LW-36J

PAKISTAN TELECOMMUNICATION COMPANY LIMITED

SE LW-36J
NETWORK STRATEGY & PLANNING WING Feb , 2005
OF PTCL

SERIES LW: LOCAL NETWORK (LINE & WIRE)

Specifications of Local Network and Allied Equipments

TERMINATING INDOOR SURFACE / CONDUIT

WIRING PVC INSULATED AND PVC SHEATHED
CABLES

PTCL Specification LW-36J

FEBRUARY 2005 ISSUE 1 LOCAL NETWORK GROUP

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 LW-36J

Change History

The table below lists the significant, product-impacting changes to the document. Editorial
changes and cosmetic changes are not listed.

Issue Date Revised By Description of Change Section

or table

I Feb, 2005 Aurangzeb Khan

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PAKISTAN TELECOMMUNICATION COMPANY LIMITED

SPECIFICATIONS FOR TERMINATING INDOOR SURFACE/

CONDUIT WIRING PVC INSULATED AND PVC SHEATHED
CABLES

TABLE OF CONTENTS

PAGE NO

1 GENERAL ------------------------------------------------------------------- 02

1.1 SCOPE --------------------------------------------------------------- 02

1.2 INTENDED USE -------------------------------------------------- 02
1.3 PERFORMANCE QUALIFICATION CERTIFICATE------- 02
1.4 RESERVED RIGHTS --------------------------------------------- 02

2. DESIGN REQUIREMENT ------------------------------------------------ 03

2.1 GENERAL-------------------------------------------------------------------- 03
2.2 MATERIAL SUITABILITY----------------------------------------------- 03
2.3 LONG TERM PERFORMANCE REQUIREMENTS----------------- 03

3. CONDUCTORS------------------------------------------------------------- 03
4. INSULATION---------------------------------------------------------------- 04
5. COLOUR CODE AND PAIRING---------------------------------------- 04
6. ASSEMBLY------------------------------------------------------------------ 05
7. JACKET----------------------------------------------------------------------- 06
8. ELECTRICAL-REQURIEMENT----------------------------------------- 06
9. DELIVERY------------------------------------------------------------------ 08
10. QUALITY SYSTEM-------------------------------------------------------- 09
11. PRE-SHIPMENT INSPECTION------------------------------------------ 09
12. CABLE MANUFACTURING CAPABILITIES------------------------ 10
13. DOCUMENTATION------------------------------------------------------- 10
14. TECHNICAL COMPLIANCE STATEMENT-------------------------- 12

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PAKISTAN TELECOMMUNICATION COMPANY LIMITED

SPECIFICATION FOR TERMINATING/INDOOR

SURFACE/CONDUIT WIRING PVC INSULATED AND PVC
SHEATHED CABLES

1. GENERAL

1.1 SCOPE

The specification covers the requirements for insulated pairs suitable for inside
wiring applications, connector cable and other multi-line installations.

1.2 INTENDED USE

The PVC Cable purchased in compliance with this specification shall be used for
telecommunication network of Pakistan.

1.3 PERFORMANCE QUALIFICATION CERTIFICATE

1.3.1 Tenderers who have not previously supplied cables under this specification (or
who have made changes to prior supplied products) shall submit a Performance
Qualification Certificate issued by Central Telecom Research Laboratory (CTRL)
H-9/4, Islamabad.

1.3.2 In the event that appropriate samples are not available until manufacture an
interim Performance Qualification Certificate may be obtained on the basis of a
compliance statement and other information from the manufacturer.

1.3.3 Performance Qualification Certificate samples shall include:

- A 5 meter length of each type of cable

- 1 kg raw material samples of polyethylene, for insulation and all sheaths

1.3.4 Approval of a sample shall not be construed as waiving any requirements of this
specification.

1.4 RESERVED RIGHTS

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1.4.1 PTCL reserves the right to reject any portion or all of the PVC Cable which
does not conform to the requirements of this specification.
1.4.2 The rejected PVC Cable is to be returned over to the agent of the supplier for
replacement at the cost of the supplier.

1.4.3 PTCL cannot guarantee that any of the requirements, standards, regulations
and conditions of these specifications are not covered or protected by
copyright or patent of a third party.

