Installed

SCHEDULE-A2

CEG/GP-2/5212A

TECHNICAL
SPECIFICATION
OF
HT CABLES
FOR
POWER STATIONS

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 INDEX

CLAUSE NO. TITLE

Special Instruction to Bidder
Qualifying Requirement of Bidder
SCHEDULE-B Technical specification for Control and
L.T./H.T. Power Cables
1.0 Scope
2.0 Standards
3.0 Climatic Conditions
4.0 General Technical/Principal Parameters
5.0 Physical Constants of Materials
6.0 Physical Constants for Galvanized Steel Wires
7.0 Freedom from Defects
8.0 Wire Sizes
9.0 Joints in Wires
10.0 Stranding
11.0 Standard Length
12.0 Operation
13.0 Tests
14.0 Type Tests
15.0 Acceptance Tests
16.0 Routine Tests
17.0 Test During Manufacture
18.0 Testing Charges
19.0 Additional Charges
20.0 Sample Batch for Type Testing
21.0 Test Reports
22.0 Test Facilities
23.0 Inspection
24.0 Quality Assurance Plan
25.0 Documentation
26.0 Packaging and Forwarding
27.0 Marking
28.0 Quantity and Delivery Requirement
29.0 Drawing
30.0 Deviations
ANNEXURE-I System Particulars

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 SCHEDULE-B7 GTP for HT Cable – 3 Core, 11 KV
SCHEDULE-C7 GTP for HT Cable – 3 Core, 11 KV - to be filled
by bidder

(This document is meant for exclusive purpose of bidding against this

specification and shall not transfer, reproduced or otherwise used for purposes
other than that for which it is specifically issued.)

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 SPECIAL INSTRUCTIONS TO BIDDER

Please read following instructions carefully before submitting your bid:

1. All the drawings, i.e. elevation, side view, plan, cross sectional view etc., in
AutoCAD format and manuals in PDF format, for offered item shall be
submitted. Also the hard copies as per specification shall be submitted.

2. The bidder shall submit Quality Assurance Plan with the technical bid.

3. The bidder shall have to submit all the required type test reports for the offered
item. Bid without type tests will not be considered for evaluation.

4. The bidder must fill up all the points of GTP for offered item/s. Instead of
indicating “refer drawing, or as per IS/IEC”, the exact value/s must be filled in.

5. All the points other than GTP, which are asked to confirm in technical
specifications must be submitted separately with the bid.

6. The bidder is required to impart training in view of manufacture, assembly,

erection, operation and maintenance for offered item, at his works, to the
person/s identified by GSECL, in the event of an order, free of cost. The cost of
logistics will be bear by GSECL.

7. Please note that the evaluation will be carried out on the strength of content
of bid only. No further correspondence will be made.

8. The bidder shall bring out all the technical deviation/s only at the specified
annexure.

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 QUALIFYING REQUIREMENT FOR BIDDER

Bidder to satisfy all the following requirements-

1. The Bidders should be original manufacturer of the quoted size of the cables
and shall have all the facilities to manufacture these sizes and higher sizes of
control and / or power cables as the case may be. Traders are not eligible for
participating in this Tender.
2. The Bidders have to submit proof of the satisfactory completion of order for
supply of quoted sizes of the cables for the quantity not less than 300 Kms
during last five years of total of all the sizes of control cables from utilities like
State Electricity Corporations, NTPC, PGCIL. Any Technical offer without this
certificate will be out rightly rejected. The proof means the Purchaser’s
certificate of completing the supply within the stipulated time limit for the
ordered quantity. However the total quantity supplied shall not be less than
the one stated above (i.e. 300 Kms).

The details are to be submitted in following format:

Sr. ITEMS ORDER ITEMS QTY ORDER STATUS, IF REMARK

No SUPP- REFEREN FULLY ORDER
LIED CE No. & EXECUTED. UNDER
TO DATE YES/NO EXECUTION

3. The cables offered must bear ISI mark. The Bidder shall invariably submit the
attested copy of ISI certificate. Any cables without this mark will be out rightly
rejected. The cables will be accepted only from the works, name and address
of which is indicated in the offer.
4. All the bids shall comprise the copy of type test reports, of any of the quoted
size, which shall not be later than five years from the date of opening of the
Tender. However GSECL reserves the right to ask any or all the suppliers to
carry out the Type Test at the Government Approved Testing Laboratory on
the ordered size/s. The GSECL reserves the right to indicate the name of the
NABL accredited Testing Lab at his own discretion and the Supplier will have
to carry out the Type Tests in the designated laboratory at his own cost.
5. The quantity of each size offered shall be indicated clearly in the Technical
Bid. The Bid will be out rightly rejected if this clause is not found clear.
6. This Specification shall be signed page to page without any addition /
alteration and shall be submitted with the Technical Bid. Any offer without this
will be out rightly rejected.

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 SCHEDULE – B

TECHNICAL SPECIFICATION FOR CONTROL AND L.T. /H.T. POWER CABLES

1.0 SCOPE:

1.1 This specification provides for design, manufacture, testing, inspection,

packing and dispatch to destination of Copper Cored Control Cables
and Aluminium cored HT / LT Power Cables, specified herein for their
satisfactory operation in various Power stations of the State. Preparation of
Drum drawings and getting it approved from C.E.-GSECL, Corporate
Office, Vadodara.
1.2 These cables are to be used as control signal carrying cables or power
carrying cables, as the case may be, in various Power stations of the
Gujarat State situated in various areas having varying atmospheric
conditions, for voltage ratings up to 400KV, from various equipments
situated in Plant area, Control rooms, switchyard etc.
1.3 These cables are generally used under ground either in the cable trenches
with no. of layers as per requirement covered with the cement covers or in
the pipes installed under ground and then pits filled with the soil.

