Page 1 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev.

‘1’

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

lR;eso t;rs

TECHNICAL SPECIFICATION
FOR
MANUFACTURE AND SUPPLY OF
SINGLE / MULTICORE 11 kV / 33 kV GRADE
XLPE INSULATED AND PVC SHEATHED
ARMOURED /UNARMOURED
POWER CABLES FOR ELECTRIC SUPPLY PURPOSES
IN INDIAN RAILWAYS
Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’
(January - 2010)
ISSUED BY
ELECTRICAL DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANIZATION
MANAK NAGAR, LUCKNOW - 226 011

S Amendment Revision Reason

N No. Date No. Date
 Specification Name – partially modified.
 Clauses 5.4, 5.5, 5.6, 5.7 5.8, 5.9, and 5.11 & 11.0 shifted to 5.8, 5.9, 5.11, 5.12, 5.6, 5.7
and 5.13 & 12.0 respectively, modified and sub clauses added for more clarification.
1. Nil NA 1st 27.01.10  New Sub Clauses 5.4, 5.5 and 11.0 incorporated in specification.
 Clauses 0.0(sub clauses added), 2.0, 5.10, 6.3.0, and 8.2 – (xii) are modified.
 Sub Clause 6.2.0 -details of test procedure incorporated, and 6.2.0-6 (Bleeding and
Blooming test for outer sheath) deleted, accordingly S.Nos. are modified.
 Clause11.0 - modified & rearranged and placed as Clause 12.0.

vuqeksfnr
Approved by

dk;Zdkjh funs’kd@bZ-,e-
Executive Director (EM)
Page 2 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

INDEX

Clause No. Description Page

0.0 Foreword 3

1.0 General 3

2.0 Scope 4

3.0 Climatic Condition 4

4.0 Standards 5

5.0 Cable Specification 6

6.0 Schedule of Tests 12

7.0 Drawings 15

8.0 Identification, Packing and Marking 16

9.0 Warranty 17

10.0 Infringement of patent rights 17

11.0 Sampling of Cable

12.0 Schedule of Guaranteed Performance 17

 Page 3 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

TECHNICAL SPECIFICATION FOR MANUFACTURE & SUPPLY OF XLPE

INSULATED AND PVC SHEATHED 11 kV / 33 kV GRADE ARMOURED /
UNARMOURED POWER CABLES FOR ELECTRIC SUPPLY PURPOSES

0.0 FOREWORD

This Specification defines the objective guidelines and requirements

for manufacture, testing and supply of 11/33 kV grade armoured /
unarmoured power cables consisting of XLPE insulation, PVC
sheathing and screened cable for general purpose electric supply
system on Indian Railways.

0.1 The need of drawing this specification is basically to standardize

uniform utilization of this safety item with additional physical
properties to cater the requirements of present geographical locations.

0.2 It is observed that considerable failures of XLPE cables occur in

service because of the damages take place due to improper storing /
handling of finished cables in the premises of the manufacturers as
well as at the site. Hence, to minimize the failures due to this reason,
storing / handling requirements of the finished cables have been
included.

0.3 To restrict the induction of less reliable (use of conventional curing

method) cables in power supply and control system, the use of Triple
Extrusion with single (Common) Cross Head Extrusion technique and
dry cure cross linking process has been made mandatory.

0.4 In view of electrification being in progress in the Northern part of the

country where very often ambient temperature falls to very low value /
frost temperature, hence cold impact test for outer sheath has also
been made mandatory. At present this test is optional test in
IS : 7098 (Part-2)-1985.

1.0 GENERAL

1.1 This specification covers the manufacture, testing and supply of

11/33 kV grade XLPE insulated and PVC sheathed cable to be used
for taking supplies from over head transmission lines to the
substations owned by railways for further distribution.

1.2 The workmanship shall be in accordance with the best engineering

practices to ensure satisfactory performance and service life.

1.3 Railways/RDSO shall witness the type tests on the first order to be
carried out by the successful tenderer. The purchaser reserves the
right to witness the entire type test or any of the type tests as
considered necessary.
1.4 Unless brought out clearly, the offer/tender shall be deemed to
conform to this specification scrupulously. All deviations from this
specification shall be brought out in the schedule of deviations. Any
Page 4 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

deviation between the specifications and the tender offered if not

clearly brought out in the schedule of deviations shall not be
considered as valid deviation.

