TECHNICAL SPECIFICATION FOR 220 KV XLPE CABLE

1.0 SCOPE OF SUPPLY

1.1 Design, manufacture, testing at works, inspection, packing, transportation and

delivery of 22 kms of 127/220 kV, 800 sq. mm. single core, compact stranded
copper conductor filled with swellable powder/yarn, conducting water swellable
tape with 50% overlap, triple extrusion (black semi-conducting conductor screen,
XLPE insulation, black semi-conducting insulation screen – all in one process),
conducting water swellable tape with 50% overlap, copper wire armoured, non-
conducting water swellable tape with 50% overlap, Poly Aluminium sheathed and
extruded HDPE outer sheathed cable to CESC Cable Yard/Site in Kolkata.

1.2 It is not the intention to specify completely herein, all details of design and
construction of the equipment. However, the equipment shall conform in all
respects to high standards of engineering, design and workmanship and be
capable of performing in continuous commercial operation up to the VENDOR’S
guarantee in a manner acceptable to the PURCHASER, who will interpret the
meaning of drawings and specifications and shall be entitled to reject any work or
material which in his judgment is not in full accordance therewith.

2.0 GENERAL

2.1 Project Information

(i) Purchaser - CESC Ltd., CESC House, Kolkata – 700 001

(ii) Name of Project - Evacuation of Power from Budge Budge
Generating Station Unit-III
(iii) Location - Kolkata Metropolitan Development Area
(iv) Nearest Railway Station - Howrah and Sealdah
(v) Nearest Airport - Netaji Subhas Airport
(vi) Altitude - Approximately 3M above M.S.L.
(vii) Data for Seismic Details
(a) Zone - Rare (Zone IV)
(b) Basic Horizontal
Seismic Co-efficient - For details information refer to Section II of
IS:875

2.2 System Parameters

(i) Nominal Voltage - 220 kV

(ii) Highest System Voltage - 245 kV
(iii) Voltage Variation - +10% and –12.5%
(iv) Frequency - 50 Hz
(v) Frequency Variation - +3%
(vi) Combined Voltage and
Frequency Variation - 10%
(vii) No. of Phase per Circuit - 3
(viii) Earthing System - Effectively earthed
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(ix) Fault Level - 40 KA rms 3 phase symmetrical equivalent to

15,240 MVA at 220 kV 3 phase 50 Hz for 1 sec.
(x) Impulse Withstand
Voltage having 1.2/50 µs
wave form (10 shot
positive, 10 shot negative) - 1050 kV peak

2.3 Installation Data

(i) No. of Circuits - Two

(ii) Type of Laying - Three single core cables will be laid directly in
the ground in trefoil formation at a depth of 1.5
metres from the surface to form one circuit. 2.5%
of the total length will be laid within HDPE
pipes.
(iii) Temperature a) Max. Ambient temperature : 45o C
b) Max. daily average ambient temperature : 35o C
c) Max. soil temperature at cable depth of 1.5 m :
30o C
(iv) The variation between daily maximum and minimum temperature is of the order
of 15o C
(v) Characteristics of Soil - Presence of micro-organisms mostly in the clay
soil shall be taken into account
(vi) Thermal Resistivity of Soil - 150o C Cm/W Maximum
120o C Cm/W Average
(vii) Type of the Road Surface - Asphalted, paved and levelled ground
(viii) Relative humidity a) Maximum : 100%
b) Minimum : 10%
c) Average annual rainfall : 750 mm
d) Average no. of thunderstorms in a year : 30
e) Average no. of rainy days per year : 50
f) Rainy months : June to October
(ix) Climatic conditions - Hot, humid and dusty
(x) Maximum wind pressure - 200 kg/sq. m.
(xi) Cable Termination - Cable shall be terminated at outdoor on
fabricated steel structure.

3.0 CABLE DETAILS

(i) Standard according to which cable system

is to be tested - IEC 62067 up to date
(ii) Rated Voltage - 127/220 kV
(iii) Conductor filled with Swellable Power/Yarn:
(a) Material - Copper
(b) Grade - Plain untinned annealed
(c) Nominal cross-sectional area - 800 sq. mm.
(d) Approx. diameter of conductor - To be specified
(iv) Longitudinal Moisture Barrier over Conductor:
(a) Material - Semi-Conducting Swellable
Type (with 50% overlap)
(b) Nominal thickness - 0.4 mm
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(v) XLPE Insulation:

