CHAPTER - D

TECHNICAL SPECIFICATION FOR FRLS POWER CABLE, CABLE TRAYS AND CABLING
2.01 2.01.1 SCOPE OF WORK: This technical specification covers complete design, engineering, manufacture, inspection and testing at manufacturer's works, packing and forwarding of (a) power cables (b) perforated cable trays complete in all respects along with their supporting/fixing arrangements (c) laying & fixing of cable trays on supporting system, earthing of cable trays and laying of various sizes of power & D.C. cables in cable trays, fixing of cables on trays, termination, ferruling of cable strands, marking of lugs & cable glands, complete erection, testing and commissioning at site of FRLS power, D.C. & control cables, cable trays and cabling etc. as detailed hereinafter in the specification. Over land transportation covering freight and insurance, FOR delivery at site. Scope also includes storage at site, site insurance, jointing, testing and commissioning of power & control cables and cable trays etc. Storage including insurance and preservation at site till installation and handing over after commissioning. Complete laying jointing, preparation of end terminals, marking, fixing of lugs & cable glands, its connection to the equipment and to overhead 22kV line with cable boxes/suitable cable termination end, testing and commissioning of HT Cables, L.T. power cables, D.C. cables and control cables for sub station at Jhakri at the following sites:(i) 2 Nos. 22kV XLPE Power cables from the point of 22kV overhead structure near Main Access Tunnel of Power House at EL-1061 m at Jhakri through main access tunnel as per Schedule of requirement appended at Annexure-E-A. (ii) LT power cable and D.C. power cables to different location from LT room at EL 1061 to various equipment as per tentative cable schedule at Annexure-E-B.

2.01.2

2.01.3

2.01.4

2.02
2.02.1

STANDARDS AND REGULATIONS

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 recognised standard which ensure a quality equal to or better

2.02.2

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. 2.02.03 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:IS-694 IS-1554 (Part-I) PVC insulated cables for working voltages upto and including 1100V. PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V. PVC insulated (heavy duty) electric cables for working voltages from 3.3kV upto and including 11kV. Recommended current ratings for cables Conductors for insulated electric cables and flexible cords. PVC insulation and sheath of electric cables. Specification of Elastomeric Insulation & Sheath of Electric Cables. Cross linked polyethylene insulated PVC sheathed cables for working voltages upto 33kV. Mild steel wires, strips and tapes for armouring cables. Aluminium conductors for insulated cables. Code of practice for installation and maintenance of power cables upto and including 33kV rating. Brass glands for PVC cables. Drums for electric cables. Method of test for cables. Polyethylene insulation and sheath of electric cables. Recommended short circuit ratings of high voltage PVC cables. Power Cables with extruded insulation & their accessories for rated voltages 1 kV to 30 kV Test methods for insulation and sheaths of electric cables and cord. Test on electric cables under fire conditions. Test on gases evolved during combustion 2 2

1. 2.

3.

IS-1554 (Part-II)

4. 5. 6. 7. 8.

IS-3961 IS-8130 IS-5831 IS-6380 IS-7098 (Part-I & II)

9. 10. 11.

IS-3975 IS-1753 IS-1255

12. 13. 14. 15. 16. 17.

IS-12943 IS-10418 IS-10810 to 63) IS-6474 IS-5819 IEC-60502

(Part

18. 19. 20.

IEC-540 & 540A IEC-60332 IEC-60754

21. 22. 23. 2.03 2.03.01

of electric cables. EC Hand Book Cable in fire regarding temperature Index for Temperature Index Chapter-6. IEC-10333 Cable joints and terminations Any other applicable standards DESCRIPTION OF CABLES: General: The XLPE 22 kV Power Cable shall be of: (a) (b) H.T. Power Cable ( 2 2 k V ) 9 L.T. Power cables Three core 95 mm2 Single core Aluminum Conductor Aluminum Conductor Unarmored Cable Unarmored Cable

2.03.02

Type of Cable: The cable shall be multi-core and outer sheath should have high resistance to flame propagation. The H.T. cable shall be XLPE insulated PVC sheathed, un-armored cable. The L.T. cable shall be of PVC insulated, PVC sheathed unarmored cable.

2.03.03

Conductor: The material for conductor for HT power cables shall consist of plain aluminum of H4 grade having tensile strength above 150 N/mm.sq. The cable conductor shall be made from stranded aluminum wire to form compacted circular conductors 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.

2.03.04

Conductor (Shield): The conductor shall have non-metallic semi-conducting shield which shall ensure perfectly smooth profile and avoid stress concentration. The conductor shield shall be extruded in the same operation as the insulation.