1.5 The tenderer shall furnish the following information:-

(i) Name of manufacturer & country of manufacture.

(ii) Credentials of firm as manufacturer of up similar cable
(iii) Description of cable of similar capacity to that quoted, supplied
and installed during the last five years with the name of the
parties/buyers to whom supplies were made, size of cable, date
of installation and performance certificate thereafter.
(iv) Details of testing facilities at manufacturer’s works.
(v) Whether manufacturer has technical collaboration with another
firm, if so provide details regarding the same.

1.6 The tenderer shall bring out clearly any additional feature which he
deems fit to include to give a complete and comprehensive offer. He
shall, however, explain reasons for offering such additional
features/items in his proposal.

2.0 SCOPE

The scope shall include manufacture and supply of 11kV/33 kV grade

single and multi core XLPE insulated, PVC sheathed, armoured /
unarmoured power cables. The cable shall be suitable for
withstanding 12.1kV/36.3 kV voltage respectively without degradation
in the performance and life of the cables.

3.0 CLIMATIC CONDITIONS

The XLPE cable covered under this specification shall be laid

underground up to a depth of 1.5 meter from the top of the soil.

The climatic condition specified in this clause are average conditions,

any specific conditions specified in the tender documents shall
override these.

Atmospheric (a) Max. Ambient temperature 50°C

temperature (b) Max. daily average ambient temp. 40°C
(c) Max. soil temp. at cable depth 35°C
(d) Minimum temperature: - 5°C
(-10°C in J&K area. Also snow fall in certain areas
during winter season)
Humidity 100% saturation during rainy season.

Reference site i) Ambient Temp. : 50° C

conditions ii) Humidity: 100%
iii) Altitude: 1000m (2000 m in J & K area) above
mean sea level.
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Rain fall Very heavy in certain areas.

Atmosphere Extremely dusty and desert terrain in certain areas.
during hot The dust concentration in air may reach a high value of
weather 1.6 mg/m³. In many iron ore and coalmine areas, the
dust concentration is very high affecting the filter and
air ventilation system.

Pollution level Humid and salt laden atmosphere with maximum. pH

value of 8.5, sulphate of 7mg per liter, max.
concentration of chlorine 6 mg per liter and maximum
conductivity of 130 micro siemens/cm.

Wind speed High wind speed in certain areas, with wind pressure
reaching 150kg/m²

4.0 STANDARDS
The XLPE cable shall conform to the following Indian Standards as
amended/revised till date unless stated otherwise, as applicable:

S.N. Specification No. Description

1. IS:7098 Part 2 - 1985 Cross linked polyethylene insulated PVC
sheathed cables.
2. IS 1255 – 1991 Code of Practice for installation and
maintenance of power cables upto and
including 33kV rating.
3. IS:9676-1987 Reference Ambient temperature for
electrical equipment.
4. IS: 8130 – 1991 Conductors for insulated electric cables
and flexible cords.
5. IS: 3043 – 1991 Code of Practice for earthing.
6. IS: 3975 – 1992 Mild steel wires, formed wires and tapes
for armouring of cables.
7. IS: 5831 – 1991 PVC insulation and sheath of electric
cables.
8. IS:10462-1983 Fictitious calculation method for
determination of dimensions of protective
covering of cable’s
9. IS:10810-1984 Method of tests for cable’s
10. IS:10418-1982 Drums for electric cable’s
Other standards shall be applicable provided the stipulation of such a
standard is at least equal to the requirement of the specified
standards.

5.0 CABLE SPECIFICATION

5.1 System Parameters:
Page 6 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

The brief particulars of the 11kV/33kV system parameters are:

1. Nominal System Voltage 11 kV 33kV

2. Highest System Voltage 12.1kV 36.3kV
3. Impulse withstand voltage 75kV(peak) 170kV(peak)
(1.2/50 micro Seconds wave
of positive/negative Polarity)
4. System Frequency 50Hz 50Hz
5. System Earthing Solid Solid
6.
7. Five minutes power 17 kV ac rms 48 kV ac rms
frequency withstand voltage
(rms)
8. Conductor continuous temp 90°C 90°C
9. Conductor short circuit 250°C 250°C
rating temp.
10. Armour maximum 200°C 200°C
temperature under short
circuit.