(a) Nominal thickness of insulation for different
make cables varying between - To be specified
(b) Specified insulation resistance at 90o C
conductor temperature - 1 x 1012 ohm cm
(c) Dia over insulation varying between values for - Min./Max.
different makes - To be specified
(vi) Impulse withstand voltage 1.2/50
micro-second wave - 1050 kVp
(vii) Power Frequency withstand voltage - 318 kV (rms) for 30
minutes
(viii) Conductor Screen:
(a) Material - Extruded Semi-Conducting
Layer
(b) Nominal thickness - 2.0 mm
(ix) Insulation Screen:
(a) Material - Extruded Semi-Conducting
Layer
(b) Nominal thickness - 1.5 mm
(x) Approx. dia. over insulation screen - Min./Max. - To be specified
(xi) Longitudinal Moisture Barrier over Insulation
Screen:
(a) Material - Semi-Conducting Swellable
Type (with 50% overlap)
(b) Nominal thickness - 0.4 mm
(xii) Concentrate Metallic Screen:
(a) Material - Round copper wire
(b) Nominal Diameter of wire - To be specified
(c) Screen Current corresponding to the rated - To be specified
current of cable with both ends of screen
earthed
(d) No. of wires - To be specified
(xiii) Longitudinal Moisture Barrier over metallic
screen wire:
(a) Material - Non-Conducting Swellable
Type (with 50% overlap)
(b) Approx. thickness - 0.4 mm
(xiv) Radial Moisture Barrier:
(a) Material - Poly-Aluminium
(b) Approx. thickness - 0.3 mm
(xv) Radial clearance allowed under the above
Radial Moisture Barrier - 0.2 mm
(xvi) Protective outer serving :
(a) Type of composition - HDPE (ST-7 Type)
(b) Nominal thickness and tolerance - To be specified
(c) Test Voltage at works (for 1 minute) - 25 kV D.C.
(xvii)
(a) Nominal overall diameter of completed single
core cable - To be specified
(b) Nominal weight per metre of complete cable - To be specified
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(xviii) Coating - A hard baked layer of

graphite shall be applied
over the outer sheath as
outer electrode for testing
the sheath
(xvix) Recommended installation:
(a) Method of laying - Trefoil
(b) Method of earthing and sheath bonding system - Solidly bonded and earthed
for the main circuit at both ends
(xx) Continuous current rating at 90o C - To be specified and also to
furnish the detailed
calculation sheet as per IEC
60287 mentioning all the
system parameters taken
into consideration
(xxi) Short circuit current rating for conductor as
well as copper armour wire at 250o C - To be specified along with
detailed calculation sheet

Note: All the dimensional measurements given above are only indicative values
and may vary with different manufacturers.

Important: As premoulded stress cone (for Outdoor Termination) and premoulded joint
body (for Straight Through Joint) can accept small variation of insulated
core diameter, the maximum and minimum limits of insulated core diameter
mentioned in item iv(c) has got prime significance.

4.0 CODES AND STANDARDS

IEC 60060 High Voltage Test Techniques

IEC 60093 Recommended tests for volume and resistivity of electrical
insulating materials
IEC 60122 Recommended method for determining the comparative tracking
index of solid insulating materials under moist condition
IEC 60183 Guide to selection of high voltage cables
IEC 60216 Guide for the determination of thermal endurance properties of
electrical insulating materials
IEC 60228 Nominal cross sectional areas and composition of conductors of
insulated cables
IEC 60229 Test on cable over sheaths which have a special protective
function and are applied by extrusion
IEC 60230 Impulse tests on cables and their accessories
IEC 60243 Recommended method of tests for electrical strength of solid
insulating materials
IEC 60250 Recommended method for determination of permitivity, dielectric
dissipation factor of electrical insulation materials at power, audio
frequencies
IEC 60270 Partial Discharge measurements
IEC 60287 Calculation of continuous current rating of cables (100% load
factor)
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IEC 60811 Common tests methods for insulating and sheathing materials of
electrical cables
IEC 60815 Guide for selection of insulators in respect of polluted conditions
IEC 60885 Test methods for electrical cables – Part 2 – Partial discharge tests
IEC 60949 Calculation of thermally permissible short circuit currents, taking
into account non-adiabatic heating effects
IEC 62067 Power cables with extruded insulation and their accessories for
rated voltage above 150 kV – Test methods & requirements

5.0 GUARANTEES

The vendor shall guarantee that the material and workmanship of all components
and operation of the cable shall meet the requirement of IEC Standards. The
vendor shall submit Guaranteed Technical Particulars of the cable offered in the
enclosed format along with cross-sectional drawing of the cable and calculations.

6.0 DELIVERY

The schedule for delivery of cable and other items of materials shall be as per the
timeframe given by CESC. The delivery shall be guaranteed under liquidated
damages.

Bids offering delivery beyond the specified delivery period will be rejected.

Each drum of 220 kV cable should have cable length of 600 metres with a
maximum allowable variance of +5% of the overall drum length.