2.03.05

Insulation: The insulation of the cable shall be designed and manufactured for the specified system voltage. 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 extrusion method should give very smooth interface between semiconducting screen and insulation. 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.

3 3

2.03.06

Insulation Shield: In XLPE cables, to confine electrical field to the insulation a non-metallic semi-conducting shield shall be put over the insulation. The insulation shield shall be extruded in the same operation as the conductor shield and the insulation by triple extrusion process.

2.03.07

Cable screening: An aluminum screening shall be provided on top of the insulation shield in case of XLPE cable.

2.03.08

Sheath: (a) 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 or wrapping 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. PVC sheath shall be extruded. The circularity of the cable should be maintained. Outer Sheath: This is extruded over the armour for armoured cables and cover the inner sheath for unarmoured cables. 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 cable should also offer a specially formulated Flame Retardant Low Smoke compound (FRLS) for outer sheath. Suitable additives 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.

(b)

2.04 2.04.01

CONSTRUCTION: 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. TESTS: Test during manufacture: During the manufacture of cables, manufacturer's standard tests shall be performed and copies of test certificate from the independent test house

2.05 2.05.01

shall be furnished. 4 4

2.05.02 2.05.02.1

Type, Routine and Acceptance Tests: 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 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. Routine test: 1. 2. 3. 4. Conductor resistance test. High voltage test. Partial discharge test. Insulation resistance test.

2.05.02.2

2.05.02.3

2.05.02.4

2.05.03

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. 2.05.04 2.05.04.01 Type Tests: The following type tests shall be conducted as per applicable standards on XLPE and PVC insulated power. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Tensile test Wrapping test Conductor resistance Partial discharge test Dielectric power factor test Bending test followed by partial discharge test Heating cycle test followed by partial discharge test Test for thickness of insulation and sheath Tensile strength and elongation test for insulation and sheath Ageing test for insulation and sheath Loss of mass tests for insulation and sheath Shrinkage Test for Insulation and Sheath Hot Deformation Test for Insulation and Sheath Cold Bend Test (up to 6mm.sq.) size Cold Impact Test for Insulation and Sheath Heat Shock Test for Insulation and Sheath Thermal Stability Test for Insulation and Sheath Test for Bleeding and Blooming of pigments for PVC Insulation & Sheath 5 5

19. 20. 21. 2.05.04.2

Fire Resistance Test Measurement of Insulation Resistance 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 alongwith 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. The following tests shall also be performed on the cables wherever applicable, as per relevant standard. Copies of the test certificate along with English version of the standard adopted shall also be furnished along with bid. i) ii) iii) iv) v) vi) vii) viii) Accelerated water absorption test for insulation Di-electric Test Oxygen Index Test Temperature Index Test Flammability Test Acid Gas Generation Test Smoke Generation Test Test for Rodent and Termite Repulsion

2.05.04.3

2.05.04.4

Test details is 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. 2.05.04.05 Test certificates for the above type tests, conducted by he 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. Acceptance Test: i) ii) iii) iv) v) vi) vii) Tensile Test Wrapping Test Conductor Resistance Test Test for thickness of Insulation and Sheath Partial discharge test HV Test Insulation resistance test

2.05.05

6 6

2.05.06

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. i) ii) iii) iv) Fire Resistance Test Flammability Test Cold Bend Test Cold Impact Test

2.06 1. 2. 3. 4. 5.

PARAMETERS:

Type of cable FRLS XLPE Cables, PCC cables Nominal system voltage 22kV H.T,433V A.C. System voltage variation A.C. system 10% Frequency 50 HZ +3%, -5% Overload capacity 10% of cables 6. Short circuit conditions H.T. a) Current b) LT 12.5kA Duration 50 kA 3 Sec. 1 Sec 2.07 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 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.

2.08 2.08.01 2.08.02 2.08.03 2.09

CURRENT RATINGS: The cables will have current ratings and derating factors as per relevant Indian Standards. The one second short circuit current rating values shall be furnished and shall be subjected to the purchaser's approval. The current rating shall be based on maximum conductor temperature depending on the type of insulation for continuous at the rated current. NORMAL SERVICE CONDITIONS: The cables shall be used in the sub-station having an ambient temperature of -5 deg.C to 45 deg.C.

