TECHNICAL SPECIFICATION FOR 220 kV XLPE (CROSS LINKED

POLYETHYLENE) INSULATED POWER CABLE:

SCOPE

The scope under this section covers design, manufacturer, testing, packing, supply, delivery and laying of 220 kV
XLPE, insulated power cable including integrated testing and commissioning, technical support, supervision of
maintenance, training of Employer’s staff and documentation for a complete System necessary to deliver the
requirements of this Specification.
STANDARDS:
Unless otherwise specified, the cables shall conform, in all respects, to IEC 62067 and IS:7098 (Part- III)/1993 with
latest amendment or latest edition for cross linked polyethylene insulated , metallic sheathed & H D P E sheathed cable
for working voltage of 220 kV.

The following standard specifications of latest version updated to as on date of opening of this bid document will
govern supply, laying testing and commissioning of cables and their accessories that are being used in this Contract.

S Title of Specification Specification No.

r
.
N
o
1 Cross linked polyethylene insulated IEC: 60502–2
Thermoplastic sheathed cables IEC: 60840,
IEC: 62067
2 Conductors for insulated cables. IEC : 60228
3 Test on cable over Sheath which have a IEC 60229
special protective function and are applied
by extrusion
4 HDPE pipes BIS 4984
5 Power cables with extruded insulation IEC 60840
and their accessories for rated voltage
above 150 kV- Test Methods &
requirements
6 Power Cables with extruded insulation IEC: 62067
and their accessories for rated voltages
above 150kV.
7 Impulse test on cables & their IEC 60230
accessories.
8 Cyclic and emergency rating of cable IEC 60852-2
9 Common test methods for insulating and IEC 60811
sheathing materialof electrical cables.
1 Electric test methods for Electric cables – IEC 60885
0 Test methods forPartial Discharge
measurements on lengths of extruded
power cables.

PRINCIPAL PARAMETERS:
220 KV (E) grade XLPE single core power cable conductor annealed electrolytic grade copper of single length, with
formation of stranded compacted circular water blocked conductor for size up to 1000 Sqmm and segmental type for
size above 1000mm2 as per IEC-60228, tapped with semi conducting water blocking tape, shielded with extruded
semi-conducting layer, insulated with dry cured cross linked polyethylene (XLPE) insulation, insulation screened
with extruded semi- conducting layer, insulated core lapped with a combination of semi- conducting water swellable,
copper wire screen with lead alloy sheath (acting as a screen and also as a mechanical protector) with anti-corrosive
layer of asphalt/ Bitumen, inner sheath (PVC ST2) of suitable thickness as per ISS/IEC standards, Hard Drawn
Aluminium Armour of suitable thickness and black HDPE ST7 (as per IEC 62067 – 2011) with extruded semi-
conductive layer over all cable confirming to IS:7098 (Part- III)/1993 or any latest amendments thereof.
Outer sheathing should be designed to afford high degree of mechanical protection and should also be heat, oil
chemicals and weather resistant.
The cable should be suitable for laying in covered trenches and/or underground for outdoor

Page 1 of 14
 The sheath/screen bonding system shall provide a continuous current path through the cable sheath and jointing kits
and shall be bonded. The bonding ends shall be suitably earthed with/without SVL as per approved
configuration/design. The sheath voltage under full load condition shall not exceed the voltage specified/allowed in
relevant standard for safety of personal as well as satisfactory working of cable i.e 65 v. Sheath shall be solidly
grounded at suitable location with or without SVL. Agency must indicate details of configuration proposed along
with sufficiency calculation at the time of approval so as to limit induced voltage of sheath within 65V. Detailed
calculation supporting selection of SVL and bonding cable size and rating with margin of protection to be submitted
at the same time.
1.3.5 CABLE PARAMETERS

