Page I of 50__| Effective from 01.01.2006 DOC No. IRS:TC 30-03 Ver. 12 0. O41 02 GOVERNMENT OF INDIA MINISTRY OF RAILWAY INDIAN RAILWAYS, STANDARD SPECIFICATION FOR UNDERGROUND RAILWAY JELLY FILLED TELECOM QUAD CABLES FOR SIGNALLING & TELECOM INSTALLATIONS FOREWORD This specification is issued under fixed serial no, IRS:TC 30 followed by the year of original adoption as standard or in the case of revision the year of last revision, Adopted - 1983, Fourth revision - 2005 ‘This specification requires reference to the following Indian Railway Specification (IRS), Indian Standard Specification (1S), British Standard Specifications (BS), American Standard Specifications (ASTM) and Association of German Electrical Engineers Specification (VDE). IS: 723 Steel Countersunk head wire nails, IS: 3975 Mild steel wires, formed wires and tapes for armouring of cables. IS: 5831 PVC insulation and sheath of electric cables, Is: 10810 Methods of test for cables. Is: 8130 Conductors for insulated electric cables flexible cords. Recommended colours for PVC insulation for LI Wrought aluminium wire for electrical purposes. Method for testing uniformity of coating on zine coated articles. Method of drift expending test on metallic tubes ires and cables. IS: 2328 Method for flattening test on metallic tubes BS: 6234 Polythene Insulation and sheath of electric cables, Polythene insulated telephone distribution cables. BS: 6469 Insulating and sheathing materials of electric cables. ASTM: D- 883 Definition of terms relating to plastics. ASTM: D-1047 Cold bend test. ASTM:D-1248 Standard Specification for Polyethylene Plastics moulding and extrusion materials, ASTM: D-1693 Standard method of test for environment stress cracking of type I Ethylene plastics. VDE: 0472/6.65 Recommendations for testing of insulated cables & flexible cords, IRS:TC-41/97 with Polythene insulated polythene sheathed jelly filled telephone cable latest amendment with poly-al moisture barrier.Page2 of 49 _| Effective from-01-612006 DOC No. IRS:TC30-05_[ Ver. 4: 03 04 Ll 22 23 24 25 26 IRS:S - 23/88 Electrical and electronic based Signalling and Interlocking Equipments Tentative). IRS:S ~ 63/89 with PVC Insulated cables for Railway signalling latest amendments Whenever in this specification, any of the above mentioned specifications are referred by number only without mentioning the year of issue, the latest issue of that specification is implied; otherwise the particular issue referred to is meant. This specification is intended chiefly to cover the technical provisions and does not include all the necessary provisions of a contract. SCOPE: This specification covers the requirements of the physical and electrical characteristics of Polyethylene insulated, polythene inner sheathed, PVC intermediate sheathed, Aluminium sereened in the form of svire/strip/ welded Aluminium tubing, galvanised steel armoured in the form of tape & PVC jacketed for telecom quad cables required for signalling & telecom installations ‘The cables covered in this specification are suitable for use where the combination of ambient temperature and temperature due to loads results in a conductor temperature not exceeding 70°C. TERMINOLOGY For the purpose of this specification terminology given in IRS:S 23, in addition to the following, shall apply; ROUTINE TESTS: Tests carried out on each cable length to check the requirements which are likely to vary during production. ‘TYPE TESTS: Tests carried out to prove conformity with the specification. These are intended to prove the general qualities and design of a given type of cable, ACCEPTANCE TESTS: ‘Tests carried out on samples taken specifically from a lot for the purpose of acceptance of the lot. QUAD: An assembly of four separately insulated conductors of a cable. Lor: The product of same type and category manufactured by the same factory during the same period, using the same process and materials.Page 3 of 49 Effective from: 01-01-2006 DOCNo. IRS:TC 30-05 | Ver. 42 312 313 314 31S 321 GENERAL REQUIREMENTS: CONDUCTOR: The conductor shall be composed of plain annealed high conductivity copper wire(s) complying with IS: 8130 except for the requirements mentioned in this specification. The dimensions and resistance of conductors shall be in accordance with the values given below = Diameter mm. (Nominal) Tolerance mm. Maximum resistance ‘Ohm/Km. At 20°C Each Core Loop 0.90 £0.02 28 56 ‘The conductor shall be uniformly drawn, circular in cross-section, uniform in quality, free from splits, cracks, corrosion and other surface imperfections. No joints shall be made in the conductor except in very exceptional cases. When it is necessary to join conductors during manufacture, it shall fulfill the requirements of clause 3.1. The joints shall be soldered, brazed or welded with smooth surfaces. The particulars of such joints shall be mentioned by the manufacturer in the routine test certificate. ‘The tensile strength of a 250 mm length of conductor containing a joint shall not be less than 95% of that of a similar sample of conductor not containing a joint. ‘The resistance of 100 cm length of conductor containing joint/s shall not be more than 101.2% of that of an adjacent sample of conductor not containing joint/s. INSULATION (DIELECTRIC): Fach conductor shall be insulated with solid polythene of one of the types specified below. Recycled or reclaimed material shall not be used. Density : Melt Flow Index: Type II (MDPE) (0.926 to Max. 1.0 gm/10 minutes 0,940 gmicc) (at 190°C, 2160 gm Load) Type Ill (HDPE) (0.941 to 0.959 gmicc) 2 Test values for these parameters shall be as per standards specification ASTM: D-1248 or BS: 6234, These values are applicable to the raw materials used and not for materials removed from the cables. The insulation shall be applied by extrusion in one continuous process and shall be homogeneous and free from joints and repairs. It shall fit closely on the conductor but shall not adhere to it so that it is possible to remove it without damage to the conductor.Page 4 of 49 Effective from : 01-01-2006 DOC No. TRS:TC 30-05 | Ver. 42 323 INSULATION THICKNESS: ‘Conductor diameter nominal inimum diameter of insulated conductor ‘Nominal t of insulation ty ‘ness 0.90 mm 1.55 mm. 0.325 mm ‘Thickness of insulation shall not fall below nominal value t; by more than 0.2 ty, 324 The colour scheme of Polyethylene insulated quads shall be as per Table given below:- ‘Quad No. Colour of the conductor insulation A-Wire | B-Wire CWire D-Wire T White Orange Red Grey 2 White Blue Red Grey 3. White Brown Red Grey 4. White Green Red Grey 5 White Yellow Red Grey 6. White Black Red Grey Note:- Wire A and wire B shall form a pair. Similarly wire C and wire D shall form a pair. 325 The colour scheme shall conform reasonably with the standard colour shown in IS:9938. 326 The insulation resistance of each insulated conductor shall not be less than 5000 M ohm/Km at room temperature. 327 Unless otherwise specified by the purchaser there shall be six quads in the cable. 328 The insulated conductor shall be subjected to spark test at 3 KV AC (RMS) or 4.5 KV DC. ‘There shall not be more than one spark over per 5 Km length of the insulated conductor on insulating line. The test shall be 33 QUADDING: done at extrusion stage. 331 Four conductors insulated as above shall be stranded to form a star quad cach, two ‘conductors diagonally opposite forming one pair and the remaining two diagonally opposite conductors forming the second pairs of the quad. Polythylene centre strings of required diameter may be used. The quad shall be held together firmly by means of an open helical whipping of cotton/nylon yarn or colored tape of suitable material of appropriate thickness. 33.1.1 The lays of the conductors forming the quads shall differ for adjacent quads. The lay of the conductor shall be so chosen as to ensure that the cross-talk between the pairs in the cable is minimum.332 Page 5 of 49 Effective from : 0012006 DOCNo, IRS:TC30-05_[ Ver. 12 ‘The colour scheme of the quad whipping shall be in accordance with the Table given below : ‘Quad Number Colour Scheme | 1 ‘Orange 2 Blue 3 Brown 4 Green 5 Yellow 6 Black | 333 34 341 342 35 352 3.6 361 362 The colour of the quad whipping shall conform reasonably with the colour shown in IS:9938. LAYING UP: The quads shall be assembled to form a symmetrical core with a right lay. Polyethylene strings of required diameter may be used as fillers, if necessary, for proper circular core formation. Each quad shall retain its position in the cable with reference to the other quads. The manufacturing process shall be such that there is no physical displacement of the quads, either during manufacture of the cable or during its subsequent handling. FILLING COMPOUND (JELLY): COMPATIBILITY OF PE INSULATION AND FILLING COMPOUND: ‘The cable core shall be fully filled with a suitable water resistant compound like Jelly which is fully compatible with the polythene insulation of the conductors. The compatibility between the polythene and the filling compound shall be established by the tests as per Annexure-I of the specification. The compatibility shall be assessed for each colour of insulation as per clause 3.2.4, CORE WRAPPING: After application of the filling compound a closed helical or longitudinal lapping of a polyester tape shall be laid over the cable core. The tape may be impregnated or flooded with jelly to meet the water penetration test requirements. POLY-AL LAMINATE MOISTURE BARRIER: Polythene coated aluminium tape shall be applied longitudinally on the quad with a minimum overlap of 6mm. The thickness of aluminium tape shall be 0.2mm +10% and that of polythene/eopolymer coating on each side 0.0Smm nominal, The thickness of composite tape shall be 0.3mm £15%. ‘The laminate shall be bonded to the inner surface of the polythene sheathing extruded over it by any suitable method. The Poly-Al laminate shall be mechanically and electrically continuous.Page 6 of 49 Effective from : 01.01.2006 DOC No. IRS:TC 30-05 | Ver. 13 363 37 371 372 393 ) ip i) 38 381 382 383 384 385 PEEL STRENGTH: he peel strength of polythene from the Aluminium shall not be less than 25 gm per mm width when tested as per Annexure-A (III). This test shall be applicable on raw material Poly-Al tape only. INNER SHEATH: Inner sheath shall be reasonably circular, free from pinholes, joints and other defects. The nominal thickness of sheath shall be 2.0mm (excluding Poly-Al laminate). The minimum thickness shall not be less than 75% of the specified nominal thickness. The average of six measurements, equally placed around the circumference, shall not be less than 85% of specified nominal value. The variation between the maximum and the minimum diameter at any cross section shall not be less than 3.0mm. ‘The inner PE sheath shall be subjected to spark test at 11 KV AC (RMS) or 17 KV DC during extrusion, There shall not be any spark