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Spec 22472
Spec 22472
1
NUCLEAR POWER CORPORATION OF INDIA LTD
TECHNICAL SPECIFICATION ON PAGE : 3 of 24
EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES REV. No. : 1
1.0 SCOPE
Manufacture, Testing, packing, delivery and Guarantee of various types and sizes
of annealed tinned copper conductor EPR insulated and LHLS Sheathed
unarmoured control cables generally conforming to IS-9968 (Part-1) and IS-6380
for two reactor units of 700 MWe PHWR project.
2.0 CONTENTS
Description Section
Applicable standards 3
Design requirements 6
Shop Tests 8
3.1 IS-9968 (Part I): Specification for elastomer insulated cables for working
voltage upto and including 1100 volts.
3.2 IS: 6380: Specification for elastomeric insulation and sheath of electric cables.
3.3 ASTM-D-2843: Standard test method for density of smoke from the burning or
decomposition of plastics.
OR
OR
3.7 IEC-754-1: Determination of the amount halogen acid gas evolved during the
combustion of polymeric materials taken from cables.
OR
3.8 IS-10810-59: Determination of the amount of halogen acid gas evolved during the
combustion of polymeric materials taken from cables.
3.9 Swedish Svensk Standard-424-14-75 (Class F-3): Swedish Chimney Flame Test
OR
3.11 BS-6360 (or IS-8130): Specification for conductors for insulated electric cables and
flexible cords.
3.14 NES 713: Determination of the toxicity index of the products of combustion from
small specimens of materials.
4.1 The materials and processes for the components of cables and their assembly shall
be chosen as specified here-in. Material shall be thermoset. Use of any substitute
shall be suitably qualified in terms of its electrical, mechanical and physical
properties and the details shall be submitted by supplier for purchaser’s approval.
All the materials and processes which are not specified herein shall be chosen so
as to enable the purchased product to meet the performance requirements of this
4.2 Workmanship
5.1 The cables shall be suitable for continuous and reliable operation at maximum
conductor temperature of 90 C and voltage upto and including 650V for core to
earth and 1100 V for core to core.
Occasional/Storage conditions
Ambient temperature from 5ºC to 55ºC and relative humidity up to 95 %
All materials used should be first class and of standard conforming to the
requirements of this specification.
6.1 Conductor
Conductors shall be made of annealed tinned solid or stranded as the case may be,
Copper conductor in accordance with BS-6380 or IS-8130. No joints of any kind
in the conductor are allowed.
6.2 Insulation
The insulation shall be 90 C EPR type IE 2 of IS-6380 and shall be meeting all
physical and electrical properties requirement of this standard. No. joints of any
kind in the insulation are permitted. Insulation shall be applied by pressure
extrusion process and curing by steam vulcanization / e-beam method. The colour
of insulation shall be as per Annexure-A of this specification for each type of
cable.
Colour code to identify the cores of all the types of cable shall be as per
Annexure-A of this specification. Shades of colour shall match with BS-6746C.
6.4 Sheath
Each conductor shall be 2.5 sq.mm annealed tinned solid copper conductor
insulated with EPR of 1.0 mm (nominal) + 10% wall thickness by pressure
extrusion process and curing by steam vulcanization / e-beam method. Such 2
cores shall be laid up. Over the laid up cores shall be applied 25 micron thick
mylar tape helically and then sheathed with 1.10 mm nominal + 20% thick wall of
LHLS by pressure extrusion process and curing by steam vulcanization / e-beam
method. A rip cord shall be provided below the sheath for easy stripping of
sheath. The overall diameter shall not exceed 11.20 mm.
The conductor shall be 0.75 sq.mm annealed, tinned, solid copper conductor
insulated with LHLS of 0.65 mm (nominal) + 10% wall thickness by pressure
extrusion process and curing by steam vulcanization / e-beam method. The overall
diameter shall not exceed 2.5 mm.
Same as 6.5.1 but stranded conductor size of 4.0 sq mm (7 x 0.85) and sheath
thickness of 1.20 mm nominal + 20%. The overall diameter of cable shall not
exceed 12.5 mm.
Same as 6.5.1 but 3 core and stranded conductor size of 6 sq.mm (7 x 1.04),
Sheath thickness of 1.2 mm (nominal) + 20%. Overall diameter shall not exceed
14.5 mm.
1 core and stranded conductor size of 10 sq.mm (7 x 1.35) , insulation with 1.20
mm nominal + 20% thick wall of LHLS material by pressure extrusion process
and curing by steam vulcanization / e-beam method. Overall diameter shall not
exceed 11 mm.