2.10 2.10.01

OPERATION: Cables shall be capable of satisfactory operation under a power supply system frequency variation of +3%, -5% voltage variation of 10%. 7

2.10.2

Cables shall be suitable for laying in conduits, ducts, trenches, channels, trays, racks or for direct burried in ground in both dry and wet locations with chances of flooding by water. Cables shall have heat and moisture resistance properties. These shall be of type and design with proven record of underground Sub-Station. QUANTITY: The various sizes and quantities of cables the Annexure-I i.e. Schedule of Requirement. required are given in

2.10.3

2.11 2.11.1

2.11.2

The quantity is approximate and can be changed at the time of placing the order to the extent of 15%. DRUM LENGTH & CABLE DRUM: Drum Length: The length of the cable on each drum shall be as per IS: 10418-1972.

2.12 2.12.01

2.12.2

Cable shall be supplied in non-returnable 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. The successful bidder shall obtain owner's approval for the drum lengths, before packing the cables on drums. PACKING: 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. The cable shall carry the following information either stenciled on the drum or contained in a label attached to it:i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) Reference to this Indian standard Manufacturer's name, brand or trade mark Type of cable and voltage grade No. of cores Nominal cross-sectional area of conductor Cable code Length of cable on drum No. of lengths on reel, drum or coil (if more than one) Gross weight Country of manufacture Year of manufacture Direction of rotation of drum (an arrow)

2.12.3

2.13 2.13.1

2.13.2

2.14 2.14.1

IDENTIFICATION: The conductor Standards. cores shall be identified with codes as per relevant Indian

2.14.2

The cables shall carry the manufacturer's name or trade mark and the word identified through out its length. The manufacturer's data shall include the name, the cable size, 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. LAYING, FIXING & TERMINATION OF CABLES: The power & control cables shall be laid on the cable racks. It will be complete responsibility of the bidder for laying, fixing, straight jointing in case of power cable if required and termination at both ends of the power & D.C. cables as per the tentative schedule given in Annexure E-A & E-B. Cable glands shall be provided at each end to support the cable. Wire termination shall be made with solder less crimping type and tinned copper lugs which firmly grip the conductor. Insulated sleeves shall be provided at all the wires termination. Engraved core identification plastic ferrules marked to correspond with Cable No./Wire No. shall be fitted at both ends of each cable, Ferrules shall fit tightly on the wire and shall not fall off when the wire/cable is disconnected from the terminal blocks. Number 6 & 9 shall have different markings for ferrules purposes. Necessary cable no./wire no. shall be marked/tagged (or the standard practice adopted) on the cable at the different locations for easy identifications during maintenance. Power cables having more number of cables per phase shall be laid in trefoil formation or shall be laid as per standard practice adopted for laying. Cables laid in horizontal cable trays as well as on vertical ladders shall be fixed at adequate number of places to hold the cable firmly. Bidder should submit a complete write up regarding laying, fixing and termination of the cable for approval before starting of the work. Any mechanical damage to the cables resulting in discarding of the cables shall be replaced by the bidder free of cost. The LT cables and D.C. cables which are not under the scope of supply will be lifted from centre store of SJVNL located at Jhakri. It will be responsibility of the bidder to lift the cables from centre store Jhakri and transport to site including loading & un-loading and utilizing at works. Cable Tags: After pulling, cables shall be provided with identification tags consisting of 1.5mm thick aluminium strips of size 30x60mm on which cable numbers shall be die-punched. The tags shall be tied to the cables with non-corrosive wire. In case of single core cables, the said wire should be non-ferrous. Cable tags shall be tied to cables at the following points: a) Inside the cubicles at the point of glanding.

2.15 2.15.1

2.15.2

2.15.3

9 9

b)

c)

Within the distances of 1 to 2 meters on either side of crossing of any wall, floor, fire stop or other barrier in cable galleries/trenches etc. One meter distance to be kept so that cable tags do not get concealed during lost/disturbed fire sealing, re-plastering, etc. At the field end termination before entry to the terminal box/junction box/marshalling box. Within the distances of 1 to 2 meters of either side of acute bends, tray jumping, and at every 30M interval in straight run. In every span over 30 meters found without any tag despite above.

d)

e) 2.15.04

Quantity measurement and Return of surplus Quantity: For payment purposes measurement shall be made on the execution drawings/physical measurements, physical measurements shall be made by the contractor in the presence of the representative of the purchaser. The measurements of cable laying shall be made on the basis of length actually laid from the lug to lug including that of loops provided and laid accordingly. All the leftover surplus, scrap and serviceable cable pieces and drums/spools/reels out of the cable quantities shall be returned by the contractor to the owner's stores in good condition. Cable of less than 5M length will be termed as scrap. Cable of length 5M and above shall be termed as serviceable material and shall be returned size wise and category-wise to the owner's stores/yard. All such cable shall carry an aluminium sheet metal tag indicating the size, and type of cable, cable of serviceable lengths being returned to the stores in drums shall have their free ends sealed and the balance lengths on the drums shall be noted. This shall be applicable only for the purpose of accounting the cables.