over. Cable shall be sheathed with the polythene grade 03C or H03C as per BS: 6234, and containing a suitable anti-oxidant system. The material shall be virgin as per ASTM-D-883 and mect the requirements specified below: Melt Flow Index- Shall not be more than 1.0 g/10 minutes (190°C, 2160 gm load) Density- For 03C shall be 0.910 to 0.940 emice. For H03C, shall be 0.941 to 0.959 gmice, ‘Anti-oxidant - OIT test in @ copper pan at 199°C as per the method in Annexure-A (v) and the value to be recorded, the value should be such that the requirement of Cl. 5.8.36 of this specification is met. NOTE: The Melt Flow Index & Density test shall be applicable on raw material while (OMT) shall be applicable on completed cable. SCREENING: The cores with inner sheath shall be surrounded Aluminium in the form of wires/strips/welded alum a reasonably close fitted screen of im tubing. ‘The aluminium used for screening shall contain not less than 99.5% aluminium and shall generally conform to 1S:2067-75 ‘The number and the size of the aluminium ysires/strips used for screening shall be such as to comply with the requirements of Cl. 5.9.9. If the Aluminium wices/strips used for screening are laid in two layers, they shall be in opposite directions. ‘The layer of the aluminium sviees/strips used for screening shall be compact and the length of the lay shall be high. It shall also be ensured that the screening wires/strips are as close as practicable-so—that-inner-sheath-is-not-visible-throwghout the ength-of-eable, The Maximum Gap between any two adjacent strips shall not exceed 10% of the nominal width of the strip used. The cumulative gap shall not exceed half of the nominal width of the strip however screening shall be such as to comply with the requirements of Cl. 5.9.9. The minimum tensile strength of Aluminium screen shall be 15 Kg/Sq. mm.[Page 7 of 49 Effective from : 01.03.2006 DOC No. IRS:TC 30-05 | Ver. 42 386 387 388 39 39.1 392 3.40 3.101 3.102 3103 3.104 3105 3106 3107 The innermost layer of the screening shall have left hand lay and the successive layer shall be laid with opposite lay. Drift expansion test to IS: 2335-1985 shall be carried out on a test piece of length, twice the external dia. of the tube by conical mandrel having height three times its base diameter. The test piece shall show no crack or flaw until the outside diameter of the expanded end is increased by at least 30%. This test is applicable where welded aluminium tubing is used for screening. Flattening test to IS: 2328-1983 shall be carried out on a test piece of not less than 5mm. long, cut from each selected tube. The test tube when close-flattened with the weld bead position equidistant from the flattening places shall not show any visible crack or flaw in the weld region. This test is applicable where welded aluminium tubing is used for screening PROTECTION: The aluminium sereen shall be wrapped with a single layer of woven tape impregnated with Barium chromate with minimum 20% overlap. ‘The tape used shall be fine woven cloth tape of about 0,15mm thickness. INTERMEDIATE SHEATH: Further protection for the screening shall be provided by extruded PVC sheath over screening, It shall be circular. The nominal thickness (t,) of intermediate sheath shall be 1.0 mm. The smallest of measured values shall not fall below the nominal value (t,) by more than (0.lmm¢ 0.1t,). ‘The average thickness shall not fall below the nominal thickness t,. The PVC used for intermediate sheath shall meet the requirements of ST-1 (General purpose sheath for use at maximum rated conductor temperature 70°C) compound of IS: 5831-84, except for the requirements mentioned in this specification. Re-cycled or re- claimed material shall not be used. ‘The colour of the intermediate sheath shall be grey. ‘The PVC used for intermediate sheath shall meet the requirements as indicated in CL.5.8. ‘The Intermediate PVC sheath shall be subjected to spark test at 6 KV AC (RMS) or 9 KV DC for all conductors sizes. There shall not be any spark over. DENSITY/SPECIFIC GRAVITY OF PVC INTERMEDIATE SHEATH: ‘The test shall be conducted on PVC intermediate sheath in accordance with BS: 6469 latest or any other approved method. The test sample shall be taken from finished cable and the value shall not exceed 1.47.Page 8 of 49__ | Effective from : 04-01-2006 DOC No. IRS:TC 30-05 |_Ver. 42 3.1 BALL 32 313 314 3s 3.12 3121 3.122 3123 3124 3125 ARMOURING: “The galvanised steel tape armouring conforming to IS: 3975 shall be applied tightly over the intermediate sheath with two layers. The armour shall be free from rust, blooming, oxidation, cracks, splits etc. ‘The sheathed cable shall be armoured with two applications of Galvanised steel tape conforming to IS: 3975, each applied helically in the same direction with a gap in the first tape of 25%+10% of the width of the tape, the second tape evenly covering the gap of first tape. In any case, the overlap of second tape over the first tape shall not be less than 20% of the width of tape. The intermediate sheath shall not be visible throughout the Tength of the cable. ‘The direction of the lay of the armour shall be opposite to that of the outermost layer of ‘screening. When joints in tapes are necessary, they shall be made by brazing or welding and any surface irregularity shall be removed. A joint in any tape shall not be less than 300 mm from a joint in any other armour tape in the completed cable. The tape shall be continuous throughout the length of cable. ‘The thickness of armour tape shall be as under :- ‘Conductor diameter nominal ‘Nominal thickness of armour tape 0.90 mm 0.8mm+ 10% OUTER SHEATH: ‘The outer sheath shall be applied by extrusion in one continuous process over the armouring and shall be homogenous and free from joints and repairs. ‘The PVC used for outer sheath shall meet the requirements of ST-1 (General purpose sheath for use maximum rated conductor temperature 70°C ) compound of 1S:5831-84, ‘except for the requirements mentioned in this specification. Re-cycled or re-claimed material shall not be used. ‘The colour of the outer sheath shall be black. The thickness of PVC outer sheath shall be determined in accordance with the procedure laid down in IS: 10810 (Part-6). The average thickness shall not be less than the nominal value (1,) specified below and the smallest of the measured values shall not fall below the nominal value by more than (0.2mm + 0.2 t,). Conductor diameter nominal [ Nominal thickness of PVC outer sheath 0.90 mm | 2.0mm The PVC used for outer sheath shall meet the requirements as indicated in CI. 5.8Page 9 049 | Effective from : 01.01.2006 DOC No. IRS:TC 30-05 Ver. 12, 3.126 3127 3.128 3.3 4 41 42 a) b) °) d e) The outer sheath shall be subjected to spark test at I5 KV AC (RMS) or 23 KV DC. There shall not be any spark over. DENSITY/SPECIFIC GRAVITY OF PVC OUTER SHEATH: The test shall be conducted on PVC outer sheath in accordance with BS: 6469 latest or any other approved method. The test sample shalll be taken from finished cable and the value shall not exceed 1.47. ‘The maximum overall diameter of the cable shall 33 mm. This shall be measured with diameter measuring tape utilizing circumference measurement. ‘The cross-sectional view of 4 quad & 6 quad cable shall be as per Fig.1& 2 respectively. MARKING: ‘The following information shall be legibly and indelibly indicated at every meter or less throughout the length of the cable by embossing or engraving/indenting on outer sheath of the cable, All the marking shall be in white or yellow colour. The marking shall be clear, distinct and visible to the naked eye from a distance of about 1 meter; the size of marking shall be of minimum 3 mm. ‘Name or trade mark of the manufacturer, IRS: TC 30-05 Month & year of manufacture Cable Drum No. Sequential length marking at every meter with an accuracy of +0.2% ‘The following information shall be stenciled on the cable drum in black paint over yellow painted background. Manufacturer's name, brand name or trade mark. IRS: TC 30-05 Type of cable Nominal diameter of conductor Cable drum number ‘Number of lengths on drums ( if more than one) Length of the cable on the drum (length of each piece to be indicated in case there is more than one length). Initial and final sequential length marking Direction of rotation of drum (by means of an arrow) ‘Approximate gross weight Country of manufacture Month and year of manufacture Address of consignee Purchase order No. and Railway Store away from fire/boiler Not be hung except by bar through center.| [Page 10 of 49] Effective from : 0.642006 DOC No. IRS:TC 30-05 | _Ver. 42 5.1 Su 52 a) b) ° d °) hy 521 522 TESTS AND PERFORMANCE REQUIREMENTS: Unless otherwise specified, all tests shall be carried out under ambient atmospheric conditions. For inspection of material, relevant clause of IRS:S-23 shall also apply. ‘TYPE TESTS: The following shall constitute type tests and shall be carried out once in three ‘years or earlier at the discretion of the inspecting authority. Physical tests for conductor (Cl. 3.1.1 to 3.1.5, 5.5) Physical test for Armour tapes (C1 5.6, 3.11) Test for thickness of insulation and sheaths (Cl.5.7) Physical test for PE Insulation, PE Inner Sheath, PVC Intermediate , Outer Sheath, Screening, and other tests on completed cable [Cl. 3.2.4, 3.2.5, 33, 3.4, 3.83 to 3.88, 3.9, 3.10.7,3.12.8,5.8 except (5.8.87, 5.8.1413, 5.84514, 5.84716 10 5.8.2221, 5.8.2423, 5.8.27-26 10 5.83430 &5,8.3433)] Visual Inspection and marking (Cl. 3.2.2, 3.2.5, 3.6.2, 4.0 and 5.82221) Electrical tests (C1. 