CHAPTER – D

TECHNICAL SPECIFICATION FOR FRLS POWER CABLE, CABLE

TRAYS AND CABLING

2.01 SCOPE OF WORK:

2.01.01 This technical specification covers complete design, engineering,

manufacture, inspection and testing at manufacturer’s works, packing and
forwarding of (a) power cables (b) perforated cable trays complete in all
respects along with their supporting/fixing arrangements (c) laying & fixing of
cable trays on supporting system, earthing of cable trays and laying of
various sizes of power & D.C. cables in cable trays, fixing of cables on trays,
termination, ferruling of cable strands, marking of lugs & cable glands,
complete erection, testing and commissioning at site of FRLS power, D.C. &
control cables, cable trays and cabling etc. as detailed hereinafter in the
specification.

2.01.02 Over land transportation covering freight and insurance, FOR delivery at site.
Scope also includes storage at site, site insurance, jointing, testing and
commissioning of power & control cables and cable trays etc.

2.01.03 Storage including insurance and preservation at site till installation and
handing over after commissioning.

2.01.04 Complete laying jointing, preparation of end terminals, marking, fixing of lugs
& cable glands, its connection to the equipment and to overhead 22kV line
with cable boxes/suitable cable termination end, testing and commissioning
of HT Cables, L.T. power cables, D.C. cables and control cables for sub-
station at Jhakri at the following sites:-

(i) 2 Nos. 22kV XLPE Power cables from the point of 22kV overhead
structure near Main Access Tunnel of Power House at EL-1061 m at
Jhakri through main access tunnel as per Schedule of requirement
appended at Annexure-E-A.

(ii) LT power cable and D.C. power cables to different location from LT
room at EL 1061 to various equipment as per tentative cable schedule
at Annexure-E-B.

2.02 STANDARDS AND REGULATIONS

2.02.01 All materials in cables shall comply with applicable provisions of the latest
editions of relevant Indian Standards, Indian Electricity Rules, Indian
Electricity Act and other applicable statutory provisions, rules and regulations
such as IEC, IEEE and other relevant International Standards.

2.02.02 Equipment meeting the requirements of IEC/ANSI or any other

internationally recognised standard which ensure a quality equal to or better
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 than as per the standards indicated below shall also be acceptable. When
the equipment conforms to any other standards, salient points of difference
between the standards adopted and those prescribed in this specification
shall be clearly brought out in the tender and a copy of the applicable
standards(s) in English language shall also be enclosed by the supplier with
the tender.

2.02.03 Unless otherwise specified, the design, manufacture and performance of all
the equipment and material provided under this specification shall generally
conform to the latest issues of the following standards:-

1. IS-694 PVC insulated cables for working voltages

upto and including 1100V.
2. IS-1554 (Part-I) PVC insulated (heavy duty) electric cables
for working voltages upto and including
1100V.
3. IS-1554 (Part-II) PVC insulated (heavy duty) electric cables
for working voltages from 3.3kV upto and
including 11kV.
4. IS-3961 Recommended current ratings for cables
5. IS-8130 Conductors for insulated electric cables
and flexible cords.
6. IS-5831 PVC insulation and sheath of electric
cables.
7. IS-6380 Specification of Elastomeric Insulation &
Sheath of Electric Cables.
8. IS-7098 (Part-I & II) Cross linked polyethylene insulated PVC
sheathed cables for working voltages upto
33kV.
9. IS-3975 Mild steel wires, strips and tapes for
armouring cables.
10. IS-1753 Aluminium conductors for insulated cables.
11. IS-1255 Code of practice for installation and
maintenance of power cables upto and
including 33kV rating.
12. IS-12943 Brass glands for PVC cables.