2.15.5

It shall be responsibility of successful bidder to work out the complete cable schedule for the cables covered under this specification which shall incorporate the details of termination markings and route etc. in consultation with project authorities and various equipment suppliers and submit the same for approval before starting the cable laying/fixing work. Testing: The contractor shall take full responsibility of testing pre-commissioning and commissioning of cabling system being installed by him. It shall be overall responsibility of the contractor to arrange and complete all activities in complete co-ordination with equipment commissioning agency keeping in view the overall commissioning programme. The contractor shall submit a check list for testing and commissioning and the activities shall be carried out in accordance with the check list. Testing and electric measurement of cable installations shall conform to IS:1255.

2.15.6 2.15.05.1

2.15.05.2

10

2.15.05.03

Prior to installation, cables shall be tested for a) b) c) Continuity of conductors Insulation resistance between conductor and earth Insulation resistance between the conductors

2.15.05.04

After installation each cable shall be tested for a) b) c) d) Insulation resistance between conductors Insulation resistance between the conductors and earth Absence of cross phasing Firmness of terminations

2.15.05.5

The check and commissioning tests shall be carried out as part of the installation work and the contractor shall not be paid any extra amount for the same. The contractor shall have to bring all testing equipment/instruments in sufficient numbers. All instruments shall be calibrated to the satisfaction of the purchaser before actual testing and tests to be conducted by qualified experienced personnel. All documents/records regarding test data and all other measured values shall be submitted for approval and subsequent record and reference. All cables shall be energised only after certification from certification personnel that cable is ready for energizing. The results of all tests shall conform to the specification requirement as well as guaranteed data. CABLE TRAYS: The hot dipped galvanized perforated cable trays and their fittings shall conform to the Indian Standards or their latest amended editions or equivalent International Standard. The bidder shall specify in the bid to which standard the material supplied shall conform.

2.15.05.6

2.15.05.7

2.16

2.17 2.17.1

DESIGN REQUIREMENTS: The hot dipped galvanized steel perforated cable trays having rectangular channel section 30mm deep shall be designed for a uniform load of at least 400N per 1000 mm ladder length for 200 mm wide tray. The trays shall be fabricated in a length of 2.5 m to 3m. The perforated cable trays shall be manufactured from good commercial, high grade strength sheet steel having minimum thickness of 2mm and shall be hot dip galvanized according to BS-729-1971 or equivalent standard suitable for indoor/out door use having moderate humidity and air pollution. The zinc coating thickness shall works out by applying a 610 gm of zinc per square meter surface with a approximate thickness of 80 micron. The zinc coating shall be smooth, clean and uniform thickness and free from defects like ash and dross inclusions, bare patches, black spots, pimples, lumpiness, rust stains, blisters etc. The galvanizing shall not adversely affect the mechanical properties of the coated material, the quality of the coating will 11

2.17.2

be established by tests as per IS-2633. All manufacturing process including punching, cutting, bending and welding of perforated cable trays shall be completed and burrs shall be removed before the application of galvanization process is applied. Zinc conforming to at least Grade Zn 98 as specified in IS-209-1966 shall be used for the purpose of galvanizing. 2.17.03 The joints of two trays shall be butt construction and shall be made with the help of coupler plates by nuts and bolts. The coupler plate and nuts and bolts shall also be properly hot dip galvanized, where the bends of the trays are required at site the same shall be supplied by the bidder without any extra cost. The spacing of rungs shall be max. 400mm centre to centre. While adopting the modules at site if cutting of any length is required the same shall be cut at site and joined by nuts and bolts with the help of coupler plates. 2.17.04 supporting i) The perforated cable trays shall be supported on the solid arrangement made from channel of minimum size 100x50mm and angle iron of size 50x50x6mm thick angle approximately at a distance of 0.1 to 1.2m center to center either from ground/wall or ceiling. However, the supporting system shall be designed by bidder suitable to bear the uniform load of 400N per 1000mm ladder length for 300mm wide tray. The calculations in respect of this design shall be supplied by the successful bidder during design stage. M.S. angle iron brackets shall be further supported/anchored either to wall or ceiling/ground as per the site requirement. The brackets and supporting system shall be painted with two coats of zinc chromate primer followed by two coats of synthetic enamel paint of approved colour conforming to relevant Indian standard. ii) Where perforated cables trays shall be routed in trenches, the necessary angle iron side support should be provided by the bidder. iii) The provision for fixing of brackets support system of vertical side of approach tunnel should be made by the bidder for fixing the supporting system. However, bidder is requested to visit the site before preparation of this bids. iv) Bidder is at its liberty to manufacture the cable supports arrangement at site or at his own workshop. Bidder shall have to bring all the tools/tackles, including welding machines etc. for the manufacturing of these cable supports. 2.17.5 The depth of trays shall be 30 mm and thickness 2 mm (min.) with width of 200 mm. Necessary standards equal and unequal 90 deg. Bends, tees and cross connections shall also be designed properly as per site requirement. The free vertical distance between parallel perforated trays/racks/ladder shall be at least 250mm and the perforated trays shall be 50mm away from the walls. The trays shall be fixed to the brackets with proper nuts and bolts system.