5.9) except 5.9.2.4 Physical tests for Poly-Al Laminate Tape (Cl. 5.83736) Test on raw materials li). Polythene for Conductor Insulation (Cl. 5.8.1413, 5.84514, 5.8.49-18 to 5.8.2420 & 5.9.24) Filling Compound (5.8.2423, 5.82726, 5.8.2827, 5.8.30-29 to 5.8.32-31 & 5.83433) )) Poly-Al Tape (Cl. 3.6 ) iv) Polythene for Inner Sheath (Cl. 3.7.3 i & ii) v) Aluminium Wire (Cl. 3.8 ) vi) Barium Chromate Tape (Cl. 3.9.2) vii) Galvanised Steel Tape (CI. 5.6.1 to 5.6.4) Test on Insulated Conductor & compatibility of PE insulation and filling compound (Cl. 5.8.2.3, 58.87, 5.8.4716,5.8.18]7, 5.8.29-28 & Annexure-I (i,j, iit & iv) In process Test (C13.2.8, 3.7.2, 3.10.6 & 3.12.6) Water Penetration Test (Cl. 5.82322) For initial Type Testing in case of new manufacturer one drum each of 6 Quad and 4 Quad cable shall be got manufactured. No failure is acceptable during type testing. Sampling plan for Type ‘Tests is enclosed as Table-3 (Clause 5.2). Validity of initial Type Approval shall be for a period of two years. For maintenance Type Testing in case of already approved manufacturer only one drum either of 6 Quad or 4 Quad cable from regular railway supply order lot shall be taken in statistically random manner, No failure is acceptable during Type Testing. Sampling plan for type tests as Table-3 (clause 5.2) stands suitably modified in this case to mean only the type of cable (6 Quad or 4 Quad) so taken.Effective from : 1-61-2006 [DOC No, IRS:TC 30-05 Ver. 42 | [Page 11 of 49 | 522 5.23.1 5232 Validity of such Maintenance Type Approval shall be for a period of three years. However if'no railway supply order exists with the firm, one drum of any type cable either 6 Quad or 4 Quad shall be got manufactured specially for the Maintenance Type Testing and validity of such Maintenance Type Approval shall be for a period of two years. Sources of Raw Materials/components. The sources of following raw materials/components shall be approved based on type testing and shall be indicated in Type Approval Certificate. If subsequently the source of any raw material is required to be changed or a different alternative component permissible under the specification is required to be used due to any reason, partial type test on the changed raw material/component and related tests on the finished cable pertaining to the raw material/component shall be carried out and if successful, shall be approved. The list of Raw ‘materials/components and corresponding partial tests are given below:~ (Annexure A-V), 5.9.11, 5.9.1.2, 5.9.1.3, 5.9.2.1, $.9.2.2, 5.9.2.3, 5.9.4, 5.9.5, 5.9.6, ‘SN [Raw Test on Raw Test on Insulated in Materialsico | Materials/components as | Completed noe mponents | per clause nos, Cables as per lucti clause nos. of filling n tests compound (Fach colour to be tested) 1. [Polythene for | 3.21 323,324,325, | 5.887, 328 lconductor 33,34, 58.11a | 5.82. insulation [O& Gi), 16, |(MDPE/HDPE) 5.8.2.1,5.8.2.3, | 5.81817, 5.8.2019 5.8.65,5.8.76, | 5.82928, 58.2120 5.82221, Annexu 59.2.4 5.82322, [@, Gi), 5.83635, (iv)| [Page 12 of 49] Effective from : 01.01.2006 DOCNo.IRS:TC 30-05 | Ver. 12 2, [PVC 3102, 3.10.7, |- 3.10.6 3.124, 5.8.1.1(0), 3.12.6 5.8.1.1(b), 5.8.2.1, 5.8.2.2, 5.83, 5.8.4, 5:85, 8.76, 5.898, 5.8409, 5.84410, 5.84312, 5.81615, 5.82221 3, | Filling 382332 | 582928, - compound (Annexure A- ID, | Annexure-1 Gelly) 5.82322, 5.83231, ii), (iii) & | Galvanised steel tape 5621, 563.1, 5.6.3.2, 5.6.4, 5.6.5 3. | Polythene for [3.7.3 , 31, S81 & |= 372 Inner _ sheath | 3.7.3 (ii) Gi), 58.21, (LDPE 5824, 5.8.16, sheathing 5.898, 5.82524, ‘compound) 5.82625, 583534, 5.83635, (Annexure AV), 5.83736 (Annesure A-IIl), © _ | Copper 311, 31.2, 313, | = 3.14, 3.1.5, 3.23, 39.1.1, ; 5.92. 5.9.2.3, 5.9.3, 5.9.4, 5.9.5, 5.9.6, 5.9.7.2,Page 13 of 49 Effective from : 01.01.2006 DOC No. IRS:TC 30-05 | Ver. 32 _ 5.3 531 532 533 34 [7 | Aluminium 3.82, > = wires/strips/welded | 3.8.5 aluminimum tubin for sereening es 8. Poly -Al tape | 3.6.1, 3.6.1, 3.6.2, | - - laminate 3.63 5.83736, is (Annexure A-II1) 2 Barium chromate | 3.9.2 3.9.1, - - tape 3.99 a) b °°) 4) ) ACCEPTANCE TESTS:~ The following shall constitute acceptance tests: Physical Tests for conductor (Cl. 5.5) Physical Tests for Armour Tape (Cl. 5.6) Tests for Thickness of Insulation & Sheath (Cl. 5.7) Physical Tests for PE Insulation, Inner PE Sheath, Intermediate & Outer PVC Sheath & other tests on completed cable (Cl. 3.8.3 to 3.8.8, 3.9, 3.10.7, 3.12.8, 5.8.1, 5.8.2, 5.8.4, 5.81410, 5.81312, 5,8.1615,5.8.2524, 5.8.36-25 & 8.3231) . Visual inspection & marking (Cl. 3.3, 3.4,3.11, 3.12, 4.0 & 5.8.2221) £ Electrical Tests (Cl. 5.9 except Cl. 5.9.2.4) §. Physical Tests for Poly-Al Laminate Tape (Cl. 3.6 except Cl. 3.6.3) h. i. ees Water Penetration Test (Cl. 5.8.2322) Any other tests at the description of inspecting authority to ensure that the offer is in conformity with the requirement of the specification, ‘Sampling plan shall be as Table-2 (Clause 7), For conductor diameter and resistance, thickness of insulation, and sheaths, zine coating of armour tape, fire resistance, high voltage, shrinkage, thermal stability, melt flow index, visual inspection and electrical tests, there shall be no failure. For annealing, %elongation and tensile strength test of insulation, sheaths and armour, not more than one specimen of a sample shall fail. If more than one specimen of a sample fails, the lot shall be rejected. If only one specimen has failed, two further samples of the same drum shall be tested. There shall be no failure. ROUTINE TESTS: The following shall constitute Routine Tests: - Physical Tests for conductor (Cl. 3.1.1 to 3.1.5, 5.5) Physical Tests for Armour Tapes (Cl. 5.6) Physical Tests for PE Insulation & Sheath, PVC Intermediate, Outer Sheathé Jelly (Cl 5.8.1 0 5.8.2, 5.8.4, 5.84410, 5.84615, 5.82221, 5.8.23-22 & 5.83231) Electrical Tests (Cl. 5.9 except 5.9.2.4) Spark Test (Cl. 3.2.8, 3.7.2, 3.10.6 & 3.12.6) to be conducted on entire lot of material offered for inspection.Page 14 of 49 Effective from : 61.01.2006 DOC No, IRS:TC 30-05 | Ver. 12 SAL 3a2 55 5.62.1 56.22 f) Process Flow Chart — to be documented in such a way that linkup/back trace history of each drum shall be identified from the outer sheathing stage to the insulation stage. Electrical tests except high voltage test (Cl. 5.9.1) & IR (Cl. 5.9.2.2 & 5.9.2.3) to be done ‘on 100% basis. High voltage tests (C1.5.9.1) & IR tests (Cl. 5.9.2.2 & 5.9.2.3) under routine tests (Cl. 5.4) shall be done at least on 20% of the offered lot for inspection. ‘The results of routine test shall be made available to the inspecting authority along with the inspection call letter. PHYSICAL TEST FOR CONDUCTOR: DIMENSIONS: ‘The diameter of the conductor (s) shall be measured on a sample from the finished cable. ‘The measurement shall be made at least at three different points (at intervals of not less than 100 mm.) with two readings at 90° along the length of the sample. The values shall meet the requirements given in Clause 3.1.1. ANNEALING TEST: ‘A sample of wire taken from finished cable, when tested as described in 1S:10810 (Part- 1), shall have elongation at fracture of not less than 23% for nominal wire diameter of 0.9mm. PHYSICAL TEST FOR ARMOUR TAPES: DIMENSIONS: The dimensions of armour tapes shall be measured in accordance with the procedure laid down in IS: 10810 (Part-36). The measured values shall meet the requirements of Cl. 3.11.5 of this specification. ‘TENSILE STRENGTH AND ELONGATION TESTS: ‘Steel tapes removed from the completed cable shall be tested as per IS: 10810 (Part- 37) and shall have the following values:~ i) Tensile strength 25 10 45 Kg/Sq. mm ii) Elongation - 10% Steel tapes taken from raw material lot shall be tested as per IS: 10810 (Part-37) and _ shall have the following values: - i) Tensile strength 30 to 45 Kg/Sq. mm ii) Elongation - 10%Effective from : 1.012006 DOC No, IRS‘TC 30-05 | Ver. 12 _ In cither case the load shall be increased gradually at a uniform rate and the rate of straining shall not be greater than 7Smm/minute. 563 TESTS FOR ZINC COATING: 563.1 TEST FOR MASS OF ZINC COATING: 5.6.3.1.1 This test shall be carried out in accordance with the procedure laid down in IS: 10810 (Part- 41). The weight of zinc coating shall be 210 g/sq. meter on each side, 5632 TEST FOR UNIFORMITY OF ZINC COATING: 5.6.3.2.1 This test shall be carried out in accordance with the procedure laid down in IS: 10810 (Part-40). The sample shall not show any red deposit of copper upon the base metal with ‘two dips of one minute each in copper sulphate solution prepared as per IS: 2633. 564 WINDING TEST (FOR GALVANISED TAPES): 5.64.1 The sample shall be tested in accordance with the procedure laid down in IS: 10810 (Part- 39). Zinc coating of the tape shall be sufficiently adherent to the base material, Compliance is checked on gauge length of 200 mm. sample. Zine coating shall show no cracks and no particles of the coating shall be detached by rubbing with a bare finger. 565 TEST FOR CLOSENESS OF ARMOUR: 5.65.1 A window shall be cut at least !.5 meters from the end or at any place in the finished cable without disturbing the armour. The armour shall satisfy Cl. 3.11.2, S7 TEST FOR THICKNESS OF INSULATION AND SHEATHS: 57.1 Determination of the thickness of insulation of round cores and sheath shall be made on a representative sample of the cable approximately one meter long taken from the drum length of the cable, 572 The measurement in case of conductor insulation, inner, intermediate and outer sheath shall be made at three different points at intervals of not less than 75mm along the length of the sample and at each point the minimum thickness of the insulation, inner, intermediate & outer sheath shall be measured along with two more readings made at equidistant points around the periphery. The minimum thickness at any point and the average thickness at the three points selected shall comply with the requirements given in clauses 3.2.3, 3.7.1, 3.10.2 & 3.12.4. 58 PHYSICAL TESTS FOR PE INSULATION, PE INNER SHEATH, PVC INTERMEDIATE AND OUTER SHEATH: 581 TENSILE STRENGTH AND ELONGATION AT BREAK: 5.8.1.1 This test shall be conducted in accordance with the procedure laid down in IS:10810 (Part- 7). ‘The speed of separation of jaws of tensile testing machine shall be between 25050 mnv/minute instead of 400mm to 500 mm/minute. The material shall fulfill the requirements indicated below;Page 16 of 49 Effective from : 03-01-2006 DOC No. IRS:TC 30-05 | Ver13 5 SHEATHS INSULATION 2), BEFORE AGEING PE PVC i) Tensile strength min, ke/em*. 70 150 100 ii) Elongation min. % 300 200 300 b). AFTER AGEING (In air oven at 804 2° C for 168 hours ) i). Tensile strength min, kg/cm’. = 150 - ii), Elongation min. _% = 200 - 5.8.12 The maximum variation after ageing shall be + 20% of the values obtained before ageing. For test before and afier ageing, samples shall be from the same drum. However, values after ageing for tensile strength and % elongation shall not be less than given in clause 5.8.1. 58.1.3 58.14 58.15 582 582.1 5822 5823 583.1 ‘The values of all the four samples in case of each sheath shall be averaged and then % variation calculated. For acceptance test, the sample shall be kept in air-oven at 130°C +2°C for 5 hours. Tensile Strength & Elongation at Break for Polythene Sheath and Insulation shall be carried out before ageing only and value shall comply as per the Table given in sub clause 5.8.1.1 SHRINKAGE TEST: ‘This test shall be conducted in accordance with IS: 10810 (Part -12). During test no cracks shall occur. For PVC Intermediate and Outer Sheath shrinkage shall not exceed 2% of original length and temperature shall be 150+2°C for 15 minutes. For PE Insulation, temperature shall be 10022°C for a period of 24 hours and average shrinkage of 4 samples of length 150mm of each colour of insulation shall not exceed 635mm. For PE Sheath tests shall be carried out as under: - ‘A sample shall be cut from the cable sheath, 50 mm long measured along the axis, 12mm wide and the same thickness as the cable sheath. The specimen with the laminate removed, shall be placed in a convective type circulating air oven operating at a temperature of 100+1°C for a period of 24 hours. At the end of this period, the shrinkage as measured in lengthwise direction shall not exceed 5%. HOT DEFORMATION TEST: This test shall be conducted in accordance with IS;10810 (Part-15). The max. depth of indentation shall be 50%. The test temperature shall be 80°C for four hours. This test shall not be applicable in case of insulation.