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19.09.2013/08.01.2014

TECHNICAL SPECIFICATION

FOR

2Cx16+25 Sq.mm
LT XLPE AB CABLE
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TECHNICAL SPECIFICATION OF 2 CORE L.T AERIAL BUNCHED CABLE.

1. SCOPE :

This specification covers the requirements of ISI marked Cross linked Polyethylene insulated
(XLPE) Aluminium Cables twisted over a central bare Aluminium alloy messenger wire (along with
associated accessories) for use on LT overhead lines in Rural/ Urban Electrification System.

The designation of the LT XLPE AB Cables are :

2 Core x 16+25 Sq.mm

The first part of the designation refers to the number and size (nominal cross sectional area) of
the phase conductor and the last part to size of the bare AAA messenger.

2) LT Aerial Bunched Cables:

2.1. Electrical Data :

1) The rated voltage of the cables shall be 0.6/1kV.

2) Highest system voltage : 1.2 kV.
3) a) 2.5 kV / 50 Hz / 5 min for routine tests.
b) 4 kV / 50 Hz / 4 Hours. for type tests.

4) Max short circuit current for 1 Sec. 1.0 KA.

5) Current carrying capacity at different ambient air temperatures of different sizes of phase
Conductors are tabulated at Annexure – III.

2.2. APPLICABLE STANDARDS:

Unless otherwise stipulated in this specification, the following standards as amended from time to
time shall be applicable.

i) IS: 8130 – 1984 for Aluminium conductors for insulated electric cables (flexibility as
per class_II)
ii) IS :14255-1995 Aerial Bunched cable for working voltage up to and including 1100
Volts.
iii) IS : 398 (Part-IV) 1994 : For all Aluminium Alloy Conductors (AAC) for overhead
transmission purposes.

A.B Cable meeting any other alternative equivalent international standards ensuring equal or
better quality than the standards mentioned above and complying with this technical specification shall
also be acceptable. In case the tenders wish to offer materials conforming to other standards a copy of
Such standard (English version only) adopted shall invariably be enclosed with the bid.

2.3. GENERAL :

2.3.1. The insulated phase conductors shall be twisted around the bare aluminium alloy messenger.
wire, which shall take all the mechanical stress. The messenger wire shall also serve as the earth-
cum-neutral wire.
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2.4. PHASE CONDUCTORS :

2.4.1. The 16 Sq.mm phase conductor shall be of Aluminium round stranded and compacted.
(The flexibility is as per IS-8130-1984 class-II), 25 Sq.mm messenger wire shall be round
stranded and suitably compacted and outer diameter shall be within the limits specified in
Annexure-I.

2.4.2. The phase conductors shall be insulated with black weather resistant Cross linked Polyethylene
(XLPE) suitable for 1100 V insulation. The insulated conductors shall generally conform to the
standards (i) & (ii) quoted in clause 2.2 above.

2.4.3. CONDUCTORS:

The properties of the Aluminium wires before stranding shall be as below.

Tensile strength not less than 90 N/mm2

Resistivity at 20 Deg. C not exceeding 0.02845 Ohm per meter.

The outer layer in standard conductor shall have a right handed direction of lay (Z), the surface of
the conductors shall be smooth.

2.5. INSULATION :

2.5.1. Material: The insulation shall be black weather-resistant cross-linked polyethylene (XLPE).

2.5.2. Phase Identification: Durable and clearly visible longitudinal ridges shall be provided as
follows on each insulated conductors as indicated in Figure – 5 for identification phases.

For 2 Core Cable 1,2

Approx. ridge dimensions are :

Width = 1.00 mm
Height = 0.4 mm
Distance between = 2.7 mm.
consecutive ridges

2.6. Messenger (Neutral Conductor):

The messenger shall be an All Aluminium Alloy conductor composed of 7 Wires each 2.34 mm
Rod is drawn from the wire, which is manufactured in a continuous casting and rolling process.
properties for the individual wires before stranding shall be.

- Tensile strength not less than 278 N/mm2

- Resistivity at 20 Deg. C not exceeding 0.0328 ohm Sq.mm/m
- 2.7 Kg/cubic dm at 20 Deg. C
No joints are allowed in the messenger except those made on the base rod or wire before final
drawing. The messenger shall be round, stranded and compacted to have a smooth round surface.

The messenger takes all the mechanical stress and also serves as a neutral conductor.
- Neutral conductor over all diameter (max) 6.5 mm
- D.C resistance at 20 Deg. C (max) 1.38 mm ohms/km.
- Min. breaking load 7.0 KN.
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2.7. DESIGN:

The cable consists of one to three black weather resistant cross linked polyethylene (XLPE)
insulated aluminium phase conductor's stranded around a bare all aluminium alloy messenger
which is also the neutral conductor. The construction data are specified in Annexure – I
The detailed design drawings shall be submitted along with the bid documents.
2.8. The resistance of the phase conductors and the messenger are determined with direct current and
the same are corrected to 20 Deg. C using the formula and co-efficient given in clause-5 of the
standard IEC 2.8 B. The values obtained shall not exceed the resistance given in Annexure-2.