2.17.6

12

2.17.7

The perforated trays shall be free from sharp edges and burns etc. so that joint between two trays shall be without any clearance and matched in proper shape. At the bends the curvature in all axis of perforated trays/racks shall be 20R or maximum size of cable. The supporting brackets/fixing bolts size shall be so calculated that the design load as specified under sub clause of clause 2.17 does not exceed. The perforated trays shall be installed in such a way that as far as possible the cables can be laid directly in place rather than be pulled through. The current carrying cables shall be laid separately than the H.T. cables, L.T. cables and D.C. cables shall be laid in different trays. The cables shall be fixed in the perforated trays by means of plastic ties or plastic coated wires etc. The number of perforated tray shall be sufficient in order to accommodate all the power D.C. cables indicated in the specification for cables. However, the approximate quantity of different trays have been given under clause 2.21, which can be ensured by the bidder by visiting the site before filling the tender. EARTHING: The perforated cable trays along with their supporting arrangements shall be properly earthed by the supplier with nut and bolts from the earthing risers provided by purchaser, generally in the vicinity of the tray routing. The earthing shall be as per latest I.E. rules and IS/IEC recommendation. The size of earth connection shall be such that its conductance should be more than the conductance of 14 sq.mm. copper conductor cross section.

2.17.8

2.17.9 2.17.10

2.17.11 2.17.12

2.17.13

2.18

2.19

CO-ORDINATION WITH OTHER CONTRACTOR During the execution of this contract, other contractor shall also be working in the Pump House and Sub-Station. The supplier shall, therefore, coordinate with other contractors to avoid any dispute with other contractor during execution of this contract.

2.20

FABRICATION OF TRAYS All fabrication of trays shall be in accordance with IS:800 and as per the approved drawings unless otherwise specified. All material shall be straight and if necessary before being worked, shall be straightened and/or flattened by pressure unless required to be of curvilinear form and shall be free from twists. Before cutting the steel, measurement should be done by appropriate gauge and according to the drawing. 13

Shearing or flame cutting may be used provided the resulting edge shall be reasonably clean and straight. Sheared members shall be free from distortion at sheared edges, when gas cutting is adopted, the flame cut edge shall be machined to a depth of 3 to 5mm. The welding and the welded work shall generally conform to IS:816 & IS:9595. Unless otherwise specified. The welding surfaces shall be smooth, uniform & free from fins, tears, notches or any other defect which may adversely affect welding and shall be free of loose scale, slag, rust, grease, paint moisture of any other foreign material. The welding procedure shall be so arranged that the distortion and shrinkage stresses are reduced to a minimum and that the welds meet the requirement of quality. 2.21 SCHEDULE OF REQUIREMENT OF PERFORATED TRAYS The schedule of requirement of trays shall be calculated from the drawings and can vary 15% as per site requirement. Description Transformer Hall & Power House etc. 2.22 2.22.1 Trays of 300 mm size 3000 m

SUBMISSION OF DRAWINGS AND DOCUMENTS: Submission alongwith Tender: Based on the specification write up and specification drawings the contractor shall submit the following drawings/documents and information with the tender:a) Drawings showing dimensional details and constructional features of all components including the following:i) ii) Cable trays and accessories Typical supporting arrangements in various locations

iii) Typical cable trays layout arrangement (showing typical bends,, T-offs, branching, reducers, coupler etc.) iv) Typical dimensional details of glands and lugs for various sizes/types v) Typical drawings for control and 415V and 22 kV termination and jointing showing splicing, glanding, lugs, screen/armour earthing etc. b) Descriptive literature, and manufacturing details. catalogues, giving design features

14

c) Installation and maintenance instructions. d) Evidence of type tests and special tests conducted on similar type of equipment/component. 2.21.2 2.21.2.1 Submission during contract: Within 60 days of the placement of order the contractor shall furnish at least 7 sets of documents showing the following for approval. i) Make, dimensional details and technical specification and catalogues of the various components such as glands, lugs, ferrules, sleeves etc. Typical samples of items like ferrules, glands, lugs, cable lugs shall also be given. ii) and Write up erection procedure for cable trays, termination including site testing of cables. iii) 2.21.2.2 Cable routing diagrams above documents, 7 cable laying

15 days after the approval of copies of drawings/documents shall be submitted.

