TECHNICAL SPECIFICATION FOR FIRE RETARDANT LOW SMOKE (FRLS)

HEAVY DUTY XLPE POWER CABLES (UP TO 1.1 KV VOLTAGE GRADE)

1.0 Scope and Application:

This specification covers the minimum requirements and guidelines for Fire
Retardant Low Smoke (FRLS) Cables (Copper/ Aluminium) upto 1.1 KV
Voltage Grade.

In closed and crowded places such as subways; road and railway tunnels;
cinema halls, hospitals, schools, office complexes and public premises in
general, the speed of spread of fire is a critical factor. Besides this, the
opacity and toxicity of the fumes are very important factors as these may
lead to intoxication and suffocation, besides causing panic among the
victims due to reduced visibility. FRLS cables are generally used in such
areas where safety of persons and/ or protection of equipment are of
paramount importance.

The FRLS cables have following features:

a) Minimum smoke emission.
b) Very low emission of toxic and corrosive fumes.
c) Fire retardant characteristics.

2.0 General requirements:

2.1 The enclosed data sheet for cables shall be filled up complete by the
manufacturer/ vendor.
2.2 The manufacturers/ vendors are responsible for design,
construction, packing, inspection and testing of the cable.
2.3 The cables should be designed and manufactured using best quality
materials conforming to latest versions of respective relevant
standards.
2.4 The cables shall be suitable for installation as specified, and shall be
capable of withstanding normal stresses experienced during
transportation, erection and commissioning.
2.5 The manufacturer shall have valid QMS certificate for ISO 9001:
2008 for manufacturing of the item.

3.0 Technical Features: (General Technical Requirements)

3.0.1 FRLS cables shall be designed and constructed so as to retard the
spread of flames along the cable route.
3.0.2 The FRLS cables shall emit low smoke levels and the emitted
fumes shall have low toxicity and corrosivity in case of fire. The
cable should pass all specified tests as per relevant standards, for
Oxygen Index, Temperature Index, Acid Gas Generation, Smoke
Density and Flammability properties.
3.0.3 Robustness: Shall have properties to withstand vibration; normal
stresses experienced during transportation, erection and
commissioning; hot impacts and shall have high corrosion
resistance to polluted atmospheres and chemicals. Outer sheath
shall be resistant to water, UV radiation, fungus, termite and rodent
attacks.
3.0.4 Duty: Shall be manufactured for continuous duty.
3.1 Codes & Standards: Unless otherwise specified elsewhere in this
specification, the rating as well as performance and testing of the FRLS
cables shall conform to the latest revisions of all the relevant standards
available at the time of placement of order, as listed in, but not limited to
the list of standards specified in this specification. The item/ equipment
shall be designed, constructed and tested as per relevant Codes &
Standards/ Standard Manufacturing Practices suitable for the intended
service. All applicable latest editions/ versions of Indian/ International
Standards are part of this specification. In case of conflict; specification
and related standards shall take precedence in the order.
3.1.1 IS 7098-1 Cross linked polyethylene insulated PVC sheathed
cables (working voltage upto and including 1100 V)
3.1.2 IS 1554-1 - Specification for PVC Insulated Heavy Duty Electric
Cables (working voltages up to and including 1100 V)
3.1.3 IS5831-1984 – Specification for FRLS (i) Sheath - Type ST2 PVC
3.1.1 IS 8130:-1984 .Stranded conductors for insulated electric cables
and flexible cords
3.1.2 IS 3975-1999: Mild steel wires, formed wires and tapes for
armouring of cables
3.1.3 IS 10810-1984: Methods of test for cables
3.1.4 ASTM D2863: Oxygen Index Test on Polymeric materials and
cable sheaths
3.1.5 ASTM D2863: Temperature Index Test on Polymeric materials and
cable sheaths
3.1.6 ASTM D2843: Smoke density test on Polymeric materials and
cable sheaths
3.1.7 IEC 60754-1: Test on gases evolved during combustion of
materials from cables: determination of halogen acid gas content
3.1.8 IEC 60331:Fire resistance Test
3.1.9 IEC 60332-I: Test for vertical flame propagation for a single
insulated wire or cable
3.1.10 IEC 60332-III: Test for vertical flame spread of vertically-mounted
bunched wires or cables

