MAHAGENCO

Maharashtra State Power Generation Co. Ltd,

VOLUME : IIF/2

SECTION-IV

TECHNICAL SPECIFICATION
FOR
CABLES

Koradi TPS Expansion Project DCPL-K8A06

[3 x 660 MW] Main Plant Package
(PCA.CD-002.E577ELE3_CABLE.DOC)
 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,

CONTENT

CLAUSE NO. DESCRIPTION PAGE NO.

1.00.00 SCOPE OF SUPPLY V.II-F2/S-IV : 1

2.00.00 CODES & STANDARDS V.II-F2/S-IV : 1

3.00.00 DESIGN CRITERIA V.II-F2/S-IV : 2

4.00.00 SPECIFIC REQUIREMENTS V.II-F2/S-IV : 3

5.00.00 TESTS V.II-F2/S-IV : 8

6.00.00 DRAWINGS DATA & MANUALS V.II-F2/S-IV : 10

ATTACHMENTS

ANNEXURE-A H.V POWER CABLES (11 & 3.3 KV) V.IIF-2/S-IV : 12

ANNEXURE-B L.V POWER CABLES V.IIF-2/S-IV : 14

ANNEXURE-C CONTROL CABLES V.IIF-2/S-IV : 15

ANNEXURE-D 1.1KV FS POWER CABLE V.IIF-2/S-IV : 16

ANNEXURE-E 1.1KV FS CONTROL CABLE V.IIF-2/S-IV : 18

ANNEXURE-F CABLE SIZES V.IIF-2/S-IV : 19

Koradi TPS Expansion Project DCPL-K8A06

[3 x 660 MW] Main Plant Package
(PCA.CD-002.E577ELE3_CABLE.DOC)
 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,

VOLUME : IIF/2

SECTION-IV

TECHNICAL SPECIFICATION
FOR
CABLES

1.00.00 SCOPE OF SUPPLY

1.01.00 Power and Control Cables shall cover the requirement of entire Plant including
the switchyard. The cables shall be furnished in accordance with this
specification and annexure.

Other cables including special cables if any which are necessary as per proven
engineering practice for satisfactory & trouble free operation of the entire cable
system of the main plant shall also be within the scope of supply. These shall
include all such cables for electrical integral with mechanical equipment
systems and subsystems.

1.02.00Cable shall be furnished in accordance with this specification and the following
annexures :

a) 11 kV & 3.3 kV Power cables : Annexure - A

b) 1100V Power Cables : Annexure – B

c) Control Cables : Annexure – C

d) Fire Survival Cables : Annexure – D&E

1.03.00 All relevant drawings, data and instruction manuals.

2.00.00 CODES & STANDARDS

2.01.00 All cable and materials shall be designed, manufactured and tested in
accordance with the latest applicable Indian Standards (IS) and IEC except
where modified and/or supplemented by this specification.

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Maharashtra State Power Generation Co. Ltd,

2.02.00 Cable and material conforming to any other standard which ensures equal or
better quality, may be accepted. In such case, copies of the English version of
the standard adopted shall be submitted along with the bid.

2.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended upto date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.

3.00.00 DESIGN CRITERIA

3.01.00 Cables will be generally laid on ladder type trays, perforated type cable trays or
drawn through rigid steel conduits.

3.02.00 For continuous operation at specified rating, maximum conductor temperature

shall be limited to the permissible value as per relevant standard and/or this
specification which one is more stringent.

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

3.04.00 Armouring shall be single round wire of galvanized steel for multicore cables
and aluminum for single core cable for power and control cables. For fire
survival control cable, the armouring over inner sheath shall consist of single
layer of wire / round galvanised steel wire as per IS 3975 amended upto date.
For Fire survival power cable, Single core cables to be used in A.C. system,
the armouring over inner sheath shall consist of single layer of round copper
wire, for multi-core cables to be used in A.C. system and single/two core cables
in D.C. System, the armouring over inner sheath shall consist of single layer of
INNER & round galvanised steel wire.

3.05.00 The outer sheath shall have flame retardant low smoke halogen evolution
(FRLSH) characteristics or fire survival characteristics as applicable and shall
meet the requirements of additional tests specified for the purpose.