2.21.2.3

Based on the layout/foundation drawings of Sub-Station and other sites which shall be handed over to the successful bidder during detailed engineering, the contractor shall prepare and submit seven sets of erection drawings for cable facilities showing various cross section of cable, tray facilities, cable tray number, supporting arrangement, plan, elevations etc. for various areas of sub-station. The drawings shall be approved by SJVNL and erection of cable facility at site shall be done according to these drawings any modification at site, if required, shall be marked upon these drawings and sketches/revised drawings got approved from the site/project authorities. The contractor shall furnish 1 (one) reproducible and 7 (seven) prints each of the "As Built" drawings of cable facilities to customer for information and record. While doing cable laying as per the cable schedules the contractor shall write down/enter the actual route followed by him. This shall be entered on two spare sets of cable schedules and returned to the customer (1 set each)

2.21.2.4

15

ANNEXURE-D-I SCHEDULE OF REQUIREMENT FOR FRLS POWER CABLES Sr. No. 1. Description 22kV Aluminum Conductor unarmored FRLS, XLPE Power Cable: i) 3-C 95 mm2 Qty. 1200 m Unit Price Ex-works/m Total Amount

2. Date: Place:

1.1 kV Grade, Aluminum Conductor unarmored FRLS PVC Cable for L.T System. 1)1C 400 mm2 Cable trays 300 mm wide and accessories

10800 m

3000 m Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company 16

ANNEXURE-D-II SCHEDULE FOR ERECTION, TESTING & COMMISSIONING OF POWER & D.C. CABLE,TRAYS AND CABLING

Sr. No. 1.

2.

3.

Description Erection/site assembly of supporting system for cable trays, i/c erection of cable trays on supporting system including anchor bolts washer etc. for typical supporting arrangement per 100 mtr. run. Laying, fixing, termination including lugging ferruling providing cable glands etc. as per Clause No. 2.15 of the specification and complete testing and commissioning of different sizes of the power cables as per given in the schedule of requirement Annexure-D-A. Laying, fixing, termination including lugging ferruling providing cable glands etc. as per Clause No. 2.15 of the specification and complete testing and commissioning of different sizes of the LT and DC cables as per given in the schedule of requirement Annexure-D-B .

Qty. Meter

Rate Per 100 meter run

Total cost

Meter

Per meter

Meter

Per meter

Optional item (not to be evaluated) Bidder should quote unit rate of glands etc. of each size of any addition/deletion of work.

Date: Place:

Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company 17

Annexure-D-A 22kV XLPE/FRLS CABLE REQUIREMENT Sr.No. 1. From 22kV over head structures (near portal of main access tunnel) To Type of Cable XLPE 3 Core unarmoured Size (mm2) 95 mm2 Length (Meters) 1200

2.

From DG incomer panel at Pot Head Yard

Transformer hall crown up to 24 kV incoming panel and then outgoing panel to HV bushing of 2.5 MVA Transformer at EL-1062 m. LT Panel incomer FRLS cable DG panel at EL-1062 m

1C400 mm2

10800

Note:- The quantity of 22 kV & LT cable is tentative and can vary 15% as per site conditions.

18

Annexure-D-B

LT, DC CABLES TO BE LIFTED FROM JHAKRI STORE FOR THE PURPOSE OF LAYING, TERMINATION ETC.: A: LT CABLES

Sr.No. 1. 2. 3. 4.

Description of Cable Al - 3 1/2 PVC FRLS Cable Al - 3 1/2 PVC Al - 3 % PVC Al - 1C 300 mm PVC

Size 35mm2 150 mm2 300 mm2 300 mm2

Length 1300 mtr. 50 mtr. 1250 mtr. 4200 mtr.

B: DC CABLES: Sr.No. 1. 2. Description of Cable Cu, 2c, PVC Cu, 2c, PVC Size 16mm2 25 mm2 Length 300 mtr. 100 mtr.

Note:- The quantity of LT and DC cables to be lifted from Jhakri Store is tentative and can vary 15% as per site conditions.

19

SCHEDULE-D-III SCHEDULE OF TECHNICAL DEVIATIONS

Sl. No.

Vol. No.

Clause No.

Page No.