2.0 STANDARDS:

2.1 The Control, Power, Telephone and Trailing cables shall conform to the
following Indian / International Standards, which shall mean latest revisions,
amendments / changes adopted and / or published as on the date of
opening of the Tender.

Sr. No. Indian Standards Title

1 IS : 1554 For Cables up to working voltage 1100 V
2 IS : 7098 For XLPE Cables
3 IS : 5831 For Insulation Sheath
4 IS : 8130 For Copper And Aluminium
5 IS : 10418 For Wooden Drums
6 IS : 3975 For Armouring
7 IS : 3961 For Current Rating
8 IS : 9968 For Trailing Cables
9 ITD: GR/CUG-01/03, For Telephone Cable
Aug-2003.

2.2 Over and above, any other standards which are relevant may be quoted
by the bidder. However, in an event where the supplier offers Control
and / or power cables conforming to standards other than the above,
then the salient points of comparison between the standards adopted
and the standards quoted herein shall be detailed in relevant schedule
with an authenticated English version of such standards referred to.
GSECL also reserves right to ask any supplier to supply the control / power
cables related to any other IS or International Standards which may be
found to give better quality and performance of the cables.

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3.0 CLIMATIC CONDITIONS:

3.1 The cables to be supplied under these Specifications are to be used in

various Power Stations of the Gujarat State, located at different locations
having varying atmospheric and climatic conditions and are suppose to
operate satisfactorily under any conditions.
3.2 However the General conditions are given as under:

1 Location In the State of

Gujarat as per
Annexure-I
2 Maximum Ambient Air Temperature -(C) 50
3 Minimum Ambient Air Temperature -(C) 0
4 Average daily ambient Air Temperature -(C) 35
5 Maximum relative humidity – (%) 95
6 Average rainfall per annum -(mm) 1150
7 Maximum altitude above mean sea level - 1000
(mtr)
8 Ceraunic level i.e. Average number of Thunder 15
storm -(Days/annum)
9 Maximum wind pressure -(KG/m 2) 200
10 Seismic level i.e. Earthquake Acceleration
a) Horizontal Seismic Co-efficient (acceleration) (a) 0.3
– g (Equivalent to zone – 5)
b) Vertical Seismic Co-efficient (acceleration) (b)0.34
– g (Equivalent to zone – 5)
11 Terrain Hot, Humid,
Tropical, Highly
Polluted,
Conductive,
Corrosive, Prone
to Fungus
Growth etc

4.0 GENERAL TECHNICAL / PRINCIPAL PARAMETERS:(SCHEDULE: B7):

4.1 CONTROL / LT CABLES:

(1) The control cables shall be round copper conductor (of required size) with
PVC insulation, armouring and sheath, color coded as per relevant
standards or as specified / instructed by the GSECL.
(2) The LT Power cables shall be of aluminium conductor (of required size) PVC
insulated, armouring and PVC sheathed, colour coded as per relevant
standards or as specified / instructed by the GSECL.
(3) The control cables shall be rated for minimum 1100V and LT Power cables
for minimum 6600V, however Bidder may quote for higher voltage ratings,
which shall be clearly brought out in the Technical Bid.

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(4) All the cables quoted / supplied shall bear ISI mark.
(5) The insulation of each core and outer and inner sheath, shall comply with
the relevant IS / this Specification, whichever is stringent, for control and /
or power cables.
(6) All the armouring shall be strip / round wire type, hot dip galvanized. The
armouring and galvanizing shall comply with relevant standards and or this
Specification shall also bear ISI mark.
(7) The copper conductor used shall be electrolytic grade annealed and shall
be made of minimum 99.5% pure copper, thus the total impurities shall not
exceed 0.5%. The Aluminium conductor shall be of EC Grade 99.5% pure
aluminium and thus the total impurities in this case also shall not exceed
0.5%. Both the copper and aluminium shall possess ISI mark.
(8) If the conductor is a bought out item or manufactured by the supplier, the
proof to satisfy the above conditions shall be produced.
(9) Current Rating: The indicative values of continuous current carrying
capacities at Maximum conductor temperature of 70º C (for design
purpose by field) of the various sizes of the cables are given in GTP. Short
circuit ratings of various sizes cable calculated for duration of one second
at maximum temperature of 160º C, are given in GTP.
(10) The cables shall be suitable for being installed directly in the ground, in the
pipes or in the cable trays/trenches. The cables shall therefore be
suitable for satisfactory operation under the tropical climatic conditions
listed in the relevant clause. The applicable design particular of the
cables to be used in the Power Stations is furnished in Annexure - I. "System
Particulars".