1.4.4 PTCL reserves the right to make changes to the specifications without further
notice.

2. DESIGN REQUIREMENTS

2.1 GENERAL

2.1.1 This section describes the cable design.

2.2 MATERIAL SUITABILITY

2.2.1 All materials shall be suitable for operation in the tropic with maximum
temperature up to 70°C.

2.2.2 All cables must be compatible with current PTCL installation standards and
operation and maintenance practices.

2.2.3 All materials used in the cable shall be non-toxic and dermatologically safe.

2..3 LONG TERM PERFORMANCE REQUIREMENTS

2.3.1 All cable supplied in compliance with this specification shall be capable of
withstanding the typical service conditions of Pakistan for a period of forty years
without detriment to the transmission or operation and maintenance characteristics
of the cable.

2.3.2 Cable shall be designed, manufactured and packaged so that exposure to the
environmental conditions of Pakistan during storage, transport, installation and
operation shall not degrade the physical, electrical or operation and maintenance
characteristics of cable.

2.3.3 Cable shall retain the electrical & mechanical properties in the specifications over
working temperature range -15°C to 70°C and humidity range of 0% to 100%.
3 CONDUCTORS

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3.1 Each conductor shall consist of a well annealed electrolytic copper wire of
uniform quality and a circular cross section.
3.2 The nominal diameter of the un-insulated conductor shall be 0.6 mm. The
diameter at any cross section shall not deviate from the specified nominal value by
more than:
(+0.02 mm)
(-0.01 mm).

3.3 The tensile strength of the conductor shall be at least 20 KP/mm². The conductor
shall not break when a sample length is closely wrapped three turns around of its
own diameter, then carefully un-wrapped and again closely wrapped three turns in
such a way that the wire is bent in the opposite direction.

3.4 The resistance of the conductor shall be based on copper resistivity not greater than
17.25 Ohms-mm²/Km 20°C. The resistance at temperature other than 20°C shall be
determined by using a co-efficient, which assumes an increase of 1/15 Ohms-
mm²/Km /°C rise in temperature. The formula for resistance calculation is shown
below:-
4
R = ---------- x 17.25 Ohms/Km
πd²
d = Nominal dia. of conductor.

The D C resistance of a conductor as measured in the completed cable shall not

exceed the value given in Table-1 column 2 when measured at or corrected to 20°C.

3.5 Joints made during manufacture shall be kept to a minimum. Unavoidable factory
joints shall be made by silver soldering or butt welding of the conductor ends. The
tensile strength of the joint shall be at least 18 Kg/mm a joint shall not increase the
resistance of the conductor by more than 1 milli Ohm.

4. .INSULATION

Each conductor shall be uniformly insulated with a semi rigid polyvinyl chloride
compound of a non fade colour conforming to British standard BS 6746 type 2. The
wall thickness of the insulation shall not be less than 0.25mm at any point.

5. COLOUR CODE AND PAIRING

5.1 The insulated conductors shall be twisted together with a lay not less than 30
mm nor exceeding 155 mm into colour coded pairs so as to identify each pair
in the completed cable.

5.2 The colour code and respective pair number shall be as shown in Table-1.

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Pair Colour of Insulation Pair Colour of Insulation

No. a-wire b-wire No. a-wire b-wire
1 White Blue 13 Black Green
2 “ Orange 14 “ Brown
3 “ Green 15 “ Slate
4 “ Brown 16 Yellow Blue
5 “ Slate 17 “ Orange
6 Red Blue 18 “ Green
7 “ Orange 19 “ Brown
8 “ Green 20 “ Slate
9 “ Brown 21 Violet Blue
10 “ Slate 22 “ Orange
11 Black Blue 23 “ Green
12 “ Orange 24 “ Brown
25 “ Slate
Table-1 Conductor Colour Code

5.3 Adjacent pairs shall have different effective lays and the lays shall be so
chosen that the cross talk between the pairs is as small as possible and meet
the capacitance unbalance and cross talk loss requirements of this
specification.

