STANDARD SPECIFICATION FOR

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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 1 OF 10

STADARD SPCIFICATION
FOR SIGNAL CABLES

0 03/03/2010 SD GP NM
Rev. No. Date Prepared By Checked By Approved By

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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 2 OF 10

CONTENTS

Clause No. ITEM Page No.

1.0 Scope 3

2.0 Bids 3

3.0 Instructions to Bidder 4

4.0 Drawings and Data 4

5.0 Design and Construction 4

6.0 Name Plate (Drum Identification) 8

7.0 Inspection and Testing 9

8.0 Shipping 10

9.0 Rejection 10

1.0 SCOPE

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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 3 OF 10

1.1 This Specification, together with the job specification attached herewith forms the require-
ments for the design, materials, manufacturing inspection, testing and shipping of PVC insu-
lated signals cables.

1.2 The related standards and codes referred to herein and mentioned below shall be of the latest
editions prior to the date of the purchaser’s enquiry:-

IEC-332-3 Part 3 Test on bunched wires and cables.

ASTM D 2863 Test method for measuring the minimum oxygen concentration to sup-
port candle, combustion of plastics (oxygen index).
BS-5308 Part 2 Specification for PVC insulated cables
DIN-50049 Document on Material testing.
IS-1554 Part 1 PVC insulated (heavy duty) electric cables-working voltage upto and
including 1100 V
IS-2633 Method for testing uniformity of coating on zinc coated articles.
IS-3975 Mild steel wires, formed wires and tapes for armouring of cables.
IS-5831 PVC insulation and sheath of electric cables.

1.3 In the event of any conflict between this specification, related standards, codes etc. the ven-
dor should refer the matter to the purchaser for clarifications and only after obtaining the
same should proceed with the manufacture of the cables.

2.0 BIDS

2.1 Vendor’s quotation shall include the following as a minimum; completed job specifications.
Pair identification method, type test certificates, technical literatures various testing methods
and cross sectional dimensional drawings.

2.2 Vendor’s quotation shall include a list of deviations if any from purchaser’s specifications
and shall also indicate the reasons for such deviations for consideration. However vendor
shall note that no deviation shall be accepted in respect of the permissible limits of resis -
tance, capacitance and L/R ratio of cables.

2.3 Vendor shall enclosed catalogues giving detailed technical specifications and other informa-
tion for each type of cable covered in the bid.

2.4 Vendor’s quotation, drawings, catalogues manuals etc. shall be in English language.

2.5 Vendor shall quote unit price per meter for each type of cable.

3.0 INSTRUCTIONS TO BIDDER

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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 4 OF 10

3.1 The quantity indicated against each type of cable in the job specification may vary by ± 25%
at the time of placement of order. Vendor shall confirm that there shall be no price implica-
tion on this account in unit price type wise.

3.2 Drum length for each type of cable shall be 500 to 1000 meters. Vendor shall indicate the
maximum drum length possible for each type of cable in his/her bid. Exact requirements of
drum length shall be specified after purchase order during detailed engineering and vendor
shall confirm that the same shall not affect the price or delivery schedule. The actual pro-
duced drum length shall not vary by more than ± 5% from the value indicated in the pur-
chase order.

3.3 Tolerance over the total ordered length shall be as following:

± 5% for total length less than 5 km.
± 2% for total length 5 km or more.

3.4 Cable dimensions furnished by vendor in his/her bid shall be firm. Vendor shall comply with
all these values during execution.

3.5 The incremental length of the cable after each meter shall be clearly marked on the outer
sheath of the cable.

3.6 All cable shall be suitable for laying in open air, corrosive hydrocarbon plant atmosphere, di-
rect sun and in trenches. The cable shall also be designed for prolonged use in tropical at-
mosphere.

4.0 DRAWINGS AND DATA

4.1 Detailed drawings, data, catalogues, manuals, etc. required from the vendor shall be as indi-
cated by the purchaser in vendor data requirement sheets attached to the enquiry. The re-
quired number of reproducible and prints should be dispatched to the address mentioned, ad-
hering to the time limits indicated.