4.2 HT CABLE:

(1) 11 KV (E) Grade XLPE, 3-Core, power cable shall be of high conductivity,
stranded compacted, H.D. aluminum circular shaped conductor with XLPE
(Cross Linked Poly Ethylene) Dry/Gas cured insulation provided with
shielding of extruded semi-conducting materials over conductor and XLPE
insulation. Each insulated core shall have copper tape screen, laid
together and provided with common covering of PVC Inner Sheath
(Extruded). Overall galvanized steel strip armour and PVC outer sheath
shall be provided. The specification for manufacture of cable shall be
conforming to IS: 7098 (Part-II) 1985 (latest edition) for 11KV (E), 3-phase, 50
Hz, Earthed systems.
(2) Outer sheath shall be designed to afford high degree of mechanical
protection and shall also be heat, oil, chemical and weather resistant,
Common acid, alkalis and sealing solution shall not have adverse effect on
material of PVC sheath.
(3) The cable conductor shall be made from high conductivity stranded High
Density aluminum to form compacted circular shaped conductor having
resistance within limits specified in IS: 8130/1984 and any latest
amendment to it.
(4) The conductor having semi-conducing screen shall ensure perfectly
smooth profile and avoid concentration of stress. The conductor screen
shall be extruded in the same operation as the insulation. The semi-
conducting polymer shall be cross linked.

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(5) Cable Parameters:

1 Voltage grade (Uo / U)- KV 6.35 / 11

2 Cores (Nos) 3
3 Nominal system voltage -KV 11
4 Highest system voltage -KV 12
5 System frequency- Hz 50
6 Variation in frequency -% ±3
7 Maximum allowable temp. of conductor during 90 º C
continuous normal operation at rated full load current - ºC
8 Maximum allowable temp. under short circuit condition-ºC 250 º C
9 1.2/50 microsecond lightning impulse withstands voltage 75
wave value - KVp
10 5 Min, Power frequency withstand voltage -KV rms 17
11 System earthling Effectively
earthed.
(6) The XLPE insulation shall be suitable for 11 / 22 kV system voltage and
should be manufactured with Dry / Gas curing process. The bidder shall
submit the description of dry / gas curing process, with the clear inclusion
of equipments / parameters involved. The manufacturing process shall
ensure that the insulation shall be free of 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 semi-conducting screen and insulation. The insulation of
the cable shall be of high standard quality generally conforming to IS: 7098
(Part – II) – 1985 and any latest amendment to it.
(7) Insulation shield: Non-metallic semi-conducting shield shall be provided
over the insulation to confine electrical field to the insulation. The insulation
shield shall be extruded in the same operation as the conductor shield and
the insulation by suitable extrusion process. The XLPE insulation shield shall
be of tended type. The copper metallic overlapped tape shield shall be
provided.
(8) Filler and Inner-Sheath: The sheath shall be suitable to withstand the site
conditions and the desired temperature. It shall be of adequate thickness,
consistent quality and free from all defects. The PVC sheath shall be
extruded. The material of fillers and inner-sheath shall be compatible with
the temperature ratings of the cable and shall have no deterious effect on
any other component of the cable. Central PVC filler shall also, be
provided with other peripheral PVC fillers to have proper circular section.
(9) Outer-Sheath: Extruded type ST-2 PVC outer-sheath, conforming to IS: 5831-
(1984) (latest edition) over armouring with suitable additives (to prevent
attack by rodents and termites), shall be provided.
(10) Armour: Armoring of galvanized steel strip shall be provided. The dimensions
of steel strips shall be as per latest edition of IS: 3975 – 1979.
(11) Cable shall be suitable for lying in covered trenches and / or buried under-
ground in outdoor.

(12) Current Rating: The indicative values of continuous current carrying

capacities at Maximum conductor temperature of 90º C (for design

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 purpose by field) of the various sizes of the cables are given in GTP. Short
circuit ratings of various sizes cable calculated for duration of one second
at maximum temperature of 250º C, are given in GTP.
(13) The cables shall be suitable for being installed directly in the ground, in the
pipes or in the cable trays/trenches. The cables shall therefore be
suitable for satisfactory operation under the tropical climatic conditions
listed in the relevant clause. The applicable design particular of the
cables to be used in the Power Stations is furnished in Annexure - II.
"System Particulars".

4.3 TELEPHONE CABLE:

Telephone Cable with annealed Copper conductor polyethylene

insulated core twisted into pair laid up jelly filled cores wrapped with poly
Aluminum Laminated moisture berried polyphone sheathed double steel
tape armored overall black polyphone jacketed cable confirm to ITD
Specification NO. GR / CUG -01 / 03, Aug 2003.

5.0 PHYSICAL CONSTANTS OF MATERIALS:

5.1 PHYSICAL CONSTANTS FOR COPPER / ALUMINIUM CONDUCTORS:

5.1.1 Resistivity:
The volume resistivity of copper / aluminium depends upon its purity and its
physical condition. However as per the specified value of purity in this
specification, the maximum value permitted is 0.01724 Ω-mm2/meter for
copper and 0.28264 Ω-mm2/meter at 20 Deg. C, for aluminium. These
values shall be used for calculation of the maximum permissible value of
resistance. This value may be checked from the measured value of the
resistance.

5.1.2 Density:
At a temperature of 20C the minimum density of electrolytic grade
annealed copper shall be 8.89 and that of hard drawn aluminum shall be
2.703 Gm/CuCm.

5.2 Constant-Mass Temperature Co-efficient of Resistance:

5.2.1 At a temperature of 20C the constant-mass temperature co-efficient of

resistance of copper and hard drawn aluminum measured between two
potential points rigidly fixed to the wire, the metal being allowed to
expand freely, has been taken as 0.0039 and 0.004 per degree Celsius
respectively for copper and aluminum..