3.06.00 Core identification for multicore cable shall be provided by colour coding.

3.07.00 HT cables shall be manufactured by triple extrusion dry cured (CCV) process
using pressurized nitrogen.

4.00.00 SPECIFIC REQUIREMENTS

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 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,

4.01.00 General Description

All Cables shall be furnished in strict compliance with ratings and requirements
and sizes as given in Annexures to this Specification.

4.02.00 Drum Length and Tolerance

SINGLE
The cables shall be supplied in non-returnable packing steel drum for 11 kV &
3.3 kV power cables, wooden drums for 1100V power and control cables,
each containing minimum 500 meters length of larger sizes of cable unless
specifically asked for. For smaller sizes of cables, each drum shall contain
MINIMUM 1000 meters length of cable. Allowable tolerance on individual drum length is
+5%.
SINGLE
4.03.00 Non-Standard Length

Owner/Purchaser may accept non-standard lengths upto 5% of the total

ordered quantity. However the Contractor will be required to obtain Owner's/
Purchaser’s approval before packing the Cables on drums. Non-standard
lengths shall not be less than 100 metres in any case.

4.04.00 Cable identification

Cable identification shall be provided by embossing on every meter on the

outer sheath the following :

a) MSPGCL

b) Manufacturer’s name or trade mark

c) Voltage grade

d) Year of manufacture

e) Type of insulation, e.g. XLPE/PVC/HR85 /IE2 etc.

f) No. of core and size of cables.

g) Type of improved fire performance, e.g. FR/FR-LSH/FS

h) IS number
i) ISI MARK
4.05.00 Packing
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[3 x 660 MW] Main Plant Package
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 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,

4.05.01 Cables shall be supplied in non returnable drums. The drums shall be of heavy
construction. All wooden parts shall be manufactured from seasoned wood. All
ferrous parts used shall be treated with suitable rust preventive finish or coating
to avoid rusting during transit or storage. Wooden cable drum shall be treated
by immersing in copper-nitrate solution. Drum number shall be indicated in cable drum.

4.05.02 Cable shall be wound and packed on drums in such a manner that it will be
properly sealed and firmly secured to the drum. The ends of each length shall
be sealed before shipment. Heat Shrinkable seal shall be used for this cable

4.05.03 The cable drums should carry the following details in printed form:

a) MSPGCL

b) Manufacturer’s name or trade make

c) Type of cable & voltage grade

d) Year of manufacture

e) Type of insulation e.g. XLPE/HRPVC/IE2

f) No. of core and size of cables

g) Cable code e.g. FRLS/FS

SINGLE
h) Length of cable on drum

i) No. of length on drum, if more than one

j) i) Direction of rotation, by arrow

k) j) Approx. gross mass.

l) k) IS/IEC number and ISI mark

4.05.04
4.06.00 Joints and Terminations

Materials of construction for a joint/termination shall perfectly match with the

dielectric chemical and physical characteristics of the associated cables. The
material and design concepts shall incorporate a high degree of operating
compatibility between the cable and joints. The protective outer covering
(jacket) used on the joints/terminations shall have the same qualities as that of
Koradi TPS Expansion Project DCPL-K8A06
[3 x 660 MW] Main Plant Package
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 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,

4.06.08 Separate cables for each type of following services/functions as applicable shall be
used for each feeder. Same multicore cable using different services shall not be
acceptable.

a) Power.

b) Control, interlock and indication.

c) Metering and measuring.

d) Alarm and annunciation.

e) C.T. Cables.

f) V.T. Cables.

4.07.00 Cable Identification

Cable identification shall be provided by embossing on the outer sheath the

following :

a) Manufacturer's name or trade mark MSPGCL

b) Manufacturer's name or trade mark

c) Voltage grade

d) Year of manufacture

e) Type of insulation, e.g. XLPE,HRPVC & IE2 etc.

h) Reference standard
f) No. of core & size of cables i) Non-erasable sequential cable length
marking at interval of 1 (one) meter throughout
g) Type of outer sheath e.g. FRLSH, FS etc. the drum length.
j) ISI Mark
4.08.00 Selected sizes of power and control cables are given in Annexure-F.