Net weight of cable drum along with the above length of cable should not exceed
13 tons.

7.0 INSPECTION AND TESTS

7.1 Inspection

The vendor shall make available to Purchaser’s representatives a complete set of

detailed drawings along with Quality Assurance Plan of the product, which will
be used by them to assist in the inspection.

7.2 Tests

Tests shall be made at the factory of the vendor/manufacturer on the individual

major components and on complete cable in accordance with relevant Indian and
International Specifications to determine the performance and operating
characteristics and to determine whether or not guarantees have been met with.

7.3 Type Tests

The vendor shall satisfy the purchaser that the cable offered has successfully
passed type tests.

Relevant type test certificates should be furnished along with the bids. Bids
without type test certificate are liable for rejection.
 …6…

7.4 Routine and Acceptance Tests

Routine and acceptance tests shall be conducted in accordance with IEC Standard
or any other Standard equivalent to or superior to IEC in the presence of
Purchaser’s representatives.

7.5 The vendor/manufacturer shall in addition indicate any special tests at works/site
recommended by them to ensure satisfactory operation of the cables and
accessories.

7.6 The tests can be modified at the discretion of the purchaser to omit or included
additional tests.

8.0 MANUFACTURER’S RESPONSIBILITIES

8.1 Manufacturing, Inspection, and Testing

(i) Manufacturing

The responsibility for manufacturing the cable as per specifications of the

purchaser shall be completely and solely that of the Manufacturer although the
Purchaser may carry out inspection at Manufacturer’s Works at different stages
during production and/or final testing after manufacture to ensure quality control.
The manufacturer shall be responsible for selection of materials as per agreed
specifications and shall use tested materials only. Material Test Certificates shall
be furnished and, in case they are not available, the manufacturer shall arrange for
the material to be tested at his expense. The manufacturer shall carry out all shop
floor running tests as specified.

(ii) Inspection, and Testing

The purchaser will carry out inspection and/or testing of the cable during and after
its manufacture to ensure the quality control and prompt deliveries and the
manufacturer will provide the necessary access and facilities. Inspection will be
carried out as per a schedule agreed with the manufacturer, at several stages
commencing from inspection of raw materials up to final testing before release for
shipment. The inspection and testing will also cover components supplied by the
Sub-Vendors. Inspection by the Purchaser shall not relieve the Vendor of the
responsibility for supplying cable conforming to the specification.

8.2 Packing and Transport

The responsibility for properly lapping the cable on the drum and packing it for
shipment shall be that of the manufacturer.
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8.3 Shipment

(i) Ocean shipment

The responsibility for shipment of cable drums by sea shall be that of the Vendor
and he shall comply with all the requirements of the contract, including all the
special requirements of the financing institutions as applicable.

(ii) Surface Shipment

The vendor shall be responsible for ascertaining the transport limitations by rail/
road and effecting shipment within the framework of these limitations. The
Purchaser may, however, assist him, if necessary, in approaching the authorities
concerned.

8.4 Unloading from carriers, customs clearance and forwarding to site

The responsibility for unloading from carriers at the port of arrival, clearance
through the customs and forwarding and unloading of cable drums at site/stores
shall be that of the Vendor, since the contract is for supply FOR (D) site/stores.
The Purchaser will provide the necessary import licence for clearance through the
customs and may also assist the Vendor, if required, in approaching the concerned
authorities for expeditious clearance to avoid demurrage, etc.

9.0 SHOP INSPECTION AND TEST PROCEDURES

9.1 General

(i) The Extra High Voltage cable covered by this contract shall be subjected to
inspection and testing. The Vendor/Manufacturer shall provide all services to
establish and maintain quality of workmanship in his works.

(ii) The representative of the purchaser shall have at all reasonable times access to the
Vendor’s premises or works and shall have the power at all reasonable times to
inspect and examine the materials and workmanship during manufacture.

(iii) The representative of the Purchaser shall within thirty (30) days from the date of
inspection as defined herein give notice in writing to the Vendor of any objection
to all or any equipment and workmanship, which in his opinion is not in
accordance with the ‘Contract’. The Vendor shall give due consideration to such
objections and shall either make the modifications that may be necessary to meet
the said objections or shall confirm in writing to the purchaser giving reasons
therein that no modifications are necessary to comply with the ‘Contract’.

(iv) The inspection by the representative of the Purchaser and issue of Inspection
Certificates thereon shall in no way limit the liabilities and responsibilities of the
Vendor in respect of the agreed quality assurance programme forming a part of
the ‘Contract”.
 …8…

(v) The Purchaser shall at all working hours have access to all parts of the Vendor’s
and his Sub-Vendor’s/Sub-Contractor’s factory where the items of the material
are being manufactured and shall be provided with all reasonable inspection
facilities by the Vendor. The inspection facilities shall include all necessary tools,
instruments, equipment and qualified operators to facilitate inspection.