5.3 Co-efficient of Linear Expansion:

5.3.1 The co-efficient of linear expansion of copper and hard-drawn aluminium

at OC has been taken as 17x10-6 and 23 x 10-6 per C respectively for

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 copper and aluminium. This value holds good for all practical purposes
over the range of temperature from 0C to highest safe operating
temperature.

6.0 PHYSICAL CONSTANTS FOR GALVANIZED STEEL WIRES:

6.1 Density:
6.1.1 At a temperature of 20C, the density of galvanized steel wire is to be
taken as 7.78 Gm/CuCm.

6.2 Co-efficient of Linear Expansion:

6.2.1 In order to obtain uniformity in calculations a value of 11.5 x 10-6 Per C
may be taken as the value for the co-efficient of Linear Expansion of
galvanized steel wires used for the cores of steel-armoured copper /
aluminium conductors.

6.3 Materials:

6.3.1 The conductors shall be manufactured from Electrolytic annealed copper

/ EC grade aluminium rods suitably hard-drawn on wire drawing machines.
The copper / aluminium rods used shall comply with all the relevant ISS, BSS,
or other standards to be specified along with the due justifications and this
Specification.

6.3.2 Galvanized steel wire shall be drawn from high carbon steel rods
produced by either acidic or basic open hearth process, electric
furnace process or basic oxygen process. All the properties of the steel
strips and wires shall conform to the relevant standards.
6.3.3 The zinc used for galvanizing shall be electrolytic high grade Zinc not less
than 99.95 percent purity. It shall conform to and satisfy all the
requirements of relevant ISS, BSS, the Specification or other Standards to be
specified with the due justification. Galvanizing has to be done by hot dip
galvanizing process. Neutral grease may be applied between the layers of
wires; however the weight of the same shall be specified and added to the
total weight of the conductor.

NOTE: Lithium soap grease corresponding to Grade II of IS: 7623-1974

(Specification for lithium soap greases) may be suitable for such
application.

6.3.4 The bidder should specify the source of raw materials along with the proof
of last purchases made. The Purchaser may reject the tender of the Bidders
whose raw material suppliers are found to be supplying any poor quality or
non-standard materials, to the purchaser of this Specification or any other
purchaser.

7.0 FREEDOM FROM DEFECTS:

7.1 The wires shall be smooth and free from all imperfections such as
spills, splits, slag inclusion, die marks, scratches, fittings, blow-holes,

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 projections, looseness, overlapping of strands, chipping of copper /
aluminium layers etc. and all such other defects which may hamper the
mechanical and electrical properties of the conductor as also the
installation of the cable at the site etc. Special care should be taken to
keep away dirt, grit etc. during stranding / applying PVC coating.

8.0 WIRE SIZES:

8.1 Nominal Size and Tolerances:

8.1.1 The copper, aluminium and galvanized steel wires for the cable covered
by this Specification / standard shall have diameters as specified in
clause respective GTP and shall be within the tolerances indicated
therein. The diameter of the steel wires shall be measured over the zinc
coating.

9.0 JOINTS IN WIRES:

9.1 Copper / Aluminium Wires:

9.1.1 No joints shall be permitted in the copper / aluminum wires in any of the
cables and any of the cores.

9.2 Galvanized steel wires:

9.2.1 There shall be no joints except those in the base rod or wire before final
drawing, in steel wires and strips forming the armouring of the copper /
aluminium cables.

10.0 STRANDING:

10.1 The wires used in the construction of galvanized steel armouring of copper
and aluminium cables before stranding and after stranding shall satisfy
all the relevant requirements as per the standards indicated or any other
standards with due justification and this Specification.
10.2 The zinc used for galvanizing shall be electrolytic high grade Zinc. It shall
conform to and satisfy all the requirements of relevant standards indicated
or any other standards with due justification and this Specification.
Galvanizing shall be done by hot dip galvanizing process. Neutral grease
may be applied between the layers of wires.
NOTE: Lithium soap grease corresponding to Grade II of IS: 7623-1974
(Specification for lithium soap greases) may be suitable for such
application.

11.0 STANDARD LENGTH:

11.1 The standard length of the conductor shall be as per GTP. A tolerance of
+/-5% on the standard length shall be permitted. All lengths outside this limit

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 of tolerance shall be treated as random lengths. Over all tolerance in total
quantity of ordered cables shall be + 2%.
11.2 Random lengths will be accepted provided no length is less than 95% of
the standard length specified and the total quantity of such random
lengths shall not be more than 5% of the total quantity ordered.
11.3 Bidder shall also indicate the maximum single length, above the
standard length, he can manufacture in the guaranteed technical
particulars. This is required for special connections like Control and Relay
Panels etc. The purchaser reserves the right to place orders for the above
length to the extent of 50% of the total ordered quantity on the same terms
and conditions applicable for the standard lengths during the pendency
of the contract.
11.4 All the cables shall be marked at every meter with-
1. Name of the manufacturer
2. Name of the purchaser
3. Rating
4. Size of the cable
5. Date of manufacture
6. Length
7. Electric/Telephone as per IS

11.5 Every core of the cable shall be marked with core no. at every meter,
serially.

12.0 OPERATION:
12.1 Cable shall be suitable for operation under frequency variation of 3% and
voltage variation of 10% -15% and combined frequency-voltage variation
of 10% (absolute sum).