| [Page 17 of 49 Effective from : 01.01.2006 DOC No. IRS:TC 30-05 | Ver12 584 LOSS OF MASS TEST: 584.1 This test shall be conducted in accordance with IS: 10810 (Part-10). The sample shall be ‘kept in air oven at 80°C + 2°C for 168 hours. The loss of mass shall not be more than 2 mg/ ‘sq cm. This test shall not be applicable in case of insulation. 584.2 For acceptance test the sample shall be kept in air oven at 130°C 42°C for 5 hours. The loss of mass shall be within the limits as indicted above. 585 COLOUR FASTNESS-TO- DAYLIGHT EXPOSURE: S84585_COLOUR FASTNESS TO WATER: 5:8.6:15.85.1 A piece of about 100 mm long is cut into small pieces and immersed for 48 hours in about 10 times its own volume of distilled water at 70°C + 2°C. At the end of the period, the water shall be examined. It shall be free from any trace of colour. 587526 BLEEDING AND BLOOMING TEST: 5:87-45.8.6.1 This test shall be conducted in accordance with IS: 10810 (Part-19). There shall be no appreciable staining of indicator compound. This test shall not be applicable in case of insulation. 588587 COLD BEND TEST: 58.8:15.8.7.1 This test shall be conducted in accordance with the procedure laid down in IS:10810 (Part- 20). The sample shall be cooled in air in refrigerator at a temperature of -15°C + 2°C, There shall be no signs of cracks or scales. This test is applicable in case of insulated conductor. $8588 COLD IMPACT TEST: | This test shall be conducted in accordance with the procedure laid down in IS:10810 (part- 21). The sample shall be cooled in air in refrigerator at temperature of ~5°C +2°C and tested. There shall be no scales or cracks. This test shall not be applicable in case of insulation, 5810589 HEAT SHOCK TEST: SRAASB9 This test shall be conducted in accordance with the procedure laid down in IS: 10810 (Part- 14). The sample shall be placed in an oven at temperature 150°C + 2° C for one hour. There shall be no signs of cracks or scales, This test shall not be applicable in case of insulation. $8115810 _THERMAL STABILITY TEST: S84115.810.1 This test shall be conducted in accordance with the procedure laid down in IS: 10810 (Part- 60). The time taken for the Universal indicating paper to change colour from a pH value of 5 to a pH value of 3 shall be measured, or the test continued for the specified duration without the colour change occurring. The colour change point shall be considered to have been reached when the red colouring of the universal indicating paper characteristic of'a pH value of 3 is just becoming visible. The universal indicating paper shall be renewed towards the end of the expected time every 5 to 10 minutes, so that the change point is better visible.Page 18 of 49 [Effective from:01,01.2006 | DOC No. IRS:TC 30-05 | Ver. 12 5.8:14258.102 The time taken for the universal indicating paper to change colour from a pH ‘value of 5 to a pH value of 3 shall be 40 minutes in case of sheaths. However, this test is not applicable in case of insulation. 58425811 For tests from clause 5.8.3 to clause 5.8.1410, at least of two samples shall be taken ffom each type of material in each colour used. There shall be no failure. 68495812 FLAME RETARDANT TEST (FIRE RESISTANCE TEST): SSASA58I21 ‘This test shall be conducted in accordance with the procedure laid down in IS:10810 (Part-61). After the test there shall not be visible damages on the test specimen within 300 mm from its upper end. 68145813 MELT FLOW INDEX TEST: 58-1445813. The test shall be conducted in accordance with the procedure laid down in 1S: 10810 (Part-23), The maximum Melt Flow Index shall be as per clause 3.2.1 and 3.7. sgis5a14_ VISCAT SOFTENING POINT TEST: 581515814.) This test shall be conducted in accordance with the procedure laid down in IS: 10 (Part-22), iscat softening point shall be minimum 85°C. This test shall not be applicable in case of sheaths, 58466815 BEND TEST: 5.8-16-15,8:15,1 The bend test shall be carried out on a sample of finished cable with open ends. ‘The sample shall be bent around a drum having diameter 10 times that of finished cable to make one complete turn, It shall then be unwound and the process repeated in the ‘opposite direction, This cycle of operation shall be carried out twice. 5.8.46258.152 The length of sample shall be sufficient to give at least one complete tum- around the test drum. The bending shall be carried out at reasonably uniform speed between 15 and 30 seconds per half cycle. 5.8:16358.15.3 The cable shall, on close examination, reveal that the cable serving is free from splits, the armour not noticeable displaced and the sheaths free from splits and cracks. 58195816 RESISTANCE TO COMPRESSION TEST: $.$17-45.8.16.1 Two lengths of insulated conductor shall be uniformly twisted so that there are 10 x 360° twists of 100 mm, Not more than 50 mm. in the middle of the twisted pair shall be placed between the flat rigid metal plates coated with polythene on the inside surface, ‘A compressive force of minimum 200N shall be applied between the plates. One minute after the application of the force, there shall be no electrical contact between the insulated conductor. The contact test shall be made at 12 volts DC with a suitable indicator. §8185817_ RETRACTION OF INSULATION TEST: 5.8:18158.17.1 Retraction of insulation on insulated conductor when cut at a point not less than ‘one meter from one end at room temperature shall not exceed 2.5 mm after one minute.Page 19 of 49 Effective from : 01.01.2006 DOC No. IRS:TC 30-05 | Ver. 12 ‘58195818 DENSITY TEST: $81945818.1 The density of the Polythylene insulation shall be tested in accordance with the procedure laid down in ASTM:D 1248, For MDPE (Type-I1) the density shall be between 0.926gmice to 0.940gm/ce and for HDPE (Type-IIl) density shall be 0.941 gm/cc to 0.959 gmice. Saaisals POWER FACTOR TEST: 19.1 ____The Power Factor of the Polythene Insulation shall be tested in accordance with the procedure laid down in ASTM: D-1248 and maximum Power Factor shall be 0.0005 at | MHz . This test is applicable on PE insulation moulded sheet made from the raw material PE granules. 'y of polythene insulation shall be tested in accordance with procedure laid down in ASTM D ~ 1248. The maximum permittivity shall be 2.35 at 20 degree C and at 1 MHz, This test is applicable on PE insulation moulded sheet made from the raw material PE granules. §8208821 VISUAL INSPECTION TEST: 582215.821.1 The physical condition of the cable shall be visually inspected by transferring it to another drum. The cable shall be reasonably circular throughout its length and shall be free from any physical defects. The whole length shall comply the requirements of clauses 3.11.1 to 3.11.4, 3.12.1, 3.12.3, 3.12.6 & 4. The measured length of cable on any drum shall not be less than one meter of the declared length. 58235822 WATER PENETRATION TEST: One metre of cable shall be supported horizontally and one meter head of water shall be applied for 14 days (type test) and 7 days (acceptance test) at ambient temperature, During this time no water shall have seeped from the cable sample, The test shall be conducted as per method out lined in Annexure ~ A (IV) 58245823 FLASH POINT : (Applicable for filling compound ice. Jelly) The flash point of filling compound (petroleum jelly) when tested as per ASTM D 92 shall not be less than 200 degree C. 58255824CARBON BLACK CONTENT: (Applicable on Inner PE Sheath) ‘The Carbon Black Content of inner PE sheath shall be determined as per BS: 6234 and shall be 2,5% +0.5% by weight, 58265825CARBON BLACK DISPERSION: (Applicable on Inner PE Sheath) ‘The Carbon Black Dispersion in inner PE sheath shall conform to BS: 6234 and shall not bbe more than rating four. 58275826 _ COLOUR: (Applicable on filling compound i.e. Jelly) The compound shall not obscure the identification of the colour of insulation of the conductors.| [Page 20 of 49 Effective from : 01-03-2006 DOC No, IRS:TC 30-05 |_Ver. 12 | 59285827 _ HANDLING: (Applicable on filling compound i-e Jelly) ‘Compound shall be readily removable from the insulated conductors by wiping. It shall be free from unpleasant odour and have no toxic or dermatic hazards. Supplier's certificate shall be submitted by the Cable Manufacturer. ‘THERMAL STRESS CRACKING: (Applicable on insulated conductor taken from ulated bobbins) 10 lengths of insulated conductor of 10cm each removed from the insulated bobbins of each colour obtained after extrusion from the extruder shall be wrapped on their own diameter with a minimum of 10 contiguous turns closely wound in a length of 2em at 701°C for 14 days, After the period they shall be removed from the oven and observed for cracks with naked eyes. There shall be no cracks. « §.8.30 5.8.29 VOLUME RESISTIVITY: (Applicable for filling compound i.e. jelly). The volume resistivity measured at 100 degree C by the method described in ASTM D 1169 or any other approved method shall not be less than 1x10" ohm — cm. « 5.8.31 5.8.30 PERMITTIVITY: (Applicable for filling compound ice. jelly) The Permittivity at 1 MHz when tested as per ASTM: D-924 shall not be greater than 2.3 at 20°C. « 58.22 58.31 SPECIFIC DENSITY: (Applicable for filling compound i.e. jelly) “The value of specific density of jelly at raw material stage shall between 0.90+ 0.05 gm/ce at 25°C and for jelly removed from the finished cable shall be between 0.90% 0.09 gmiee at 25°C. | + $8.33 5.8.32 DRIP TEST:(Applicable on completed cable): ‘When tested as the method described in Annexure-A (Il) of the specification, there shall be no dripping of Filling Compound. «5,834 §.8.33 STABILITY: (Applicable on Filling Compound i.e. Jelly). When held at a temperature of 65+1°C for 5 days, the compound shall not show any separation of the constituents of the filling compound. The tests shall be conducted as per method outlined in Annexure-A (I). «5.835 5.834 ENVIRONMENTAL STRESS CRACKING: (Applicable for inner PE sheath of completed cable) ‘Test specimen without laminate cut from the polythene inner sheath shall be subjected to ‘an environmental stress cracking test as described in ASTM: D1693 when tested with 10% IGEPOL solution at 50 £1° C for 48 hours. There shall be no failure. 5.8.36 5835 OXIDATION INDUCTION TIME TESTS: (Applicable for each colour of PE Insulation ‘and Inner PE sheath taken from completed cable). The induction time on oxygen when tested with copper pan as per the method described in ‘Annexure-A (V) of this specification shall not be less than 15 minutes in case of polythene sheath and shall not be less than 30 minutes in case of each colour of polythene insulation removed from the finished cable.Page 21 of 49_ Effective from : 01.01.2006 DOC No. IRS:TC 30-05 | Ver. 32 * §.