(vi) None of the material to be furnished or used in connection with the contract shall
be despatched until shop inspection satisfactory to the Purchaser has been made.
However, such shop inspection shall not relieve the Vendor of his responsibility
for furnishing materials conforming to the requirements of the Contract nor
prejudice any claim, right or privilege which the Purchaser may have because of
the use of defective or unsatisfactory items of the Plant. Should the Purchaser
waive the right to inspect any item of the material, such waiver shall not relieve
the Vendor in any way from his obligation under the Contract. In the event of the
Purchaser’s inspection revealing poor quality of goods, the Purchaser shall be at
liberty to specify additional inspection procedures, if required, to ascertain the
Vendor’s compliance with the Equipment Specifications.

9.2 Material Tests

(i) In the event of the Purchaser being supplied with the particulars of tests, which
have been carried out for the Vendor by the suppliers of material, he may, at his
own discretion, accept the same as proper evidence of compliance with the
requirements of appropriate specifications for the materials.

(ii) The Vendor is to provide test pieces as required by the Purchaser to enable him to
determine the quality of material supplied under this contract. If any test piece
fails to comply with requirements, the Purchaser may reject the whole material
represented by the test piece.

9.3 Tests at Manufacturer’s Works

(i) General

The tests at works shall include electrical, chemical and physical tests in
accordance with the appropriate clauses of IEC and Indian Standards and in
addition, any test called for by the Purchaser to ensure that the material supplied
fulfils the requirements of the specification.

(ii) Test Certificates

Test Certificates including test records and performance curves shall be supplied
by the vendor. All the tests shall be carried out in accordance with the provisions
of this ‘contract’.

All test certificates must be endorsed with sufficient information to identify the
cable to which the certificates refer and must carry in the top right hand corner the
identification of the Purchaser and the ‘Contract’.
 …9…

10.0 GUARANTEE AND PATENT RIGHTS

With respect to the cable covered in the specifications, the Vendor/Contractor

shall provide the following guarantees to the purchaser.

10.1 Performance

The Vendor shall guarantee that the cable furnished by him shall be in full
accordance with the requirements of the enquiry specifications.

10.2 Quality

(i) The Vendor warrants that the cables are new and of high quality and that the
cables and accessories will be free of defects in design, materials or workmanship
for a period of 5 (five) years from the date of commissioning.

(ii) If within the stipulated guarantee period, the subject goods or any parts thereof are
found defective because of design, workmanship or materials, the Vendor shall, at
his own expense, repair or supply and install replacement parts of design,
workmanship and material as approved by the Purchaser. The guarantee period
for replaced parts or repair work in respect of cable shall be 5 years from the date
of replacement.

11.0 EMBOSSING ON OUTER SHEATH

The following details must be embossed on the outer sheath of the cable at a
regular interval of 2 (two) metres.

(i) Name the customer, i.e. CESC Limited

(ii) Conductor size, type of insulation and voltage grade
(iii) Manufacturer’s name

12.0 SPECIFICATION OF CABLE DRUM

The cables should be securely packed in non-returnable sturdy steel drums so as

to withstand rough handling during transportation and subsequent storage, steel
drums shall be suitably protected against corrosion.

The diameter of the barrel of the drum should be more than 20D-35D, where D is
the nominal outer diameter of the cable.

Each drum of 220 kV cable should have cable length of 600 metres with a
maximum allowable variance of +5% of the overall drum length.
 … 10 …

The following information shall be indicated by painting or stencilling on the

outside of both flanges:

(i) Manufacturer’s name with trademark

(ii) Type of insulation and voltage grade
(iii) Conductor cross-section and material
(iv) Cable drum number
(v) Length of the cable on the drum
(vi) Approximate gross weight of the drum
(vii) Year and country of manufacture
(viii) Direction of rotation of the drum (for ground movement)
(ix) Location of the cable outer end and inner end shall be marked distinctly
and differently by an arrow

The drum construction, cable placement on the drum and the installation of
protective wrappings and lagging, etc. shall be carefully co-ordinated to prevent
damage to the cable during normal handling and transportation.

Each cable end shall be hermetically sealed by means of water blocking

compound followed by heat shrinkable caps totally coated inside with mastic so
as to protect the cable from moisture penetration during transit, storage and
laying. Steel pulling socks capable of taking a pulling tension of 4.0 ton is to be
provided for each length of cable.

The vendor shall be responsible for any damage to the cables during transit due to
the cable or cable drum not having been properly fastened, packed and secured.

*****
RL