SPECIFICATION FOR ELECTRICAL
CABLES FOR 415/240 V SYSTEM
Table of Contents page
1. SCOPE...................................................................................................3
2. APPLICABLE CODES AND STANDARDS .........................................3
3. SITE CONDITIONS................................................................................4
3.1 General........................................................................................4
3.2 Special Design Conditions...........................................................4
4. Design and Construction.....................................................................4
5. MATERIALS ..........................................................................................5
5.1 Conductors ..................................................................................5
5.2 Insulation .....................................................................................5
5.3 Laying & Bedding ........................................................................5
5.4 Armour.........................................................................................5
5.5 Outer Sheath ...............................................................................5
5.6 Marking........................................................................................5
5.7 Sealing and Drumming ................................................................5
6. INSPECTION AND TESTING ................................................................6
7. QUALITY REQUIREMENTS..................................................................6
8. DOCUMENTATION ...............................................................................6
1. SCOPE
This specification defines the requirements for supply of electrical cables 600/1000V
XLPE/SWA/PVC type for the system voltage of 415/240 V, 3 phase and neutral and
frequency 50 Hz.
2. APPLICABLE CODES AND STANDARDS
The following codes and/or standards (latest editions inclusive of all amendments) are
applicable.
IEC 60502-1 Power cables with extruded insulation and their accessories for rated
voltages of 1 kV (Um = 1.2 kV) and 3 kV (Um = 3.6 kV)
IEC 60332-1 Tests on electric cables under fire conditions- Part 1: Test on a single
vertical insulated wire or cable
IEC 60228 Conductors of insulated cables
IEC 60230 Impulse tests on cables and their accessories
IEC 60724 Guide to the short-circuit temperature limits of electric cables with a
rated voltage not exceeding 0.6/1.0 kV
IEC 60811 Common test methods for insulating and sheathing materials of electric
cables.
IEC 60287-1 Calculation of continuous current rating of cables - current rating
equations
IEC 60287-2 Calculation of continuous current rating of cables - thermal resistance
IEC 60287-3 Calculation of continuous current rating of cables - operating conditions
The CONTRACTOR/VENDOR shall also note that it is not the intent of this specification to
deviate from good engineering practices. The absence of specifications shall imply that the
best engineering practices shall prevail, utilising first quality materials and workmanship.
The CONTRACTOR/VENDOR shall seek clarification from the ADWEA/ENGINEER of any
confusing or conflicting information contained in this specification and the accompanying
documents.
Any deviation from this specification shall be indicated by the CONTRACTOR/VENDOR along
with his bid. Otherwise the ADWEA/ENGINEER shall assume full compliance with this
specification while accepting the bid.
3. SITE CONDITIONS
3.1 General
For general climatic conditions applicable to the project installations, refer to Specification for
General Technical requirements.
3.2 Special Design Conditions
The maximum temperature for cables buried directly underground shall be assumed as 40
deg C.
4. Design and Construction
The design and construction of electrical power and control cables shall be in accordance
with the codes and standards as specified.
All electrical power and control cables shall have coloured cores as follows and as specified
in IEC 60173
Power Cables Control Cables
Single core - red or black red or black
Two cores - red and black red and black
Three cores - red, yellow, blue red, yellow, blue
Four cores - red, yellow, blue, black red, yellow, blue, black
Five cores - red, yellow, blue, black, green white numericals printed on black
insulation
The black sheath is for the neutral and the other colours are for the phase conductors.
For multicore cables (i.e. above 4 cores) for control applications, the core numbers shall be
printed on each cable core for identification (i.e. nos. 1,2,3,4,5,6,7..... upwards).
All cables shall be suitable for operation under the following conditions :
- Directly buried in ground.
- Run in buried P.V.C., concrete or all steel ducts.
- Runs fastened to cable rack or tray in open air.
The cables shall be capable of continuous operation at highest system voltage as specified
with maximum conductor operating temperature of 90°C and maximum temperature under
fault conditions of not more than 250°C.
5. MATERIALS
5.1 Conductors
The cable conductors shall be of stranded, annealed high conductivity copper conductors laid
up and rendered smooth and free from defects likely to injure the insulation.
Conductors shall be of high conductivity copper and meet the requirements of IEC 60228.
Smaller sizes shall be circular in formation and comprise several strands. Larger conductors
to be stranded and shaped to produce a compact, less costly design. For cables having two
or more than two core, shall have all cores of uniform cross section.
5.2 Insulation
Power and control cables shall be insulated with cross-linked polyethylene (XLPE)
compound and insulation thickness complying with the requirements of IEC 60502-1
5.3 Laying & Bedding
The laying of cores of cables and bedding shall be as per IEC 60502-1.
5.4 Armour
The power cables having two or more cores shall comprise a single layer of spirally applied
galvanised steel wires.
The electrical conductivity of the armour shall be such that it is capable of carrying the eart
fault current specified in data schedule.
Wire armour for single core cables shall consist of a single layer of aluminium wires.
5.5 Outer Sheath
The outer sheath of cables shall be an extruded layer of black PVC, intrinsically flame
retardant and anti termite protected. The cables shall meet the requirements of IEC 60502-1
and IEC 60332-1.
5.6 Marking
The external surface of the cover-sheath shall be embossed along two or more lines with
electrical cable 600/1000V according to IEC 60502-1. Also manufacturer's name and year of
manufacture shall be provided through out the cable length.
5.7 Sealing and Drumming
Both ends of every length of cable shall be sealed properly immediately after tests at
manufacturer's premises.
The cables shall be rolled on suitable wooden or steel drums. The drum shall be marked to
indicate the direction of rolling, type of cable, voltage and cable length. For all cut lengths of
cables which are to be delivered to ADWEA/ENGINEER, approved sealing caps of correct
size shall be supplied and properly mounted immediately after the respective cable length is
cut.
6. INSPECTION AND TESTING
Performance and acceptance tests for electrical power and control cables shall be carried out
at manufacturer's works which shall be witnessed by ADWEA/ENGINEER or alternatively
subject to ADWEA/ENGINEER'S prior approval, factory test certificates shall be accepted.
Copies of type test certificates as per IEC-60502 shall be furnished by the cable VENDOR
along with the bid.
The required tests, test conditions and acceptance criteria for the cables shall be in
accordance with the latest edition of IEC-60502-1(Sections 14 to 18) .
The required tests on the cables shall include but not limited to the following :
- High Voltage Test
- Conductor Resistance Test
- Armour Resistance Test
- Thickness of Insulation
- Test for Flame Retardance
- Insulation Resistance Test
7. QUALITY REQUIREMENTS
The supplier shall operate a quality management system complying with ISO 9002 module
requirements.
8. DOCUMENTATION
The VENDOR shall provide the following documents as minimum. The number of copies shall
be as specified in general specifications.
• Detailed technical particulars for the cables including current carrying capacity, short
circuit current ratings, de-rating factors, thickness of each material and composition,
weighting, etc.
• Test certificates for all type tests and materials if specified on data sheets.
• Installation data.