13. IS-10418 Drums for electric cables.

14. IS-10810 (Part 0 to Method of test for cables.
63)
15. IS-6474 Polyethylene insulation and sheath of
electric cables.
16. IS-5819 Recommended short circuit ratings of high
voltage PVC cables.
17. IEC-60502 Power Cables with extruded insulation &
their accessories for rated voltages 1kV to
30 kV
18. IEC-540 & 540A Test methods for insulation and sheaths of
electric cables and cord.
19. IEC-60332 Test on electric cables under fire
conditions.
20. IEC-60754 Test on gases evolved during combustion

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 of electric cables.
21. IEC Hand Book for Cable in fire regarding temperature Index
Temperature Index Chapter-6.
22. IEC-10333 Cable joints and terminations
23. Any other applicable standards

2.03 DESCRIPTION OF CABLES:

2.03.01 General:

The XLPE 22 kV Power Cable shall be of:

(a) H.T. Power Cable Three core Aluminum Unarmored

(22 kV) 95 mm2 Conductor Cable
(b) L.T.Power cables Single core Aluminum Unarmored
Conductor Cable

2.03.02 Type of Cable:

The cable shall be multi-core and outer sheath should have high resistance
to flame propagation. The H.T. cable shall be XLPE insulated PVC
sheathed, un-armored cable. The L.T. cable shall be of PVC insulated, PVC
sheathed unarmored cable.

2.03.03 Conductor:

The material for conductor for HT power cables shall consist of plain
aluminum of H4 grade having tensile strength above 150 N/mm.sq. The
cable conductor shall be made from stranded aluminum wire to form
compacted circular conductors having resistance within the limits specified in
relevant IEC/Indian Standard. The minimum number of strands in the
conductor shall not be less than the appropriate minimum numbers specified
in the relevant standard.

2.03.04 Conductor (Shield):

The conductor shall have non-metallic semi-conducting shield which shall

ensure perfectly smooth profile and avoid stress concentration. The
conductor shield shall be extruded in the same operation as the insulation.

2.03.05 Insulation:

The insulation of the cable shall be designed and manufactured for the
specified system voltage. The manufacturing process shall ensure that
insulation shall be free from voids. The insulation shall withstand mechanical
and thermal stress under steady state and transient operating conditions.
The extrusion method should give very smooth interface between semi-
conducting screen and insulation. The insulation of the cables shall be of
high standard quality. The thickness of the insulation shall not be less than
that specified in the relevant standards.

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2.03.06 Insulation Shield:

In XLPE cables, to confine electrical field to the insulation a non-metallic

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 triple extrusion process.

2.03.07 Cable screening:

An aluminum screening shall be provided on top of the insulation shield in

case of XLPE cable.

2.03.08 Sheath:

(a) Inner Sheath: In case of cables consisting of two or more cores

inner sheath suitable to withstand the site conditions and the
desired temperature shall be provided on the individual core
and then surrounded by common covering applied either by
extrusion or wrapping of a filling material containing
thermoplastic material. It shall be of adequate thickness and
applied by continuous process to produce a sheath of
consistent quality free from all defects. PVC sheath shall be
extruded. The circularity of the cable should be maintained.

(b) Outer Sheath: This is extruded over the armour for armoured
cables and cover the inner sheath for unarmoured cables. It
shall be specially formulated heat resistant black PVC
compound conforming to the requirement of type ST2 of
IS:5831-1984, extruded to form the outer sheath. The cable
should also offer a specially formulated Flame Retardant Low
Smoke compound (FRLS) for outer sheath. Suitable additives
be added to prevent attack by rodents and termites. All serving
must be given anti-termite treatment. The thickness of the
sheaths shall be as per relevant standards.

2.04 CONSTRUCTION:

2.04.01 Cables shall have suitable fillers laid up with the conductor to provide a
substantially circular cross section before the sheath is applied. Fillers shall
be suitable for the temperature of the cable and compatible with the
insulating material. The material shall be of the best quality and
workmanship should be neat and clean and of highest grade. The fillers and
sheath material be non-hygroscopic. All materials shall be new, unused and
of the finest quality.

2.05 TESTS:

2.05.01 Test during manufacture:

During the manufacture of cables, manufacturer’s standard tests shall be

performed and copies of test certificate from the independent test house
shall be furnished.

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2.05.02 Type, Routine and Acceptance Tests:

2.05.02.01 After completion of manufacture of cables, type, routine and acceptance

tests shall be performed strictly as per applicable standard specifications and
copies of tests certificates shall be furnished.