5.2 CABLE

5.2.1 The cross linked polyethylene insulated (XLPE) cable shall be

manufactured with Triple Extrusion using single (Common) Cross
Head Extrusion technique and dry cure cross linking process.

5.2.2 The cable shall be suitable for laying in an area likely to be flooded by
water and shall be designed to be protected against rodent and termite
attack.

5.2.3 To make the cable water tight, semi-conducting moisture barrier ie

water blocking tape shall be applied over the core (under copper
screen) to prevent water penetration in the cable. The tape shall be of
non-woven material having non-biodegradable characteristic.

5.2.4 The cable shall be bonded at both ends during installation.

5.2.5 STORAGE

In order to avoid the damages to the cable during storage at the

manufacturers’ works following shall be ensured:

(i) Cable drums should be stored on dry hard and solid concrete
surface.
(ii) Sufficient space should be in between the drums for air
circulation.

(iii) The drums should on the wooden battens if supplied on wooden

drums. In no case, the drums shall be kept with flange
horizontal on the floor.
Page 7 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

(iv) Cable should be protected from direct sun rays.

(v) Drums should be protected from heavy rain fall during

monsoon.

(vi) Rolling of drums on the ground should be avoided as much as

possible. In case it is absolutely necessary, the drum should roll
in the direction of arrow marked on the drum.

(vii) The cable ends shall be sealed effectively to avoid ingress of

water in to the cable conductor.

5.3 CONDUCTOR

The tenderer shall quote for single/multi- core XLPE cable with plain
copper/Aluminum conductors which shall comply with the
requirement specified in IS: 8130-1984.

5.4 CORE IDENTIFICATION

Identification of cores shall be provided in line with the

recommendations contained in Clauses 13.1 and 13.1.1 of IS: 7098
(Part-2)-1985.

5.5 LAYING UP OF CORES

In three core cables, the cores shall be laid together with a suitable
right hand lay. The interstices shall be filled with non hygroscopic
material.

5.6 INSULATION

The Insulation envelope shall be of cross-linked polyethylene (XLPE)

insulation applied by extrusion. Insulation (XLPE) shall be clean
compound completely dust free & extrusion be done in chemically
clean environment.

The physical properties shall be as follow:

i) Tensile strength before ageing 12.5 N/m2 (min)

ii) Elongation at break before ageing 200% min

iii) Ageing in air oven

a) Treatment :
Temperature 135 ± 3º C
Duration 168 hrs.
b) Variation from corresponding values before ageing:

Tensile strength ± 25% max

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Elongation at break ± 25% max

iv) Hot set
a) Treatment: Temperature 200 ± 3ºC
Time under load 15 minutes
Mechanical stress 20 N/cm2

b) Elongation under load 175 % max

c) Permanent elongation after cooling 15% max

v) Shrinkage
a) Treatment: Temperature 130 ± 3º C
Duration 1 hour
b) Shrinkage 4% max
vi) Water absorption (gravimetric):
a] Treatment Temperature 85 ± 2º C
Duration 14 days
b] Water absorbed 1 mg/cm2, max
vii] Volume Resistivity:
a] at 27 º C 1x1014 ohm-cm, min
b] at 90 º C 1x1012 ohm-cm, min

5.6.1 The insulation compound shall be of high quality. It shall also be heat,
moisture, ozone and corona resistant.
XLPE compound should be of following makes:
a. Borealis, Sweden
b. NUC, Japan

The insulation shall be suitable for operation in wet or dry locations at

conductor temperature not exceeding 90ºC for normal operation, and
250ºC for short circuit conditions.

5.6.2 The Insulation shall be applied by extrusion and vulcanized using dry
curing process to form a compact homogenous body free from micro
voids and contaminants.

5.6.3 Thickness of the insulation and its tolerance shall be as per Clauses
11.2 & 11.3 of IS: 7098- Part- II, 1985.

5.7 INSULATION SCREEN

Screening shall be of smooth black semi-conducting compound firmly

bonded. The conductor screen, insulation and insulation screen shall
be extruded simultaneously in Dry Cure Process.

