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DCPL Volume IV: Ch 22: HV Cables

Sheet l 1 of 11
Electrical Works

CHAPTER 22 : HV CABLES

1.00.00 SCOPE OF SUPPLY

The HV cables shall be supplied, installed and commissioned in accordance


with the following specification.

Other cables including special cables if any which are necessary as per proven
engineering practice for satisfactory & trouble free operation of the entire
cable system of the power plant shall also be within the scope of supply. These
shall include all such cables for electrical integral with mechanical equipment
systems and subsystems.

2.00.00 CODES & STANDARDS

All standards, specifications and codes of practice referred to herein shall be


the latest editions including all applicable official amendments and revisions as
on date of opening of bid. In case of conflict between this specification and
those (IS: codes, standards, etc.) referred to herein, the former shall prevail.
All the cables shall conform to the requirements of the following standards and
codes:

IS:7098 Cross linked polyethylene insulated PVC sheathed cable for


(Part -II) working voltage from 3.3 KV up to & including 33 KV.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low Carbon Galvanized steel wires, formed wires and tapes
for armouring of cables.
IS : 4905 Methods for random sampling.
IS : 5831 PVC insulation and sheath of electrical cables.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D - Standard test method for density of smoke from the
2843 burning or decomposition of plastics.
ASTM-D- Standard method for measuring the minimum oxygen
2863 concentration to support candle like combustion of plastics.
IEC-754 Test on gases evolved during combustion of electric cables.
(Part-I)
IEEE-383 Standard for type test of Class IE Electric Cables.
IEC -332 Tests on Electric cables under fire conditions.
Part-3 : Tests on bunched wires or cables (category -B)
IEC: 60 High voltage test techniques.

3.00.00 DESIGN CRITERIA

3.01.00 The cables will be used for connection of power circuits of the system. Actual
cable sizes will be selected by the Contractor. Number of different sizes
selected will be kept to a minimum for optimization.

3.02.00 Cables shall be generally laid on ladder type cable trays or drawn, through
rigid Steel pipe conduits. For interplant connection cables shall be routed along
overhead cable bridge.

1 x 660 MW - Panki Thermal Power Station

Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 2 of 11
Electrical Works

3.03.00 For continuous operation at specified rating, maximum conductor temperature


shall be limited to the permissible value as per relevant standard and/or this
specification whichever is more stringent.

3.04.00 The insulation and sheath materials shall be resistant to oil, acid and alkali and
shall be tough enough to withstand mechanical stresses during handling.

3.05.00 Armouring shall be single round wire / strip of galvanized steel for multicore
cables and aluminium for single core cable as per the relevant standards.

3.06.00 The inner and outer sheath shall have fire resistant low smoke (FRLSH)
characteristics and shall meet the requirements of additional tests specified for
the purpose.

3.07.00 Core identification for multicore cable shall be provided by colour coding.

3.08.00 Cables shall be so designed and manufactured that no damage occurs during
handling, transit, storage, installation under any operative conditions which
they may be subjected to.

3.09.00 HT XLPE FRLS power cables shall be manufactured by triple extrusion dry cure
(CCV) process using nitrogen.

3.10.00 Minimum value of volume resistivity for XLPE insulation shall be 1.0x1014
ohms-cm at 27 deg C and 1.0x1012 ohms-cm at 90 deg C.

3.11.00 Maximum continuous operating temperature shall be 90 deg C under normal


operation and 250 deg C under short circuit condition.

4.00.00 SPECIFIC REQUIREMENTS / CONSTRUCTIONAL REQUIREMENTS

4.01.00 HV CABLES

11/3.3 kV system cables shall be unearthed grade, single or multi core,


stranded copper /aluminium conductor, screened by extruded semi-
conducting compound, extruded XLPE insulated, cores screened with extruded
semi-conducting compound in combination with copper tape, inner sheathed
extruded FRLSH HRPVC compound type ST – 2, armoured with galvanized wire
or strips for multi core cables and aluminium wire armoured for single core
cables and overall sheathed with extruded FRLS HRPVC type ST-2 cable
conforming to IS 7098, Part II, IEC-502 for constructional details and tests

4.02.00 Generator Excitation System

The cables shall be 3.3kV grade, heavy duty, stranded copper conductor,
insulated with heat resistant PVC of type-C, hard drawn aluminium wire
armoured, flame retardant low smoke (FRLS) extruded PVC Type–ST2 outer
sheathed.