13. TESTS:

13.1 The type, acceptance, routine tests, any tests specifically demanded by
the Purchaser and tests during manufacture shall be carried out on the
cables free of cost.
13.2 Type tests shall mean those tests, which are to be carried out to prove the
process of manufacture and general conformity of the material to
this Specification and relevant Standards. These tests shall be carried out
on samples prior to commencement of commercial production against
the order. The Bidder shall indicate his schedule for carrying out these tests
in the activity schedule. These tests shall have to be carried out at the
Government Approved Testing Laboratory only in presence of the
Purchaser’s representative. Purchaser reserves the right to specify the
name of the laboratory also, if so felt.

13.3 Acceptance Tests shall mean those tests, which are to be carried out on
samples taken from each lot offered for pre-dispatch inspection, for the
purposes of acceptance of that lot. These tests shall be carried out at the

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 manufacturer’s works in presence of Purchaser’s representative before the
dispatch of the materials to the site.
13.4 Routine Tests shall mean those tests which are to be carried out on
each strand / spool / length of the cable to check requirements which
are likely to vary during production. These tests shall be carried out by the
manufacturer on each drum and shall have to furnish these reports to the
GSECL’s representative during his visit for acceptance tests.
13.5 Tests during manufacture shall mean those tests, which are to be carried
out during the process of manufacture and end inspection by the
supplier to ensure the desired quality of the end product to be supplied
by him, including all Quality Control checks and Raw Materials testing.
13.6 Samples for individual wires for tests shall be taken before stranding from
not less than ten percent of the spools in the case of copper and
aluminium wires and ten percent of the coils in the case of steel wires. If
samples are taken after stranding, they shall be obtained by cutting 1.2
meters from the outer end or inner end of the finished cable from at least
ten percent of the finished reels.
13.7 The standards to which these tests will be carried out are listed against
them. Where a particular test is a specific requirement of this
specification, the norms and procedures of the test shall be as specified
in this Specification or as mutually agreed to between the Bidder and the
purchaser in the Quality Assurance Programme.
13.8 For all type and acceptance tests, the acceptance values shall be the
values guaranteed by the Bidder in the "Guaranteed Technical Particulars”
of his proposal or the acceptance value specified in this specification,
whichever is more stringent for that particular test.

14.0 TYPE TESTS:

14.1 All the type tests as per relevant Standards (IS 1554-Part-I, IS 7098-Part-II and
IS 9968) and this Specification shall be conducted once on each sample /
samples of cables for every 50 KMs or less of production from each
manufacturing facility. However if the Supplier has carried out the Type
Tests within 5 years of opening of this Tender, the same will be considered
acceptable, subject to submission of the same in original. However GSECL
may ask any of the suppliers to carry out the Type Test at its own discretion,
even if the same are not older than 5 years, but the same will be subject to
allotment of minimum 15% of the total quantity indicated in this
Specification. Some tests are listed below AT Cl. No. 14.4.

14.2 All the Type Tests shall be carried out by the supplier at no extra cost to the
GSECL, (for any number of times, as may be required) at the Government
Approved Laboratory or at the Laboratory specified by the GSECL, at its
own discretion.

14.3 All the new suppliers, for the size offered or full lot, shall have to
compulsorily carry out the Type Tests i.e. if the supplier has supplied one size
of cable to the Company in past and is having type test certificate but has
been allotted some other size for the first time by the GSECL then even if he

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 possess the Type test, he has to carry out the same in presence of the
GSECL’s representative.
14.4 List of Type Tests:
(A) As per IS 1554:
(a)Tests on conductor:
(1)Annealing test
(2)Tensile test
(3)Wrapping test
(4)Conductor Resistance test

(b)Tests for armoring strips / wires:

(c)Tests for thickness of insulation and sheath:

(d)Physical tests for insulation and outer sheath:

(1)Tensile strength and elongation at break
(2)Ageing in air oven
(3)Shrinkage test
(4)Hot deformation test
(5)Thermal stability

(e) Insulation resistance test

(g)High voltage test (water immersion)

(m)Flammability test

(B) As per IS 7098-Part-II:

(a) Tests on conductor:

(1)Annealing test
(2)Tensile test
(3)Wrapping test
(4)Conductor Resistance test

(b) Tests for armoring strips / wires:

(c)Tests for thickness of insulation and sheath:

(d)Physical tests for insulation:

(1)Tensile strength and elongation at break
(2)Ageing in air oven
(3)Hot set test
(4)Shrinkage test
(5)Water absorption
(6) Degree of cross linking

(e)Physical tests on outer sheath:

(1)Tensile strength and elongation at break
(2)Ageing in air oven

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 (3)Shrinkage test
(4)Hot deformation
(5)Thermal stability

(f)Partial discharge test

(g)Bending test

(h)Dielectric power factor test

(1) as a function of voltage
(2) as a function of temperature

(i)Insulation resistance test (volume resistivity)

(j)Heating cycle test

(k)Impulse withstand test

(l)High voltage test

(m)Flammability test

(n)Test on extruded semi conducting screens

(a) Test for strippability of semiconducting strippable insulation
screen(when applicable)
(b) Volume resistivity

(o) Test on extruded semi conducting screens

15.0 ACCEPTANCE TESTS:

15.1 All the cables ordered shall be accepted only after carrying out of all the
acceptance tests, as per the relevant IS or the Specification, in presence
of the GSECL’s Representative. Some tests are listed at Cl. No. 15.3.
15.2 The supplier shall possess all the facilities to carry out all the Acceptance
Tests. If it is found that the testing equipment/s are not performing to the
Standard or they are not duly Calibrated the related test/s shall be carried
out at the Government approved laboratory in presence of Purchaser’s
Representative, at no extra cost to the GSECL. The GSECL may specify the
name of the laboratory.