2.05.02.02 The tests reports on the cables shall be got approved from the purchaser
before dispatch of the cables.

2.05.02.03 The tests on the cables that will be conducted by the supplier shall be
mentioned in the schedule of tests.

2.05.02.04 The purchaser reserves the right to witness all tests and the supplier shall
provide all facilities, to the purchaser in this regard and shall inform the
purchaser sufficiently in advance to enable the purchaser to depute his
representative to witness the same.

2.05.03 Routine test:

1. Conductor resistance test.

2. High voltage test.
3. Partial discharge test.
4. Insulation resistance test.

The above test shall be as per relevant Indian/International standards. The

test method, condition of test and test requirement shall comply with those
given under the type tests. Apart from these conductor examination, check of
dimensions etc. shall also be carried out as routine tests.

2.05.04 Type Tests:

2.05.04.01 The following type tests shall be conducted as per applicable standards on
XLPE and PVC insulated power.

1. Tensile test
2. Wrapping test
3. Conductor resistance
4. Partial discharge test
5. Dielectric power factor test
6. Bending test followed by partial discharge test
7. Heating cycle test followed by partial discharge test
8. Test for thickness of insulation and sheath
9. Tensile strength and elongation test for insulation and sheath
10. Ageing test for insulation and sheath
11. Loss of mass tests for insulation and sheath
12. Shrinkage Test for Insulation and Sheath
13. Hot Deformation Test for Insulation and Sheath
14. Cold Bend Test (up to 6mm.sq.) size
15. Cold Impact Test for Insulation and Sheath
16. Heat Shock Test for Insulation and Sheath
17. Thermal Stability Test for Insulation and Sheath
18. Test for Bleeding and Blooming of pigments for PVC Insulation &
Sheath
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 19. Fire Resistance Test
20. Measurement of Insulation Resistance
21. Impulse withstands Test.

2.05.04.02 Sequence of electric tests shall be as per the relevant Indian/International

standards. The Bidder shall submit the sequence of tests for the approval of
the purchaser before conducting the tests. A copy of the adopted standard
shall also be supplied.

2.05.04.03 The cables covered under this specification shall be subject to above
mentioned tests alongwith any other test specifically required for the
material. The cables other than PVC insulation shall be subjected to tests as
per the respective IS/International Standards.

2.05.04.04 The following tests shall also be performed on the cables wherever
applicable, as per relevant standard. Copies of the test certificate along with
English version of the standard adopted shall also be furnished along with
bid.

i) Accelerated water absorption test for insulation

ii) Di-electric Test
iii) Oxygen Index Test
iv) Temperature Index Test
v) Flammability Test
vi) Acid Gas Generation Test
vii) Smoke Generation Test
viii) Test for Rodent and Termite Repulsion

Test details is to be given by the manufacturer. The numbering of cores of

the cables shall be prominent and indelible and shall be checked after the
various physical tests such as ageing test, heating cycle test, bleeding and
blooming test etc. The test method is to be given by the manufacturer.

2.05.04.05 Test certificates for the above type tests, conducted by he manufacturer on
cables similar to the cables covered herein by an Independent Agency
approved by Govt./NABL (National Accreditation Board for Laboratories)
shall be acceptable in lieu of the type tests. However, type test certificates
from the collaborators shall not be acceptable.

2.05.05 Acceptance Test:

i) Tensile Test
ii) Wrapping Test
iii) Conductor Resistance Test
iv) Test for thickness of Insulation and Sheath
v) Partial discharge test
vi) HV Test
vii) Insulation resistance test

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2.05.06 Optional Test:

The purchaser reserves the right to conduct the following tests at an

additional cost, if considered necessary. The supplier shall furnish the price
for conducting these tests separately.

i) Fire Resistance Test

ii) Flammability Test
iii) Cold Bend Test
iv) Cold Impact Test

2.06 PARAMETERS:

1. Type of cable FRLS XLPE Cables, PCC cables

2. Nominal system voltage 22kV H.T,433V A.C.
3. System voltage variation A.C. system ±10%
4. Frequency 50 HZ +3%, -5%
5. Overload capacity of 10%
cables
6. Short circuit conditions H.T. L.T
a) Current 12.5kA 50 kA
b) Duration 3 Sec. 1 Sec

2.07 CABLE PARTICULARS:

Full technical details and descriptive literature shall be furnished indicating

the construction details, standard applicable for the components of the cable
and current ratings of the cables in air and ground. De-rating factors to be
considered for the ambient temperature, ground temperature and grounding
of cable in air and ground shall be furnished. The certificates for the type
tests conducted on cables similar to the cables covered herein shall be
submitted along with the tender.

