DAMODAR VALLEY CORPORATION HT CABLE

TERMINATION
TECHNICAL SPECIFICATION KIT

TECHNICAL SPECIFICATION FOR INDOOR/OUTDOOR HT TERMINATION KIT

1. SCOPE:
i. This specification covers design, manufacture, assembly, testing before supply,
inspection, packing and delivery and other basic technical requirements in respect of
Heat Shrinkable Indoor and Outdoor Termination for 11 KV 120 mm2 cables suitable for
armoured, HT, PVC/XLPE, Aluminum/Copper conductor cables as per IS:13573,2011.
The Heat Shrinkable termination to be supplied against this specification are required for
vital installations where continuity of service is very important. The design, materials and
manufacture of the Indoor and Outdoor Termination shall, therefore, be of the highest
order to ensure continuous and trouble-free service over the years.

ii. The Heat Shrinkable Indoor and Outdoor Termination offered shall be complete with all
parts necessary for their effective and trouble-free operation. Such parts will be deemed
to be within the scope of the supply irrespective of whether they are specifically indicated
in the commercial order or not.

iii. The Termination offered shall be complete with all parts necessary for their effective and
trouble-free operation. Such parts will be deemed to be within the scope of the supply
irrespective of whether they are specifically indicated in the commercial order or not.

iv. It shall be reliable, fast and easy to install jointing termination system to assure and
maintain high network reliability in the most severe conditions and under high electrical,
thermal, mechanical and environmental stress.

2. SYSTEM PARTICULARS:
a. Nominal System Voltage 11kV
b. Voltage variation on supply side 10 %
c. Highest System Voltage 12kV
d. Frequency 50 Hz with  3 % tolerance
e. Transient condition -20 % or + 10 % combined variation of voltage
and frequency
f. Number of Phase 3 Phases
g. Neutral earthling Solidly earthed.
h. Fault level (minimum) kA 12.5 for 3 sec.
i. Lightning Impulse Withstand 75
Voltage (kVp)
j. One minute dry/wet power 24.5
frequency withstand voltage
primary (kV rms)
k. Rated Dynamic Withstand 62.5
Current for 1 second duration
(kAp)

3. SERVICE CONDITIONS :
The Heat Shrinkable Indoor and Outdoor Termination for 11 kV Cables to be supplied against
this specification shall be suitable for satisfactory continuous operation under the following
tropical conditions.

i. Maximum ambient temperature : 50 0C.

ii. Minimum ambient temperature –: 4 0C
iii. Thermal resistance of soil : 150 0C –cm/watt
iv. Maximum daily average ambient temperature: 45 0C Page 1 of
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TECHNICAL SPECIFICATION KIT

v. Maximum relative humidity-:100%

vi. Average rainfall per annum: 200 cm
vii. Maximum height above the sea level : 1000 meter
viii. Maximum wind pressure/wind speed: 150 kg/sq. m/50m/sec
ix. Average no. of thunderstorm days per annum: 200

The material shall be for use in moderately hot and humid tropical climate, conducive to rust and
fungus growth.

4. STANDARDS :
a) The design, manufacture and performance of the Heat Shrinkable Indoor and Outdoor
Termination shall comply with all currently applicable statutes, regulations and safety codes.
Nothing in this specification shall be construed to relieve the bidder off his responsibilities.
b) Unless otherwise specified, the Heat Shrinkable Indoor and Outdoor Termination offered
shall conform to the latest applicable Indian, IEC, British, U.S.A. or International Standards
and in particular, to the following:-

Sr. No. Standards Particulars

1. IS: 13573- Part 2, 2011 Type Test and Performance requirement for Cable
Termination & Joints on XLPE cable for 6.6KV up-to
33KV
2. ESI09-13 issue 1:1981 Performance specifications for higher voltage Heat
shrinkable components for use with High Voltage Solid
Cables up-to and including 33KV.
3. IEC 61238-1- Class A Mechanical Connectors for Power Cable.