15.3 List of Acceptance Tests:

(A) As per IS 1554:

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 (a)Annealing test
(b)Tensile test
(c)Wrapping test
(d)Conductor Resistance test
(e)Tests for thickness of insulation and sheath:
(f)Tensile strength and elongation at break of insulation and sheath
(g)Insulation resistance test (volume resistivity)
(h)High voltage test

(B) As per IS 7098-Part-II:

(a)Annealing test
(b)Tensile test
(c)Wrapping test
(d)Conductor Resistance test
(e)Tests for thickness of insulation and sheath
(f) Hot set test for insulation
(g)Tensile strength and elongation at break of insulation and sheath
(h) Insulation resistance test
(i)High voltage test
(k)Partial discharge test

16.0 ROUTINE TESTS:

16.1 All the routine tests shall be carried out by the supplier during the
production of the cable and a copy of the same shall be provided to the
Inspecting Officer, during inspection. Some tests are listed below at Cl. No.
16.2.

16.2 List of T Routine Tests:

(A) As per IS 1554:

(a)Conductor Resistance test

(b) High voltage test
(c) Armour resistance test

(B) As per IS 7098-Part-II:

(a)Conductor Resistance test

(b) High voltage test
(c) Armour resistance test
(d) Partial discharge test

17.0 TEST DURING MANUFACTURE:

a Chemical analysis of zinc used for Relevant IS with latest

galvanizing Amendment and this

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 Specification.
b Chemical analysis of copper and Relevant IS with latest
aluminium used for making Amendment and this
copper / aluminium conductors. Specification
c Chemical analysis of steel used Relevant IS with latest
making steel armouring. Amendment and this
Specification

18.0 TESTING CHARGES:

18.1 The testing charges for the type tests specified and as per relevant IS /
international standards, shall be borne by the Supplier. All the Suppliers
irrespective of their registration etc. will have to carry out the Type Test, as
per the terms of this Specification at their own cost and the Purchaser will
not have any financial or technical implication on this account.
18.2 In case of failure in any of the type test/s, the supplier is either required to
modify the design of the material or repeat the particular type test three
times successfully at his own expenses. The decision of the purchaser in this
regard shall be final and binding. The Purchaser at its own desecration may
also cancel the order at the risk and cost of the contractor, if the material
fails twice successively in the Type Test.

18.3 Bidder shall indicate the laboratories in which they propose to conduct the
type tests. They shall ensure that the tests can be completed in these
laboratories within the time schedule guaranteed by them in the
appropriate schedule. The Purchaser reserves the right to specify the name
of the laboratory also, if so felt.
18.4 The entire cost of testing for the type, acceptance routine tests and tests
during manufacture, special tests etc specified herein or in the relevant
Standards shall be treated as included in the quoted unit price of cable.

19.0 ADDITIONAL TESTS:

19.1 The Purchaser reserves the right of getting done any other test(s) of
reasonable nature carried out at Purchaser's premises, at site, or in any
other place in addition to the aforesaid type, acceptance and routine
tests to satisfy himself that the material comply with the specifications. In
such case all the implications (financial and / or Technical) will be to
Suppliers account.

20.0 SAMPLE BATCH FOR TYPE TESTING:

20.1 The Bidder shall offer minimum five (5) drums or the full quantity, which ever is
less, for selection of samples required for conducting all the type tests.
20.2 The Bidder is required to carry out all the acceptance tests successfully in
the presence of Purchaser's representative before dispatch of the selected
sample to the testing laboratory for type test.
20.3 However the new supplier will have to offer the first lot for selection of
sample for type test, after successfully carrying out the acceptance tests on

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 it, in presence of the GSECL’s Representative. The first lot shall be minimum of
5 drums or full allotted quantity.

21.0 TEST REPORTS:

21.1 Test reports shall be furnished in at least two (2) copies along with one
original. One copy shall be returned duly certified by the Purchaser only
after which the material already inspected i.e. the materials manufactured
for selection of sample for type test, shall be dispatched on receipt of
Dispatch Instructions from the C.E.(Generation), Corporate Office, GSECL,
Vadodara.
21.2 Record of routine test reports shall be maintained by the Bidder at his works
for periodic inspection by the purchaser’s representative.
21.3 Test Certificates of test during manufacture shall be maintained by the
Bidder. These shall be produced for verification as and when desired by the
Purchaser.

22.0 TEST FACILITIES:

22.1 The following additional facilities shall be available at Supplier's works:

(a) Calibration Reports from Government approved testing laboratory of
various testing and measuring equipment including tensile testing
machine, resistance measurement facilities, burette, thermometer,
barometer etc.
(b) Standard resistance for calibration of resistance bridges.
(c) Finished cable shall be checked for length verification and surface finish
on separate rewinding machine at reduced speed (variable from 8 to 16
meters per minute). The rewinding facilities shall have appropriate clutch
system and free of vibrations, jerks etc. with transverse layering facilities.
(d) The bidder should have all the routine and acceptance testing facilities, in
house.