5.01.01 Conductor

Stranded, compacted circular aluminium conductor of H2 grade, conforming to


class-2 of IS:8130 (1984).

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Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 3 of 11
Electrical Works

5.01.02 Conductor Screening

Cross linked semi-conducting compound extruded in the same operation as


the insulation.

5.01.03 Insulation

Cross linked polyethylene (XLPE) of natural colour, extruded over screened


conductor. This shall be conforming to IS:7098 Part-2 (1985).

5.01.04 Insulation Screening

All cables shall be provided with insulation screening. The insulation screening
shall consist of extruded cross linked semi-conducting compound in
combination with a layer of lapped copper tape of thickness not less than 0.1
mm.

5.01.05 Core Identification

Three (3) core cables, core identification shall not be done with different
colouring of XLPE insulation, but with natural colour with coloured strips
applied on the cores or by numerals printing on the cores.

Laying up of cores:
Cores shall be laid up together as per IS 7098 Part – 2 (1985).

5.01.06 Inner Sheath

Three (3) core cables, after laying up of cores, shall be provided with extruded
HRPVC, FR-LSH inner sheath conforming to type ST2 of IS:5831/1984. Such
inner sheath shall be provided by pressure extrusion process without filler.

However, if in the process, the centre filler is required, the same shall be
provided and material of centre filler shall be the same as inner sheath
material.

Extruded FR-LSH inner sheath shall also be provided for single core cables.

5.01.07 Armour

For Single Core Cables: - Armour shall be of Non magnetic material


consisting of single hard drawn aluminium round wires conforming to H4
grade of IS:8130 / 1984.

For three (3) core cables: - The arouring shall be of galvanised steel strip
as follows:-

Calculated nominal dia of cable Size and Type of Armour


under armour
i) Upto 13 mm 1.4 mm dia GS wire

ii) Above 13 & upto 25 mm 0.8 mm thick GS formed wire /


1.6 mm dia GS wire

iii) Above 25 & upto 40 mm 0.8 mm thick GS formed wire /


2.0 mm dia GS wire

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DCPL Volume IV: Ch 22: HV Cables
Sheet l 4 of 11
Electrical Works

iv) Above 40 & upto 55 mm 1.4 mm thick GS formed wire /


2.5 mm dia GS wire

v) Above 55 & upto 70 mm 1.4 mm thick GS formed wire /


3.15 mm dia GS wire

vi) Above 70 mm 1.4 mm thick GS formed wire /


4.00 mm dia GS wire

The aluminium used for armouring shall be of H4 grade as per IS; 8130 with
maximum resistivity of 0.028264 ohm-sq.mm/mtr at 20 deg. C. The types and
sizes of aluminium armouring shall be same as mentioned for galvanized steel
at 5.01.07 above

The gap between armour wires / formed wires shall not exceed one armour
wire/ formed wire space and there shall be no cross over / over-riding of
armour wires / formed wires. The minimum area of coverage of armouring
shall be 90%. The breaking load of armour joint shall not be less than 95% of
that of armour wire / formed wire. Zinc rich paint shall be applied on armour
joint surface of GS wires / formed wires.

5.01.08 Overall Sheath

A tough overall sheath of extruded HRPVC,FR-LSH compound conforming to


type ST2 of IS:5831 / 1984 shall be provided over armour.

The colour of outer sheath shall be black.

5.02.00 FLEXIBLE TRAILING CABLES

11kV/3.3kV Unearthed Grade flexible trailing cable, annealed tinned copper


conductor, Class – 5 of IS – 8130, insulated with EPR, conductor and
insulation shielded with EPR, cores screened with ATC wire braiding, cores laid
up, HD CSP inner sheathed, proof cotton taped and FRLS HD CSP sheathed
overall, conforming to IS: 9968. Alternatively PCP sheathing may be
acceptable.

6.00.00 The standard cable sizes, amp capacities, derating factors. as given in IS/IEC
will be generally followed:

a. For breaker protected circuits minimum size of the cable shall be as


follows: 11kV & 3.3kV Power XLPE : 240 Sqmm.

7.00.00 For motor circuits the selection of size will be made ensuring that the cable
shall withstand a short circuit fault directly following a second hot start.

8.00.00 GENERAL REQUIREMENTS

8.01.00 Drum Length & tolerance

HV cables shall be supplied on steel drums (non returnable). Each drum


shall contain minimum 500 metres single length of cable. Allowable
tolerance on individual drum length is (+/-)5%.