%375.8.36 BOND STRENGTH: (Applicable on Poly-Al bonded inner PE sheath from completed cable) The bond strength of the Poly-Al Laminate to the Polythene Sheath and at the overlap shall ‘meet the requirements indicated in Annexure-A (III) of the specification. 59 ELECTRICAL TESTS: 591 HIGH VOLTAGE TEST: 59.1.1 This test shall be conducted on complete drum length. The cable shall withstand an AC voltage of 2 KV (rms). The AC voltage used for testing shall be approximately of sine waveform at a frequency between 40 and 60 Hz, 59.12 The insulation shall be capable of withstanding for ten seconds without intermittent or permanent breakdown, when the above voltage is applied between a conductor and all other conductors bunched together. 5.9.1.3 All the conductors shall be bunched together and 2 KV rms applied between them and the steel armouring connected with screening wires for ten seconds. There shall be no intermittent or permanent breakdown of the dielectric. 592 INSULATION RESISTANCE TEST: 5.9.2.1 This test shall be carried out on drums which have been subjected to the high voltage test. 5.9.2.2 Insulation resistance test may be conducted on factory length between each conductor and all other conductors in accordance and shorted with the armouring in air at the prevailing temperature, The drum shall be in the test room at a reasonably constant temperature for sufficient time to ensure that the core insulation is at ambient temperature. The DC test voltage shall be 500 volts and shall be applied for one minute, The value of insulation resistance shall not be less than 5000 mega ohms/Km at room temperature irrespective of the size of the conductor. 5923 WET IR TESTS: A three-meter length of cable shall be taken and all cores removed without damage to the insulation, These cores shall be immersed in water at 50+2° for a period of not less than 2 hours. The insulation resistance between each conductor and water in which the cores are immersed shall than be measured by using a suitable insulation tester. The measurement of insulation shall be made after one-minute electrification at 500 volt DC. The value of insulation resistance shall not be less than 5000 Mega ohm per km. 5924 VOLUME RESISTIVITY: (Applicable on PE insulation moulded sheet made from the raw material PE granules.) ‘The volume resistivity at room temperature shall be conducted on Polythelene Insulation in accordance with the procedure laid down in ASTM: D 257. The volume resistivity shall not be less than 1x10'* Ohm-cm.Page 22 of 49 __| Effective from : 01.01.2006 DOC No, IRS:TC30-05_[ Ver. 13 593 593.1 5.93.2 3933 5934 5935 5941 595.1 5952 596 59.6.1 CONDUCTOR RESISTANCE TEST: Conductor resistance shall be measured on complete length. The cable drum under test shall be at reasonably constant temperature for sufficient time to ensure that the cable temperature is equal to the ambient temperature. The measurement shall be carried out to an accuracy of at least one part in hundred. ‘The DC resistance of the conductor shall be measured at room temperature, It shall be corrected to 20° C by means of the appropriate factors given in Table-1. ‘The corrected resistance shall not exceed the value given in Cl. 3.1.1. ‘The maximum loop resistance of any pair in a finished cable shall not exceed the average value by more than 2%. ‘The maximum specific resistance of the conductor shall be 17.241»10"7 ohm em. MUTUAL CAPACITANCE TEST: “The mutual capacitance of the pairs shall have nominal value of 0.05 microfarad per Km. In any length the average value of mutual capacitance of all the pairs shall not differ by more than + 5% from nominal value, The mutual capacitance of any pair shall not differ by more than + 12% from the nominal value, CAPACITANCE UNBALANCE TEST: The capacitance unbalance measurements between pairs in the same quad and between pairs in the adjacent quads shall be made forall the pairs at 800 Hz to 1000 Hz at ambient temperature on each length of cable. All conductors other than those under test shall be connected to the sereen and earthed. ‘The capacitance unbalance/km shall not exceed the value given below: Between pairs in the same quad = 300 pf Between pairs in the adjacent quad - 300 pf Between any pair and earth = 1500 pf Length shorter than 500 meters shall satisfy the same condition as length of 500 meters. CHARACTERISTIC IMPEDANCE: ‘The characteristic impedance of any pair shall be in accordance with the table below : Conductor diameter Frequency Characteristic impedance mm. KHz ‘Ohms + 15% 0.90 08 470 0.90 5.0 195,Page 23 of 49 Effective from : 01.01.2006 DOC No. IRS:TC 30-05 Ver. 12 597 59.71 59.72 5.9.7.21 5.9.7.2.2 Note: 59.73 $.9.7.3.1 5.9.73.2 5.9.7.3.3, 599 5.9.9.1 CROSS TALK TEST: The cross talk test shall be carried out at 150KHz, SKHz & 0.8 KHz. FAR END CROSS TALK (ELFEXT): At 150 KHz, the RMS & individual value shall be better than 67.84B/km & 5SdB/km. respectively. At5 KHz & 0.8 KHz, the RMS & individual value shall be better than 60dB/km & 55dB/km respectively at both the frequencies. 1. The RMS dB is given by RMS (4B) = 10 Logia [510-4 n where m (i,j) = eross talk value between the i and j pairs umber of pair combinations For lengths other than | Km, the measured value shall be corrected by10 logioL/1000, L being the cable length, tested in meters. NEAR END CROSS TALK: At 150 KHz the near end cross talk between adjacent pairs shall be better than 55dB, AtS KHz the near end cross talk between adjacent pairs shall be better than 60dB, At0.8 KHz the near end cross talk between adjacent pairs shall be better than 65dB, ATTENUATION TEST: At 150 KHz. The average attenuation of the pairs shall not exceed 4.4dB/km at 20° C. ALS KHz. The average attenuation of the pairs shall not exceed 2.54B/km at 20° C. At 0.8 KHz. The average attenuation of the pairs shall not exceed 1.2dB/km at 20° C. Attenuation at 20°C = Attenuation at T°C/ {140.0018 (T-20)} T being the ambient temperature, REDUCTION FACTOR TEST: The reduction factor shall be measured in accordance with Cl. 507 of VDE specification 0472/6.65.Page 24 of 49 Effective from: 01012006 | DOC No. JRS:TC 30-05 | Ver. 42 a] 5992 62 a co) éil ‘The screening of the cable shall be suitable so as to give a reduction factor in the field intensity of 50 volts to 450 volts per km as specified below : ‘Conductor diameter in mm Reduction 0.90 PACKING: The cable shall be wound on strong wooden drums of suitable size treated with ASCU fungicide. The timber used for the manufacture of drums shall be seasoned, reasonably straight grained, uniform in thickness, free from insect attack, splits, warping and other defects which may reduce the overall strength of the drums. “The drums shall be of general construction as shown in Fig.3. The dimensions D, X, Xi end Y shall be suitable for the size of the cable and the ratio of X; to Y shall not be greater than 0.65, Dimensions D shall not be less than 20 times the overall diameter of the cable. The Sive of drum must be such that the cable when packed the outer most layer of cable is 50 ‘mm below the flange tp. Nails used in the manufacture of the drums shall be of the clout headed type to 18:723- ‘They shall be properly clenched and shall be so driven as to avoid splitting of the wood. ‘The end shall not protrude into the surface where the cable has to be wound. “The thickness of batons fitted on the circumference of the cable drum shall not be less than 25 mm and the gap between the batons shall not be more than 5 mm to cater for unevenness in the wooden surface. Flange made of wooden planks shall not be less than 25 mm thick. Wooden planks shall be Closely fitted and gap in between planks shall not be more than 5 mm to cater for unevenness in the wooden surface. Steel boss shall be fitted with its diagonal at right angles to wooden planks of flange and shall not be fitted over not less than 2 wooden planks of flange. ‘Steel boss shall be painted with red oxide. Hexagonal head bolts shall be used for fitting of steel boss. The bolt diameter shall not be Jess than 10 mm. Stee! strapping of not less than 12mm wide and 0.6mm thick shall be used. MANUFACTURED LENGTH: Unless otherwise specified, the cable shall be supplied either in length of 500 meters or 1000 meters. The tolerance shall be +5%, -2% irrespective of the length of cable. Non- standard length, each not less than 200 meters shall be acceptable up to 2% of the total quantity ordered. Unless otherwise specified by the purchaser the tolerance on total ‘quantity shall be + 2%. Before dispatch the drums shall be effectively lagged with suitable closely fitted batons of| (Page 25 of 49 Effective from : 01-01.2006 DOC No. IRS:TC 30-05 | Ver. 12 62 6B 64 1 72 13 14 15 81 82 84 Thickness 25 mm, minimum. Every baton shall be secured to prevent it from getting displaced or damaged during transit and storage. The lagging shall further be strengthened by steel straps bound circumferentially over the drum, The steel strapping of not less than 12 mm wide and 0.6mm thick shall be used. The flange portion of drum shall be made of two batons. The thickness of each baton shall be 25 mm for flange dia. Upto 1070 mm. If the flange dia. exceeds 1070 mm, the baton thickness shall be 37.5 mm. The batons on the drums to be removed for obtaining access to the cable end shall be painted red. Both the ends of the cable shall be firmly secured and brought to the outer layer of the drum with suitable protective arrangement to prevent damage during testing and transit. In the inside portion of one side flange, suitable arrangement to guide lower end of the cable upto the top must be provided. The initial and final sequential length marking shall be properly visible at the outer layer. The batons coming above the top and bottom SLM shall be marked with red paint. SAMPLING: All cable drums having cable of same conductor diameter, number of cores and similar construction shall constitute a lot. For taking samples, drums shall be chosen at random from the lot. From each of these drums, one sample of cable shall be taken. The length of the sample shall be sufficient so as to provide test pieces of required length as laid down in various test clauses, The number of drums to be random selected for taking samples shall be as per column 3 of table 2. The number of drums has been expressed as a percentage of the total number of drums in the lot, ‘The number of the test pieces to be taken from each sample shall be as per column 4 of Table 2 ‘The lot shall be offered to the inspecting authority within wo months of the month of manufacture, INFORMATION TO BE SUPPLIED BY THE PURCHASER: IRS Specification number, (Default number IRS:TC 30-05) ‘Number of quads ~ Four quads or six Quads. (Default 6 Quads) Size of conductor. (Default 0.9mm) Any other requirements. (Default cable length 1000 meters) In case any of the above information is not provided by the purchaser, default value shall be assumed. “All the provisions contained in RDSO’s ISO procedure laid down in Document No. QO-D-7.1-11 dated 19.07.2016 ({itled “Vendor- Changes in approved status”) and subsequent versions/amendments thereof, shall be binding and applicable on the successful Vendor/ Vendors in the contracts floated by Railways to maintain quality of products supplied to railways.”Page 26 of 49 Effective from : 61-63-2006 DOC No. IRS:TC 30-05, Ver. ¥: TABLE ‘TEMPERATURE CORRECTION FACTOR FOR CONDUCTOR RESISTANCE FOR ANNEALED HIGH CONDUCTIVITY COPPER (Clause 3.1.1) Temp. | Correction | Temp. | Corre. | Temp | Corre. | Temp. | Corre. | Temp. | Corre, DegC | factor | degC | Factor | degC | factor | degC | factor | degC | Factor i a 1 eerie lee 1 |e Tes lee E 10638 [17 [1.0122 |29 [0.9653 [41 [0.9225 (53 | 0.8834 | 35 [1.0618 [175 | 1.0101 [295 | 0.9634 415 [0.9208 | 53.5 | 0.8818 6. 