23.0 INSPECTION:

23.1 The Purchaser's representative shall at all times during the tendency of the
contract be entitled to have access to the works and all places of
manufacture where conductor is being manufactured and the
representative shall have full facilities for unrestricted inspection of the
Supplier’s works, raw materials and process of manufacture and
conducting necessary tests as may be deemed fit, for certifying the quality
of product.
23.2 The Supplier shall keep the Purchaser informed in advance of the time of
starting and of the progress of manufacture of cable in its various stages so
that arrangements can be made for inspection.
23.3 No material shall be dispatched from its point of manufacture before it
has been satisfactorily inspected, tested, and necessary dispatch
instructions are issued in writing, except for the cases where waiver of
inspection is granted by competent authority of the Purchaser, and even
in this case also written dispatch instructions will be issued. Any dispatches

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 before the issue of Dispatch Instructions in writing will be liable for rejection
and non acceptance of the materials by the consignee.
23.4 The acceptance of any quantity of material shall in no way relieve the
Bidder of any of his responsibilities for meeting all requirements of the
Standards / Specification, and shall not prevent subsequent rejection if
such material is later found to be defective. The dispatch of the
manufactured materials shall not be delayed beyond 10 days from the
date of issue of the Dispatch Instruction. Any delay beyond this will be
treated as late delivery and all deductions as per late delivery will be
affected.
23.5 At least 5% of the total number of drums subject to minimum of two in
any lot put up for inspection, shall be selected at random to ascertain
the length of cable by following method:
"At the works of the manufacturer of the cable, the cable shall be
transferred from one drum to another at the same time measuring its
length with the help of a graduated pulley and Cyclometer. The
difference in the length (higher of the total measured lengths) thus
obtained and as declared by the Bidder in the packing list shall be
applied to all the drums if the cable is found short during checking."
23.6 The sample cut off from any numbers of drums for carrying out any type of
tests will be to the suppliers account.

24.0 QUALITY ASSURANCE PLAN:

24.1 The bidder shall invariably furnish following information along with his
offer, failing which his offer shall be rejected.
(i) Statement giving list of important raw materials, proposed to be used in
the manufacture of the cable against this Specification, names of sub
suppliers for the raw materials, list of standards according to which the
raw materials are tested, list of tests normally carried out on raw
materials in presence of Bidder's representative as routine and / or
acceptance during production and on finished goods, copies of test
certificates.
(ii) Information and copies of test certificates as in (i) above in respect of
bought out accessories.
(iii) List of manufacturing facilities available.
(iv) Level of automation achieved and list of areas where manual
processing exists.
(v) List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and
inspections.
(vi) List of testing equipment available with the Bidder for final testing of
Cable specified. In the case if the Bidder does not possess all the
Routine and Acceptance testing facilities the tender will be
rejected.
(vii) The Purchaser reserves the right for factory inspection to verify the
facts quoted in the offer. If any of the facts are found to be
misleading or incorrect the offer of that Bidder will be out rightly
rejected and he may be black listed.

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 (viii) Special features provided to make it maintenance free and also any
marking for identification after installation.

24.2 The bidder shall also submit following information to the purchaser along
with the technical Bid. .

(i) List of raw materials as well as bought out accessories, and the
name of suppliers of raw materials as well as bought out accessories.
(ii) Type test certificates of the raw material bought out accessories and
finished cables, offered. The reports shall not be older than 5 years
on the date of opening of the Tender.
(iii) Quality assurance plan (QAP) with hold points for purchaser's
inspection.
24.3 The Bidders shall submit the routine test certificates of all the
cables, bought out items, accessories etc.

25.0 DOCUMENTATION:

25.1 Two sets of type test reports, duly approved by the Purchaser shall be
submitted by the Bidder, before commencement of supply. A copy of
acceptance and routine test certificates, duly approved by the
purchaser shall accompany the dispatch consignment.

25.2 The manufacturing of the cables shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the
written approval of the Purchaser. All manufacturing and fabrication
work in connection with the cable prior to the approval of the drawing
shall be at supplier's risk.
25.3 Approval of drawing etc. by the purchaser shall not relieve the Bidder of his
responsibility and liability for ensuring correctness and correct
interpretation of the latest revision of applicable standards, rules and
codes of practices. The cables shall conform in all respects to high
standards of engineering, design, workmanship and latest revisions of
relevant standards in vogue on the day of opening of the Technical Bid
and purchaser shall have the power to reject any work or material which in
his judgement is not in full accordance therewith.