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Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 5 of 11
Electrical Works

8.02.00 Non-standard length

Bidder will be required to obtain Owner’s approval before packing the non
standard length of cables on drums. Non-standard lengths shall not be less
than 100 metres in any case.

8.03.00 Cable identification

Cable identification shall be provided by embossing on every meter on the


outer sheath the following:

a) UPRVUNL
b) Manufacturer’s name or trademark
c) Voltage grade
d) Year of manufacture
e) Type of insulation and sheath, e.g. XLPE /HRPVC FRLS & IE2 as
applicable.
f) Type of improved fire performance, e.g. FR/FR-LSH/FS
g) No. of core and size of cables.
h) Reference Standard
i) ISI Mark
j) Sequential length marking at an interval of 1m through out the length
of the cable.

9.00.00 PACKING

9.01.00 Cables shall be supplied in non-returnable drums. The drums shall be of heavy
construction as per relevant IS. All ferrous parts used shall be treated with
suitable rust preventive finish or coating to avoid rusting during transit or
storage.

9.02.00 Cable shall be wound and packed on drums in such a manner that it will be
properly sealed and firmly secured to the drum. The ends of each length shall
be sealed before shipment. Heat shrinkable cable seals shall be used for this
purpose.

9.03.00 A label shall be securely attached to each end of the reel indicating the details
mentioned below. A tag containing the same information shall be attached to
the leading end of the cable inside. Drum numbers are to be indicated on cable
drums.

9.04.00 The cable drums should carry the following details in printed form (non
returnable):

a) UPRVUNL & Manufacturer’s name or trade make


b) Type of cable & voltage grade
c) Year of manufacture
d) Type of insulation / sheath e.g. XLPE /HRPVC FRLS & IE2 as applicable.
e) No. of core and size of cables
f) Cable code
g) Length of cable on drum
h) ISI Mark
i) Direction of rotation, by arrow
j) Approx. gross mass.
i) IS/IEC number

1 x 660 MW - Panki Thermal Power Station

Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 6 of 11
Electrical Works

10.00.00 Joints and Terminations

Materials of construction for a joint/termination shall perfectly match with the


dielectric chemical and physical characteristics of the associated cables. The
material and design concepts shall incorporate a high degree of operating
compatibility between the cable and joints. The protective outer covering
(jacket) used on the joints/terminations shall have the same qualities as that
of the cable outer sheath in terms of ambient/operating temperature withstand
capability and resistance to hazardous environments and corrosive elements.
Straight through joints and terminations for HT cables shall be heat shrinkable
type.

11.00.00 TESTING PROCEDURE

11.01.00 TESTS DURING MANUFACTURE:-

During the manufacture of cables, manufacturer’s standard tests shall be


performed and record / test report shall be made available to purchaser’s
representative during inspection / testing.

11.02.00 TYPE ROUTINE & ACCEPTANCE TESTS:-

After completion of manufacture of cables, type, routine and


acceptance tests shall be performed strictly as per relevant IS & other
applicable standards amended upto date.

Routine tests shall be carried out on 100% drums.

11.03.00 TYPE TESTS :-

11.03.01 The type test as per applicable standards and as given below shall be
conducted on one drum selected on random basis out of every 10 drums or
less of each type and size of cable. Size shall mean area of cross section in
sq.mm read in conjunction with the number of cores. Type shall mean type of
insulation, sheath, volt grade FRLS/FS etc. In case, facilities of any of the type
tests are not available at the works of the supplier, then such type tests shall
be carried out by the supplier at independent recognized Govt. approved
laboratory at the cost of supplier.
1. Tensile test (for aluminium) as per IS:8130
2. Wrapping test (for aluminium) as per IS:8130

Note:- In the case of compacted circular & shaped conductors these tests shall
be carried out before compacting/shaping for ensuring use of H2 grade
aluminium.

3. Conductor Resistance test as per IS:8130.

4. Test for armour wire/strip as per IS:3975

5) Test for thickness of XLPE Insulation and HRPVC,FR-LSH sheath :-

Requirements and methods of tests for the thickness of insulation,


inner sheath and outer sheath shall be as per IS: 7098 (Part-2).