2.08 CURRENT RATINGS:

2.08.01 The cables will have current ratings and derating factors as per relevant
Indian Standards.

2.08.02 The one second short circuit current rating values shall be furnished and
shall be subjected to the purchaser’s approval.

2.08.03 The current rating shall be based on maximum conductor temperature

depending on the type of insulation for continuous at the rated current.

2.09 NORMAL SERVICE CONDITIONS:

The cables shall be used in the sub-station having an ambient temperature

of –5 deg.C to 45 deg.C.

2.10 OPERATION:

2.10.01 Cables shall be capable of satisfactory operation under a power supply

system frequency variation of +3%, -5% voltage variation of ±10%.
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2.10.02 Cables shall be suitable for laying in conduits, ducts, trenches, channels,
trays, racks or for direct burried in ground in both dry and wet locations with
chances of flooding by water.

2.10.03 Cables shall have heat and moisture resistance properties. These shall be of
type and design with proven record of underground Sub-Station.

2.11 QUANTITY:

2.11.01 The various sizes and quantities of cables required are given in the
Annexure-I i.e. Schedule of Requirement.

2.11.02 The quantity is approximate and can be changed at the time of placing the
order to the extent of ±15%.

2.12 DRUM LENGTH & CABLE DRUM:

2.12.01 Drum Length:

The length of the cable on each drum shall be as per IS:10418-1972.

2.12.02 Cable shall be supplied in non-returnable wooden drums of heavy

construction. The wood used for construction of the drum shall be properly
seasoned, sound and free from defects and wood preservative shall be
applied to the entire drum.

2.12.03 The successful bidder shall obtain owner’s approval for the drum lengths,
before packing the cables on drums.

2.13 PACKING:

2.13.01 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.

2.13.02 The cable shall carry the following information either stenciled on the drum
or contained in a label attached to it:-

i) Reference to this Indian standard

ii) Manufacturer’s name, brand or trade mark
iii) Type of cable and voltage grade
iv) No. of cores
v) Nominal cross-sectional area of conductor
vi) Cable code
vii) Length of cable on drum
viii) No. of lengths on reel, drum or coil (if more than one)
ix) Gross weight
x) Country of manufacture
xi) Year of manufacture
xii) Direction of rotation of drum (an arrow)

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2.14 IDENTIFICATION:

2.14.01 The conductor cores shall be identified with codes as per relevant Indian
Standards.

2.14.02 The cables shall carry the manufacturer’s name or trade mark and the word
identified through out its length. The manufacturer’s data shall include the
name, the cable size, voltage rating together with any other information
which the manufacturer considers appropriate. This identification endorsed
or print shall be done only on the outer sheath.

2.15 LAYING, FIXING & TERMINATION OF CABLES:

2.15.01 The power & control cables shall be laid on the cable racks. It will be
complete responsibility of the bidder for laying, fixing, straight jointing in case
of power cable if required and termination at both ends of the power & D.C.
cables as per the tentative schedule given in Annexure E-A & E-B. Cable
glands shall be provided at each end to support the cable. Wire termination
shall be made with solder less crimping type and tinned copper lugs which
firmly grip the conductor. Insulated sleeves shall be provided at all the wires
termination. Engraved core identification plastic ferrules marked to
correspond with Cable No./Wire No. shall be fitted at both ends of each
cable, Ferrules shall fit tightly on the wire and shall not fall off when the
wire/cable is disconnected from the terminal blocks. Number 6 & 9 shall
have different markings for ferrules purposes. Necessary cable no./wire no.
shall be marked/tagged (or the standard practice adopted) on the cable at
the different locations for easy identifications during maintenance. Power
cables having more number of cables per phase shall be laid in trefoil
formation or shall be laid as per standard practice adopted for laying. Cables
laid in horizontal cable trays as well as on vertical ladders shall be fixed at
adequate number of places to hold the cable firmly. Bidder should submit a
complete write up regarding laying, fixing and termination of the cable for
approval before starting of the work. Any mechanical damage to the cables
resulting in discarding of the cables shall be replaced by the bidder free of
cost.