5.8 FILLERS AND INNER SHEATH

Filler & Inner sheath shall be either vulcanized /un-vulcanized rubber

or thermoplastic materials. Filler & Inner sheath materials shall be
Page 9 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

compatible with the temperature ratings of the cable and shall have
no deleterious affect on any other component of the cable.

5.8.1 In laid up cable cores shall be provided with inner sheath

applied either by extrusion or by wrapping. It shall be ensured
that it is as circular as possible. Inner sheath shall be so
applied that it fits up the cores closely and does not damage
insulation when removed.

5.8.3 In case of single core cables where there are both metallic
screening & armouring, there shall be extruded inner sheath
between them.

5.8.3 Thickness shall be as per Table-3 of IS: 7098-2-1985. Single

core unarmoured cables shall have no inner sheath.

5.9 ARMOURING

Armouring shall be of galvanized round/formed steel wire (IS: 3975 –

1999) or non magnetic metallic wire/strip (as agreed to between the
purchaser and the supplier).
5.9.1 Armouring shall be applied over the non-metallic part of
insulation screening, in case of single core cables or over inner
sheath in case of screened single core cables and over the inner
sheath in case of three-core cables.
5.9.2 The armour wires/strips shall be applied as closely as
practicable.

5.9.3 The direction of lay of armour shall be left hand.

5.9.4 Type of armour, dimension and joints in armour shall be as per

clause 16.2, 16.3 & 16.4 of IS: 7098-2-1985.

5.9.5 The round steel wire/formed wires taken from the cable shall
meet the following requirements:
a. The tensile strength of round steel wire/formed steel wire
shall be not less than 250 N/mm2 and not more than 580
N/mm2
b. The elongation at break of round steel wire/formed steel
wire shall be not less than 6 percent.
c. Round steel wire shall meet the requirements of torsion
test. The gauge length between Vices and the minimum
number of turns without break shall be as per Table 6 of
IS: 3975 : 1999.
d. The zinc coating shall not show any cracks and shall not
flake off on rubbing by the bare finger when the formed
wire is subjected to winding test.
Page 10 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

e. The uniformity of zinc coating of round steel wire/formed

steel wire shall comply with the requirements of IS: 3975 :
1999 subject to the following
- The minimum number of dips shall be reduced by one
half-minute dip.
- In case of formed wires, dip test is applicable only for
the face.

f. The mass of zinc coating of round steel wire shall be not

less than 95 percent of the mass specified in Table 2 of IS:
4826 : 1979.
The mass of zinc coating of formed steel wire shall be not
less than 95 percent of the mass specified in IS: 3975 :
1999.
g. The resistivity of the round steel wire/formed steel wire
shall meet the requirements of IS: 3975 : 1999.

5.10 OUTER SHEATH

It should be extruded PVC compound (blue colour) conforming to

type ST2 of IS: 5831-1984.
The outer sheath shall be applied
a) Over the non magnetic metallic part of insulation screening in
case of unarmoured single core cables.

b) Over the armouring in case of armoured cables.

5.10.1 Thickness of the outer sheath of armoured / unarmoured cables

and its tolerance shall be as per Clause 17.3.1 & 17.3.2 of IS: 7098
Part- II, 1985.
5.10.2 Colour of outer sheath shall be blue or any other colour as
agreed to between the purchaser and the supplier.

5.11 CONSTRUCTION OF CABLE

5.11.1 The conductor shall be of stranded compacted circular

construction, size 25 sq. mm and above for 11 KV (E) & 50 sq. mm and
above for 33 KV (E), complying with Class-2 of IS: 8130/1984.

5.12 CONDUCTOR SCREEN

The conductor screen consisting of a layer of smooth black extruded

semi-conducting compound shall be provided. A semi-conducting
tape(s) may be provided below the extruded semi-conducting
conductor screen to prevent penetration of the compound into the
underlying conductor.

5.13 ISO ACCREDITATION

Page 11 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

The cable shall be manufactured by a company having ISO

certification for cable manufacturing facility. The Purchaser may
decide to visit the works of cable manufacturer to confirm the
manufacturing process and quality of the product.

6.0 SCHEDULE OF TESTS

6.1 GENERAL
6.1.1 Prototype inspection shall be done by RDSO, Lucknow, and after
successful completion of all the type and routine tests as per this
specification, prototype approval shall be issued. After approval of
prototype, acceptance & routine tests on the balance quantity shall be
done by the authorized representative of the Indian Railways as per
purchase order.