Sr. System Particulars 220kV

No.
i) Voltage Grade (Uo/U) 127/220 kV
ii) No. of Cores Single
iii) Size (mm2) 630mm2, 800mm2,
1000mm2, 1200
mm2, 1600 mm2
iv) Nominal system voltage KV 220
v) Highest system voltage KV 245
vi) System Frequency Hz 50
vii) Variation in Frequency ± 5%
viii) Fault level individually for
i) Conductor 50 kA for1sec
ii) Lead alloy with copper wire screen & 50 kA for1sec
tape sheath
ix) Maximum allowable temperature
a) Design continuous operation at rated full load 90
current, the max. temp. of conductor shall not
exceed.0C
b) The conductor temperature after a short 250
circuit for 1.0 sec shallnot exceed. 0C
x) Basic insulation level (1.2/50 MicroSecond 1050 KVP
Wave)
xi) System earthing Solidly earthed

GENERAL TECHNICAL REQUIREMENTS:

CONDUCTOR:
The cable conductor shall be made from electrolytic grade annealed copper with formation as stranded
compacted circular conductor for size upto 1000 sqmm and segmental type as per IEC-60228 for the size
above 1000mm2.The conductor shall confirm to IS:8130/2013. Conductor should be water blocked. Water
blocking shall be achieved by combination of water blocking yarn and non-conducting water blocking tapes
in intermediate layers of conductor.

CONDUCTOR SCREEN:
A Conductor screen made of semiconducting compound shall be provided over the conductor, by
extrusion. The extruded coat shall be continuous, with a constant mean depth, without bump, perfectly
adhering to the insulation envelope. A semiconducting water blocking tape(s) shall be provided below the
extruded semi-conducting conductor screen to prevent penetration of the compound into the underlying
conductor with min 50 % overlap. The conductor having a semi-conducting screen shall ensure perfectly
smooth profile and avoid stress concentration. The conductor screen shall be extruded in the same operation
as the insulation; the semi- conducting layer shall be cross-linked. Minimum thickness of the conductor
screen shall be nominal 1.50 mm (nominal). The electric resistivity of the conductor screen shall as per IS
7098 (part 3).

INSULATION:
The Insulation envelope shall be of cross-linked polyethylene (XLPE) insulation applied by extrusion
should be suitable for 220 kV system voltages. The thickness of insulation shall not be less than 27 mm (no
negative tolerance is accepted) shall be as per IS 7098 (part 3)/ IEC 62067. The manufacturing process shall
ensure that the Insulation shall be applied by extrusion and vulcanized using dry curing process to form a
compact homogenous body free from micro voids and contaminants. The insulation compound shall be of
high quality, heat, moisture, ozone and corona resistant. The insulation shall withstand mechanical and
thermal stressed under steady state and transient operating conditions. The extrusion method should give
very smooth interface between semi-conducting screen and insulation. The mechanical characteristics shall

Page 2 of 14
 be as per IS 7098 (Part 3). The isolating envelope shall be as per IS 7098 (Part 3).
Test for surface irregularities shall be carried out as below

Item (For XLPE/TR XLPE insulation) Claus Unit Requirement

e
of
AEIC
CS8
Protrusions into insulation from 3.2 mm ≤ 0.076
conductor screen
Protrusions into conductor screen 3.2 mm ≤ 0.18
Strand Convolutions 3.3 mm ≤ 0.18
Protrusions into insulation from 5.2 mm ≤ 0.13
insulationscreen
Protrusions into insulation screen 5.2 mm ≤ 0.18

Page 3 of 14
INSULATION SCREEN:

To confine electrical field to the insulation, non-magnetic semi- conducting shield shall be put over the
insulation. The insulation shield shall be extruded in the same operation as the conductor shield and the insulation
by suitable extrusion process (triple extrusion). The insulation shield should be bonded type. It shall be lapped
by semiconducting tape with min thickness of 1 mm. Metallic screening shall be provided by lead alloy E
Sheath with copper wire screen and copper tape.

METALLIC SHEATH

The metallic screen shall be of lead alloy E sheath over copper wire screen and copper tape having fault current
capacity 50KA for 1-sec with initial temperature of screen as 80 degC and final temperature as 250 degC
calculated by adiabatic method. It shall be lapped by semi conducting water swellable tape. Supporting
calculations shall be submitted at the time of approval.