4.09.00 Fire Survival Cables shall be used for important auxiliaries / area as
recommended by Standard Technical Specification by CEA as below for the
following :

Fire Survival Power & Control Cables shall be used for important
auxiliaries/areas like-

i. DC emergency lube oil pump

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[3 x 660 MW] Main Plant Package
(PCA.CD-002.E577ELE3_CABLE.DOC) V.II-F2/S-IV : 7
 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,

ii. DC hydrogen seal pump

iii. Turbine lube oil pump/barring gear

iv. DC emergency lighting for main building and service building

v. DC cables for battery to charger & DC distribution boards

vi. Jacking oil pump

vii. Emergency turbine trip in control room

viii. Boiler Turbine : Generator inter trip which include the interconnection
between

• Boiler master fuel trip and turbine trip relays

iX) Scanner air fan & fire/smoke • Generator trip relays & turbine trip relays
detector system • Generator trip relays & generator breaker
• Generator trip relays & field breaker
• Generator trip relays & unit auxiliary transformer breaker
• Incomer cables for DG board, emergency board, DC lighting board
etc.

5.00.00 TESTS

5.01.00 Shop Tests

The Cables shall be subject to shop tests in accordance relevant IS/IEC

standards to prove the design and general qualities of the Cables as below: -

5.01.01 Routine tests on each drum of cables. or less number of

5.01.02 Acceptance Tests on 1 drum out of every 10 drums chosen at random for
acceptance of the lot for every size. type and size of cable.

5.01.03 Type test on each type and size of cable, inclusive of measurement of armour
DC resistance of power cables on one drum out of every 10 drums of cable.
On one sample cable drum selected on random
basis in each lot. size of cable shall be read in sq.
mm in conjunction with number of cores. Type of
5.02.00 Additional Tests cables shall mean voltage grade, XLPE, HRPVC,
FRLS, FS etc.

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[3 x 660 MW] Main Plant Package
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 MAHAGENCO
Type &
Maharashtra State Power Generation Co. Ltd,

Following additional acceptance tests shall also be performed on each type of

cables having outer sheath with improved fire performance (Type FRLSH,FS):

5.02.01 Oxygen index test Inner &

The Oxygen index shall not be less than 29.

5.02.02 Temperature Index Test

The measured value of temperature index shall be 21 at a temperature of

250°C for FRLS cables and 350°C for FS cables

5.02.03 Flame Retardance test on single cable and on bunched cables

After the test, there should be no visible damages on the test specimen within
300mm from its upper end.

After burning has ceased, the cables should be wiped clean and the charred or
affected portion should not have reached a height exceeding 2.5 meter above
the bottom edge of the burner, measured at the front and rear of the cable
assembly. 3 Hours fire rating test shall be carried out for FS cable as per
IEC331

5.02.04 Halogen acid gas evolution test

The level of HCL evolved shall not exceed 20 per cent by weight. HCL evolved
shall not be exceed 2% for FS cable.

5.02.05Smoke density test

The cables shall meet the requirements of light transmission of minimum 40%
after the test. Minimum transmission shall be 80% for FS cable.

5.02.06Test for specific optical density of smoke

The cables shall meet the requirements of IS/IEC.

5.02.07 Test for rodent & termite repulsion property

The test shall be carried out to note the presence of rodent and termite
repelling chemical in PVC compound. Normal procedure is that a few
chippings of the PVC compound are slowly ignited in a porcelain dish or
crucible in a muffle furnace at about 600°C. The resulting ignited ash is boiled
with a little ammonium acetate solution (10%). A drop of aqueous sodium
Koradi TPS Expansion Project DCPL-K8A06
[3 x 660 MW] Main Plant Package
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 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,

sulphide solution is placed on a thick filter paper and it is allowed to soak.

The spot is touched with a drop of above extract. A black spot indicates the
presence of anti-termite & rodent compound.

Flammability test shall be carried on finished cables as per following

standards-

a) Swedish Chimney test – SS:424-14-75

b) IEEE std.383 – 1974 latest

c) IEC std. 332-1 and IEC 331

5.03.00 Test Witness

Tests shall be performed in presence of Owner/Purchaser's representative.