6) Tensile strength and elongation test for insulation & sheath :-

1 x 660 MW - Panki Thermal Power Station

Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 7 of 11
Electrical Works

This test shall be carried out as per IS:7098 Part-2 for XLPE cable.

7) Ageing test for insulation and sheath:-

The method of test shall be as per the relevant IS standard. The period
of test shall be 168 hours (7 days). At the end of the ageing period, the
tensile strength and elongation test shall be carried out as per
Sr.No.(6) above. The value obtained must not differ from the
corresponding values obtained before ageing by more than + or - 25%
in case of XLPE compound.

8) Loss of mass test for HRPVC, FR-LSH sheath :-

This test shall be carried out as per IS 583/1984 012 IEC 540 & IEC
502, on cables of all voltage grades. The maximum permissible loss of
mass is 2 mg/sq.cm for PVC.

9) Shrinkage test for XLPE insulation & HRPVC FR-LSH sheath:-

This shall be carried out as per IS:5831 – 1984 for sheathed and as per
IS 7098 (Part 2) 1985 for XLPE insulation.

10) Hot deformation test for HRPVC,FR-LSH sheath :-

This shall be carried out as per IS:5831 / 1984.

11) Cold Impact test for HRPVC,FR-LSH sheath :-

This shall be carried out as per IS:5831.

12) Heat shock test for HRPVC,FR-LSH sheath :-

This test shall be carried out as per IS 5831 / 1984 and IEC 540 and
IEC 502 & sheath shall pass the requirements of this test.

13) Thermal stability test for HRPVC,FR-LSH sheath :-

This test shall be carried out on cables as per IS 5831 / 1984 and IEC
540 and cables shall pass the minimum requirements of 80 minutes for
sheath.

14) Hot set test for XLPE Insulation :-

This test shall be carried out as per IS:7098 Part-1 and Part-2 and
cable shall pass the requirements given therein.

15) Test for bleeding and blooming of Pigments for HRPVC,FR-LSH Sheath
:-

This shall be carried out as per IS:5831 / 1984.

16) Fire Resistance Test

This test is compulsory and shall comply with the relevant clause of
applicable IS.

1 x 660 MW - Panki Thermal Power Station

Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 8 of 11
Electrical Works

17) Partial Discharge Test for XLPE Cables:-

The partial discharge test for XLPE insulation shall be carried out as per
IS:7098 (Part-II).

18) Bending Test for XLPE Cables :-

The test method and test requirement shall be as per IS:7098 (Part-
II). On completion of this test, the sample shall be subjected to partial
discharge measurement and comply with the requirements given in
above sub-clause 17.

19) Insulation Resistance / Volume resistivity -

As per IS 7098 Part-2 / 1985.

20) Dielectric Power Factor Test

As per IS 7098 Part-2 / 1985.

21) Heating cycle test for XLPE Cables :-

This test shall be as per IS:7098 (Part-II)

22) High Voltage Test

This test shall be performed as per the relevant Indian Standard 7098
Part 2 / 1985.

23) Test for Rodent & Termite Repulsion Property of Sheath :-

A few chipping of the PVC compound is slowly ignited on a porcelain


dish or cubicle in a muffle furnace at about 60 degree C. The resulting
ignited ash is boiled with a little ammonium acetate solution (10%).
Place a drop of aqueous sodium sulphide solution on a thick filter paper
and allow to soak. Touch the spot with a drop of above extract. A black
spot indicates the presence of lead, the anti-termite and rodent
compound.

24) Impulse Withstand Test

As per IS – 7098 (2) (amended upto date).

25) Water Absorption Test

As per IS 7098 Part-2 / 1985.

11.03.02 The normal sequence of the electrical tests shall be as per Clause 16.1.1 of
IEC-502/1978 and / or as per IS 7098 Part – 2 / 1985 . All the tests listed
herein shall be applied successively to the same sample.

11.03.03 The inner and outer sheath of the XLPE insulated cable shall be subjected to all
the tests applicable for PVC sheath as per IS 5831 / 1984.

11.04.00 SPECIAL TESTS ON HRPVC ‘FR-LSH’ MATERIAL

1 x 660 MW - Panki Thermal Power Station

Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 9 of 11
Electrical Works

All the sizes of XLPE power cables of the ‘FRLS’ HRPVC sheathed type shall
pass following special test requirements. Inner sheath wherever applicable
shall also be of the ‘FR-LSH’ type ‘HRPVC’ to meet these special tests.

i) Oxygen/Temperature Index test on sheath material :-

This test shall be carried out as per American National Std. A STM-D-
2863/77.