ANTI-CORROSIVE LAYER.
An anticorrosive layer of asphalt/ Bitumen compound followed by tape shall form the anti- corrosive layer.

INNER SHEATH

The Inner sheath shall be of extruded black PVC Type ST-2 Compound. Minimum Thickness of inner
sheath shall be as per IS: 7098 (P-3)

ARMOUR

The armouring shall be of hard drawn aluminium round wire armouring. Nominal dimensions shall be as
per IS: 7098(P-3). A suitable binder to be provided over the armour.

OUTER SHEATH:
The outer extruded semiconducting layer sheath shall be embossed/printed red/yellow/blue colour or similar (as
per phase). Suitable semi conducting layer coated on black HDPE ST7 with extruded conductive layer
confirming to IEC: 62067, with suitable additives to prevent attack by rodents and termites.
The Mechanical Characteristics shall be as follow :
a) - In delivery condition
1) - minimal traction resistance : 12.5 Mpa
2) - minimal elongation before breaking : 200%
b) - After ageing of 240 h at 135°C:
1) - traction resistance:
2) - minimum value : 12.5MPa
3) - maximum variation : □ 25%
4) - elongation before breaking:
5) - minimum value : 200%
6) - maximum variation : 25%
The variation is the difference between the medium value obtained after ageing and the medium value
without ageing, expressed in percentage of the last.

CONSTRUCTION:

All materials used in the manufacture of cable shall be new unused and of finest quality. All materials should
comply with the applicable provision of the tests of the specification and any other applicable statutory
provisions rules and regulations (IS, IEC, Indian Electricity Rules, Indian Electricity Act).

CURRENT RATING:

The cable will have current ratings and de-rating factors as per relevant standard IEC.
The one-second short circuit rating values each for conductor; Metal sheath shall be furnished and shall be
subject to the purchaser's approval.

The current ratings shall be based on maximum conductor temperature of 90 deg. C with ambient site condition
specified for continuous operation at the rated current.

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SIZE:
The different sizes of cable shall be 220 kV Single Core
a) 630mm2
b) 800mm2
c) 1000mm2
d) 1200mm2
e) 1600 mm2

OPERATION:
Cables shall be capable of satisfactory operation under a power supply system frequency variation of plus
minus 5%, voltage variation of plus, minus 10% and combined frequency voltage variation of 10% (absolute
sum).

Cable shall be suitable for laying in ducts or buried under ground.

Cable shall have heat and moisture resistance properties. These shall be of type and design with proven record
on transmission network service.

TESTS
Type Tests
The equipment offered should be type tested as a cable system with terminations and both type of joints.
Validity duration for Type test report shall be as per latest CEA guidelines carried out in accordance with
IEC 62067/ IS 7098 P-III, from Govt./Govt. approved test house, shall be submitted at the time of its
approval.
The failure to do so will be considered as a non-responsive.
ROUTINE TESTS AND ACCEPTANCE TESTS
All routine and acceptance tests shall be carried as per relevant ISS/IEC in the presence of Employer's
representative.

INSPECTION

The material shall be inspected and tested before dispatch by an authorized representative of BSPTCL in
respect of quality as per respective ISS/ IEC standards. The inspecting officer shall also satisfy himself about
the correctness of length of cables.

TEST CERTIFICATES
Test certificates of raw materials and calibration certificates of all measuring instruments shall be submitted
during the acceptance test of material.

PACKING
The cable shall be supplied in returnable Steel drum as per so constructed, as to enable the cable to be
transported on each drum. The cable wound on such drum shall be one continuous length. The ends of
cables shall be sealed by means of non-hygroscopic sealing material. The Top end shall be provided with
Suitable Pulling eye.

MARKING

The marking on the drum shall have the followinginformation: -

a) Reference to Indian Standard & cable code.
b) Name of the manufacturer & trade name.
c) Nominal cross section area of conductor for the cables.
d) Number of core.
e) Sequential No. at each meter.
f) Type of the cable & voltage for which it is suitable.
g) Length of cable on the drum.
h) Approximate gross weight.
i) Net weight of the cable.
j) Drum identification number.
k) Consignee's name with designation.
l) Year of manufacture.