5. Technical Parameters of Heat Shrinkable Indoor and Outdoor Termination:

a) The Heat Shrinkable Indoor and Outdoor Termination materials & components shall be
offered in the form of kits. The kits shall be supplied complete with all necessary tubing
components (Non-Tracking Main Tube / Stress Control Tubing / Mechanical Connector /
Earthing / Non tracking Rain Skirts (For Outdoor Joints) / Cable Preparation, etc) to form a
ready to energize Heat Shrinkable Indoor and Outdoor Termination.

b) Heat Shrinkable Indoor and Outdoor Termination suitable for overhead application type
tested as per IS: 13573- Part 2, 2011. Jointing kit with less numbers of components without
affecting function and performance of Joints are preferred.

c) The Heat Shrinkable Indoor and Outdoor Termination covered under this specification shall
conform to specific parameters given below:

i. Heat Shrinkable Non Tracking Main Tube and Stress control tubing: The entire surface,
from the high voltage point (lug) to the earthing point of the XLPE core/ cable shall be
non-tracking, weather and erosion resistant, and hydrophobic in nature. Heat
shrinkable flexible polymeric tubing possessing non-tracking erosion and weather
resistant properties shall be used as an external covering for the cable cores, for both
indoor and outdoor terminations.
The tubes must be extruded and expanded by irradiation process only. The tube
material shall conform to the requirements of ASTM-D-2303. Molded tubing is not
acceptable. Stress Control Tubing shall have below characteristics:
a) Volume resistivity: 5 X 1010 Ohm-CM min.
b) Dielectric constant: 15 min.
c) Tensile Strength: 10 MPa min.
d) Ultimate Elongation: 200% min.
e) Accelerated Ageing: 168 hrs. at (120±2) °C. Page 2 of
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TECHNICAL SPECIFICATION KIT

f) Tensile Strength after aging: 8 MPa min.

g) Ultimate Elongation after aging: 100% min.
h) The impedance of stress control tubing shall not change over a range of
temperature from 0 0C to 125 0C.
ii. Heat Shrinkable Non tracking Rain Skirts: The material for Heat Shrinkable Non
tracking Rain Skirts shall be Polyolefin. The basic resin is mixed with chemical
additives offering protection against fire, oxidation, ozone and other environmental
effects. The sealant is a butyl rubber based red mastic which is water-proof, electrical
insulating and anti-tracking.
The properties of Heat Shrinkable Non tracking Rain Skirts shall be as follow:
Sr. No. Properties Value Standard
A Thermal
1. Continuous Temperature -55 0C to 125 0C
Limit
2. Shrink Temperature >125 0C
3. Heat shock Test (30 Mint. at No Cracking/ No
200°C) Flow
4. Low Temp. Flexibility (4 No Cracking ASTM D-2671
hours at - 40°C)
B Physical
Tensile Strength >8 N /mm2(min) ASTM D 638
Elongation >=200 %(min) ASTM D 638
Hardness 28 Shore D
Water Absorption <=0.5 %
C Electrical
Volume resistivity 1 x 10¹² Ohm cm ASTM D-257
Dielectric Strength 10 kv / mm(Min.) ASTM D-149

d) Mechanical Lug with Shear bolt:

a. The Mechanical Lugs with Shear bolt shall be made from a high-tensile, tin-
plated aluminum alloy suitable for both aluminum & copper conductor as per
IEC 61238-1 Class -A. The internal surfaces of the conductor holes are grooved.
The Mechanical Connector with Shear bolt should be type tested product as
per IEC 61238-1 Class -A.

b. The shear head bolts to be made of a special aluminum alloy, these contact
bolts should be shear-head bolts with hexagon heads. The bolts are to be
treated with a highly lubricating agent. A mechanical connector with bolts that
shear off when proper torque is applied. Maintain smooth surface over
connector after cut the shear head bolt. Contact bolts are irremovable once
their heads have been sheared off.

c. The Mechanical Lugs with Shear bolt should be designed with removable
inserts so as to accommodate lower cross section cable conductors & centre it.

e) Environmental Sealing:
Adhesives and sealants shall be provided in the Indoor and Outdoor Termination
kits for environmental sealing against ingress of moisture and aggressive gases.
The adhesives and sealants shall flow due to heating of heat shrinkable
components or otherwise during installation and shall fill all voids and adhere to
metal components and cable sheaths.

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TERMINATION
TECHNICAL SPECIFICATION KIT

f) Mastic:
The stress control tubing in combination with the stress grading mastic at the
screen cut provide a precisely defined impedance characteristic which smoothens
the electrical field. For ease of installation, stress control mastic (high Permittivity
mastic) is applied around the connector which shall also be used as void filler over
the connector.

g) Non Tracking Mastic:

The Non-Tracking Mastic shall be used in Heat Shrink Joint Indoor and Outdoor
Terminations for providing a water-tight seal between heats shrink components
and the cable parts. The Non-Tracking Mastic shall be electrically insulating, non-
tracking and water resistant. It shall be self-fusing and can be used for filling voids
and irregular shapes. It shall be water resistant and has high adhesion property
to connectors and cable components and provide excellent sealing functions. The
base material of the non-tracking sealant is thermally stabilized, blended rubber.

h) Screen, Earth continuity:

Screen continuity and earth continuity by using tinned copper braids of
appropriate sizes, shall be provided for transfer screen / earth in Heat Shrink
Indoor and Outdoor Terminations.