6.1.2 Only after all the designs and drawings have been approved and
clearance given to this effect by RDSO, the manufacturer shall take up
manufacture of the prototype for inspection/testing by RDSO. It is to
be clearly understood that any changes to be done on the prototype as
required by RDSO, the same shall be done expeditiously.

6.1.3 Prior to giving a call for inspection and testing of the prototype, the
successful tenderer/manufacturer shall submit a detailed test
schedule consisting of test procedures, schematic circuit diagrams,
items/parameters to be checked and values required as per
specification for each of the tests and the number of days required to
complete all the tests at one stretch. The schedule shall also indicate
the venue of each of the tests. Once the schedule is approved, the
tests shall invariably be done accordingly. However, during the
process of type testing or even later, the DG/EM/RDSO, Lucknow,
reserves the right to conduct any additional test(s), besides those
specified herein, on any equipment/item so as to test the
equipment/item to his satisfaction or for gaining additional
information and knowledge.

6.1.4 In case any dispute or disagreement arises between the successful

tenderer/manufacturer and the representative of the DG/EM/RDSO,
Lucknow, during the process of testing as regards the procedure for
type tests and/or the interpretation and acceptability of the results of
type tests, it shall be brought to the notice of the DG/EM/RDSO,
Lucknow, as the case may be whose decision shall be final and
binding. Only after the prototype of the equipment is manufactured
and ready in all respects, shall the successful tenderer/manufacturer
give the actual call for the inspection and testing with at least 30 days
notice for the purpose.

6.1.5 The tests shall be conducted on the prototype of the cable at the works
of the manufacturer or at any NABL approved testing house or
laboratory in the presence of DG/EM/RDSO, Lucknow, or his
authorized representative. The prototype shall be complete in all
Page 12 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

respects, as would be supplied if it had passed the tests. The tests

shall be conducted to the governing specification and as modified or
amplified herein.

6.1.6 For tests conducted in the laboratories of Central Power Research

Institute, Bhopal/ Bangalore, Electrical Research Development
Association, Vadodara or any such testing house or laboratory, a
certificate to the effect that the equipment has passed the tests as per
specification shall be obtained by the manufacturer and submitted to
the DG/EM/RDSO, Lucknow. Full details of the tests and test
parameters shall be furnished along with the test reports.
6.1.7 Irrespective of the cables being a standard/proven item of the
manufacturer for which type tests have already been conducted and
the test results are available, the type tests shall nevertheless, be
conducted for the procurement against this specification. The
routine/acceptance/type tests to be carried out on the cables, as part
of above inspection, are given in para 6.2.0 below.
6.1.8 Six copies of the following test certificates shall be submitted to the
Purchaser for record:-
(i) Type test certificate as issued by RDSO for the power cable

(ii) Acceptance test certificate for complete lot of the cable.

(iii) Routine test certificates for each drum of cable.

6.1.9 Test certificates shall be completed with all the results. Purchaser’s
approval shall be obtained before dispatch of cables from the
works.

6.1.10 Manufacturer shall advise the purchaser one month in advance when
the cable shall be ready for inspection and tests, so that the latter’s
representatives may be deputed to witness the test(s). No material
shall be shipped or dispatched until inspection and tests upto the
satisfaction of the purchaser have been carried out. Such inspection
and approval shall not relieve the manufacturer from full
responsibility as defined in scope to the requirement of the
specification nor prejudice any claim, right or privilege which the
purchaser may have because of the use of defective or unsatisfactory
equipment.

6.2.0 TESTS
The tests shall be carried out as per the stipulations of IS: 7098
(Part II)-1985. The test plan shall be got approved by RDSO before
carrying out the test. Following tests shall be carried out on the cable
as a minimum:
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S. Requirement Type Routine Accept Test