2.9. CROSS LINKED POLYETHYLENE INSULATION

The polyethylene insulation shall generally conform to IS-14255/1995. The following properties
shall be guaranteed by the supplier. For methods of testing IS:10810 (relevant parts) may be
referred.

Tensile strength. = Min 12.5 N/Sq.mm.

Percentage elongation = Not less than 200.
Hot set percentage elongation under Load= Max 175%
Permanent set = Max 15%

Volume Resistivity of insulation

At 27 degrees Celsius. = 1 x 1013ohm cm (min)
At 70 Degrees Celsius = 1 x 1011ohm cm (min)
Shrinkage at 115 Deg. C 24 Hrs max. =4%

2.10. TESTS ON LT AB CABLE :

2.10.1. Type Tests as per Cl.10.1 and 11.4 of IS:14255/1995:

a) Tests on phase/street light conductor
Tensile Test
ii) Wrapping Test
iii) Resistance Test
b) Tests on messenger conductor
i) Breaking Load
ii) Elongation Test
iii) Resistance Test
c) Physical Test for XLPE Insulation
i) Tensile strength and elongation at break
ii) Hot Set index
Shrinkage Test
iv) Ageing in Air
v) Water absorption (Gravimetric)
d) Test for thickness of insulation
e) Insulation resistance (volume resistivity)
f) High voltage test
g) Bending test on complete cable
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2.10.2. ACCEPTABLE / ROUTINE TESTS as per Cl.10.2 of IS:14255/1995 and P.O:

a) Tensile tests for phase/street light conductor

b) Wrapping Test for phase/street light conductor
c) Breaking load test for messenger conductor
d) Elongation test for messenger conductor.
e) Conductor resistance test.
f) Test for thickness of insulation.
g) Tensile strength and elongation at break
h) Insulation resistance test
High voltage test
j) Hot Set

2.11. BENDING TEST ON THE COMPLETE CABLE :

The test shall be performed on a sample of complete cable. The sample shall be bent around a
test mandrel at room temperature for at least one complete turn. It shall then be unwound and the
process shall be repeated after turning the sample around its axis 180 degrees. The cycle of these
operations shall then be repeated more. The diameter of the mandrel shall be 10 (D+d).

Where D= actual diameter of the cable (i.e., minimum circumscribing circle diameter in mm)
d = actual diameter of the conductor in mm.
No cracks visible to the naked eye are allowed.

2.12. PACKING AND MARKING :

The Cable shall be wound on non-returnable wooden drums conforming to IS:10418/1982 with
latest amendment thereof. The ends of the cable shall be sealed by means of non-hygroscopic
sealing materials. The drum shall be marked with the following.

a. Manufacturer’s Name or Trade Mark.

b. Type of cable and voltage grade.
c. Drum number or identification number.
d. Number of cores and size of cable.
e. Number and length of pieces of cable in each drum.
f. Gross / Net mass of the cable.
g. Direction of rotation of drum. (By means of an arrow).

2.12.2. The drums shall be of such construction as to assure delivery of conductor in the field free from
displacement and damage, should be able to withstand all stresses due to handling and the
stringing operation so that cable surface is not dented, scratched or damaged in any way during
transport and erection. The cable shall be properly lagged on the drums.

2.12.3. The cable drum should be suitable for wheel mounting.

2.12.4. The mass of finished cable in a drum (without the mass of the drum) of various designations shall not
exceed by more than 10% of the following values.

Designation Gross mass.

2 x 16 + 25 Sq.mm 800 Kg
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2.13. The minimum length of each cable shall be 1 Km.

While longer lengths shall be acceptable, shorter lengths not less than 500 meters shall be
acceptable to the extent of 10% of the size wise ordered quantity only.

2.14. MARKING OF CABLE :

All the cables shall have the following marking embossed on the insulated phase conductors for
identification: AP-PDCL, XXXX (XXXX is purchase order number) in addition to
manufacturer’s name and year of manufacture at regular intervals of not more than one meter.
3. The Companies are requested to furnish the valid BIS certificate along with the Bid. Without
which, the bidder shall be treated as non responsive.

4.0 TESTING EQUIPMENT:

The following guidelines are issued for completion of inspections.

• All the testing equipment for testing the offered material shall be available in good condition.
condition.

• The testing equipment shall be calibrated yearly at any of the NABL labs and a
certificate to this effect made available to the inspection officer.

• If the testing equipment is not available as indicated above, the third party inspection
officers will not carry out the inspection until the above stipulations are complied with and
Subsequent visits charges for inspection of the material shall be borne by the supplier.