1 core and stranded conductor size of 16 sq.mm (7 x 1.7), insulation with 1.20
mm nominal + 20% thick wall of LHLS material by pressure extrusion process
and curing by steam vulcanization / e-beam method. Overall diameter shall not
exceed 12 mm.
The following particulars shall be embossed on the cable outer sheath through out
the length of all the cables at a span of 1 meter.
b) Year of manufacture
c) LHLS cable
e) Size of cable
It may be noted than embossing on the cable outer sheath is preferred to printing.
The cables shall be supplied in coil lengths of 500 meters 10%. Coil lengths of
100m to 449m are considered non-standard lengths and such lengths of only 10%
of ordered quantity are acceptable. Lengths less than 100m are not acceptable.
The Supplier shall be responsible for all the tests and inspection as mentioned in
this specification and any other tests which may be necessary to assess the
required performance of the cable. The characteristic and performance of the
cable shall conform to this specification on completion of tests.
The purchaser shall have right to conduct at his own expenses any additional
inspection and testing deemed necessary by him.
Three copies of test reports and certificates of compliance stating the material is
in accordance with the requirement specified in the specification shall be
furnished by the supplier.
Applicable Standard
The following acceptance tests shall be carried out on samples taken from the lot
of each type of cable. The total number of drums of each type of cable offered at
a time shall be treated as lot size. The sample size for the acceptance test shall be
as per Appendix-B of IS-694.
Supplier shall not ship the material without the prior approval of the purchaser or
his authorised representative and subsequent instruction to do so.
ANNEXURE-A
Black
Black
Blue
Black
Blue
Orange
Green
ANNEXURE-B
1.1 Make
1.10 Confirm whether Cable can pass fire retardant test as per Swedish chimney test
3.0 Insulation
5.0 Sheath
5.9 Deviations
Following deviations if any from the specification shall be clearly brought out in
the offer, otherwise it will be presumed that the offer is in compliance with
NPCIL specification requirements.
Whether colour code is followed as per Annexure A and section no. 6.3 of our
Specification.
7.1 The bidder shall submit a list of similar supplies made by him to standards and
tolerances specified in this tender document. The bidder shall also submit copies
of purchase orders of similar cables executed by them as a proof of capability.
7.2 The bidder shall submit alongwith the offer, a list of manufacturing equipment
available with him on the date of submitting the quotation and a list of inhouse
test facilities available with them for carrying out all tests specified in section no.
8.0 of this specification.
7.3 The bidder shall submit along with the offer the test reports of all the tests
specified in 8.0 carried out by him on similar type of cables.
Bidder shall submit along with the offer descriptive and illustrative literature
covering construction and materials used for the cables offered.
7.4 The vendor information form enclosed shall be filled and submitted along with the
bid.
Five (5) copies of History Docket in hard form and soft form shall be furnished.
History Docket shall be made as per PRD-PROC-19. A sample History Docket
shall be submitted to the purchaser for clearance. Once purchaser clears the same,
5 copies of History Docket shall be submitted in hard form and soft form.
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component Characteristic Class TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK CHECK DOCUMENT NORMS OF
RECORDS P W V
1.0 RAW
MATERIALS
1.1 CONDUCTOR
1.1.1 Copper Surface finish B Visual Random sample The conductor shall be The conductor T.C. 2 2 1
conductor smooth & free from shall be smooth &
scratches & burrs free from scratches
& burrs
Diameter B Physical One sample NPCIL Spec.& NPCIL Spec. & -do- 2 2 1
from lot of 10 IS-8130 IS-8130
Conductor C Electrical bobbins/Baskets “ --do-- -do- 2 2 1
Resistance at 20 /Drums or part
deg.C there of
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component Characteristic Class TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK CHECK DOCUMENT NORMS OF
RECORDS P W V
1.3 BINDER
(Mylar type) Visual check of A Visual Random Sample Shall be smooth Shall be smooth T.C. 2 2 1
Tape
Tensile strength C Physical “ IS-6380 & BS 6899 IS-6380 & BS 6899 -do- 2 2 1
& Elongation
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component Characteristic Class TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK OF CHECK DOCUMENT NORMS OF
RECORDS P W V
2.0 PROCESS
INSPECTION
2.1 Insulation Type of insulation B Physical Each setting & Approved Data Sheet Approved Data T.C. 2 2 1
Compound once in a shift & NPCIL spec. Sheet & NPCIL
Dimensions/Dia. B Physical -do- “ spec.