No. Name of test Ref Test Test ance Method
Test IS: 10810
1. Test on Conductor
a) Annealing test for copper. IS: 8130-1984  - Part-1
b) Tensile test for aluminum IS: 8130-1984  - * Part-2
c) Wrapping test for aluminum IS: 8130-1984  - Part-3
d) Resistance test IS: 8130-1984   Part-5
2. Tests for armouring wires/ IS:7098 (Part-II)
strips  - - Part-36
(i) Dimensions Claus 16.3 &
Table-4
(ii) Physical Test on RDSO Specn
round/form wire
(a) Tensile Strength Clause 13.5 (a)  - - Part-37
(b) Elongation at break Clause 13.5 (b)  - - Part-37
(c) Torsion Test for round wires Clause 13.5 (c)  - - Part-38
Clause 13.5 (d) 
(d) Winding Test for formed wire  - - Part-39
Clause 13.5 (e)
(e) Uniformity of Zinc coating Clause 13.5 (f)  - - Part-40
(f) Mass of Zinc coating Clause 13.5 (g)  - - Part-41
(g) Resistivity - - Part-42
3. Test for thickness of insulation Clause 11, 15
and sheath & 17  -  Part-6
Table 2, 3 & 5
4. Physical tests for insulation
a) Tensile strength and Table-1  -  Part-7
elongation at break -
b) Ageing in air oven Table-1  - - Part-11
c) Hot test Table-1  - - Part-30
d) Shrinkage test Table-1  - - Part-12

e) Water absorption Table-1 Part-33
(gravimetric)
5. Physical tests for outer
sheath
a) Tensile strength and IS: 5831-1984  -  Part-7
elongation at break - -
b) Ageing in air oven IS: 5831-1984  - - Part-11
c) Shrinkage test IS: 5831-1984  - - Part-12
d) Hot deformation IS: 5831-1984  - - Part-15
6. Partial discharge test IS:7098 (Part-II)    Part-46
Clause 19.2
7. Bending test IS:7098 (Part-II)  - - Part-50
Clause 19.3
8. Dielectric power factor test
a) As a function of voltage IS:7098 (Part-II)  - - Part-48
b) As a function of temperature. Clause 19.4  - -
9. Insulation resistance IS:7098 (Part-II)  -  Part-43
(volume resistivity) test Table-1
10. Heating cycle test IS:7098 (Part-II)  - - Part-49
 Page 14 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

Clause 19.5
11. Impulse withstand test IS:7098 (Part-II)  - - Part-47
Clause 19.6
12. High voltage test IS:7098 (Part-II)    Part-45
Clause 19.7
13. Flammability test IS:7098 (Part-II)  - - Part-53
Clause 19.7
14. Cold Impact test for outer IS: 5831-1984  - - Part- 21
sheath

* Test shall not be applicable for stranded conductor

NOTE :
1. Test Sl. Nos. 6, 7, 8, 10 and 11 are applicable only to screened
cables. It shall be permissible to carry out test 8 on different
sample.

2. If the test sample fails in high voltage test, one more test sample
shall be taken for a high voltage test preceded by bending test
followed by partial discharge test and heat cycle test followed by
partial discharge test.

3. The type test certificate approved by RDSO shall be valid for five
years. The type test may also be repeated within this five years
period if any change introduced in cable material or design.

4. If the test sample fails in high voltage test, one more test sample
shall be taken for a high voltage test preceded by bending test
followed by partial discharge test and heat cycle test followed by
partial discharge test.

5. One or more of the above type tests may be repeated in event of

any major design change or adverse performance of the product.

6.3.0 OTHER REQUIREMENTS

Only after approval of the original drawings incorporating changes, if
any, as a result of the prototype tests and clear written approval of the
results of the tests on the prototype is communicated by the
Purchaser/DG (EM), RDSO, Lucknow, to the successful
tenderer/manufacturer, shall he take up bulk manufacture of the
cables. In no circumstances shall materials other than those approved
in the design/drawings and/or during the prototype testing be used
for bulk manufacture on the plea that they had been obtained prior to
the approval of the prototype.

7.0 DRAWINGS:
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Cross-sectional drawing and colored isometric view of the cable

construction in triplicate incorporating the detailed dimensions shall
be submitted with the tender for the purpose of preliminary study.
After award of the contract the successful tenderer shall be required
to submit reproducible copies of final cross-sectional drawing and
colored isometric view for the cable ordered.

8.0 IDENTIFICATION, PACKING AND MARKING

8.1 The manufacturer shall be identified throughout the length of cable by

manufacturer’s name or trade-mark and the voltage grade and year of
manufacture indented, printed or embossed or by means of tape
bearing this information.

The cable shall be wound on non-returnable drums of suitable size

and packed conforming to national standards.