2.15.02 The LT cables and D.C. cables which are not under the scope of supply
will be lifted from centre store of SJVNL located at Jhakri. It will be
responsibility of the bidder to lift the cables from centre store Jhakri
and transport to site including loading & un-loading and utilizing at
works.

2.15.03 Cable Tags:

After pulling, cables shall be provided with identification tags consisting of

1.5mm thick aluminium strips of size 30x60mm on which cable numbers
shall be die-punched. The tags shall be tied to the cables with non-corrosive
wire. In case of single core cables, the said wire should be non-ferrous.

Cable tags shall be tied to cables at the following points:

a) Inside the cubicles at the point of glanding.

9
 b) Within the distances of 1 to 2 meters on either side of crossing of any
wall, floor, fire stop or other barrier in cable galleries/trenches etc.
One meter distance to be kept so that cable tags do not get
concealed during lost/disturbed fire sealing, re-plastering, etc.
c) At the field end termination before entry to the terminal box/junction
box/marshalling box.

d) Within the distances of 1 to 2 meters of either side of acute bends,

tray jumping, and at every 30M interval in straight run.

e) In every span over 30 meters found without any tag despite above.

2.15.04 Quantity measurement and Return of surplus Quantity:

For payment purposes measurement shall be made on the execution

drawings/physical measurements, physical measurements shall be made by
the
contractor in the presence of the representative of the purchaser.

The measurements of cable laying shall be made on the basis of length

actually laid from the lug to lug including that of loops provided and laid
accordingly.

All the leftover surplus, scrap and serviceable cable pieces and
drums/spools/reels out of the cable quantities shall be returned by the
contractor to the owner’s stores in good condition.

Cable of less than 5M length will be termed as scrap. Cable of length 5M

and above shall be termed as serviceable material and shall be returned size
wise and category-wise to the owner’s stores/yard. All such cable shall carry
an aluminium sheet metal tag indicating the size, and type of cable, cable of
serviceable lengths being returned to the stores in drums shall have their
free ends sealed and the balance lengths on the drums shall be noted. This
shall be applicable only for the purpose of accounting the cables.

2.15.05 It shall be responsibility of successful bidder to work out the complete cable
schedule for the cables covered under this specification which shall
incorporate the details of termination markings and route etc. in consultation
with project authorities and various equipment suppliers and submit the
same for approval before starting the cable laying/fixing work.

2.15.06 Testing:

2.15.05.01 The contractor shall take full responsibility of testing pre-commissioning and
commissioning of cabling system being installed by him. It shall be overall
responsibility of the contractor to arrange and complete all activities in
complete co-ordination with equipment commissioning agency keeping in
view the overall commissioning programme. The contractor shall submit a
check list for testing and commissioning and the activities shall be carried
out in accordance with the check list.

2.15.05.02 Testing and electric measurement of cable installations shall conform to

IS:1255.
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2.15.05.03 Prior to installation, cables shall be tested for

a) Continuity of conductors
b) Insulation resistance between conductor and earth
c) Insulation resistance between the conductors

2.15.05.04 After installation each cable shall be tested for

a) Insulation resistance between conductors

b) Insulation resistance between the conductors and earth
c) Absence of cross phasing
d) Firmness of terminations

2.15.05.05 The check and commissioning tests shall be carried out as part of the
installation work and the contractor shall not be paid any extra amount for
the same.

2.15.05.06 The contractor shall have to bring all testing equipment/instruments in

sufficient numbers. All instruments shall be calibrated to the satisfaction of
the purchaser before actual testing and tests to be conducted by qualified
experienced personnel.

2.15.05.07 All documents/records regarding test data and all other measured values
shall be submitted for approval and subsequent record and reference. All
cables shall be energised only after certification from certification personnel
that cable is ready for energizing. The results of all tests shall conform to the
specification requirement as well as guaranteed data.

2.16 CABLE TRAYS:

The hot dipped galvanized perforated cable trays and their fittings shall
conform to the Indian Standards or their latest amended editions or
equivalent International Standard. The bidder shall specify in the bid to
which standard the material supplied shall conform.