6. ASSEMBLY

6.1 Cables of 25 pairs and less are formed by stranding pairs together in
concentric layers.

6.2 In cables having more than 25 pairs, the twisted pairs shall be arranged in
groups, each group being bound with non-hygroscopic threads or tapes.

6.3 Each group shall contain not more than 25 pairs.

6.4 When desired for lay-up reasons, the basic 25 pairs groups may be divided
into two or more sub-groups called units.

6.5 Each unit in a particular 25 pairs group shall be enclosed in bindings of the
colours indicated for its particular 25 pairs count.

6.6 In 30 pairs cable the unit may be configured in 13,12 & 5 pairs (preferable) or
9,8,8,5 pairs.

6.7 The pair count indicated by the colours of insulation, shall be consecutive
(from 1 to 25 as given in clause 5.2) through the units in a group.

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6.8 When desired for manufacturing reasons, two or more 25 pairs groups may be
bound together with non-hygroscopic thread or tape in "Super Units".

6.9 The group binders and the "Super Unit" binders shall be colour coded such
that the combination of the two binders shall positively identify each 25 pair
group in the cable.

6.10 A group (including its sub groups if any) will have binder colour in the order of
pairs in a group e.g. Ist group will have white-blue binder and the 2nd group white-
orange etc.

7. JACKET

7.1 The jacket to be applied over the core shall consist of abrasion resistant polyvinyl
chloride.

7.2 The nominal jacket thickness shall be as given in Table-2.

NUMBER OF PAIRS NOMINAL JACKET THICKNESS

(mm)
6 or less 1
12 1
18 1
25 1
50 1.25
75 1.25
100 & above 1.25

7.3 T he jacket surface shall be smooth, free from bumps, blisters grooves or other
surface imperfections.

7.4 A Nylon cord shall be provided over the core to facilitate stripping of the jacket.

8. ELECTRICAL REQUIREMENT

8.1 Insulation Resistance

The insulation resistance when measured with a DC potential 500 Volts applied for
one minute at 20°C shall not be less than 4000 Meg Ohms/300 Meter.

8.2 Mutual Capacitance

The mutual capacitance of each pair measured at 1000 Hz + 10% at 20°C shall be
85 nF/Km for 0.6 mm conductor diameter
8.3 Dielectric Strength

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The cables shall withstand a D.C. potential of 2000 volts applied for three seconds
between each conductor and all other conductors grounded.

8.4 Cross-Talk Coupling Loss

i) In a factory length of 300 meters, the average production level for far end
output to output cross talk loss at 150 KHz shall not be less than 73 dB (RMS). The
RMS calculation is based on the combination of adjacent and alternate pairs within the
same layer and centre to first layer pairs.

ii) 58 dB/Km at 150 KHz (102 dB/Km at 1 KHz) between

adjacent pairs and any pair combination of a cable.

8.5 ATTENUATION

8.5.1 Attenuation shall be measured in accordance with ASTM standard D-4566

by using a level oscillator and a level meter.

8.5.2 The pairs under test shall be terminated in their nominal characteristic
impedance ± 1%.

8.5.3 Automatic and semi-automatic test equipment can also be used for
measuring attenuation.

8.5.4 The measured attenuation shall be corrected to 20°C by using the following
equation for temp..correction.

Attenuation t°C
Attenuation at 20°C = ---------------------
1+0.0022 (t-20)

Correction factor for attenuation = 0.0022/1°C

8.5.5 The maximum value of attenuation when measured at or corrected to 20°C

according to the above specified method shall be as per Table-11 in this
document.

8.6 The conductor parameters e.g. resistance, resistance gradient, elongation, resistance
unbalance , attenuation etc. for different conductor sizes shall be in accordance with
those given in Table-3 below:-

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Conductor Conductor Resistance Elongation Pair Resistance Attenuation at
OR on removal 1KHZ
from
completed
cable

Diameter Resistance Gradient / Unbalance %

°C
(mm) (ohm/Km) (ohm/ km) (%) Ave Max dB /Km
0.6 63 0.26 MIN 15 1.5 4.0 1.25
Table-3