6. PROPERTIES OF HEAT SHRINKABLE COMPONENTS:

Sr. Properties Anti-Tracking Tubing Stress Control Tubing

No.

1. Dimensions
a) Wall Thickness Ration 0.6 Min 0.6 Min
10% Max 10% Max
b) Longitudinal Change
As per Size of Cable As per Size of Cable
c) Length - Expanded
d) Internal Dia. - Expanded As per Size of Cable As per Size of Cable

e) Internal Dia. – Fully As per Size of Cable As per Size of Cable

Recovered
2. Electric Strength Min. 10 kV / mm N/A
3. Heat Shock No splitting, cracking, No splitting, cracking,
dripping of flowing after dripping of flowing after 30
30 mins at 200°C Min mins at 200°C Min
4. Low Temperature Flexibility No cracking after 4 hours No cracking after 4 hours at
at - 20°C Max - 20°C Max
5. Relative Permittivity 3 Min. to 5 Max. 15 Min.
6. Tensile Strength 6 N/ mm² Min. 10 N/ mm² Min.
7. Ultimate Elongation 200% Min. 200% Min.
8. Thermal Aging 500 hours Min. at 120 ± 500 hours Min. at 120 ± 3°C.
3°C.
Tensile Strength 7 N/ mm² Min 8 N/ mm² Min

Ultimate Elongation 100 % Min. 100 % Min.

9. Visual Examination Free from pin holes, cracks, Free from pin holes, cracks,
inclusions and other visible inclusions and other visible
defects defects Page 4 of
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TECHNICAL SPECIFICATION KIT

10. Volume Resistivity 1 x 1010 ohm meters Min. 1 x 1010 ohm meters Min.
11. Water Absorption 0.5 Max. 24 hr. @ 25°C 0.5 Max. 24 hr. @ 25°C
1.0 Max. 24 hr. @ 50°C 1.0 Max. 24 hr. @ 50°C
12. Tracking Resistance 2.5 kV, 0.15 ml/min for 1
Hours.
2.75 kV, 0.15 ml/min for 1
Hours. NA
3.0 kV, 0.30 ml/min for 1
Hours.
3.25 kV, 0.30 ml/min for
20 minutes.

7. HEAT SHRINKABLE INDOOR TERMINATIONS KIT CONTENTS:

Sr. No. Description 3C X 120 sq.mm 11 kV Indoor Cable

Size Quantity
1. H.S. Non Tracking Main Tube 38/12 mm L – 450mm 3 Nos.
2. H.S. stress control tubing 32/14mm L – 130mm 3Nos.
3. H.S. Non tracking Lug Seal Tube with Non 50/16mm L – 120mm 3 Nos.
Tracking Adhesive coated.
4. H.S. Breakout with Adhesive 1 Nos.
5. Stress control mastic W-20mm L-100mm 3 Nos.
6. Non Tracking Red Mastic W-25mm L-150mm 3 Nos.
7. Armour earthing
i)T.C. earthing braid with lug 25sqmm L-500mm 1 Nos.
ii)G.I. Back up ring 71 mm x 50 mm 1 Nos.
iii)S.S. Clips 50 – 90 mm 2 Nos.
8. Metal screen continuity
i) T.C. earthing braid 7 sq mm L-150mm 3 Nos.
ii) Roll Spring Range 17 mm -28 mm 3 Nos.
9. Mechanical Lug with torque controlled shear 95 sq mm to 240 sq. mm L-
head bolts 12mm 3 Nos
10. Filler putty for Mechanical connector 1 Nos.
11. Silicon grease 6 grams 1 Nos.
12. Aloxide Paper P80 40cmX25mm 1 Nos.
Aloxide Paper P150 40cmX25mm 2 Nos.
Aloxide Paper P220 40cmX25mm 2 Nos.
13. Nylon string for cutting XLPE Insulation 1 Meter 1 Nos.
14. PVC adhesive tape W-25mm L-5Meter 1 Nos.
15. Core cleaning solvent 1 Nos.
16. Cleaning Cloth 300mm X300mm 1 Nos.
17. Copper binding wire 18 SWG x 2000mm 1 Nos.
18. Copper binding wire 20 SWG x 1000mm 1 Nos.
19. Packing List 1 Nos.
20. Instruction Manual 1 Nos.