over conductor “ -do- 2 2 1
Dimensions/Dia. B Physical “ “
over core “ -do- 2 2 1
Thickness of C Physical “ “
insulation (Avg. & “ -do- 2 2 1
Min)
Spark Testing Electrical 100% IS-9968 IS-9968 -do- 2 2 1
Surface Finish Visual Each setting Smooth and free Smooth and free -do- 2 2 1
from porosity from porosity
Colour Visual -do- NPCIL Spec. NPCIL Spec. -do- 2 2 1
2.2 Laying up Direction of lay C Visual Each setting & Approved data Sheet Approved data sheet -do- 2 2 1
Diameter over B Physical twice in a shift Approved data Sheet Approved data sheet -do- 2 2 1
laidup
Lay length B Physical -do- Approved data Sheet Approved data sheet -do- 2 2 1
2.3 Binding %age overlap/ C Physical -do- NPCIL spec. NPCIL spec. -do- 2 2 1
coverage
Tape Dimensions C Physical -do- Approved data sheet Approved data sheet -do- 2 2 1
NPCIL Spec NPCIL Spec
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component Characteristic Class TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK OF CHECK DOCUMENT NORMS OF
RECORDS P W V
2.4 LHLS Type of C Physical Each setting & IS-6380 IS-6380 T.C. 2 2 1
Sheath Compound at random
(Type SE3)
Thickness C Physical Each setting & NPCIL Spec. NPCIL Spec. -do- 2 2 1
Average/ twice in a shift
Minimum
Dia over outer B Physical Each setting & -do- -do- -do- 2 2 1
sheath twice in a shift
Surface finish B Visual In each shift Surface shall be Surface shall be -do- 2 2 1
smooth & free from smooth & free from
porosity porosity
Embossing/ B -do- Each setting & Approved Data Sheet Approved Data -do- 2 2 1
Printing/ twice in a shift and NPCIL Spec. Sheet and NPCIL
Sequential Spec.
Marking
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component Characteristic Class TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK CHECK DOCUMENT NORMS OF
RECORDS P W V
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component Characteristic Class TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No and Operations CHECK CHECK DOCUMENT NORMS OF
RECORDS P W V
TYPE TESTS
ON FINISHED
CABLE
3.13 Oxygen index on sheath C Physical -do- ASTM-D-2863 NPCIL Spec. -do- 2 1,2 1
/IS-10810-58
3.14 Temperature index on C Physical -do- ASTM-D-2863 NPCIL Spec. -do- 2 1,2 1
sheath /IS-10810-58
3.15 HCL emission on sheath C Physical -do- IEC-754-1 NPCIL Spec. -do- 2 1,2 1
/IS-10810-59
3.16 Smoke density on sheath C Physical -do- ASTM-D-2863 NPCIL Spec. -do- 2 1,2 1
/IS-10810-63
3.17 Toxicity Index on sheath C Chemical -do- NES 713 NES 713 -do- 2 1,2 1
3.18 Termite Proof on sheath C Chemical -do- Supplier spec. Supplier spec. -do- 2 1,2 1
3.19 Measurement of Mutual C Physical -do- VG 95218-Part Approved data -do- 2 1,2 1
Capacitance between 66 sheet
cores and between core
and earth
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component and Characteristic Class TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
No Operations CHECK CHECK DOCUMENT NORMS OF
RECORDS P W V
4.0 ROUTINE
4.1 TESTS Conductor resistance test C Electrical 100% IS-8130 IS-8130 TR 2 1,2 1
5.0 ACCEPTANCE
5.1 TESTS Annealing test on cu C Physical Samples as per IS-8130 IS-8130 TR 2 1,2 1
IS-9968 Part I
5.2 O.D. of cable C Physical -do- NPCIL Spec NPCIL Spec TR 2 1,2 1
5.5 Thickness of insulation C Physical -do- NPCIL Spec NPCIL Spec TR 2 1,2 1
sheath
0
5.6 IR at 27 C C Electrical -do- IS-6380 IS-6380 TR 2 1,2 1
ANNEXURE-C
QUALITY ASSURANCE PLAN FOR EPR INSULATED LHLS SHEATHED UNARMOURED UNSHIELDED CONTROL CABLES (SAMPLE)
Sl. Component and Characteristic Class TYPE OF QUANTUM REFERENCE ACCEPTANC FORMAT AGENCY REMARKS
No Operations CHECK OF CHECK DOCUMENT E NORMS OF
RECORDS P W V
ACCEPTANCE
TESTS
.
5.8 Temperature index C Physical Samples as per ASTM-D-2863/ NPCIL Spec. TR 2 1,2 1
on sheath IS-9968 Part I IS-10810-58