8.7 FACTORY TESTING

8.7.1 Factory electrical test results for each drum of cable shall be submitted to PTCL
before dispatch of cable.

9. DELIVERY

9.1 The cable shall be unless otherwise specified, delivered in factory lengths of
approx. 500 meters.

9.2 The cable shall be closely wound on strong lagged drums of adequate sizes.

9.3 The drum itself shall be distinctly marked with :-

1. The name of the supplier.

2. The number of the drum.

3. An arrow denoting the direction of rolling.

4. Length of cable.

5. Designation of cable.

6. Designation of sheath.

10. QUALITY SYSTEM

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10.1 Manufacturers of cable must show evidence that the cable has been
manufactured according to a Quality System conforming to ISO 9001:2000

10.2 A valid QUALITY SYSTEM ACCREDITATION of the manufacturer shall

be submitted.

10.3 Last and Next calibration date along with technical properties of the test
and manufacturing equipments for various tests shall be available in the
factory.

10.4 Manufacturers may be required to supply a copy of the Quality Manual

which shall be utilized for the manufacture and delivery of cable complying
to this specification at the time of tender award.

10.5 PTCL may require the manufacturer to be accredited to the above standards
by assessors on behalf of PTCL.

10.6 The PTCL or its authorized representatives may inspect the Tenderer's
facilities at any time for the purpose of Quality Assurance surveillance.

10.7 All cables manufactured to this specification shall be inspected and tested by
PTCL to check compliance.

10.8 The inspector reserves the right to request proof of compliance with this
specification, either by witnessing actual performance of this specification's
prescribed tests and / or the provisioning of documented test results at the
discretion of the inspector.

10.9 In the case of a dispute, testing shall be performed by an independent

authority at the expense of the tenderer.

10.10 Local manufacturers shall indicate the current status with evidence and the
time frame required for grant of QUALITY SYSTEM ACCREDITATION
conforming to ISO 9001 : 2000 for manufacture of underground cables.

11. PRE-SHIPMENT INSPECTION

11.1 The Pre-shipment factory tests performed by PTCL inspectors shall be at

the cost of the bidder.

11.2 The extent of testing shall be as under:-

11.2.1 Constructional tests shall be 5% of the cable offered for shipment.

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11.2.2 Physical tests shall be 5% of the cable offered for shipment except water
penetration test.

11.2.3 Electrical tests shall be 10% of the cable offered for shipment.

11.2.4 The drums in a certain categories shall be arranged in batches of 100s. 5% of

drums for physical & construction tests and 10% for electrical tests shall be
selected. If any selected drums fails, then five (5) more drums in case of
physical & construction tests and ten (10) more drums in case of electrical
shall be selected. If any of the drums now fails, the total batch of 100 drums
shall be rejected. If the fresh selected drums pass the tests then only those
drums which failed in first testing shall be rejected.

11.2.5 The drums selected for physical & construction tests and electrical tests shall
be mutually exclusive.

12. CABLE MANUFACTURING CAPABILITIES

12.1 The factory shall have adequate capabilities for production of cables .

12.2 Testing facilities for raw materials during production and for finished cable
including testing of electrical properties shall be available in the factory.

12.3 The manufacturer shall have ready availability of test records for a period of
not less than five years of all tests required by this specifications in a format
which identifies individual drums and is readily readable.

13. DOCUMENTATION

DOCUMENTS TO BE SUPPLIED WITH BID

13.1 Tenderers shall provide the following documents along with the bid.
He shall give the list of documents attached and their location in the
technical compliance. Failing compliance to provision of this clause shall
render the compliance in effective.

13.1.1 Manufacturers' certificate: In which the manufacturer shall under take to

supply product in accordance with PTCL Technical Specifications. In case
bidder is not himself a manufacturer, he shall also produce an authorization
from manufacturer in which the latter shall under take to supply the cable at
the rates quoted by the bidder.

13.1.2 Clause by clause technical compliance statement as per clause 14.1.

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13.1.3 Technical literature shall comprise, (1) drawings (2) data (such as annual
turn over in US Dollars and annual production capacity in Km-pairs) and (3)
performance characteristics of the offered cable which shall include.

(i) Primary Parameters:

Resistance /km, Capacitance/km, Inductance /km and
Conductance/km.