DRAWINGS & INSTRUCTION MANUAL

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 The agency shall have to supply the following drawings at the time of approval: -
i) Detailed drawing of the cable showing conductor, screening insulation, Armouring,outer sheath etc.
ii) Detailed drawing showing jointing of cable and sealing of end boxes.
Copies of instruction manuals for testing, installation jointing operation and maintenance of cables shall also be
submitted with the offer for reference of the purchaser.

TERMINATION KITS AND STRAIGHT THROUGH JOINTS

The entire necessary Straight through joints and Sealing Ends for 220 kV shall be supplied and erected. The
Straight through joints and Sealing Ends wherever required shall be pre-moulded/ Heat Shrink Type or
equivalent whichever is applicable, of reputed make with shear head type mechanical connectors or cold
shrink type of proven technology & make.

ISO Accreditation

The cable shall be manufactured by a company having ISO accreditation for quality. The manufacturing
process of XLPE cable shall consist of conductor screen, insulation & insulation screen shall be extruded in
a single process (Triple extrusion) and cross linked by a suitable proven & latest Process having dry curing
technology to ensure homogeneity and absence of micro voids. The cables shall be manufactured by “Dry
Curing” Process.

Page 6 of 14
 PART II

TECHNICAL SPECIFICATION FOR LAYING, TESTING AND COMMISSIONING OF 220 kV

XLPE UNDERGROUND POWER CABLE

SECTION-1 SPECIFICATION FOR LAYING OF CABLE:

1.1 GENERAL
The Cable Laying works shall be executed according to the rules of the Art pertaining to professional grade and
generally in compliance with International Standards and Indian Standards.
The EHV Cables shall be laid in ground depending upon the site conditions of the selected route, any of the
following conditions or additional condition as per relevant standards, may be adopted and shall be finalized
only during detailed engineering.
Cable Laying Cases
Case 1 : Direct buried, with all cables laid in flat formation.
Case 2 : Direct buried, with the cables (3) of each circuit laid intrefoil formation and side
by side in one trench.
Case 3 : Laid in underground duct.
Case 4 : Laid in Trench less piping.
Case 5 : Laid in abutment crossing
Case 6 : Laid in Rail Track crossing
Case 7 : Laid in Air, supported on piers/walls, for nallah-crossing
Cable protection at changeover location
The cable path, when changing from buried in ground to underground duct or trenchless piping shall beadequately
protected by proper sealing in concrete or other suitable means of sufficient mechanical strength to avoid cable
from suffering damage due to heat/fire/water ingress etc.
Pulling Chambers
Pulling chambers shall be provided, as necessary, along the route. Such pulling chambers shall be designed as per
detailed engineering. The masonry structure should be of adequate strength with water proofing to avoid any
accumulation of seepage of water inside. The edges of RCC covers and masonry shall be lined in GI angles to
achieve a long service life.
Route Markers
The route shall be appropriately marked by suitable retro-reflective cable markers, at suitable intervals and
positions of straight through joints shall be indicated by suitable boards.
2.0.0 CABLE ACCESSORIES AND BONDING
Straight Through Joints
The straight through Joints should be HEAT SHRINKABLE type or cold shrink type
of proven technology and make, suitable for underground buried cables. The joint should comprise of stress
control sleeves, insulating sleeves and co-extruded dual wall Tubing comprising of an insulating and semi-
conducting layer. A mechanical connector with shear head bolts shall make the conductor connection.
The product should be type tested as per IEC /IS specifications
GENERAL SPECIFICATIONS
a. List of past supplies in India to be furnished. Performance certificates to be submitted along with the offer.
b. The product offered should have unlimited shelf life.
c. Offers should be supported with type test certificates from either at CPRI/ERDA or a govt.
Approved lab, as per IEC /IS specifications, failing which the offers shall be ignored.
GENERAL SPECIFICATIONS FOR JOINTS AND TERMINATIONS FOR 220 KV XLPE CABLES
Suitable Terminations (Outdoor & Indoor Sealing ends) and Straight through Joints having proven
technology & of 220 kV grade or higher for single core 220 kV cables.
Bonding

Page 7 of 14
Suitable bonding methods viz., Single End, Both End and Cross Bonding shall be used.
Link boxes with & without SVL shall be used as required.