1.0593 [18 [1.0081 |30 | 0.9615|42 [0.9191 | 54__| 0.8803, 65 | 10571 [185 | 1.0060 [30.5 _| 0.9597 [425 | 0.9174 [54.5 | 0.8787 fs 1.0549 | 19. | 1.0040 [31. [0.9579 |43. | 0.9158 [55.__| 0.8772 | 75 [1.0526 | 193 | 1.0020] 31.5 [0.9560 [43.5 | 0.9141 | 55.5 _| 0.8757 8. 7.0504 |20. | 1.000032. | 0.9saz|44.. [0.9124 [56 | 0.8741 85 | 10482 [20.5_| 0.9980] 325 [0.9524 | 44.5 | 0.9107 | 56.5 | 0.8726 9. 7.0460 [21.1 0.996033. | 0.9506 | 45. [0.9091 |57,__| 0.8711 95 | 1.0438 [21.5 | 0.9940 | 33.5 | 0.9488 [45.5 [0.9074 | 57.5 | 0.8696 10. | Loai7[22. [0.9920] 34. | 0.9470 | 46. | 0.9058 | 58. 0.8681 10.5 | 1.0395 [22.5 | 0.9900 | 34.5 | 0.9452 [46.5 | 0.9048 [58.5 _ | 0.8667 11. [1.0373 [23.__| 0.9881 |35. [0.9434 | 47. [0.9025 [59.__| 0.8651 TLS [1.0352 [23.5 | 0.9862 [35.5 | 0.9416 | 47.5 | 0.9009 | 59.5__| 0.8636 72, [1.0331 | 24, | 0.9843 [36. [0.9398 | 48. [0.8993 | 60. | 0.8621 12.5 | 1.0309 | 24.5 | 0.9823 | 36.5 | 0.9380 [48.5 _| 0.8977 | 60.5 | 0.8606 13. | 1.0288 [25. [0.9804 [37. | 0.9363 |49. [0.8961 (61. | 0.8591 13.5 | 1.0267 [25.5 0.9785 [37.5 | 0.9346 [49.5 | 0.8945 [61.5 | 0.8576 14, [1.0246 |26. | 0.9766 [38, [0.9328 [50 | 0.8929 | 62. | 0.8562 145 [1.0223 [265 [0.9747 | 385 | 0.9311 | 50.5 | 0.8913 | 62.5 | 0.8547 15, }1.0204[27. [0.9728 | 39. [0.9204 | 51, | 0.8897 | 63. [0.8532 | 15.5 | 1.0183 [27.5 |0.9709 [39.5 [0.9276 | 51.5 | 0.8881 [63.5 [0.8518 16. | 1.0163] 28. [0.9690 | 40. | 0,9259 | 52. [0.8863 | 64. | 0.8503 165. [1.0142 [285 [0.9671 [40.5 | 0.9242 [52.5 | 0.8850 [64.5 [ 0.8489Page 27 of 49 Effective from : 04-04-2006 DOCNo. IRS:TC 30-05 _[ Ver. 32. ‘Table-2; SAMPLING PLAN FOR ACCEPTANCE TEST (Clause 7) No, IRS: TC 30-05 [ ‘SN Tests ‘Sample size (Nos. of drums) | Nos. of test pieces to be taken from each sample. T. | Conductor Giameter | 10% subject to minimum one | All insulated conductors (CLS.5.1) drum from each lot. 2. | Overlap & continuity of ~do- ne sample from each Poly-Al Tape (Cl. 3.6.1 & sampled drum.. 3.6.2) 3.__| Annealing test (CI. 5.5.2) ~do- Ail Insulated conductors. 4. | TS. & % Elongation of ~do- Both the tapes from each Armour (C1.5.6.2.1) sampled drum. 3.__| Winding test (C1.5.6.4) do =do- 6. | Mass of Zine coating test ~do- -do- (Cl. $63.1) 7. _ | Uniformity of zine coating ~do- ~do- (CL.5.6.3.2) 8, _ | Dimensions of Steel Tapes ~do- ~do- (1.5.6.1) 9, | Test for closeness of tapes ~do- Both the tapes from each __| (CI. 5.6.5) sampled drum. 10. | Thickness of insulation and ~do- 100% of the sampled drum. sheaths (Cl. 5.7) 11, | TS. & % Elongation of PVC sheaths (Cl. 5.8.1) i) Before ageing 4% subject to minimum of | 4 samples each from each cone drum from each lot. sheaths from sampled ii) After ageing -do- drums -do- 12, |Loss of Mass test of | 4% subject to minimum of ~do- sheaths (Cl. 5.8.4) one drum from each lot. 13. | TS. & % Elongation of | 10% subject to minimum of | Minimum two samples insulation (CI. 5.8.1) one drum from each lot, from each colour used. 14, [Shrinkage test of PE | 4% subject to minimum of | Min. four samples of each insulation (CI, 5.8.2.3) | one drum from each lot. colour from each sampled drum, 15, | Shrinkage test_of PVC| 4% subject to minimum of _ | Minimum one sample from sheaths (Cl. 5.8.2.2) one drum from each lot. each sampled drum. 16. | Thermal stability test of | Minimum one drum from | Minimum two samples PVC sheaths (CI. 5.84410) | each lot from each sheath for each sampled drum. 17. | Bend test (CI. 5.84615) Minimum one drum from each | One sample from sampled lot drum.Page 28 of 49 [Effective from : 04-01-2006 [DOC No. IRS:TC 30-05 | Ver. $2 18. ] Density/specific gravity of | 4% subject to min. ofone | Min. one sample from each’ PVC Sheaths (CI. 3.10.7) _ | drum from each lot. sampled drum, 19, T.S. & % Elongation of PE | 4% subject to min. of one Min. two samples from sheath before ageing only | drum from cach lot. each sampled drum. (C1.5.8.1.5) 30. | Shrinkage test of PE sheath | 4% subject to min. ofone | Min, one sample from each (C1.5.8.2.4) drum from each lot. sampled drum. Zi. [Number of size, | 10% subject to min. of | All sampled drums. compacmess & _lay| drum from each lot. direction of aluminium wires (Cl. 3.8.3, 3.84 & 3.8.6) = 22, | Tensile strength of | 10% subjecttomin. of || Minimum 5 wires or 2 aluminium sires! strips! | drum from each lot, stripstubing from each welded aluminium tubing sampled drum, (CL. 3.8.5) 33, | Drift Expansion test of | 5% subject to min, of | drum | Min. 2 samples from each welded aluminium tubing | from each lot. sampled drum. (1.387) 24, | Flattening test of welded ~do- ~do- aluminium tubing (Cl. 3.8.8) | 25, | Dimensions & Overlap of | 10% subjecttomin. of | | All sampled drums. Barium Chromate Tape | drum from each lot, CL.39) 2 76. | Flame Retardant Test (Cl, | 4% subject to min. ofone | Min. one sample from each 584312) drum from each lot. sampled drum. 2H. | Visual Inspection test (Cl. | 5% subject to min.2 drums | All sampled drums. 5,822], 3.3 & 3.11) from cach lot. 7B] Conductor resistance & | 20% subject to minimum 2 | All insulated conductors & oop resistance tests (Cl. | drum from each lot. pairs of all quads of 5,9.3) except 5.9.3.5 sampled drums. 29, [High voltage tests (Cl. ~do- ‘All insulated conductors 5.9.1) 30, | Mutual capacitance test ~do- ~do- (C1.5.9.4) 31. | Capacitance unbalance test ~do- ~do- (1.595) a 32, | Characteristic impedance =o ~do- test (CI.5.9.6) 33.__| Cross-talk test (CI. 5.9.7) ~do- =do- | 34. _| Attenuation test (C1.5.9.8) =do- =do- 35. | Insulation resistance test -do- =do- ry) (15921 & 5.9.2.2)| [Page 29 of 49 Effective from ; 01.01.2006 DOCNo. IRS:TC 30-05 | Ver. 42 36. Reduction factor test (Cl. 5% subject to minimum of 2] 2 conductors from one 5.9.9) drums from each lot. drum. The conductors may be selected randomly without repeating the same colour code or conductor from drums in the lot. 37. | Water Penetration Test (CI. | 20% subject to minimum of | All sampled drums. 58.2322) 5 drums from each lot. 38. | Insulation Resistance Test | 4% subject to minimum of |_| Minimum one conductor (Wet) (Clause No. 5.9.2.3) | drum from each lot. selected from each colour of insulated conductor of sampled drum. 39. | Carbon Black Content of | Minimum of | drum from | All sampled drums, PE inner sheath (Cl. | each lot. | 5.8.2524) 40. | Carbon Black Dispersion | Minimum of I drum from | All sampled drums, of PE inner sheath (Cl. each lot. 5.8.26) | 41. | Drip test (Cl. 5.83332) | Minimum of I drum from | Minimum one sample each each lot. from inner and outer end of the sampled cable drum. 42, | Water Penetration Test (CI. | Minimum of I drum from|One sample from the $.8.2322) (from middle | each lot. ( One meter sample | sampled drum from the lot. portion of the drum) to be taken from exactly middle portion of the sampled cable drum). 43. | Conductor diameter | Minimum of 1 drum from | All insulated conductors. (15.5.1) each lot. ( Sample taken for W.P.T test at S.No, 42 shall be tested). 4. | Overlap & continuity of | Minimum of | drum from | Minimum one sample from Poly-Al Tape (Cl. 3.6.1 & | each lot. (Sample taken for each sampled drum. 3.6.2) W.P.T test at S.No, 42 shall be tested). 45. | Specific resistance tests | 4% subject to minimum of | One sample of each colour (CL5.9.3.5) one drum from each lot of insulation from sampled drums. 46. | Specific Density of jelly (| Minimum of one drum from | Minimum one sample from | Cl. 5.8.3231) each lot. cach sampled drum. NOTE:- _1.The shortage in cable drum length on account of tests at S.No. 42 to 44 above shall be accepted as good length in the lot in addition to short length permissible in the specification. n_100 meter to 900 meter length from randomly 2. At least one sample to selected drum computerized generated by D1 from his office. This will be one of the sample for all tests,| [Page30 oF 49 [Effective from 07.03.2006 [ DOC No. IRS:TC 30-05 | Ver. #2 3..D1.or his authorized jick up one small piece of. each lot and sec it i duly identified. This le mi ‘chan;Page 31 of 49, Effective from : 01-03-2006 [DOC No. IRS:TC 30-05 [ Ver. 42 TABLE-3 : SAMPLING PLAN FOR TYPE TEST (CLAUSE 5.2) BAW MATERIALS SN] Raw Material CI. No. OF Test ‘Sampling Spec. iF Polythene for 3.2.1, Density T sample from the same conductor 58.4918 bag used for insulation, manufacturing cable for type test. 321, Melt Flow Index ~do- 5.82019 | Dissipation =do- factor (Power factor) 58.2120 | Permittivity ~do- (Dielectric constant) Volume =do- resistivity 384514 | Viscat soflening ~do- point test 2 Filling Compound | 5.82433 | Stability T sample from the jelly barrel used for manufacturing cable for type test. 58.2827 | Handling/Toxic/ | Compound supplier's dermatic hazards | test certificate to be furnished. 383029 | Volume T sample from the jelly resistivity barrel used for ‘manufacturing cable for type test. 3.83231 __| Specific Density -do- | 5.8.3130 | Permittivity =do- 58.2423 =do= 5.82726 | Colour =do= 3. | Poly-Al Tape 3.6.1 Thickness 3 samples from the coil Laminate. used for manufacturing cable for type test 363 Peel strength ~do- a Polythene for inner | 3.7.3() Melt Flow index | 7 sample from the bag sheath used for manufacturing, cable for type test __ 73a Density =do-Page 32 of 49 Effective from : 01-01-2006 DOC No. IRS:TC 30-05 | Ver. 33 3. | Aluminium 382 Purity of tests ‘wires/strips/welded Aluminium to be aluminium tubing furnished or the test to for screening be performed if facility exists at firm's premises. 385 Tensile sirengih | 5 samples each from ssiees/strips/welded aluminium tubing from the coil/lot used for manufacturing cable 6 Barium Chromate | 3.9.2 Thickness & 5 samples from coil Tape Width used for manufacturing cable for type test. 7, | Galvanized Steel Dimension’ 5 samples from coil Tape (Thickness & | used for manufacturing Width) cable for type test. Tensile strength =do- Elongation at =do- break ip test (Test for -do- uniformity of zine coating) | 363.1 Mass of zinc =do- coating 2 | 364 Winding test ~do- Note: In case of Maintenance Type testing only one cable drum either of 6 Quad or 4 Quad type taken in statistically random manner from regular railway supply order lot shall be tested instead of both 6 ‘Quad and 4Quad types as indicated in *Sampling’ column above.