26.0 PACKING AND FORWARDING:

26.1 The cables shall be supplied in non-returnable strong wooden drums

provided with lagging of adequate strength, and displacement during
transit, storage and subsequent handling and laying operations in the field.
The drums shall generally conform to relevant IS except otherwise specified
hereinafter.
26.2 The drums shall be suitable for wheel mounting and for jetting off the cable
under a minimum controlled stress of the order of 5 Kg/m2 for copper
cables and 15 Kg/m 2 for aluminium cables.
26.3 The bidder should submit the proposed drum drawings along with
the bid. However, the same shall be in line with the requirements as stated

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 herein. After placement of the Letter of Award, the Bidder shall submit two
copies of fully dimensioned drawing of the drum, for Purchaser’s approval
before taking up manufacturing of Cables and or drums. After getting
approval from the Purchaser, Bidder shall submit 6 copies of the
approved drawing to Purchaser for further distribution and field use at
Purchaser’s end.
26.4 All wooden components shall be manufactured out of seasoned soft
wood free from defects that may materially weaken the component
parts of the drums. Preservative treatment for anti-termite/anti-fungus
(Aldrime / Aldruse) etc. shall be applied to the entire drum with
preservatives of a quality which is not harmful to the cable or to the
persons using or storing the same.
26.5 The flanges shall be of minimum two ply or higher construction with each
ply at right angles to the other and nailed together. The nails shall be
driven from the inside face flange, punched and then clenched on the
outer face. The tolerance in thickness of each ply shall be +3 mm only.
There shall be at least 3 nails per plank of ply with maximum nail spacing of
75 mm. Where a slot is cut in the flange to receive the inner end of the
cable, the entrance shall be in the line with the periphery of the barrel.
26.6 The wooden battens used for making the barrel of the cable shall be of
segmental type. These shall be nailed to the barrel supports with at least
two nails. The battens shall be closely butted and shall provide a round
barrel with smooth external surface. The edges of the battens shall be
rounded or chamfered to avoid damage to the cable.
26.7 Barrel studs shall be used for construction of drums. The flanges shall be
holed and the barrel supports slotted to receive them. The barrel studs
shall be threaded over a length on either end, sufficient to
accommodate washers, spindle plates and nuts for fixing flanges at the
required spacing. Barrel studs should be tack welded with the nuts after
tightening.
26.8 Normally, the nuts on the studs shall stand stroud of the flanges. All the nails
used on the inner surface of the flanges and the drum barrel shall be
countersunk. The ends of barrel shall generally be flushed with the top of
the nuts.
26.9 The complete drum including inner cheek of the flanges and drum barrel
surface shall be painted with bitumen based paint.
26.10 Before reeling, card board or double corrugated or thick bituminized
waterproof bamboo paper shall be secured to the drum barrel and
inside of flanges or the drum by means of a suitable commercial
adhesive material. The paper should be dried before use. After reeling the
cable, the exposed surface of the outer layer of cable shall be wrapped
with thin polyphone sheet across the flanges to preserve the cable from
dirt, grit and damage during transportation and handling and also to
prevent ingress of rain water during storage / transport.

26.11 A minimum space of 125 mm shall be provided between the inner surface
of the external protective layer and outer layer of the power cables;
however 75 mm shall be acceptable for all control cables.

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26.12 Each batten shall be securely nailed across grains as far as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not
be less than twice the thickness of the battens. The nail shall not protrude
above the general surface and shall not have exposed sharp edges or
allow the battens to be released due to corrosion.
26.13 Outside the protective layer, there shall be minimum of two binders
consisting of hoop iron / galvanized steel wire. Each protective layer shall
have two recesses to accommodate the binders.
26.14 The cable ends shall be properly sealed and secured with the help of
U-nails on one side of the flanges. The cable shall be banded by use of
galvanized steel wire / aluminium wire.
26.15 Wire shall be bound at least at three locations at the most 75 mm apart
covered with PVC adhesive tape so as to avoid loosening of cable in
transit and handling.
26.16 Only Single length of cable shall be wound on each non returnable drum
as per IS 10418 (Latest).
26.17 If any bidder wishes to supply the cables in the non returnable steel drums
the same will be acceptable, however they shall be without any additional
cost to the GSECL.

27.0 MARKING

27.1 Each drum shall have the following information stenciled on it in indelible
ink along with other essential data:

1. Contract Award letter / order number

2. Name and address of consignee
3. Manufacturer’s name and address
4. Drum Number
5. Size of cable
6. Length of cables in meters
7. Gross weight of drum with cable
8. Weight of empty drum with lagging
9. Arrow marking for unwinding.

28.0 QUANTITY AND DELIVERY REQUIREMENT

28.1 Schedule of requirement and desired delivery is shown in attached

SCHEDULE-A.

29.0 DRAWINGS

29.1 All the bidders have to submit the drawings for the cables and drums to be
utilized for packing of the control and power cables, for the lengths
specified in this Tender Specification. The cable drawing shall be enclosed
with the calculations of current rating, dimensions etc and drum drawings
with calculations in support of the size of the drum to accommodate the
required length of cable.

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30.0 DEVIATIONS

30.1 Any deviation to this tender Specification will be out rightly rejected. All the
Bidders have to submit this specification duly authenticated without any
alterations, additions etc. on each page along with the Technical Bid. Any
offer without this will be out rightly rejected.

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 ANNEXURE-I

SYSTEM PARTICULARS

ELECTRICAL SYSTEM DATA:

1 System Voltage
a) Control Cables (DC Volts) 110/220
b) LT Power Cables (AC Volts) 440
2 Max. Voltage
a) Control Cables (DC Volts) 130/250
b) LT Power Cables (AC Volts) 470
3 Short circuit level (KA) 40
4 Radio interference voltage at one MHz when 1000
subjected to 50Hz AC. Voltage 320KV (rms)
Line to ground – Micro Volts.
5 Corona Voltages in 50 Hz AC system – KV (rms)
Inception
I) Dry >320
II) Wet >320
Extinction
I) Dry >320
II) Wet >320

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