Deviation/ Variation

Extra price to be paid in case deviation is required to be withdrawn by the bidder

Bidder's Guarantee: We guarantee that the above deviations in no way shall adversely affect the performance and other requirements of the equipment stipulated in the specifications.

Date: Place:

Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company
20

SCHEDULE-D-IV SCHEDULE OF TECHNICAL DATA PARTICULARS OF POWER CABLE

A. 1.0 1.1

POWER CABLE General: Manufacturer's name and address Location of factory Cable Wire Type and size of cable Standard applicable Voltage rating Permissible variation in voltage frequency and combined voltage and frequency Suitable for earthed/unearthed system No. of cores Conductor and its hardness Standard applicable Material copper/aluminium/grade Nominal cross-sectional area Form of conductor circular/shaped No. of strands Nominal dia of each strand

22 kV

1.2 2.0 2.1 2.2 2.3 2.4 2.5

2.6 3.0 3.1 3.2 3.3 3.4 3.5 3.6

21

3.7 3.8

Whether strands are tinned or not Temperature co-efficient of resistance at 20 deg.C. Conductor Screen Standard applicable Material Minimum thickness Whether extruded Insulation Standard applicable Material (mention type) Minimum average thickness Tolerance on the smallest of the measured values of thickness of insulation Dia of core over insulation (a) Minimum volume resistivity at 27 deg. C. (b) Minimum volume resistivity at 70 deg.C.

4.0 4.1 4.2 4.3 4.4 5.0 5.1 5.2 5.3 5.4

5.5 5.6

5.7 5.8 5.9

Colour scheme of identification of cores Average dielectric strength Suitability with regard to moisture ozone, acid, oil and alkaline surroundings Insulator Screen
22

6.0

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

Standard applicable Whether extruded semi conducting screen is applied Material of the semi-conducting screen Thickness of the semi-conducting screen Whether extruded under triple extrusion process Whether copper type screening is applied Thickness of the copper tape For braided screen material and dia of screen wire and min. percentage coverage Inner Sheath Standard applicable Material thickness of inner sheath Whether extruded Minimum thickness of inner sheath Calculated diameter over stranded cores of the cables Whether the inner sheath and the filling material are suitable for the operating temperature of the cable

7.0 7.1 7.2 7.3 7.4 7.5 7.6

8.0 8.1 8.2 8.3

Outer Sheath/Overall Covering Standard applicable Material (mention type if any) Whether extruded

23

8.4 8.5

Minimum average thickness Tolerance on the smallest of the measured values of thickness of outer sheath Calculated dia. Under the sheath Whether anti-termite treatment has been given in the outer sheath Whether flame retardant low smoke compound added in outer sheath Electrical Properties Conductor resistance at 20 deg. C. per km. Maximum permissible conductor temperature: a) Under continuous full load b) Under transient conditions Loss tangent at normal frequency Reactance at 50 C/S per km. Capacitance at 50 C/S per km. Current ratings In air (continuous) In duct (continuous) Reference ambient temperature of the above Short circuit current rating for 1 sec. duration Derating factors For an ambient temperature of 50 deg.C. For grouping of 6 to 9 cables in cable trench/cable rack trays and in 4 to 6 tiers for different

8.6 8.7 8.8

9.0 9.1 9.2

9.3 9.4 9.5 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.7 9.7.1 9.7.2

24

spacings and also touching each other 10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 Mechanical Data Overall dia of the cable Dia of the cable under the sheath Diameter under armouring Diameter over the stranded cores Wight of cable per km. Drum length Tolerance on drum length Total weight of the drum Dimension of the drum Recommended minimum installation radius Maximum safe pulling force Whether identification as per clause 2.14 of the specification is being provided Whether packing has been done as per clause 2.13 of the specification CABLE TRAYS General Manufacturer's name and address Location of factory Type and size of a) Trays

10.13

B. 1.0 1.1

1.2 1.3

25

1.4 1.5

Standard applicable Thickness a) Trays b) Supports c) Brackets Earthing system Weight per 100 m a) Trays b) Supports c) Brackets

1.6 1.7

1.8

Distance between parallel Layer of trays Galvanisation of: a) Trays Nuts & b) Bolts

1.9

1.10 1.11

Painting of support system Supporting arrangement system

2.0 2.1 2.2 2.3 3.0 3.1 3.2 3.3 3.4 3.5

Cable Clamps Material Type Thickness Cable Termination Kit Manufacturer Applicable standard AC withstand voltage (ph/Ground & time duration) (kV) Partial Discharge at 1.1 ph/ground volt (Pc)

Impulse withstand 1.2/50 us (kV)