(ii) Secondary Parameters:

Characteristics Impedance over range 100 HZ to 2 MHZ &
Propagation Constant over range 100 HZ to 2 MHZ..

(iii) Graphical representation of variation in primary and secondary

parameters vs frequencies.

(iv) Cross talk and reflection.

(v) Transmission loses vs impedance mis-match.

(vi) Echo and Singing

(vii) Impedance Irregularities

(viii) Capacitance and Resistance Un-balances.

(ix) Test results of Raw materials used in manufacture verified from a

reputed laboratory.

13.1.4 Full details of the production and testing facilities available with the
manufacturer, his production capacity and actual production shall be
indicated by the bidder.

13.1.5 List of available Quality Controlling on-line and off line test equipment (with
latest calibration certificate) like Tensile Tester, Cold Bend Chamber,
Environmental Stress Crack equipment, Oxidation Induction Test equipment,
Air Circulating Heating Chamber, Resistance Meter, Capacitance Meter,
Dielectric Tester, Insulation Tester, Automatic Testing Console along with
details of Test Performed, etc, shall be indicated by the bidder.

13.1.6 Supply record of the offered product to various users in other countries
including home country for the last five years as a minimum along with
certificates from these users confirming satisfactory performance of the
product.

13.2 DOCUMENTS TO BE SUPPLIED LATER

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The supplier shall provide the following documents at his own cost before
start of manufacturing.

13.2.1 The supplier shall provide factory test procedures before start of
manufacturing.

13.2.2 Factory electrical test results for each drum of cable shall be submitted to
PTCL before dispatch of the cable.

13.2.3 Pre-shipment factory test results performed by PTCL inspectors shall also
be submitted.

14 CLAUSE BY CLAUSE COMPLIANCE STATEMENT

14.1 The Bidder shall furnish a clause-by-clause compliance for each and every clause
of technical specification separately both in hard copy and softcopy formats on
separate CD. As far as possible, the Bidder shall provide the detailed technical
description for each compliance statement. The page number shall be indicated
whenever an attached document is referred. More over the softcopy of the
compliance statement shall contain the hyperlinks to the reference documents.

i) "FULLY COMPLIANT", if the systems and functions offered fully meets the
tender requirement without any ifs or buts.

ii) "PARTIALLY COMPLIANT", if the systems and functions offered meet the
tender requirement partially, the bidder shall state the reason why the offer is
partially compliant. However, if the bidder is able to fulfill the specified
requirement later, the time schedule for this shall be stated. In such cases, the
bidder shall clearly mention the extent to which other requirements or
specifications are affected.
iii) "NON COMPLIANT", if systems and functions cannot meet the requirements, the
bidder shall also state the reasons for it.
iv) In case of absence or unclear statements of compliance for any specified
requirement, PTCL will interpret that particular requirement as being "NON
COMPLIANT".

14.2 Bidder shall submit clause-by-clause technical compliance according to the format
as under with the bid.

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Clause No. Complied Non- Partially Deviation/Details Hyperlinks to the
Complied Complied in case of Partially referenced documents
Compliance (of soft copy).

14.3 The bidder shall include in his proposal the detailed technical information,
drawings and functional descriptions of the offered equipment to provide the
compliance to the technical requirements.

14.4 The documents submitted with the bid shall be in appropriate format and well
organized. A table of contents must be attached in the beginning of the document.

15. Responses from the bidders shall be a valid part of the contractual commitment
process. Any clarification against a query if received and agreed by the PTCL will
stand as a condition of the contract – for which potential penalties ‘could’ be
levied if it is felt necessary and contractually correct.

16. The Query shall be submitter according to the following format

i) Tender/contract No:
ii) Title of Project:
iii) Bidder's Name:
iv) Query No:

Sr. No. Relevant Clause No Original Question Response

Document /Page No Statement

16. PTCL may ask any bidder to raise the standard and capability of its offered system
to match with better standard or capability of the system offered by its competitor
for PTCL required network.

17. PTCL reserves the right to add (on the quoted price) or drop any item in the order
placed on the successful bidder.

18. Along the statement of compliance the bidder shall submit in the technical
proposal un-priced BoQ for technical evaluation.

-----------------------------------------------: End of Specifications: -----------------------------------------

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