The Contractor shall give at least thirty (30) days' advance notice of the date
when the tests are to be carried out.

5.04.00 Test Certificates

5.04.01 Certified reports of all the tests carried out at the works shall be furnished for
approval of the Owner/Purchaser.

5.04.02 Test reports shall be completed with all details and shall also contain IS/IEC
specified limit values, wherever applicable, to facilitate review.

5.04.03 The cables shall be dispatched from works only after receipt of Owner/
Purchaser's written approval of the test reports.

6.00.00 DRAWINGS, DATA & MANUALS

6.01.00 Drawings, Data and Manuals shall be submitted with the bid and for approval/
reference and subsequent distribution after the issue of Letter of Intent in
quantities and procedures as specified in General condition of contract and/or
elsewhere in this specification.

6.02.00 To be submitted with the Bid

Koradi TPS Expansion Project DCPL-K8A06

[3 x 660 MW] Main Plant Package
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Maharashtra State Power Generation Co. Ltd,

a) Manufacturer's catalogues giving cable construction details and

characteristics.

b) Cable current ratings for different types of installation, inclusive of

derating factors for ambient temperature, grouping etc.

c) Write-up on Manufacturer’s recommended method of splicing, jointing,

termination etc. of the cables.

d) Type test reports on 11 KV, 3.3 KV Power, LT FRLS Power & control,
FS power and control cables

e) Filled-up proposal particulars.

6.03.00 To be submitted after award of contract

6.03.01 Guaranteed Technical Particulars

6.03.02 Quality assurance plan

6.03.03 Shop Test reports

6.03.04 Instruction manuals

The manual shall clearly indicate method of laying, termination, check-ups

and tests to be carried out before commissioning.

6.04.00 The bidder may note that the drawings, data and manuals listed herein are
minimum requirement only. The bidder shall ensure that all other necessary
write-up, information, etc required to fully describe the cable are to be
submitted with the bid.

Koradi TPS Expansion Project DCPL-K8A06

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 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,
ANNEXURE-A

RATINGS AND REQUIREMENTS

(POWER AND CONTROL CABLE)

11 KV & 3.3 KV Power Cable

1.0 11000/11000V & 3800/6600V grade 900 C continuous rating under normal
condition and 2500 C rating under short circuit condition heavy duty XLPE
power cable suitable for use in 11000V/3300V non-effectively earthed system
conforming to following requirement and in line with IS-7098, IS-8130, IS-5831
& IS-3975 ,manufactured by Triple Extrusion Dry Cure(CCV) process using
pressurized Nitrogen. Circular

1.1 Conductor : Stranded and compacted aluminium

conductor of grade H2 & class 2 for all
sizes,generally conforming to IS:8130.

1.2 Conductor Screen : Extruded semi-conducting compound.

1.3 Insulation : Extruded cross linked polyethylene

(XLPE) conforming to IS7098 (Part-2)

1.4 Insulation Screen : Extruded semi-conducting compound

with a layer of non-magnetic metallic
tape. For single core armoured cables,
the armouring shall constitute the
metallic part of screening. The
semi-conducting tape shall be easily
strippable.

1.5 Core Identification : By coloured strips applied on (For three

core cables) cores or by numerals.

1.6 Inner Sheath : Extruded HRPVC/FRLS compound

conforming to type ST2 of IS: 5831 for
three core cables. Single core cables
shall have inner sheath. Filler material
shall also be of type ST2 PVC.

Koradi TPS Expansion Project DCPL-K8A06

[3 x 660 MW] Main Plant Package
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 MAHAGENCO
Maharashtra State Power Generation Co. Ltd,
ANNEXURE-A

1.7 Armour : Galvanised single round steel wire

armour for twin and multicore cables.

Non-magnetic hard drawn aluminum

single round wire conforming to H4 of
IS-8130 latest for single core cables.

1.8 Overall Sheath : Extruded FRLSH HRPVC compound

conforming to type ST2 of IS: 5831.

1.9 Drum : Steel Drum

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