................................................... 3

4. 1100 V Single/Multi Core LV Power Cables...................................................................................3

5. 1100 V Two Core DC Power Cables................................................................................................4

6. Cable Identification.......................................................................................................................... 5

7. Construction..................................................................................................................................... 5

8. Drum Length & Tolerance...............................................................................................................6

9. Warranty........................................................................................................................................... 6

10. Tests................................................................................................................................................. 7

11. Technical Particular......................................................................................................................... 7

12. Standard Power Cable Used:..........................................................................................................7

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1. Scope

This document covers the specification of design, manufacture, testing and supply of power cable for operation & control of the power plant.

2. Code and Standards

Following standards shall be referred in general

i) IS: 7098 (Part I) XLPE insulated (heavy duty) electric cables for working voltage upto & including 1100 V

ii) IS: 8130 – 1984 Conductors for insulated electric cables and flexible cords

iii) IS: 5831 - 1984 PVC insulation and sheath of electric cables

iv) IS: 10810 - 1984 Methods of tests for cables

v) IS: 3975 – 1988 Specification for mild steel wires, formed wires and tapes for armouring of cables

vi) IS: 10462 (Part I)-1983 Fictitious calculation method for determination of dimensions of protective coverings of cables

vii) IS: 10418 - 1982 Specification for drums for electric cables

viii) ASTMD 2863 Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics

3. General Requirement

Cables shall be generally laid on ladder/perforated type trays/covered trenches. For interplant connection cables may be directly buried in ground or through pipes. Hence cable shall be suitable for directly laying in buried trenches with uncontrolled backfill having chances of flooding by water and susceptible to rodent and termite attack at times.

For continuous operation at specified rating, maximum conductor temperature shall be limited to the permissible value as per relevant standards.

The insulation and sheath materials shall be resistant to oil, acid, alkalli and shall be tough enough to withstand mechanical stresses during handling.

Armouring shall be single round/strip wire of galvanized steel for all cables.

4. 1100 V Single/Multi Core LV Power Cables

LV Power Cable will be 1100 V grade, single / multicore, stranded aluminium conductor, XLPE insulated, extruded PVC inner sheathed of type ST-2, galvanized single round/strip armoured and with outer sheath made of FRLS PVC compound of type ST-2. Inner sheath is not applicable for single core cables. Minimum conductor cross section of power cables will be 2.5 sq.mm copper and 10sq mm Aluminium.

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5. 1100 V Two Core DC Power Cables

DC Power Cable will be 1100 V grade, two core, copper conductor, XLPE insulated, extruded PVC inner sheathed of type ST-2, galvanized round/flat armoured and with outer sheath made of FRLS PVC compound of type ST-2. The cables used for DC system will be of two core copper type.

XLPE insulated cables shall conform to the requirements of IS 7098, Part 1 for LV Power cables.

The conductor shall be composed of plain copper or aluminium wires, complying to IS 8130.

The insulation shall be XLPE insulated, extruded, conforming to the requirements of Table 1 of IS 7098, Part 1.

For all cables, PVC inner sheath shall be applied over laid up cores by extrusion. The inner sheath shall be Type ST2, extruded PVC compound, conforming to the requirements of IS 5831.

For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables, armouring shall be of galvanised steel single round wire as per IS 7098, Part 1.

The outer sheath shall be Type ST2, extruded PVC compound, conforming to the requirements of IS 5831 applied over the armouring.

XLPE insulation shall be suitable for continuous conductor temperature of 90°C and short circuit conductor temperature of 250 °C. Insulation thickness should conform to Table 3 of IS 7098, Part 1.

The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground buried installations with chances of flooding by water.

Cables shall be able to withstand all mechanical, electrical and thermal stresses under the foreseen steady state and transient/fault operating conditions and shall be suitable for proposed method of installation.

The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core cable shall have distinct extruded PVC inner sheath of black in colour as per IS: 5831.

Armouring shall be single round wire of galvanised steel for multicore cables and aluminium for single core cable.

Outer sheath shall be of PVC, black in colour for LV power cables. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the FRLS properties.

The insulation and sheath materials shall be resistant to oil, acid and alkali and shall be tough enough to withstand mechanical stresses during handling.

Cables shall be suitable for laying outdoors exposed to direct sunlight, with resistance to ultraviolet radiation. Cables shall be suitable for operation in high ambient, high humid tropical Indian climatic conditions.

All environmental and safety guidelines are to ensured while selecting the raw materials for the cables to be supplied.

PVC outer sheath will have following properties

Oxygen Index : Min.29 Smoke Density : Min 40% light transmittance Acid Gas : Max 20% by weight Flame propagation : As per IEC-60332-1, IEEE-383

6. Cable Identification

Core Identification for various control cable shall be as follows.

1 core - Black 2 core - Red & Black

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3 core - Red, Yellow & Blue 4 core - Red, Yellow, Blue & Black For reduced neutral conductors in 3½ core cables, the core shall be black.