The minimum oxygen index shall be 29 at room temperature.

For determination of the temp.index, the oxygen index test shall be


carried out at different temperature upto 250°C. However, the test
shall be carried out by extra-polation method beyond temperature at
which the material of sheath may start deformation. The minimum
temp. index (i.e. the temperature at which the oxygen index is
minimum 21) shall be 250°C generally as per BICC Hand Book
Chapter-6.

ii) Acid gas emission test on sheath material :-

This test shall be carried out as per IEC Std. 754-1. The maximum acid
gas emission shall be less than 20 by weight.

iii) Smoke density test on sheath material :-

This test shall be carried out as per American National Standard ASTM-
D-2843/1977 and also as per UITP method (3M cube test on finished
cable sample). The ASTM test method is compulsory. For passing this
test, the requirement of light transmission shall be minimum 40% after
the test.

iv) Flammability test on finished cable sample :-

This test shall be carried out as per the following method :

Swedish Std.SS:424-14-75 Class-F3. This test known as Swedish Chimney


test is compulsory.

IEEE std. 383-1974 – This test known as the vertical tray flame
propagation test shall be conducted if insisted by purchaser.

IEC Std: 332-1. – The cable should meet the requirement of all the above
standards.

12.00.00 ROUTINE TESTS :

The following tests shall be carried out as Routine tests on each and every
drum length of cable, as per IS 7098 (Part 2) / 1985.

High Voltage Test


Conductor Resistance Test
Partial discharge test (for screened cables) – on full drum length.

1 x 660 MW - Panki Thermal Power Station

Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 10 of 11
Electrical Works

13.00.00 ACCEPTANCE TEST :

The following test shall be carried out as Acceptance Test in the presence of
UPRVUNL Inspecting Engineer on samples taken from the delivery lot. One
drum out of every 10 number of drums or less shall be selected at random
sampling basis in each lot for the Acceptance Tests which shall be carried out
at manufacturer’s/supplier’s cost.

1. High Voltage Test


2. Conductor Resistance Test
3. Tensile / wrapping test.
4. Partial discharge test (In screened cables).
5. Insulation Resistance/Volume resistivity test
6. Measurement of thickness of insulation and sheath and other
dimensions
7. Tensile strength & elongation at break for insulation & sheath.
8. Hot set test on XLPE insulation
9. Flammability test as per Swedish standard SS:424-15-75 Class-F-3
(Swedish Chimney test)
10. Acid gas generation test as per IEC-754-1.
11. Smoke density test as per ASTM-D-2843/1977
12. Oxygen index test as per ASTM-D 2863/1977
13. Temp. index test as per ASTM-2863/77

14.00.00 TEST WITNESS

Tests shall be performed in presence of UPRVUNL representative. The


Contractor shall give atleast fifteen (15) days advance notice of the date on
which the tests are to be carried out.

15.00.00 TEST CERTIFICATES

Certified reports of all the tests carried out at the works shall be furnished for
approval of the Owner/Purchaser.

Test reports shall be completed with all details and shall also contain IS/IEC
specified limit values, wherever applicable, to facilitate review.

The cables shall be dispatched from works only after receipt of Owner/
Purchaser's written approval of the test reports.

16.00.00 SITE TESTS

The contractor shall carry out the following commissioning tests and checks
after installation at site. In addition the contractor shall carry out all other
checks and tests as recommended by the manufacturers.

a) Check for physical damage

b) Check for insulation resistance before and after termination/jointing.

c) HV cables shall be pressure tested (test voltage as per IS: 7098) before
commissioning.

d) Check of continuity of all cores of the cables.

1 x 660 MW - Panki Thermal Power Station

Bidding Doc. No. : 14A14-SPC-G-0001


DCPL Volume IV: Ch 22: HV Cables
Sheet l 11 of 11
Electrical Works

e) Check for correctness of all connections as per relevant wiring diagrams.


Any minor modification to the panel wiring like removing/inserting,
shorting, change in terminal connections, etc., shall be carried out by the
Contractor.

f) Check for correct polarity and phasing of cable connections.

g) Check for proper earth connections for cable glands, cable boxes, cable
armour, screens, etc.

h) Check for provision of correct cable tags, core ferrules, and tightness of
connections.

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Bidding Doc. No. : 14A14-SPC-G-0001

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