Page 8 of 14
 TECHNICAL DATA FOR 220kV SINGLE CORE 1000 SQMM & 1600 SQMM XLPE
INSULATED, HDPE SHEATHED CABLE:
S Name of the Particulars
l
. Desired Value
N
o
1 No. of cores 1(Single) 1(Single)
2 Size (in mm2) 1000 1600
3 Voltage Grade( in kV) 127/220(245) kV 127/220(245) kV
4 Type of cable
5 Standard according to which cable has been IS: 7098- Part 3, IS: 7098- Part 3,
manufactured and tested IEC-60840, IEC- IEC-60840, IEC-
60502-2, Testing 60502-2, Testing
as per IEC- as per IEC-
62067. 62067.
6 Permissible Voltage & Frequency variation
for satisfactory operation.
Voltage ± 10% ± 10%
Frequency ± 5% ± 5%
7 Maximum rated conductor temperature 90degC 90degC
8 Max. allowable conductor temperature during short 250degC 250degC
circuit
9 Conductor Details
Normal Cross-Sectional Area 1000 mm2 1600 sqmm
Material and Grade Annealed Annealed
electrolytic grade electrolytic grade
Copper to IEC Copper to IEC
60228 60228
Shape of Conductor Stranded Stranded
Segmental Segmental
Circular (Miliken) Circular (Miliken)
Water swellable yarn/non-conducting water
blocking tape provided (between Layers of Yes Yes
Conductor)
Separator over conductor Semiconducting Semiconducting
water blocking water blocking
tape with 50% tape with 50%
overlap overlap
1 Conductor Screen
0 Material Extruded Semi- Extruded Semi-
Conducting Conducting
XLPE Compound XLPE Compound
layer as per IS- layer as per IS-
7098Pt3 7098Pt3
Nominal Thickness 1.5 mm 1.5 mm
1 Insulation
1 Material Cross linked Cross linked
Polyethylene to Polyethylene to
IEC 62067 IEC 62067
Minimum Thickness 27.0 mm 27.0 mm
1 Insulation Screen
2 Material Extruded Extruded