All finished cables shall be identified by surface markings at intervals of not more than one meter containing the following information:

i) Name of the manufacturer

ii) Rated voltage

iii) Cable type (including insulation and sheath material)

iv) Conductor size

v) Year of manufacture

vi) Number of cores

The above markings or indications shall remain legible for the life of the cable.

7. Construction

i) Insulation thickness shall be decided on the basis of electrical stresses and adequate mechanical strength. Shall meet the relevant standard for a given voltage class.

ii) Cable insulation resistance and break down strength (dielectric strength) shall not be affected by moisture i.e. non-hygroscopic. Insulation shall not contain any impurities. Insulation material shall be resistant to oil, acid and alkali and shall be tough enough to withstand mechanical stresses during handling.

iii) Flexible, mutlistrand, copper conductor.

iv) Inner sheath shall be easily removable at the time of jointing. End dressing shall be of softer consistency compared to the insulation such that while removing the inner sheath insulation shall not get affected.

v) Common covering of PVC sheath shall be extruded together with suitable non-hygroscopic fillers in the interstices.

vi) Core identification shall be as per BIS"1554/1/88.

vii) Cable shall be capable of overload for short period without any effect on cable.

viii) Cables shall be supplied in one Length, as per requirements.

8. Drum Length & Tolerance

i) Cable drum shall be non returnable and made of good quality wood, pressure impregnated against fungal and insect attack.

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ii) Cables shall be supplied in wooden drums conforming to IS. Cables can be supplied in drums with 500mtr or more cable length as per requirement. Allowable tolerance on individual drum length is +5 %. (with no negative tolerance)

iii) The ends of each length of cable shall be sealed before dispatch.

iv) Purchaser reserves the right to indicate the cable drum length to the bidder, while placing the order or in course of manufacture.

The cable drum shall carry the following information either stencilled on the drum or contained in a label attached to it:-

i) Reference to applicable standard

ii) Manufacturer's name, brand or trade mark

iii) Type of cable and voltage grade

iv) No. of cores

v) Nominal cross-sectional area of conductor

vi) Cable code

vii) Length of cable on drum

viii) No. of lengths on reel, drum or coil (if more than one]

ix) Gross weight

x) Country of manufacturer

xi) Direction of rotation of drum (an arrow)

xii) Year of manufacture

9. Warranty

i) Warranty shall remain valid for 18 months after the cables or any portion there of as the case may be, have been delivered to the final destination and after final acceptance is given after commissioning or for 24 months after the receipt at site, of the last consignment, whichever period concludes earlier.

ii) If the cable is found defective, upon receipt of such notice, the supplier shall, with all reasonable speed, repair or replace the defective cables or parts thereof, without any costs to the purchaser.

iii) The repaired / replaced cables shall be further warranted for a period of 12 months from the date of repair / replacement.

10. Tests

Cables shall be subject to shop tests in accordance with the relevant standards to prove the design and general qualities of the cables as below.

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i) Routine tests on each drum

ii) Acceptance tests on drums chosen at random

iii) Type tests on each type of cable inclusive of measurement of armour D.C. Resistance

11. Technical Particular

1100 V grade, 90ºC rating, XLPE Power cable conforming to following requirement and in line with IS:7098, IS:8130, IS:5831 and IS:3975.

Voltage grade 650/1100 V grade

Conductor Stranded Annealed Copper

Insulation XLPE

Outer sheath Extruded PVC

Armouring Galvanized steel strips round/flat wire (if required)

Cont. conductor Temperature rating 90° C

Short circuit withstand temperature 250°C

12. Standard Power Cable Used:Core Number Materia

lInsulation

1Cx400 Sq mm Al/Cu XLPE




3Cx2.5 Sq mm Cu XLPE

3Cx4 Sq mm Cu XLPE

3Cx6 Sq mm Cu XLPE

3Cx10 Sq mm Al XLPE

3Cx16 Sq mm Al XLPE

3Cx25 Sq mm Al XLPE

3Cx35 Sq mm Al XLPE

3Cx50 Sq mm Al XLPE

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3Cx70 Sq mm Al XLPE

3Cx95 Sq mm Al XLPE

3Cx120 Sq mm Al XLPE







3.5Cx25 Sq mm Al XLPE













4Cx4 Sq mm Cu XLPE

4Cx6 Sq mm Cu XLPE

4Cx10 Sq mm Al XLPE

4Cx16 Sq mm Al XLPE

4Cx25 Sq mm Al XLPE

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4Cx35 Sq mm Al XLPE

4Cx50 Sq mm Al XLPE

4Cx70 Sq mm Al XLPE

4Cx95 Sq mm Al XLPE









2Cx4 Sq mm Cu XLPE

2Cx6 Sq mm Cu XLPE

2Cx10 Sq mm Cu XLPE

2Cx16 Sq mm Cu XLPE

2Cx25 Sq mm Cu XLPE

2Cx35 Sq mm Cu XLPE

2Cx50 Sq mm Cu XLPE

2Cx70 Sq mm Cu XLPE

2Cx95 Sq mm Cu XLPE

2Cx120 Sq mm Cu XLPE





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lv power cable specification_06.11.2009

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