[Page 33 of 49 | Effective from : 01.01.2006 [DOCNo, IRS:TC 30-05 | Ver. 12 I,__ PHYSICAL TESTS ON COPPER CONDUCTORS: SN] Clause Test Sampling ‘No. T. [5.5.1 | Conductor diameter All insulated conductors from & both the drums of 6 Quad & 4 3.1.1 a Quad Cable. 2,_|5.5.2 | Annealing of copper conductor =do- 3. [3.1.2 _| Cireularity of copper conductor in eross ~do- & 3.1.3] section, uniform in quality, free from splits, cracks, corrosion and other surface| infection. No joint shall be made in copper conductor. Joint can be made in exceptional cases. In that case, the ‘manufacturer has to give details of joints made in conductor during routine test. 4. [3.14 | Resistance and tensile strength with and | One joint each in each colour of & | without joint. insulated conductors to be made 3.15 from both the drums of 6 & 4 Quad cables.Page 34 0f 49 | Effective from 01.01.2006 | DOC No. IRSITC 30-05_| Ver. 32 1 INSULATED CONDUCTORS & COMPATIBILITY OF FILLING COMPOUND (EACH COLOUR TO BE TESTED) SN_[ Clause No. Test Sampling 1 [5.84216 | Resistance to compression No, of sets such that at feast one ‘conductor for each colour is tested. 2 [58817 _ | Retraction of insulation ‘One sample from each bobbin of each colour of insulation. 3 (5823 Shrink back of insulation ‘A minimum of 4 samples of each colour of insulated conductor from each bobbin. 4 [5887 Cold bend 70 samples of each colour of insulated conductor from each bobbin. 3 ‘Thermal stress eracking =do- =| 6 ‘Absorption of Filling Compound | One set (approx. 20 samples) each colour of insulation from each bobbin. oe ‘Tensile strength & Flongation at break Ann. (i) () Before ageing _| (i) 10 samples of each colour of insulation from each bobbin Ann.(iii) Gi) Afterageing _| Gi) 10 samples of each colour of insulation shall be taken from the samples tested for absorption 8 | Annie (iv) | Environmental stress cracking 10 samples each of each colour of insulated conductor from each bobbin. IV. IN-PROCESS PRODUCTION TESTS: SN | Clause Tests Sampling Number T (328 Spark test on insulated conductor ‘Manufacturing records to be checked up Den [ane Spark test on inner Polythene sheath =do- 3_[3.106 ‘Spark test on PVC intermediate sheath =do- [4 [3.12.6 Spark test on PVC outer sheath =do-| [Page 35 oF 49 [Effective from: 01.01.2006 | DOC No. IRS:TC 30-05_| Ver. 12 V. ‘TESTS ON COMPLETED CABLES: 'SN_| Clause Number Tests ‘Sampling Ve [sas Thickness of PE insulation | All insulated conductors of both the & dia of insulated drums. conductors. 3.2.4,3.2.5,3.3 | Colour, & lay of pairs of | Both the drums of 6 Quad & 4 Quad &34 each Quad Cables. 2 [361 Overlap of Poly-Al Tape | -do- 3.6.2 Continuity of Poly-Al Tape | -do- 3. [5.83332 Drip test One sample each from each end from (Annexure-A both the drums of 6 and 4 Quad cables. ay 4 | 5.83231 Specific Density of Jelly _ | Minimum one sample from the offered lot. 3. [5.83635 Oxidation Induction test | One sample each of each colour of (Annexure-A insulation from both the drums of 6 and mw) 4 Quad cables. 6 Bond strength between 5.83736 i) Poly-Al at Over lap 5 samples each from both the drums of (Annexure. A. 6 and 4 Quad cable ay) ii) Poly-Al & Sheath -do- cB Polythene for Inner Sheath 3.7.1 ‘Thickness Both the drums of 6 & 4 Quad cables. 58.1.1a(i) | i) Tensile Strength 4 samples each from both the drums of 6 and 4 Quad cables. 5.8.1.1a (ii) | il) Elongation at Break ~do- 5.8.3534 iii) Environmental Stress | 2 samples each from sheath from both Cracking (ESCR) the drums of 6 and 4 Quad cables. S821 & iv) Shrinkage -do- 58.2.4 58.2524 v) Carbon Black Content | 1 Sample each from sheath from both the drums of 6 Quad & 4 Quad cables. 58.2625 vi) Carbon Black -do- Dispersion 58.3635 vii) Oxidation Induction -do- (Annexure-A (V)) Test_ SarsPage 36 of 49 [Effective from 01-01-2006 [ DOC No. IRS:TC 30-05 | Ver. #2 aa [50.8 Protection (Barium Chromate Tape) 3.9.1 Overlap Both the drums of 6 and 4 Quad cables. 3.9.2 Width Both the drums of 6 and 4 Quad cables. 3.92 Thickness Both the drums of 6 & 4 Quad Cables. 9. ~*([38 Screening (Aluminium) 3833.86 | Layingof Al Wirestrins | Both the drums of 6 quad and 4 quad cables. 3.84 {Compactness of Al ¥ire-strips: -do- 385 [Tensile strength Minimum 40-ires-or-5 strips/welded aluminium tubing from both the drums of 6 and 4 Quad Cables. 3.87 Drift Expansion Test 5 samples each of welded aluminium tubing from both the drums of 6 Quad & 4 Quad cables. 388 Flattening Test, -do- 10, [56 Galvanized Steel Tape 3.112 Gap in the application of | Both the drums of 6 and 4 Quad cables. the first tape 3.2 Overlap of 2™ tape over the -do- first one on either side 3.115 ‘Thickness 2 Samples cach from inner and outer steel tape from both the drums of 6 and 4 quad cable 5.6.2.1 Tensile strength -do- 5.62.1 Elongation at break -do- 3.63.2 Dip Test (test for -do- uniformity of zine coating) Mass of zine coating -do- Winding Test -do- Closeness & direction of lay | Both the drums of 6Quad & 4 Quad of Armour Cables| [Page370f49 [Effective from: 01.01.2006 | DOC No, IRS:TC 30-05 _| Ver. 12 ii. PVC Intermediate, Outer Sheath , PE Insulation & Inner Sheath 3.10.7 Density of PVC Inter & — | 2 Samples from each sheath from both Outer Sheaths the drums of 6 & 4 Quad cables. 3.10.2. & 3.12.4 | Thickness of PVC Inter & | 4 Samples each from PVC intermedi Outer Sheath. and outer sheath from both the drums of 6 and 4 Quad cables 5.8.1.1 (a) Tensile Strength and -do- Before ageing | Elongation at Break 5.8.1.1 (b) After -do- -do- ageing for PVC, Intermediate & Outer sheath 58.1.1(ay(iii) -do- Minimum 4 samples from each colour before aging for PE insulation 58.21% 5.8.2.2 5.8.2.1 & 5.8.2.3 5.8.2.1 & 5.8.2.4 5.8.3 5.8.4 Shrinkage test for PVC Intermediate and Outer Sheaths Shrinkage test for PE Insulation Shrinkage test for PE Inner Sheath Hot Deformation Loss of Mass (before and after ageing) Colour Fastness-te-day Light Exposure of PE insulation from both the drums of 4 Quad cable, 1 Sample each from PVC intermediate & outer sheath from both the drums of 6 Quad & 4 Quad. 4 Samples cach from each colour of insulation from both the drums of 6 Quad & 4 Quad cables. 2 Samples each from both the drums 1 Sample each from PVC intermediate & outer sheath of both the cables of 6 Quad & 4 Quad. 4 Samples each from PVC intermediate and outer sheath from both the drums of 6 and 4 Quad cables ; from PVC s And-outer sheath from-6-Quad &4 Quad| CablePage 38 of 49 | Effective from : 01.01.2006 | DOC No. IRS:TC 30-05 | Ver. #2 8.65 feotow Fasiness to Water | 1 Samples each from each colour of insulation from both the drums from 6 Quad and 4 Quad cables. 5.8.96 Bleeding and Blooming 1 Sample each from inner PE sheath, tests PVC intermediate and outer sheath from both the drums of 6 Quad and 4 Quad Cables. & 1 Sample each of each colour of insulation from both the drums of 6 & 4 ‘Quad cables. 12, [5.898 Cold Impact Test T Sample each from inner PE sheath, PVC intermediate and outer sheath from both the drums one each of 6 and 4 Quad Cable. 12, [58109 Heat Shock Test ‘One sample each fiom PVC intermediate and outer sheath from both the drums — one each of 6 quad and 4 quad cable. 14, [58000 Thermal Stability Test 2 Samples each from PVC intermediate ~ | and outer sheaths from both the drums of 6 Quad & 4 Quad cables. 15, [584312 Flame Retardant Test T Sample each from both the drums of 6 Quad and 4 Quad cables. 16. Bend Test ~do- 17. High Voltage between Between a conductor and all other conductor to conductor. _| insulated conductors of both the drums of 6 and 4 Quad cables. 18. High Voltage between all | Between all insulated conductors conductors and shield bunched together and the steel armouring with screening wires from both the drums of 6 and 4 Quad cable. 19, [592.18 Insulation Resistance (Dry) | Between each conductor and all other 59.22 insulated conductors shorted with the armouring from both the drums of 6 and 4 Quad cable. 20, (5.9.2.3 Tnsulation Resistance Between conductor and water in which (Wet) cores are immersed from both the drums of 6 and 4 Quad cable. 2. Conductor Resistance and | All insulated conductors and pairs of all Joop resistance Quads of 6 and 4 Quad cable.Page 39 of 49, Effective from : 01.01.2006 DOC No. IRS:TC 30-05 [ Veri2 228/55: Specific Resistance One insulated conductor of each colour of insulation from both the drums of 6 and 4 Quad cable. 2. | 594 Mitual Capacitance ‘All pairs of insulated conductor of all Quads of 6 and 4 Quad cable. 4. | 595 (a) Capacitance Between all pairs of insulated Unbalance ( pair to pair) | conductor in the same and adjacent and adjacent pair of same | quad of both the 6 and 4 Quad cable. and adjacent quad (b) Capacitance Between all pairs of insulated unbalance pair to ground | conductor and earth of both the 6 and 4 Quad cable. 25. | 596 Characteristic impedance | Between all _ pairs of insulated conductors of all the Quads of 6 and 4 Quad cable. 26. | 59.72 Far End Cross Talk Between all pairs of insulated conductors of all the Quads of 6 and 4 Quad cable, 2. | 5973 Near End Cross Talk ~do- 28. | 598 ‘Attenuation ~do- 29. | 5992 Reduction Factor Alll the insulated conductors of all the Quads of 6 and 4 Quad cable. 