The third party inspecting officers are entrusted with the work of capacity, inspection of the
factory covering the various manufacturing and testing equipment available, sources of purchase of raw
material, quality control, available manpower etc.

The bidders are requested to extend full support to the third-party agencies wherever they want to.
Conduct the capacity inspection of the factory.
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ANNEXURE – I

THE CONSTRUCTIONAL DATAAND DIMENSIONS OF LT AERIAL BUNCHED CABLES.

Number and Phase conductor Messenger Complete cable.

cross Number Diameter Insulation Overall Diameter of Tensile Overall Total
sectional & of un thickness day of uninsulated strength diameter mass
area of sectional insulated in conductors conductor. (approx) (approx) (approx)
conductors area. conductor
Sq.mm Square millimeters
Max.mm Mm Mm Max. mm Min mm. kg/km
Kg.
2x16+25 2x16 4.7 1.2 7.0 6.0 7.0 16 190

ANNEXURE - II
D.C. RESISTANCE AND INSULATION OF LT AB CABLE.

Nominal cross DC resistance at 20 degrees Celsius Insulation

sectional area of Number of strands. average thickness
ohm/km/max.
conductor. min. mm
16 Aluminum 7 1.910 -- 1.2
25 Al. Alloy 7 -- 1.38 Bare

Note:

1. The average value of the thickness of the insulation shall not be less than the specified average.
value.

2. The thickness at any place may be less than the specified average value, provided that the
difference does not exceed 0.1 mm + 0.1(t1) of the specified average value.

3. For the thickness of insulation, six measurements are made radially on a piece of insulation, as far as
possible equally spaced around the circumference but not on the ridges.

ANNEXURE – III

APPROX. CURRENT CARRY CAPACITY (in Amps) OF PHASE CONDUCTORS

AT DIFFERENT AMBIENT AIR TEMPERATURE

No. and area 00 +50 +100+150+200+250+300+350 +400+450+500+550 +600

of conductor C C C C C C C C C C C C C
CURRENT CARRYING CAPACITY IN AMPS.
2X16+25 99 96 93 89 85 81 77 73 69 64 58 52 44
Square millimeters
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GUARANTEED TECHNICAL PARTICULARS FOR

LT. AERIAL BUNCHED CABLE

Sl.
Particulars 2C x 16 + 25 sq.mm.
No.
1. Name of manufacturer.
2. Applicable standard/specification.
3. Type of Cable
(construction to be described)
4. Size of Cable.
5. Phase Conductor - A1 Portion.
i) Material of conductor.
ii) Applicable standard.
iii) No. of strands.
iv) Nominal diameter of strand (mm).
v) Max. diameter of bare conductor (mm)
Nominal area of cross-section of bare conductor
(Sq.mm)
vii) Lay ratio.
Elongation (%)
x) Tensile strength (min)/breaking load (KN)
6 Phase conductor – Insulation portion.
i) Material of insulation.
ii) Insulation thickness (mm)
iii) Diameter of insulated conductor (mm)
Whether the insulation conforms to the standards
specified in the technical specification.
7 Messenger/neutral conductor - AAA portion.
i) Material of conductor.
ii) Applicable standard
Number of strands
iv) Nominal diameter of strand (mm).
v) Max. diameter of bare conductor (mm)
vi) Nominal area of cross-section of bare conductor
(Sq.mm)
vii) Lay ratio.
Elongation (%)
x) Tensile strength (min)/breaking load (KN)
8. Complete AB Cable
Overall diameter (mm)
ii) Total weight (kg/km)
iii) Standard drum length offered (meters) and tolerance.
iv) Gross weight of the cable drum
v) Code or method of cable identification.
9. Electrical Data
i) Max. DC resistance of the phase conductor at 200C
ii) Max. DC resistance of the neutral conductor at 200C
iii) AC resistance at – 90 Deg. C phase conductor
(ohms/km)
iv) AC resistance at - 75 Deg C messenger/ neutral
conductor (ohms/km)
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v) Approx. inductive reactance at 50 Hz. Phase

conductor (ohms/km)
vi) Approx. inductive reactance at 50 Hz. Messenger/
neutral conductor (ohms/km)
vii) Approx. zero sequence reactance at 50 Hz. Per
phase (ohms/km)
viii) Short circuit current for 1 Sec. Max. (KA)
ix) current carrying capacity (amps) at various
ambient temperature in degrees of 00C,100C,200C,300C,400C & 500C
10. Specification climatic conditions to which AB Cable are
manufactured.
a) Mx. Solar radiation (w/sq.m)
b) Min. wind velocity (m/sec.)
11. Tests.
i) Details of type tests and factory tests conducted
on each side of AB Cable.
ii) Whether one complete set of test certificates
thereof are enclosed to the bid.
12. BENDING RADIUS OF CABLE :
13. Any other relevant technical information the bidder may desire to
furnish in respect of
i) AB Cable.