26

3.6 3.7 3.8 3.9

Short circuit current 1 sec (KA) Dynamic Short Circuit withstand (kV) Type test report for above tests plus for humidity and salt-fog tests furnished (Yes/No) Kit particulars: a) Material of tubling/ moulded part b) Method of stress control c) Method of environmental seal d) List of items included in the kit furnished (Yes/No) 1. 2. For termination For splices s

4.0 4.1 4.2 4.3

Cable lugs Make Type Material

4.4

Applicable Standard

5.0 5.1 5.2 5.3 5.4 6.0 6.1

Cable Glands Make Type Material Surface Treatment Fire Sealing System Type

27

6.2 6.3 6.4

Make Material of fire stop Pressure withstand capacity of fire stop system Weight of fire stop assembly Shelf life of fire stop material Life of fire stop assembly

6.5 6.6 6.7

Note:1. Bidder can supply above information for different types of cables.

28

SCHEDULE-D-V SCHEDULE OF TRANSPORTAITON WEIGHTS & DELIVERY PERIOD

Sr.No.

Item

Qty.

Shipping weights Tones/Units

Total length

Delivery date of components

Date: Place:

Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company 29

SCHEDULE-D-VI SCHEDULE OF STANDARDS & CODES APPLICABLE FOR MATERIALS COMPONENTS, MANUFATURE, ASSEMBLY, TESITNG, INSTALLATION & COMMISSIONING OF POWER CABLES, TRAYS ETC.

Sr.No. 1. 2. 3. 4. 5. 6. 7. Date: Place:

Subject/Title Material Components Manufacture Assembly Testing Installation (laying, fixing and connecting) Commissioning

Standard/Code

Other Remarks

Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company

30

SJVN Shimla

Manufacturer Name & Address

Manufacturing/Field Quality Plan QP No. Rev. No. Dated

Acceptan ce Norms

Project : Nathpa Jhakri H ydro Electric Project Ref. No. Supplier:

Item

Sr. No.

Component & operation

Characteri stics

Class

Type of Check

Quantum of Reference Sub-system check Document

Format of record

Agency M C S

Remarks

LEGEND M : MANUFACTURER C : CONTRACTOR S : SJVN INDICATE "P" PERFORM & VERIFIED BY QC DEPT "W" WITNESS AND "V" VERIFICATION MANUFACTURER /SUBCONTRACTOR CONTRACT

FOR SJVN USE

DOC. NO.

REVIEWED BY

NAME & SIGN OF APPROVI AUTHORITY & SEAL C/>

o
m
SIGNATURE NG D

c
I-

SCHEDULE-D-VIII SCHEDULE OF DELIVERY & COMPLETION PERIOD

Sl. No. Activity Period in days from the date of issue of LOI / LOA

1. 2. 3. 4. 5. 6.

Submission of general layout ,fixing arrangement drawings & design for approval of SJVNL Approval of above by SJVNL Order placement for bought out items (if any) by contractor Opening of site office at Jhakri by contractor Submission of cable schedule and remaining construction drawings and commencement of supplies Inspection of: i) 24 KV Switchgear ii) Sub-Station Transformer iii) 415 V ACDB/DG Set panel iv) Cable, Cable Tray & earthing v) Fire fighting arrangement

7.

Commencement of despatch of supplies of : i) 24 KV Switchgear ii) Sub-Station Transformer iii) 415 V ACDB/DG Set panel iv) Cable, Cable Tray & earthing v) Fire fighting arrangement

8.

Completion of receipt of material at Jhakri site i) 24 KV Switchgear ii) Sub-Station Transformer iii) 415 V ACDB/DG Set panel iv) Cable, Cable Tray & earthing v) Fire fighting arrangement

9.

Commencement of erection activities at site i) 24 KV Switchgear ii) Sub-Station Transformer iii) 415 V ACDB/DG Set panel iv) Cable, Cable Tray & earthing v) Fire fighting arrangement

10.

Completion of erection i) 24 KV Switchgear ii) Sub-Station Transformer iii) 415 V ACDB/DG Set panel iv) Cable, Cable Tray & earthing v) Fire fighting arrangement

11.

Testing, commissioning & taking over *The period should not be more than 150 days.

Date: Place:

Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company
32

SCHEDULE-D-IX RECOMMENDED SPARES Sr. No. Particulars/Description Qty. Remarks

Date: Place:

Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company 33

SCHEDULE-D-X SCHEDULE FOR SUBMISSION OF DRAWINGS Sr. No. Date: Place: Name of the Drawings When to be submitted (to be given in days after receipt of order) Signature of bidder Name: Status: Whether authorized attorney of tendering company Name of tendering Company
34