8. HEAT SHRINKABLE OUTDOOR TERMINATIONS KIT CONTENTS:

Sr. No. Description 3C X 120 sq.mm 11 kV Indoor Cable
Size Quantity
1. H.S. Non Tracking Main Tube 38/12 mm L – 450mm 3 Nos.
2. H.S. stress control tubing 32/14mm 3Nos.
L – 130mm
3. H.S. Non tracking Lug Seal Tube with Non 50/16mm L – 120mm 3 Nos.
Tracking Adhesive coated. Page 5 of
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TECHNICAL SPECIFICATION KIT

4. H.S. Breakout with Adhesive 1 Nos.

5. Stress control mastic W-20mm L-100mm 3 Nos.
6. Non Tracking Red Mastic W-25mm L-150mm 3 Nos.
7. Armour earthing
i)T.C. earthing braid with lug 25 sq mm L-500mm 1 Nos.
ii)G.I. Back up ring 71 mm x 50 mm 1 Nos.
iii)S.S. Clips 50 – 90 mm 2 Nos.
8. Metal screen continuity
i) T.C. earthing braid 7 sq. mm L-150mm 3 Nos.
ii) Roll Spring Range 17 mm - 28 mm 3 Nos.
9. Mechanical Lug with torque controlled shear 95 sq. mm to 240 sq.
head bolts mm L-112mm 3 Nos
10. Filler putty for Mechanical connector 1 Nos.
11. Silicon grease 6 grams 1 Nos.
12. Aloxide Paper P80 40cmX25mm 1 Nos.
Aloxide Paper P150 40cmX25mm 2 Nos.
Aloxide Paper P220 40cmX25mm 2 Nos.
13. Nylon string for cutting XLPE Insulation 1 Meter 1 Nos.
14. PVC adhesive tape W-25mm L-5Meter 1 Nos.
15. Core cleaning solvent 1 Nos.
16. Cleaning Cloth 300mm X 300mm 1 Nos.
17. Copper binding wire 18 SWG x 2000mm 1 Nos.
18. Copper binding wire 20 SWG x 1000mm 1 Nos.
19. Packing List 1 Nos.
20. Instruction Manual 1 Nos.

9. Details of Heat Shrinkable Indoor and Outdoor Terminations Kit Contents:

a. The above mentioned Heat Shrinkable Indoor and Outdoor Terminations are specified for
general guidance. However supplier shall include necessary components in the Heat
Shrinkable Indoor and Outdoor Terminations kit for improving performance and thorough
Heat Shrinkable Indoor and Outdoor Terminations of HV cables thereby restoring continuity
of the cable parts giving same performance as that of cable. The supplier shall give full
justification for inclusion of necessary components in the Terminations kit.

b. The supplier shall furnish complete list of components describing functioning of each
component along with the consignment. Various tapes, wires etc. listed above shall be
supplied in standard lengths, sizes etc.

c. All these components shall have adequate dimensions and also electrical, chemical,
mechanical and physical properties, generally as per prevailing/applicable standards
amended to-date, to ensure reliability of joints to be installed.

d. The Heat Shrinkable Indoor and Outdoor Terminations kits shall be suitable for storage
without deteriorating at a temperature upto 500 Celsius under normal conditions of storage
and shall have unlimited shelf storage life. The certificate of shelf life shall be submitted along
with the consignment. The jointing procedure should be quick, simple and absolutely
reliable.

e. For identification purpose, a suitable name plate made of acrylic sheet (Thickness: 04 to 05
mm , Size:- Width: 50 mm, Length: 70 mm) shall be provided below the crutch region. Name
plate shall be suitably packed in polyethylene bag/aluminum foil pouch (with sealing
arrangement at one end) and shall be provided for each termination kit on which following
information shall be engraved. Also holes shall be provided at four corners of identification
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TECHNICAL SPECIFICATION KIT

tag for fixing the tag.

