Annexure-A

Technical Specifications for Heat Shrinkable Cable Terminations

and Joints for 6.6kV, XLPE Cables

1. SCOPE:
This specification defines the requirements for Cable Joints and
Terminations for XLPE insulted power cables for 6.6kV. The requirements
cover the material properties of the components used in the Cable Joints
and Terminations as well as the performance of these products after
installation on cables. Heat shrinkable components are based on polymeric
materials and are to be supplied in an expanded state. Heating of these
components to a temperature generally above 120°C would activate their
elastic memory and cause these components to recover or shrink down on
a substrate within a specific application range.

2. SYSTEM DATA:
The distribution system in which the cables along with the joints and
terminations are expected to perform reliably over a period of 30-35 years,
is a three phase, 3-wire System operating at 6.6kV with solidly
earthed/unearthed neutral at the source neutral terminal with maximum
possible continuous voltages being 7.2kV, and cable conductor
temperatures up to 90°C on a continuous basis and under short circuit
conditions up to 250°C.

The Service conditions include ambient temperatures range from -5°C to

50°C, height of installation up to 1800m above sea level, dusty, industrially
polluted as well as salt laden sea coast environments, humidity levels up to
95% and heavy average rainfall of 1,000mm (annually).

3. GENERAL REQUIREMENTS:

All materials used and products provided under this specification must be
in accordance with the standards listed in clause 9 of this specification.

The scope of the certification shall cover the design, development,

production, installation and servicing of the components and kits offered.
In case of tenderers who act as kitters, the scope of the certification shall
cover the production of the kits offered. This is in addition to the
requirement for the design of the offered kits, which shall be under the
QMS certificate of the manufacturer of the components. The kitter shall
have a valid understanding with the manufacturer of the components
(either an indigenous manufacturer or a foreign manufacturer) and a
confirmation that the kits, which have been Type tested at CPRI or any
other Nationally or Internationally recognized laboratories have
components, which have been sourced from them.

All materials components and products offered, shall be of the latest

designs, incorporating any improvements in materials and installation
 procedures knowledge of which has been gained through the
manufacturers’ research or experience.

The jointing termination materials and components shall be offered in the

form of kits. The kits shall be supplied complete with all necessary tubings
components (ferrules / lugs / earthing/ cable preparation etc) to form a
ready to energise joint / termination.

Kits referred for single core cables shall include materials for terminations
or joints for single core cables.

4. PACKING AND MARKING:

The packing of the kits shall be such as to prevent any ingress of moisture
and or dust as well protects the contents against mechanical damage.
The external packing shall carry a cable with the following information
clearly marked
¾ Name of the manufacturer
¾ Manufacturer’s Batch No.
¾ Manufacturers Reference Kit No., Size(s), ratings of the Cable for
which it is offered.
¾ Year of manufacturer.
¾ Expiry date of kit or any component(s) included in the kit contents.

A checklist stating the description and quantities of each component

contained in the kit shall be supplied in each kit with an illustrated
installation instruction containing complete step-by-step instruction.

Each component of the kit shall be separately packed in a sealed

polyethylene wrapping and the component’s name and part No. shall be
marked on the packing. All components comprising the kit shall be clearly
and permanently marked with the suppliers and manufacturers names,
product identification, batch number and year of manufacture. Extruded
and moulded components shall additionally be marked with their expanded
(as supplied) diameters and fully recovered internal diameters.
Components and kits shall be capable of being stored without deterioration
in an ambient air temperature between –5°C to 45°C when protected from
direct sunlight or exposure to rain

5. INSPECTION AND TESTING

All materials covered by this specification shall be subject to Inspection and
testing during manufacture and before final dispatch from manufacturers
works. Before any part of the jointing materials are packed or dispatched
from the manufacturers works, all tests called for are to have been
successfully and satisfactorily carried out in the presence of the inspector
and a certificate issued to that effect by the Inspector in writing. The
jointing materials and components are to be fully tested in accordance with
the provisions of the latest relevant standards as specified in clause 9 of
this Specification.

6. ACCELERATED LABORATORY TESTS

 Proof of accelerated laboratory tests and or long term field usage to confirm
the retention of the properties of the materials within permissible limits
under variations for Temperature and Thermal ageing must be submitted
with the Tender

7. TERMINATIONS:
The termination design offered for both Indoor and Outdoor Application
shall comprise of a single non-tracking, erosion and weather resistant heat
shrinkable tubing, which is combined with a ceramic based, highly non
linear stress control system forming an integral layer inside the tubing.

The stress control system must guarantee excellent electrical stress

distribution of the electrical field along the length of the termination and
prevent any overstressing of the material. The ceramic particles in the
stress control layer must switch through to prevent an electrical stress at
any point along the termination exceeding 1.5KV/mm.

The Tenderer must submit electrical field calculations to show that the
ceramic stress control system will not allow a stress level exceeding 1.5
kV/mm even under Impulse voltages upto 170kV.

The material comprising the outer non-tracking erosion and weather

resistant tubing as well as the moulded components like sheds which are
used to provide additional as well as dry creepage distance for outdoor
terminations should be tested for
¾ Thermal Endurance
¾ Tracking & Erosion resistance Tests as per ASTM D2303
¾ Weather resistance in an Atlas Weather O meter to confirm a life
expectancy of 30 –40 years.

Mastics or adhesives used as sealants for these tubings must be similarly

non-tracking and weather – resistant.

8. STRAIGHT THROUGH JOINTS:

The design of the joint must include following features
A) STRESS CONTROL: The electrical stress control for the cable
insulation screen ends and over the connectors shall be achieved with a
combination of a high permittivity void filling mastic and a heat shrinkable
stress control tubing. The stress control tubing shall have a defined
impedance property comprising of a resistance and high permittivity. The
AC Impedance of this tubing material shall remain constant inspite of
temperature rise and thermal ageing as a consequence of the temperature
rise of the conductor.

Tenderers must submit

a) A technical explanation as to how the tenderer has arrived at the

correct electrical properties of the material i.e. specific volume resistivity
and permittivity to give a specific AC Impedance.
 b) Documentary evidence showing the effects of temperature and
thermal ageing on the impedance of the stress control material offered.

c) The recommended lengths of the stress control material.

d) Data of the stress relieving void filling mastic, must include the
volume resistivity and permittivity of the material.

B) The Electrical Insulation and Screening shall be achieved with a

single triple extruded dual wall tubing comprising two inner insulating layers viz.
an insulating elastomeric layer and an outer conducting layer. The tenderer
must give the thickness of insulation provided in the joint.

C) LUGS and FERRULES:

Only mechanical shear bolt type lugs and ferrules made from the corrosion
resistant, high strength, high conductivity aluminium alloy and tin plated with
bolts that shear off when proper torque is achieved, should be supplied with the
kits
Manufacturer must submit Type Test Certificates for the Performance of the
mechanical connectors supplied by the as per IEC 61238.

9. REFERENCES:
1. Standard Number ESI-09-13- Performance Specification for high voltage,
heat shrinkable components for use with high voltage solid cables up to an
including 33,000 volts.
2. IS 13573-2010 Type Test and Performance Requirements for cable
Terminations and Joints on XLPE Cables from 6.6 KV to 33 KV ratings.
3. IEC 61238-1: Compression and Mechanical Connectors for Power Cables
with copper or aluminum conductors - Tests Materials and Requirements.