Required guaranteed values for FRLS cable properties are as follows:

 Sl.
Property Guaranteed value Test method
No.
A Oxygen Index 29 % (Min) ASTM D2863
B Temperature Index 250 Deg C (Min) ASTM D2863
C IEC 60754-1/
Acid Gas Generation 20 % (Max)
IS 10810-59
D Smoke Density 60% (Max) ASTM D 2843
E Fire Resistance Test As per IEC 60331
E Flammability
As per IEC 60332-I and IEC 60332-III
Characteristics

3.3 Constructional Features: The cable shall be designed and constructed in

accordance with current versions of relevant Indian/ International Standards
for FRLS cables and should fulfill all specified test requirements.

3.4 Material: Vendor to ensure that material of construction of offered cable

shall be compatible with specified operating conditions and parameters; and
shall be suitable for the intended service, except as required or prohibited by
the data sheet/ indenter or the relevant codes and standards.

3.5 Data Sheet: as per enclosed format.

4.0 Name Plate/ Marking Details:

4.1 On Cable Drum: Following information shall be securely stamped/

stenciled on the body of the cable drum/ packing or through a metallic
plate tagged on the face of the drum.

4.1.1 Manufacturer's name, brand name or trademark

4.1.2 Number of cores and nominal cross-section area of conductor
4.1.3 Type of cable and voltage grade
4.1.4 Reference to Indian/ International Standard No. ………
4.1.5 Length of cable on the drum and No. of lengths of reels/ coils
4.1.6 Direction of rotation of drum (by means of an arrow)
4.1.7 Approximate gross weight
4.1.8 Serial Number/ Purchase Order Number
4.1.9 Country / Year of Manufacture

4.2 On Cable: Following information shall be embossed / printed in legible

and non-erasable manner on the cable sheath at intervals not exceeding
one meter throughout the length of the cable. Cables with poor, illegible
and erasable printing shall be liable for rejection.

4.2.1 Manufacturer's Name

 4.2.2 Voltage Grade
4.2.3 Size of Cable
4.2.4 Type of Insulation
4.2.5 Type of Outer Sheath
4.2.6 Year of Manufacture
4.2.7 Successive Length
4.2.8 If possible emboss ONGC emblem with “ONGC” at certain
intervals

5.0 Inspection:
Inspection shall be carried out in conformity with the ordered
Specifications; IS 7098-1, IS 1554-1, IS 3975-1999, IS5831-1984, IS
8130-1984, IS 10810-1984, ASTM D2863, ASTM D2843, IEC60331,
IEC 60332 and other relevant standards

Visual Inspection:
Manufacturer’s Name; Voltage Grade of cable; No. of cores; Size of cable;
Length of cable; Type of armouring; Material of Conductor; Year of
Manufacture

Routine Tests:
Conductor resistance test; High voltage test.

Type Tests:
All Type tests listed in Relevant Conformance Standard shall be reviewed
and confirmed by authorized ONGC inspecting authority to be in order
and the certificates thereof have been submitted.

Acceptance Tests:
All Acceptance tests listed in Relevant Conformance Standard shall be
performed on cable samples drawn by authorized ONGC inspecting
authority and shall be witnessed by him.

Additional Tests for FRLS Cables:

1. Oxygen Index Test as per ASTM D2863
2. Temperature Index Test as per ASTM D2863
3. Smoke Density Test ASTM D 2843
4. Acid Gas Generation Test as per IEC – 60754-I
5. Fire Resistance Test IEC60331
6. Flammability Test as per IEC: 60332-I and IEC 60332-III

Documentation:
1. Test reports for the cable.
2. Warranty/ Guarantee certificate.
3. Certificate that the item has been designed, manufactured and tested to
meet the specified requirement.
4. Calibration reports/ status reports of instruments used in testing.
5. Proof of ISO 9001-2008 Certification.