Make --------
Brand--------
P.O.no./date ----------
Lot no.----------
Supply month/year ---------

10. PACKING AND MARKING OF KIT COMPONENTS:

a. Each component shall be supplied in separately sealed package. All components together
shall form complete jointing kit and packed in cartons bearing legible kit description. Packing
cartons shall be sufficiently strong to withstand damage during transport, storage and
handling.
b. For the purpose of identification, each component shall bear legible description such as name
of the component, supplier's name, component serial number, batch reference etc.
Electrically conducting components shall be marked as "conducting" clearly and
permanently.
c. Instruction manual and bill of materials strictly as per kit contents indicating component
dimensions and quantity supplied shall be furnished with the kit.
d. Instruction manual shall clearly bring out detailed procedure in steps for cable preparation
and joint installation with the help of necessary drawings.

11. TESTS :
a. Type Test :
The Heat Shrinkable Indoor and Outdoor Terminations Kit offered should have been
successfully type tested at NABL laboratories for the tests indicated as follow in line with the
IS:13573(Part 2),2011; IS:13573(Part 3),2011 and technical specification. These Type Tests
should have been carried out within 10 (Ten) years prior to the date of supply.
The following type tests shall be carried out on the termination kit:
i. Conductor Resistance.
ii. AC or DC Voltages Test.
iii. AC (Wet)Test.
iv. Test at Elevated Temperature.
v. Partial Discharge Test.
vi. Impulse Voltage Test.
vii. Heating Cycle Test in air.
viii. Thermal Short Circuit Test (Conductor).
ix. Impulse Withstands.
x. Dynamic Short Circuit Test.
xi. Humidity.
xii. Salt Fog.
xiii. Examination.

b. Routine Test:
i. Electric Strength test for Anti tracking tubing.
ii. Elongation tests for all types of tubing.
iii. Tensile Strength.

12. PERFORMANCE GUARANTEE:-

The Heat Shrinkable Terminations Kits shall be suitable for storage without deteriorating at a
temperature up to 50 0C under normal conditions of storage and shall have unlimited shelf
storage life. The stored joints Kits materials found defective, it shall be replaced by the supplier
free of cost within one month of receipt of intimation. The Heat Shrinkable Indoor and Outdoor
Terminations Kit offered shall be guaranteed as per DVC Clauses.
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TECHNICAL SPECIFICATION KIT

13. GUARANTEED TECHNICAL PARTICULARS FOR HT HEAT SHRINKABLE TERMINATIONS KIT

Sr. Particulars of GTP Parameter Requirement
1. Manufacturer’s Name and Address
2. Manufacturer’s kit Type
3. Rated Voltage in KV 11kV
4. Frequency (HZ) 50 Hz
5. Equipment Conforming to Standards IS: 13573- Part 2, 2011
6. Kit Storage Temperature 500 C max
7. Material to be used Polyolefin
8. Type Of Kit Offered a) Indoor Termination
b) Outdoor Termination
9. Shelf life of components in the kit Unlimited
10. Time Required for energization after Immediate
completion of joint
11. Conductor resistance test(As per cable cross Conductor resistance shall not vary
section area) more than 10% of initial value
12. A.C. withstand voltage ph/ground) @ 4.5 U o 4.5 U o for 5 min
13. Heat Cycle in air 8 hours total with >hours 60 Cycles at 2.5Uo
steady heating and >3 hours cooling
14. Partial discharge test @ 1.73 Uo 10pC max Max 10 pC
at max temp as well as room temperature
15. Triple extruded hybrid tube Size as per specification
16. Dielectric Strength for
1) Anti tracking Tubing. 1) 18 Min.
17. Dielectric constant for
1) Stress control tube. 1) 15 Min.
2) Anti tracking Tubing. 2) 3.5 Min.
3) Stress control mastic 3) 9.0 Min.
18. Tensile strength for
1) Stress control tube.
2) Anti tracking Tubing. 8N/mm2 (common foreach)
19. Ultimate Elongation for
1) Stress control tube. 1) 50%.
2) Anti tracking tube 2) 100%.
20. Water Absorption for
1) Stress control tube. 1) 0.3%.
2) Anti tracking Tubing. 2) 0.3%.
3) Stress control mastic 3) 0.5%.
21. Longitudinal Change for
1) Stress control tube. 2)Anti tracking tube 10%.
22. Heat Shock for
1) Stress control tube. 30 min. @ 200 0C.
2) Anti tracking Tubing.
23. Mechanical Lug with Shear bolt As per specification
24. Service Temperature for Stress control mastic 90 0C
25. List Of Contents Of Kit(To be Furnished Detailed component
Separately) list with Quantity etc.

Vendor list: (1) 3 M ; (2). Raychem RPG, Mumbai Page 8 of