8.2 The cut ends of the cable shall be sealed by means of non-hygroscopic
sealing materials so as to protect the cable from outside moisture
during transit and laying.

The following information shall be marked on the drum:

(i) Trade name or trade mark; if any
(ii) Name of the manufacturer;
[iii] Type of cable and voltage grade,
[iv] Number of cores,
(v) Nominal sectional area of the conductor,
(vi) Cable code,
(vii) Length of the cable on the drum,
(viii) Number of lengths on drum (if more than one),
(ix) Direction of rotation of drum [ by means of an arrow],
(x) Gross mass,
(xi) Country of manufacturer, and
(xii) Month and Year of manufacturer.

8.3 The drum shall be of such construction so as to ensure delivery of

cable at site free from displacement and damage and should be able to
withstand all stresses during handling in transit and laying. The cable
drum shall be suitable for wheel mounting.

8.4 All wooden component of the drum shall be constructed from wood,
properly seasoned, sound and free from defects. Wood preservative
treatment shall be applied to the entire drum.

8.5 Drums or parts of drums made from ferrous metals shall be treated
with a suitable rust-preventive finish or coating to minimize rusting
during transit or storage.

8.6 Bolts, screws, nails etc. if used in the construction of drums shall be
counter sunk so that the heads are below the surface of the flange.
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8.7 The tenderer shall clearly indicate in the offer, the normal length of
cable in one drum. Normal single length should not be less than 500
meters per drum. Lesser length preferably not less than 40% of the
normal drum length as per site conditions shall also be accepted
subject to the approval of purchaser.

9.0 WARRANTY:
The cables and joints & termination must be guaranteed for
satisfactory operation for a period of 60 months from the date of
commissioning.

10.0 INFRINGEMENT OF PATENT RIGHTS

10.1 Indian Railways shall not be responsible for infringement of patent

rights arising due to similarity in design, manufacturing process, use
of similar components in the design & development of this item and
any other factor not mentioned herein which may cause such a
dispute. The entire responsibility to settle any such disputes/matters
lies with the manufacturer/ supplier.

11.0 SAMPLING OF CABLE

Sampling plan for carrying out acceptance tests shall be as per the
recommendations of Appendix “A” of IS: 7098 (Part-11)-1985 and
tested from each lot for ascertaining the conformity of the lot to the
requirements of the specification.

12.0 SCHEDULE OF GUARANTEED PARAMETERS

The following information shall be given by the tenderer in addition to
any other relevant data:-

S. No. Description
1.0 Type of Cable
2.0 Conforming Standard
3.0 Rated voltage
4.0 Conductor
4.1 Nominal cross-sectional area of conductor
4.2 Conductor Material to IS:8130/84
4.3 Shape of conductor
4.4 DC resistance of the conductor at 20C (ohm per Km)
4.5 Maximum D.C. resistance of conductor at 90° C (ohm
per Km)
5.0 Conductor screen
a) Material
b) Minimum thickness in mm
6.0 Insulation
a) Material
Page 17 of 17 Effective From Jan. 2010 Specification No. RDSO/2009/EM/SPEC/0002, Rev. ‘1’

S. No. Description
b) Nominal thickness in mm
7.0 Insulation screen
a) Material
b) Minimum thickness in mm
8.0 Inner Sheath
a) Material
b) Minimum thickness in mm
9.0 Armouring
a) Material
b) Nominal dimension of wires / strips in
mm
10.0 Outer Sheath
a) Material to IS:5831/1984
b) Minimum thickness of outer sheath in mm
11.0 Nominal overall diameter of completed cable.
12.0 Nominal weight per meter of complete Cable.
(Single/multi core)
13.0 Standard drum length with tolerance in (meters)
14.0 Minimum permissible bending radius
15,0 Short circuit current carrying capacity of cable for one
second duration (KA)
16.0 Recommended continuous current ratings under
STD IS conditions:
16.1 In ground, at 30C ground temperature (Amps.)
16.2 In duct, at 30C ground temperature (Amps.)
16.3 In air, at 40C ambient temperature (Amps.)
17.0 Approximate reactance at 50 Hz (ohm per km)
18.0 Approximate impedance at 50 Hz (ohm per km)
19.0 Approximate capacitance at 50 Hz (micro farad per
km)