30. | 7582322 ‘Water Penetration Test From both the ends of both the drums of 6 and 4 Quad Cable, 3. | 5.82321 Visual Inspection Both the drums of 6 and 4 Quad Cable to be visually inspected by rewinding iton to another drum to comply the Requirement as given in relevant clause of 5.8.22.Page 40 of 49 Effective from : 03-04-2006 DOC No. IRS:TC 30-05 | Ver. 12 ANEXURE-I COMPOUND ‘The cable core shall be fully filled with a suitable water resistant compound like Jelly, which is fully compatible with the Polythene insulation of the conductors. ‘The compatibility between the polythene insulation and the filling compound shall be established by the tests as per annexure below. at insulated conductor stage. (D ABSORPTION OF FILLING COMPOUND: For this test 15 cm length of insulation carefully removed from any conductor shall be weighed (about 2 gm) correct to | mg, The lengths (suitably coiled and bend, if necessary); shall be placed in a test tube or beaker full of filling compound with its ends 1 em. Above the level of the compound and maintained at 70° C+I°C for 14 days. At the end of this period, the insulation sample shall be removed; the surface shall be wiped clean and again weighed accurately. Increase in weight shall not be more than 10%. (I) ELONGATION AND TENSILE STRENGTH: 20 lengths of insulation shall be carefully removed from any conductor and made into 2 sets of 10 each. The first set shall be tested on a tensile machine keeping 50 mm between the 250250mm per minute. The percentage of elongation at break and the breaking load for the 10 lengths shall be noted and the average worked out. These values shall not be less than 300% and 100kg/cm sq respectively. (11) The second set of 10 samples shall be aged in a test tube or beaker full of filing ‘compound and maintained at 70° C+1°C for 14 days. After ageing as above, the 10 lengths shall be tested in a tensile testing machine for tensile properties in a similar manner as above. “The average percentage elongation at break and tensile strength after ageing shall not change by more than 30% and 15% respectively of the values before ageing, (1V)_ ENVIRONMENTAL STRESS CRACKING: 10 lengths of insulated conductor of 150mm each removed from the extruder, shall be immersed in filling compound for 24 hours at 70° C+1°C and insulated conductors will then be removed from the compound and wiped clean. They will then be wrapped round its own diameter for a minimum of 10 contiguous turns closely wound in a length of 2 cm of insulated conductor. They will then be suspended in an air oven maintained at 70° C+1°C for 14 days. At the end of this period they will be removed from the oven and observed for eracks with naked eye. There shall be no cracks.Page 41 of 49 Effective from : 01.01.2006 DOC No. IRS:TC 30-05 _[_Ver. 12 ANNEXURE-A L STABILITY TEST METHOD: Experimental sct up is indicated in fig. 4. About 5 grams filling compound is filled in a glass | container with both ends open and held with the axis of container + hheld-swith-the-aaisofdhe-container in a horizontal plan, The outer surface of the glass tube is. covered with a copper wire mesh to ensure uniform temperature and prevent local hot spots. This container is suspended vertically in (accurately weighed) test tube so that it hangs freely. The temperature of the jelly is monitored by a thermometer, The test tube is now placed in a constant temperature bath maintained at 65°C41° C for 120 hours. The compound shall remain intact in the container after 120 hours and shall not show any separation of the constituents of the compound. (i) DRIP TEST: The test specimen of 30cm in length shall be cut from a completed cable. One end of the sheath shall be stripped for approximately 5 cms. And the conductors with the jelly wiped clean shall be flared out approximately 45° angle. The same shall then be suspended in air ‘oven with a glass disc placed directly below the flared end of the cable. The oven temperature shall be set at 65° C+1° C for a period of 24 hours. At the end of the test the compound which might have dripped. There shall be no dripping of filling compound. (I) PEEL STRENGTH FOR LAMINATE AND COMPOSITE SHEATH & BOND STRENGTH: 1.0(a) A parallel sided test piece 150mm long and 13 to 16mm wide of the laminate or sheath shall be cut longitudinal from the Laminate or sheath in one operation using a sheath. (b) Test piece taken for testing the strength of the bond between the sheath and Aluminium tape shall exclude the overlap of Aluminium foil. For small diameter cables, it may not be possible to get sheath test pieces 13 ems wide. In such cases test pieces of less width may be taken (excluded the Poly-Al Overlap). (©) Test pieces taken for testing the strength of the bond between the interfaces of the ‘Aluminium tape at the seal shall include only the overlap of the tape 2.0 (a) For testing Pee! Strength of Laminate only, separate the Aluminium and Polythene tape at ‘one end. Insert the Aluminium in the fixed grip and Polythene tape in the moving grip of the tensile tester. (b) For testing bond strength of sheath, insert the Aluminium in the fixed grip and polythene sheath in the moving grip. (©) For testing Bond Strength of Laminate at the overlap, insert the Aluminium tape in the fixed grip and Poly-Al — Polythene sheath {other edge) in the other grip. For 4.0 a, b & c of this item, the grip can be brought closer up to 3 ems, An electric operated tensile tester shall be used. Rate of separation between grips shall be 100 to 135 mm/min. and the steady force required to separate the materials shall be noted.Page 42 of 49 [ Effective from : 04-04-2006 DOC No. IRS:TC 30-05_[_Ver. 43 3.0. Initial separation of the Laminate or laminated sheath to facilitate insertion in the grips can 40 ) be made by immersing about 25mm at the end of the test piece in boiling industrial alcohol for about 30 seconds. Sampling and Requirements: - (@) Peel Strength of the Laminate raw material shall be 25-gms/mm width (minimum). 5 samples shall be tested. (b) Bond Strength of the Laminate to Sheath shall be 40gms/mm (Minimum) and ‘60gms/mm width (Average) on 5 samples. (© Peel Strength of the Laminate at overlap shall be the same as (b) above on 5 samples. WATER PENETRATION TEST: ‘Sample Preparation: A piece of three-metre length shall be cut from the end of the cable. The inner one-meter length as indicated in the fig.5 shall then be cut for test ensuring minimum disturbance to the cable core during the cutting process. This inner 1 metre sample shall be subjected to the Water Penetration Test. The outer 2 metres shall not be used for this test. However, for acceptance test, piece of only one metre length shall be taken from the end of the cable drum for tests without discarding two-metre length. ‘Testing Arrangement: This arrangement is shown in fig.5. The sample under test is kept straight in a horizontal plane on a test bench prepared for this purpose. One end of the sample shall be connected suitably through a watertight gland to a water pipe containing 1 metre head of water. The connection shall be such that the cable sheath shall not be squeezed tight ‘or shall in allow leakage of water at this point. The other end of the cable shall be free. ‘One metre head of water shall be applied for 7/14 days at ambient temperature. The pipe connecting the water tank to the cable shall be vertical. No air bubbles shall remain trapped in this pipe. Any bubbles that may be present initially should be removed by agitating the water column using a thin wire for this purpose. ‘The test shall be deemed to have started after ensuring that the head of water is one metre and all air bubbles have been eliminated. The sample shall not be disturbed during the period under test, During this period, no water shall have seeped from the cable sample. This test shall be conducted after inner sheath stage. OXIDATION INDUCTION TEST: ‘A short length section (approximately 30 cms) of 10 pairs or larger cable shall be sealed at the ends and placed in an oven at a temperature of 68°C+1° C for eight hours, The sample will then be allowed to cool down to room temperature for a total of twenty-four hours. After[Page 43 of 49] Effective from : 01.01.2006 DOC No. IRS:TC30-05_[_Ver. 12 equilibration, five samples shall be taken of each colour of insulation, each one from a different conductor. Each sample shall be wiped clean of grease and foreign objects using a dry cloth (without solvents). Each sample shall be individually tested by means of a Differential Scanning Calorimeter (DSC) or by Differential Thermal Analysis (DTA). The sample shall be clean and dry, Instrument Test Procedure: Cell Cleaning: Hold cell at approximately 400°C for 10 minutes in nitrogen. Cell should be cleaned after standing overnight and between testing of different formulations, ‘Temperature Calibration: The temperature scale should be adjusted according to the instrument manual until the determined melting point of pure indium metal is 156.6°C at a heat rate of 5° C per minute, Engineering Notes: Dupont 990 with DSC Cell With instrument in isothermal mode, calibrate STARTING TEMPERATURE dial according to instrument manual alternatively, the dial may be set to a reading, which results in a corrected thermocouple read-out of 199°C. Perkin-Elmer DSC-I or DSC-2: Run several pure metal standards (c.g. indium, tin, lead, zinc) through their melting point at a heating rate of $°C per minute, Plot melting temperature and interpolate to find the correct set point for 199°C. Repeat calibration require only adjustment for the indium melt temperature, Copper Pan Preparation: Prepare fresh copper oxide coating by holding the pan in the flame of a fisher burner u begins to glow (about 3 seconds). Remove the pan from the flame and immediately cool in a Gentle stream of air. Sample preparation: Remove the insulation from the conductor. Flatten the resin to bout 15 mils thickness ( not critical) clip sample to approximate roundness, bout 2mm in diameter. Sample should weigh approximately | to 2 mg. Position in center of oxidized copper pan, cover with clean 316 stainless steel sereen (40 mesh) and erimp the pan. Nitrogen Purge: Place sample pan in instrument cell. Flush 5 minutes minute. cylinder nitrogen at 6010 cc per Oxidation Test: Rapidly increase sample temperature (20°C+1°C. After thermal equilibrium (steady recorder signal) simultaneously switch to 50+Scc/minute oxygen flow and start time- base recording. Other flow rates, 150cc/minute inclusive maximum, can be used. Record rate flow used. Oxygen should be equivalent to or better than 99.66 extra dry grade.| (Page 44 of 49” | Effective from : 01.01.2006 [DOC No. IRS:TC 30-05_| Ver. 42 Induction Period: This oxygen induction point shall be recorded as time zero, and the chart speed shall be sufficient to provide a clearly discemible slope at the start of the exothermic shall continue until the exothermic peak is produced, The intersection of the tangent of the exothermic sloped line with the extended base line will be drawn. The time from time zero to this intersection point is read from the base line and recorded as oxidation induction time.IRS:TC 30-05 CLAUSE No.:3.13 ‘CORE WRAPPING OF POLYSTER TAPE POLYTHENE INSULATED COPPER CONDUCTOR (4 QUAD) CROSS SECTION VIEW OF THE UNDERGROUND RATLMAY 4 ELLY EILLED CABLES FOR SI & TELECOM INSTALLATION FIG.1 a= 6h JO Sh aBed] | SRETHTS: Woy SANA $0-0 D1SUI°N DOG TBAPage 46 of 49 Effective from : 01.01.2006 DOC No. IRS:TC30-05_[ Ver. 42 Z é H CLAUSE No.:3.13, [FILLED SELBOOM QUAD CABLES FOR SIGNALLING 6 TELECOM INSTALLATION25) 37S 1 OAMETERT SHALL BENIN 20 TES THE OVAL CALE DERE, 2 OMBXGONS MAREDDILL 6 Y SHALL BE ADE TOSUT LNGHOF HE CLE, 2, ALLOMENSONS MULUMETERS, 64 50 Ly 980d Doe TO TO: Woy Sanda $0-0€ D.LSUI ON 300 TERA[Page 48 of 49 Effective from : 04-01-2006 DOC No. IRS:TC30-05_[ Ver. 32 x} STABILITY TESTING HETHOD ee CLAUSE No, 52.34 ‘SUSPENSION WIRE ‘THERMOMETER FOR He eather BATH THERMOMETER ACCURATELY. WEIGHED TEST TUBE Fret roe PED HOLLOW HORIZONTAL, CONTAINER TEAPERATURE FULL OF COMPOUND FIG, - 4 ce a an ee[Page 49 of 49 Effective from : 01,01.2006 DOC No. IRS:TC 30-05 _[ Ver. 42 ANNEXURE. b-TY WATER PENETRATION TEST ta i Shas ‘VERTICAL WATER COLUMN 1 PETRE. HEAD WATER TIGHT SEAL OR CLAMP: TAPE ETC, OVER THE CABLE END CABLE SANPLE UNDER TEST STRAIGHT HORIZONTAL, ‘START / BEGINNING INNER 1 METRE SAMPLE 1H—e— en END OF THE CABLE eee a OUTER 2 NETRE SAMPLE TO BE DISCARDED,