Technical specification of LT single core, two core, three core, 3.

5 core and four core, Cross linked

Polyethylene (XLPE) insulated, FRLS, PVC sheathed, armored power cables

1. Scope:
The specification covers design, manufacturing, testing, packing, supply & delivery in a sealed drums and supervision of
Cable laying of 1100 volts grade, LT Cable, multiple cores, Cross linked Polyethylene (XLPE), FRLS, insulated, PVC
sheathed, armored power cables for effectively earthed systems.

2. Standards:

The design, manufacture and testing of the cable shall comply with the latest editions/amendments of the following
Indian Standards, unless otherwise specified. Equipment’s complying with equivalent standards shall also be acceptable.

a. IS-7098, 1998 (Part-I) : Cross linked polyethylene insulated PVC sheathed cables for
Working voltage upto 1100V
b. IS-3961 : Recommended current ratings for cables
c. IS 8130-1984 : Specification for conductors for insulated Electric Cable and
flexible cords
d. IS-3975, 1999 : Low Carbon galvanized steel wires, formed wires & tapes for
armoring of cables
e. IS-4759 : Specifications for Hot dipped galvanized
Coating on round steel wires
f. IS-5831 : PVC insulation and sheath of electric cables.
g. IS-10418 : Drums for electric cables

2.1 Technical Parameters

 Cable Type : A2XWY/ 2XWY

 No. of Cores : 3/3.5
 Voltage Level : 1.1 kV
 System Grounding : Solidly Grounded
 Nominal System Voltage : 400V ±10%
 Nominal System Frequency : 50Hz ±3%
 Maximum Conductor Temperature at
 Rated current : 90°C
 Maximum Conductor Temperature at
 Short- circuit : 250°C
 Conductor
 Conductor Material : H4- Grade Aluminium of purity >99.6%
Electrolytic Grade Copper purity >99.97%
 Conductor Type : Stranded with number of strands as per IS
8130(Part-I) 1984
 Insulating Material : Cross Linked Polyethylene (XLPE) Compound
 Core Identification Strips : Red, Yellow, Blue & Black
 Material of Inner Sheath : FRLS, PVC ST-2 Compound
 Armor : Single layer of Galvanized steel round wire
according to IS-3975
 Outer Sheath : FRLS, PVC ST-2 Compound according to IS-5831
3. Conductor:

ALUMINIUM
The Aluminium conductor used shall be of H-4 grade (Tensile strength above 150 N/mm2). High conductive aluminium,
stranded (Class-II, stranded circular shaped), uniform in quality and free from scale, inequalities, spills, splits and other
defects. The aluminium used shall have purity meeting the criteria for maximum resistance allowed.

COPPER
The conductors shall be made from high conductivity copper rods complying with IS: 613-1964. The conductor material
used shall be electrolytic grade with high purity.

4. Insulation:

The insulation shall be suitable for LT system voltage and the insulating material shall be cross linked Poly Ethylene
(XLPE), and applied by extrusion process as per IS 7098 Part-1 and its latest amendments. The insulation shall be an
extrusion of thermosetting cross linked poly ethylene rated for 90ºC continuous operation.

The insulating material shall have excellent electrical properties with regard to resistivity, dielectric constant and loss
factor and shall have high tensile strength and resistance to abrasion. This shall not deteriorate at elevated temperatures
or when immersed in water. The insulation shall be preferably fire resistant and resistant to chemicals like acids, alkalis,
oils and ozone.

The insulation properties shall be stable under thermal conditions arising out of continuous operation at conductor
temperature of 90ºC rising momentarily to 250ºC under short circuit conditions. It shall be free from any foreign
material or porosity visible to the unaided eye. The insulation shall be so applied that it fits closely on the conductor and
it shall be possible to remove it without damaging the conductor.

The average thickness of insulation shall not be less than the nominal value as specified in IS: 7098 (Part I) with latest
amendments.

Tolerance on insulation thickness shall be as per IS-7098 Part-1.The insulation shall withstand mechanical and thermal
stress under both steady state and transient operating conditions.

5. Core identification (for multiple core cables):

Individual core of multi-core cables shall be colour coded and/or numbered for proper identification in accordance
with clause 10.1 of IS: 7098 (Part – I).

6. Fillers and Laying up of cores (for multiple core cables):

In multi core cables, the cores shall be laid together with a suitable right hand lay. The interstices shall be filled with non-
hygroscopic material. Further, the compounds used with fillers shall be such as to have no deleterious effect on other
components of the cable and to be stable at cable temperatures.