Semi-Conducting Semi-
layer as per IS- Conducting layer
7098Pt3 as per IS-
7098Pt3
Nominal Thickness 1.2 mm 1.2 mm
Longitudinal Water Sealing Semiconducting Semiconducting
water blocking water blocking
tape(s) with min tape(s) with min
10% over lap 10% over lap
1 Copper Wire Screen Helically applied Helically applied
3 plain Copper wire plain Copper
wire screen
Number of wires As per design As per design
Thickness As per design As per design
1 Copper tape Open Helix of Open Helix of
Page 9 of 14
4 Copper binder Copper binder
tape of thickness tape of thickness
of Nom. 0.1mm of Nom. 0.1mm
1 Longitudinal Water Sealing Semiconducting Semiconducting
5 water blocking water blocking
tape(s) with 50% tape(s) with 50%
overlap of min. overlap of min.
thickness 0.3 mm thickness 0.3 mm
1 Metallic Sheath
6
Material Lead alloy E Lead alloy E
sheath with anti sheath with anti
corrosion corrosion
protection protection
(Bitumen/ Asphalt) (Bitumen/
Asphalt)
Thickness As per IS 7098 P- As per IS 7098 P-
III III
Short Circuit current of metallic screen for 1 sec Min. 50 KA for 1 Min. 50 KA for 1
(kA) sec sec
(Lead, copper wire (Lead, copper
screen) wire screen)
1 Inner sheath
7 Material PVC TYPE ST2 PVC TYPE ST2
Colour BLACK BLACK
Thickness (min) As per IS: As per IS:
7098(P-3)/ IEC 7098(P-3) / IEC
1 Armouring Hard drawn Hard drawn
8 Aluminum wire as Aluminum wire
per IS 7098-3/ as per IS 7098-3/
IEC IEC
Material Aluminium Aluminium
Nominal diameter of armour wire As per IS:7098(P- As per IS:7098(P-
3) / IEC 3) / IEC
Suitable binder tape to be provided over the 8our As per IS / IEC As per IS / IEC
1 Outer Sheath
9
Material Extruded HDPE Extruded
Type ST-7 to IEC HDP
62067 E Type ST-7 to
IEC 62067
Colour Black Black
Thickness (Nom/Min) As per IS-7098 P- As per IS-7098 P-
III/ IEC-62067 III/ IEC-62067
Conducting layer over outer sheath Extruded Extruded
Semiconducting Semiconducting
compound compound
compatible with compatible with
outer sheath outer sheath
2 Nominal overall Diameter of cable As per detailed As per detailed
0 enginnering enginnering
2 Nominal Overall Weight of Cable per Meter As per detailed As per detailed
1 enginnering enginnering
2 Standard Drum Length with Tolerance As per detailed As per detailed
2 enginnering enginnering
2 Minimum Bending Radius allowable during 20 x OD 20 x OD
3 installation
2 Safe Pulling force 5kg/mm2 of CU 5kg/mm2 of CU
4 area. area.
2 Impulse Withstand Voltage 1050kVp 1050kVp
5
2 One minute Power Frequency Withstand Voltage 318kV for 30 min 318kV for 30 min
6 (kV)
2 Short circuit current of conductor for one 143 228.8
7 second(kA)
2 Max conductor DC resistance at 200C As per IEC-60228 / As per IEC-60228
8 IS-8130-2013 / IS-8130-2013
Approx. AC resistance at 90degC As per detailed As per detailed
engineering engineering
Page 10 of 14
 Max. capacitance As per detailed As per detailed
engineering engineering
2 Continuous Current Rating for cable laid in close B SPB
As per detailed
9 trefoil formation E
engineering
B
BEB: Sheath both end bonded SPB: Sheath single point/ Cross bonded

Page 11 of 14
(D) TECHNICAL SPECIFICATION CABLE SEALING END KIT for 220KV, 132
KV & 33 KV

(a) Specifications of 245 KV, 145 kV & 33 KV Dry type.

(b) Termination, Dry type O/D Termination & St through Joints
(c) Applicable IECs: IEC 60840 for technical data, IEC 62271-209 for dimensioning, EN50089 for
routine tests on Epoxy insulators

TYPE & MAKE OF CABLE KITS

OUTDOOR TYPE SEALING END.

The Dry type cable sealing end (where no oil filling is required in the Termination), conforming to IEC-
60840 will be preferred, for maximum continuous voltage of 245 KV, 145 kV & 33 KV cables at the
outdoor yard shall be supplied by the cable manufacturer. The contractor shall be responsible for correct
termination of each cable to sealing ends, installation of the cable sealing end and providing of
terminal connectors for connecting to terminal conductor. The requisite interconnection between line end
& sealing end is required to be designed (as per safety and statutory provision aspects) and executed
(after approval of BSPTCL) by agency.

The silicone rubber /composite bushing termination of rated capacity, suitable for outdoor installation in
heavily polluted atmosphere shall be used. The minimum creepage offered should not be less than
25mm/kV. It should resistant to UV exposure. The termination stress control shall be means of stress
cone.

The stress cone made of EPDM rubber shall inhibit possible mechanical stress and deformation of the
cable insulation surface during operation and also shall be capable of accommodating minor radial and
longitudinal movement without determent to the dielectric stress in the insulation shield.

STRAIGHT THROUGH JOINTS

The Pre-Moulded type straight through joints for XLPE cable, conforming to IEC 60840 shall be suitable
for underground buried installation with incorporated back fill and chances of flooding by water. The
straight through joints should be absolutely impervious to the entry of water. The manufacturer shall use
the proven technology and design to prevent entry of water or any other liquid inside the straight through
joints and cables.

The stress cone made of EPDM rubber shall inhibit possible mechanical stress and deformation of the
cable insulation surface during operation and also shall be capable of accommodating minor radial and
longitudinal movement without determent to the dielectric stress in the insulation shield.