4.2 Vendor shall provide test certificates for all the tests indicated in Para 7.0 of this specifica-
tion. In addition, vendor shall provide the “Manufacturer’s certificate of conformity to pur -
chaser’s specification’s as per Clause2.2 of DIN50049.

5.0 DESIGN AND CONSTRUCTION

5.1 Type I (Single pair/triad shielded cable)

5.1.1 Each core shall be 1.5mm2 made of 7 stranded annealed electrolytic copper conductors. Each
strand shall be 0.53 mm dia.

5.1.2 Primary insulation shall be 850C polyvinile chloride (PVC) as per IS 5831 type C. Thickness
shall be 0.5 mm minimum.
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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 5 OF 10

5.1.3 A pair or triad shall have twisted cores and number of twists shall be not less than 10 per me-
ter. Colour of core insulation shall be black blue in pair and black, blue and brown in a triad.

5.1.4 Individual pair and triad shall be shielded. Shield shall be aluminium backed by Mylar /
polyester tape with the metallic side down helically applied with both side 25% overlap and
100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall be 0.5 mm 2
multistrand bare tinned annealed copper conductor. The drain wire shall be in continuous
contact with aluminium side of the shield.

5.1.5 Inner and outer jacket shall be made of extruded flame retardant 90 0C PVC to IS 5831- type
ST2. Oxygen index of PVC shall be over 30 % temp, index shall be over 250 oC. The thick-
ness of the jacket shall be as per IS-1554 part 1.

Inner jacket colour shall be black except, for cable to be used in intrinsically safe system it
shall be light blue. A trip cord shall be provided for inner jacket.

5.1.6 Armour over an inner jacket shall be of galvanized steel wire/flat as per IS-1554 Part 1.

5.1.7 Tolerance in overall diameter of cable shall be within ±2 mm. over offered value.

5.2 Type-II (Multipair / Multitriad cable with individual pair shield and overall shield)

5.2.1 Generally the cable shall be same as the single pair shielded cable except conductor size
shall be 0.5 mm2 made of 7 strand of annealed electrolytic copper conductor. Each strand
shall be 0.3 mm dia.

5.2.2 Overall shield shall be of aluminium backed up bymylar/polyester tape heilically applied
with the metallic side down with either side 25% overlap and 100% coverage. Minimum
shield thickness shall be 0.075 mm. drain wire shall be similar to individual pair drain wire
and shall be of the overall shield.

5.2.3 Overall twist of all pair /triads shall be as per vendor standard.

5.2.4 A pair of communication wire shall be provided for multipair/multitriad cables. Each wire
shall be 0.5 mm2 of plain annealed single or multistrand copper conductor with 0.4 mm thick
850C PVC insulation. Insulation shall be green and red colour coded.

5.2.5 A pair identification shall be with numbers at interval of not more than 250 mm as per ven-
dor’s standard.

5.3 Type-III (Multipair/Multitriad cable with only overall shield)

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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 6 OF 10

5.3.1 These cable shall be same as type-=II cable s except that the individual pair/triad shall not
have shielding.

5.4 Type-IV (Multipair/Multitriad cable with individual pair shield and overall shield)

5.4.1 The cable shall be same as Type-II except conductor size shall be 1.5 mm 2 made of 7
stranded annealed electrolytic copper conductor. Each strand shall be of 0.53 mm dia.

5.5 Type-V (Multipair/Multitriad cable with overall shield only)

5.5.1 The cable shall be same as type IV except that the individual pair / Triad shall not have the
shielding.

5.6 Type-VI (K –type Compensating cable)

Generally KX Type Compensating Cable compatible with ‘K’ type (Chromel Alumel,
NiCr-NiAl) Thermocouple. PVC insulated Stranded conductor ,Twisted pair, Individually
and Overall Screened, PVC inner sheathed ,Steel wire armoured and FRLS PVC Outer
sheathed

5.6.1 Each core shall be 1.5mm2 made of 6 stranded Alloy conductors. Each strand shall be 0.56
mm dia.

5.6.2 Primary insulation shall be 850C polyvinile chloride (PVC) as per IS 5831 type C. Thickness
shall be 0.5 mm minimum.