7. Inner sheath (common covering):

The inner sheath shall be extruded FRLS PVC, Type ST2, compatible with thermal rating of insulation conforming to IS-
6380-1984. The sheath shall have adequate thickness, mechanical strength and elasticity, as specified in IS 5831. The
material shall be soft thermoplastic type, applied by extrusion method. The thickness of the inner sheath shall be as per
IS: 7098 (Part I) and the color of the inner sheath shall be Grey. The inner sheath shall be so formed that it fits closely on
the laid-up cores and could be easily removed without damaging insulation. One or more layer of proofed plastic tape
shall be provided over the laid-up core before extrusion.
8. Armoring:

The armour of cables shall consist of either galvanized round steel wires or galvanized steel strips as per clause 13.2 of IS:
7098 (Part I). The armouring shall be applied such that the minimum area of coverage shall be 90% and the gap between
any two armour strips/ wire shall not be more than the width of strip/ diameter of armour wire. The galvanized steel
strips/wire shall comply with the requirements of IS: 3975- with latest amendments. In case of Single core cable
armouring shall be of Non-magnetic material conforming to IS: 3975 – 1999 (amended upto date). The dimensions of the
galvanized steel strip/wire shall be as per IS: 7098 (Part-I) (Table 6, Clause 13.3, armoring size and dimension shall be as
per method (b), method (a) is not acceptable) with latest amendments. No tolerance on the negative side shall be
acceptable. Tolerance on size of armour shall be as per IS:7098 Part-1 &IS:3975.

9. Outer sheath:

The outer sheath shall consist of extruded tough outer sheath of PVC compound insulation over the armouring. The PVC
compound for the outer sheath shall conform to type ST-2 of IS: 5831 - 1984 (amended up to date) with suitable
additives (to prevent attacks by rodents and termites) shall be provided.

The colour of the outer sheath shall be black. The cable must meet all the requirements of the IS: 7098 (Part 1) amended
up to date and shall bear ISI mark.

10. General:

All materials used in manufacturing of cable shall be new, unused and of finest quality. All materials should comply with
the requirements / tests as per applicable IS / IEC specification, Indian Electricity Rules and any other statutory provision
of rules & regulations.

11. Tests:

A. Type tests:

All the cable types and sizes i.e., items offered should have been fully type tested as per IS 7098 (Part-1) with
amendments up to date at any NABL accredited Laboratory/ Test house. If the manufacturer’s lab is accredited by NABL
then it shall be acceptable for type testing. These type tests must have been conducted within last five years prior to
date of submitting offer. For any change between design/type of already type tested and the design / type offered
against this specification, the purchaser reserves the right to demand repetition of type tests without any extra cost. For
each type and size the type test shall be got carried out independently.

The purchaser also reserves the right to have tests carried out at his own cost from an independent agency, whenever
there is a dispute regarding the quality of supply.

The type test shall be in accordance with IS:7098 part-1,1998.

a. Test on Conductor
 Annealing test for copper conductors
 Tensile test for aluminium conductor
 Wrapping test for aluminium conductor
 Conductor Resistance Test

b. Test on Insulation
 Physical dimension measurement
 Tensile strength and elongation at break
  Hot set test
 Shrinkage test
 Ageing in air oven
 Water absorption test

c. Test on round Armor

 Physical dimension measurement
 Tensile strength
 Elongation at break
 Torsion test for round wires
 Winding test for firmed wire
 Mass of zinc coating.
 Uniformity of zinc coating
 Resistivity measurement, Resistance test for armor

d. Test on Sheath
 Physical dimension measurement
 Tensile strength & Elongation at break test
 Ageing in air oven
 Loss of mass in air oven
 Shrinkage test
 Hot deformation test
 Heat shock test
 Thermal stability test

e. Insulation Resistance Test

f. High Voltage Test at room temperature
g. Volume resistivity at room temperature & at 90o C. (IS-10810-Part 43)
h. Flammability test
i. Test requirement of FRLS inner and outer sheath

The inner and outer sheath of cables shall meet the following test requirements related to flame retardant,
low smoke emission, low acid and toxic gas emission. The BIDDERs shall have proper test apparatus to
conduct all the relevant tests as per the applicable standards:
 Flame retardant test on single cable
Oxygen Index Test
The critical oxygen index value shall be minimum 29 when tested at 27+2ºC as per ASTMD-2863
Temperature index test
Temperature index value shall be minimum 250ºC at oxygen index of 21 when tested as per NES 715.
Flammability test
Cables shall pass test under fire conditions as per IS-10810- Part-53. Cables shall also pass tests as
per IS-10810 Part- 61 & Part-62.
Flammability shall be as per IEC 332-1 and IS 694: 1990.
Smoke Density Test
The cables shall satisfy the tests conducted to evaluate the percentage obscuration by smoke in an
optical system placed in the path of the smoke. The maximum smoke density rating shall not be
more than 60% when tested as per ASTM-D-2843.
Acid Gas Generation test (halogen acid gas evolution)
 The hydrochloric acid generation when tested as per IEC 754-1 shall be less than 20% by weight.
 Test for specific optical density of smoke
 Anti termite and rodent property test

The Sequence of Electric Test to be carried as per relevant Indian Standards.