Type tests conducted for offered make cable and accessories separately will be considered for evaluation.

Type test for cable conducted shall be as per IEC 60840 or equivalent/higher standard for 245 KV, 145 kV &
33 KV copper cable & pre moulded joints and end terminations.

******

Page 12 of 14
(E) TECHNICAL SPECIFICATION OF LINK BOXES FOR

Sl PARTICULARS
.
N
o

1. Link boxes and sheath voltage limiters

0
1. General
1
1. Cross Bonding
2
1. Mechanical Design
3
1. Electrical Design
4
1. Applications
5
1. Type Tests
6
1. Dimensions
7
1. Factory Type Tests
8
1. Routine Tests
9

CROSS BONDING OF EHV CABLES:

Link boxes and sheath voltage limiters:

General
Link boxes are used with cable joints and terminations to provide easy access to shield breaks for test
purposes and to limit voltage build-up on the sheath. Lightening, fault currents and switching
operations can cause over voltages on the cable sheath. The link box optimizes loss management in the
cable shield on cables grounded both sides.

Cross Bonding:
For cross bonding, the cable length is divided into 3 equal sections. Each of the alternating magnetic
fields induces a voltage with a phase shift of 120° in the cable shields.The cross bonding takes place in
the link boxes. Ideally, the vectorial addition of the induced voltages becomes zero. In practice, the
cable length and the laying conditions will vary, resulting in a small residual voltage and a negligible
current. Since there is no current flow, there are practically no loses in the screen. The total of the three
voltages is zero, thus the ends of the three sections can be grounded. However sections for cross bonding
may vary depending on the length of cables.

Mechanical Design:
Made of stainless steel
Compact design
Single phase and 3-phase link boxes
Hermetically sealed
Resists water pressure up to 1 bar (20 psi)
Lugs and bonding cables are heat shrink sealed inside and outside

Suitable for different applications

Single point bonding

Page 13 of 14
Cross bonding
Direct grounding
Grounding through SVL
Combined direct and SVL grounding
Cross bonding and transposition

Electrical Design:
Grounding box
Link box
ZnO sheath voltage limiter
3 kV and 6kV protection levels
Same outer dimensions for both levels

Applications:
Can be installed in underground pits at a depth of 2mtr and more.
Use with single core or concentric bonding lead

Type Tests:
Tested to ANSI/IEEE Std 575-1988 IEEE-Guide for the application of sheath- bonding methods for single
conductor cables and the calculation of induced voltages and currents in cable sheaths.
Any NABL accredited laboratories..

Dimensions:
Single Phase Link Box: L 300 x W 190 x H 165 (mm)
Three Phase Link Box with or Without SVL: L 310 x W 310 x H 255 (mm)
Note: This is Dimensions are indicative only which will be finalized during detailed engineering.

Factory Type Tests:

Water Immersion Test (IP 68- IEC 60529)
Impulse Voltage Withstand Test
Dust Test
Water Jet Test

Routine Tests:
DC Withstand Test:
25 kV DC voltage is applied for 5 minutes to each cable lug meanwhile all other lugs to be earthed. If
exist(s), SVL(s) dismounted during test. In the DC withstand test is no breakdown and flash over.
Insulation Resistance Measurement Test:
5 kV DC voltage is applied for 1 minute to each cable lug meanwhile box itself to be earthed. If exist(s),
SVL(s) dismounted during test. At the end of test duration insulation resistance of each link box is
greater than 100 MΩ.
Contact Resistance Measurement Test:
50 A DC current will be applied to each contact points which had been squeezed with 40 kN torque. If
exist(s), SVL(s) dismounted during test. Contact resistance each contact point is less than 10μΩ.
Water Sealing Test:
All underground type link boxes after manufacturing with cover bolted closed, and phase glands capped,
filled with water trough earthing gland will be subject to equivalent 3.0 meter water pressure (0.3 bars)
for 15 minutes. VISUALLY inspection ofexternal surface, There is no leaks and water spots.

*******

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