5.6.3 A single pair and Multi pair shall have twisted cores and number of twists shall be not less
than 10 per meter. Colour of core insulation shall be (+) Red, & (-) Green and overall Green.

5.6.4 Individual pair and overall for multi pair shall be shielded. Shield shall be aluminium backed
by Mylar / polyester tape with the metallic side down helically applied with both side 25%
overlap and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall
be 0.5 mm2 multistrand bare tinned annealed copper conductor. The drain wire shall be in
continuous contact with aluminium side of the shield.

5.6.5 Inner and outer jacket shall be made of extruded flame retardant PVC to IS 5831- type ST1.
Oxygen index of PVC shall be over 30 % temp, index shall be over 250 oC. The thickness of
the jacket shall be as per IS-1554 part 1-1988, minimum thickness 0.3mm.

5.6.6 Armour over an inner jacket shall be of galvanized steel wire/flat as per IS-1554 Part 1.

5.6.7 Tolerance in overall diameter of cable shall be within ±2 mm. over offered value.

5.7 Type-VII (S-type simplex Compensating cable)

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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 7 OF 10

Generally SX Type Compensating Cable compatible with ‘S’ type (Pt.Rh10%/Pt) Ther-
mocouple PVC insulated Stranded conductor ,Twisted pair, Individually and Overall
Screened, PVC inner sheathed ,Steel wire armoured and FRLS PVC Outer sheathed

5.7.1 Each core shall be 1.5mm2 made of 6 stranded Alloy conductors. Each strand shall be 0.56
mm dia.

5.7.2 Primary insulation shall be 850C polyvinile chloride (PVC) as per IS 5831 type C. Thickness
shall be 0.5 mm minimum.

5.7.3 A single pair and Multi pair shall have twisted cores and number of twists shall be not less
than 10 per meter. Colour of core insulation shall be (+) Red, & (-) White and overall White.

5.7.4 Individual pair and overall for multi pair shall be shielded. Shield shall be aluminium backed
by Mylar / polyester tape with the metallic side down helically applied with both side 25%
overlap and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall
be 0.5 mm2 multistrand bare tinned annealed copper conductor. The drain wire shall be in
continuous contact with aluminium side of the shield.

5.7.5 Inner and outer jacket shall be made of extruded flame retardant PVC to IS 5831- type ST1.
Oxygen index of PVC shall be over 30 % temp, index shall be over 250 oC. The thickness of
the jacket shall be as per IS-1554 part 1-1988, minimum thickness 0.3mm.

5.7.6 Armour over an inner jacket shall be of galvanized steel wire/flat as per IS-1554 Part 1.

5.7.7 Tolerance in overall diameter of cable shall be within ±2 mm. over offered value.

5.8 Type-VIII (Instrumentation Control cable)

Generally comprising PVC insulated stranded Copper conductor, Cores laid up

together ,PVC inner sheathed , Steel wire armoured and FRLS PVC Outer sheathed

5.8.1 Each core shall be 1.5mm2 made of 7 stranded High conductivity Electrolytic grade An-
nealed Bare Copper conductor (IS:8130-1984). Each strand shall be 0.52 mm dia.

5.8.2 Primary insulation shall be 850C polyvinile chloride (PVC) as per IS 5831-1984 type C.
Thickness shall be 0.8 mm minimum.

5.8.3 Individual pair and overall for multi pair shall be shielded. Shield shall be aluminium backed
by Mylar / polyester tape with the metallic side down helically applied with both side 25%
overlap and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall
be 0.5 mm2 multistrand bare tinned annealed copper conductor. The drain wire shall be in
continuous contact with aluminium side of the shield.
Inner jacket colour shall be black except, for cable to be used in intrinsically safe system it
shall be light blue. A trip cord shall be provided for inner jacket.
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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 8 OF 10

5.8.4 Inner and outer jacket shall be made of extruded flame retardant PVC to IS 5831- type ST2.
Oxygen index of PVC shall be over 30 % temp, index shall be over 250 oC. The thickness of
the jacket shall be as per IS-1554 part 1-1988, minimum thickness 0.3mm.