B. Routine Tests:

The following shall constitute the routine tests. The Inspector may also inspect the routine tests at the
time of inspection.
(a) Conductor resistance test
(b) High-voltage test for 5 minutes [as per Clause 16.2 of IS: 7098 (Part-I).

C. Conductor purity test:

Two samples of aluminium and copper shall be taken from any of the finished set of cables at random and the
sample shall be tested for its purity at a NABL accredited lab.

Qualifying Criteria:

The test results should be within limits as per IS 7098. All the routine tests as per IS 7098 / IEC shall be conducted
and passed as per the limits given in the standards. All the bought-out certificates will be verified and the test
results shall be as per respective standards.

1. Identification mark:

The outer sheath of the cable shall bear following identification parameters embossed at intervals of length of one
meter of cable, throughout the cable:
 Name of manufacturer
 Year of manufacture
 Voltage grade
 Size of cable
 Cable code
 ISI certification mark.
 Successive length
 Marking for FRLS cable

2. Packing and forwarding:

i. Cables shall be supplied in non-returnable steel drums. The cable drums shall comply to relevant Indian
standards.
ii. Cable drums shall be so constructed as to have required mechanical strength so that the drum flanges
and other components do not break during transport, in actual use or in storage.
iii. The flanges and the outside surface of the barrel shall be free from protruding materials or projections or
unevenness capable of damaging the cable or hands of operator during rotation of drums.
iv. A metal preservation shall be applied to the entire drum. All ferrous parts used shall be treated with a
suitable rust free finish or coating to avoid rusting during transit or storage.
 v. The barrel diameter of the drum shall be greater than 15 times of OD of the cable.
vi. 3 rounds of black colour high density plastic sheet shall be wrapped on cable on cable drum.
vii. Wrapping of plastic cover is required for storing the cable for longer time at site.
viii. Name plate on Painted 2 mm thick MS plate on cable drum for identification shall be provided.
ix. Proper drum rotation mark shall be marked on the finished cable drums.
x. Each drum shall consist of single length cable ≥ 500 meters.

xi. Packing shall be sturdy to protect the cable from any injury during transportation, handling and storage.
The cut ends of the cable shall be sealed by means of non-hygroscopic sealing material preferably Heat
shrinkable end caps.
xii. One end of the cable shall be brought out of the drum and suitably clamped to the drum flange with
proper mechanical protection. Location of the other end may be marked on the drum.
xiii. The cable shall be placed on drums in such a manner that it will be protected from injury during transit.
Each end of the cable shall be firmly and properly secured to the drum. The drums shall be secured firmly
in position so that they will not shift during transit. No undue stress shall appear on cables when laid on
drums.
xiv. The cable drum shall carry the following information stenciled on a metallic label, securely attached to
each end of the drum:
a. Reference to the Indian standard
b. Manufacturer’s name, brand or trade mark
c. Type of cable and voltage grade
d. No. of cores
e. Nominal cross-sectional area of conductor
f. Cable code
g. Length of cable on drum
h. Gross weight
i. Country of manufacture
j. Year of manufacture
k. Direction of rotation of drum (an arrow)
l. ISI Certification Mark
14. Preferred Make:
FINOLEX/POLYCAB/RR KABEL/KEI or reputed brand possessing system certification on ISO 9001:2008, ISO 14001:2004,
OHSAS18001:2007 & EN16001-2009 and product certification IS:7098 (Part 1), CE,UL etc
Preferred make of bought out materials:
a. Aluminium for Conductor : Hindalco/Balco/Nalco
b. Copper for Conductor : Hindustan Copper/Hindalco
c. XLPE Compound of Insulator : Dow/Borealis
d. Armor Steel : TATA/Jindal

15. Guarantee:
All the cables shall be guaranteed against faulty material, defective design & poor workmanship for a
period of 18 months from the date of supply. The materials becoming defective during the guarantee
period shall be replaced free of cost and the defects arising out of the works shall be rectified free of
charge without delay.