5.8.5 Armour over an inner jacket shall be of galvanized steel wire/flat as per IS-1554 Part 1.

5.8.6 Tolerance in overall diameter of cable shall be within ±2 mm. over offered value.

5.9 Electrical Characteristics

5.9.1 Maximum DC resistance of the conductor of the completed cable shall not exceed 12.3Ω /
km at 200C for cable with 1.5 mm2 conductors and 39.7Ω /km at 200C for cables with 0.5
mm2 conductors.

5.9.2 Capacitance:

Mutual capacitance
The mutual capacitance of the pairs or adjacent cores shall not exceed a maximum of
400pF/m at a frequency of 1 kHz.

Capacitance between any core or screen

The Capacitance between any core or screen shall not exceed a maximum of 400pF/m at
frequency of 1kHz.

5.9.3 L/R ratio of adjacent core or screen shall not exceed 40 µH /Ω for cables with 1.5 mm 2 con-
ductors and 25 µH /Ω for cables with 0.5 mm2 conductors.

5.9.4 The drain wire resistance including shield shall not exceed 30 Ω/ km.

5.9.5 Electrostatic noise rejection ratio shall be over 76 dB.

6.0 NAME PLATE (DRUM IDENTIFICATION)

6.1.1 Each cable drum shall be marked with the following information at a visible place;

a) Manufacture’s name
b) Details of the cable
c) Length of the cable in meters contained in the drum.
d) Gross weight
e) Direction of rotation of drum for unwinding by means of an arrow.
f) Purchase order number.

7.0 INSPECTION AND TESTING

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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 9 OF 10

7.1 Unless otherwise specified, Purchaser reserves the right to carry out testing and inspection dur -
ing various stages of the assembly of the ordered items at the vendor’s works.

7.2 On demand vendor shall furnish documents such as invoices and test certificates to prove the
quality and composition of the materials used for manufacturing the cable to the satisfaction of
purchaser or their authorized representative during various stage of expediting and inspection.

7.3 Type Test

7.3.1 Certificates from third party or client/consultant’s authorized representative for these shall be
furnished by vendor along with offer for cables similar to those being offered.

7.3.2 Cable shall be flame retardant to IEC 332-3 Part 3 Cat A.

7.4 Routine Tests

7.4.1 These tests shall be carried out by vendor during various stages of manufacture. Purchaser
shall review the related documents.

7.4.2 Insulation and sheaths: All test as per IS-5831 except insulation resistance, voltage and spark
test shall be as per BS-5308 Part 2.
7.4.3 Armour test as per IS-3975

7.4.4 Conductor resistance.

7.4.5 Cable capacitance and L/R ratio.
7.5 Acceptance Test
7.5.1 The following tests shall be carried out in the presence of purchaser or his/her authorized
representative:

a. Continuity test
b. Voltage test as per BS-5308 part 2
c. Conductor resistance and drain wire resistance.
d. Cable capacitance and L/R ratio test.
e. Electrostatic noise rejection test, typewise for each lot.
f. Test for uniformity of galvanization of armour as per IS-2633.
g. Oxygen index test as per ASTM D 2863.
h. Dimensional check for overall diameter and under armour/ over armour diameter.
i. Overall finish check. In case of any lump purchaser will have the right to cut outer
sheath for lump portion and reject the cable.
j. Check of drum length and overall length tolerance.

7.6 Immediately after completion of electrical tests, the end of the cable shall be sealed to pre -
vent ingress of moisture with suitable PVC/Rubber caps.
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STANDARD SPECIFICATION NO : 09-SP-6101 PAGE NO: 10 OF 10

7.7 In case of not witnessed by purchaser, the test shall any way be completed by the vendor and
documents for the same submitted for scrutiny.

8.0 SHIPPING

8.1 Cable shall be dispatched in wooden drum, securely battened with takeoff end fully pro-
tected against damage.

8.2 The ends of the cable shall be sealed with suitable PVC/Rubber caps to prevent ingress of
moisture.

9.0 REJECTION

9.1 Vendor shall make his offer in detail, with respect to every item of the purchaser’s specifica-
tions. Any offer not conforming to this shall be summarily rejected.

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