2.17 DESIGN REQUIREMENTS:

2.17.01 The hot dipped galvanized steel perforated cable trays having rectangular
channel section 30mm deep shall be designed for a uniform load of at least
400N per 1000 mm ladder length for 200 mm wide tray. The trays shall be
fabricated in a length of 2.5 m to 3m.

2.17.02 The perforated cable trays shall be manufactured from good commercial,
high grade strength sheet steel having minimum thickness of 2mm and shall
be hot dip galvanized according to BS-729-1971 or equivalent standard
suitable for indoor/out door use having moderate humidity and air pollution.
The zinc coating thickness shall works out by applying a 610 gm of zinc per
square meter surface with a approximate thickness of 80 micron. The zinc
coating shall be smooth, clean and uniform thickness and free from defects
like ash and dross inclusions, bare patches, black spots, pimples, lumpiness,
rust stains, blisters etc. The galvanizing shall not adversely affect the
mechanical properties of the coated material, the quality of the coating will
11
 be established by tests as per IS-2633. All manufacturing process including
punching, cutting, bending and welding of perforated cable trays shall be
completed and burrs shall be removed before the application of
galvanization process is applied. Zinc conforming to at least Grade Zn 98 as
specified in IS-209-1966 shall be used for the purpose of galvanizing.

2.17.03 The joints of two trays shall be butt construction and shall be made with the
help of coupler plates by nuts and bolts. The coupler plate and nuts and
bolts shall also be properly hot dip galvanized, where the bends of the trays
are required at site the same shall be supplied by the bidder without any
extra cost. The spacing of rungs shall be max. 400mm centre to centre.

While adopting the modules at site if cutting of any length is required the
same shall be cut at site and joined by nuts and bolts with the help of
coupler plates.

2.17.04 i) The perforated cable trays shall be supported on the solid supporting
arrangement made from channel of minimum size 100x50mm and
angle iron of size 50x50x6mm thick angle approximately at a distance
of 0.1 to 1.2m center to center either from ground/wall or ceiling.
However, the supporting system shall be designed by bidder suitable
to bear the uniform load of 400N per 1000mm ladder length for
300mm wide tray. The calculations in respect of this design shall be
supplied by the successful bidder during design stage. M.S. angle iron
brackets shall be further supported/anchored either to wall or
ceiling/ground as per the site requirement. The brackets and
supporting system shall be painted with two coats of zinc chromate
primer followed by two coats of synthetic enamel paint of approved
colour conforming to relevant Indian standard.

ii) Where perforated cables trays shall be routed in trenches, the

necessary angle iron side support should be provided by the bidder.

iii) The provision for fixing of brackets support system of vertical side of
approach tunnel should be made by the bidder for fixing the
supporting system. However, bidder is requested to visit the site
before preparation of this bids.

iv) Bidder is at its liberty to manufacture the cable supports arrangement

at site or at his own workshop. Bidder shall have to bring all the
tools/tackles, including welding machines etc. for the manufacturing of
these cable supports.

2.17.05 The depth of trays shall be 30 mm and thickness 2 mm (min.) with width of
200 mm. Necessary standards equal and unequal 90 deg. Bends, tees and
cross connections shall also be designed properly as per site requirement.

2.17.06 The free vertical distance between parallel perforated trays/racks/ladder

shall be at least 250mm and the perforated trays shall be 50mm away from
the walls. The trays shall be fixed to the brackets with proper nuts and bolts
system.

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2.17.07 The perforated trays shall be free from sharp edges and burns etc. so that
joint between two trays shall be without any clearance and matched in
proper shape.

2.17.08 At the bends the curvature in all axis of perforated trays/racks shall be 20R
or maximum size of cable.

2.17.09 The supporting brackets/fixing bolts size shall be so calculated that the
design load as specified under sub clause of clause 2.17 does not exceed.

2.17.10 The perforated trays shall be installed in such a way that as far as possible
the cables can be laid directly in place rather than be pulled through.

2.17.11 The current carrying cables shall be laid separately than the H.T. cables,
L.T. cables and D.C. cables shall be laid in different trays.

2.17.12 The cables shall be fixed in the perforated trays by means of plastic ties or
plastic coated wires etc.

2.17.13 The number of perforated tray shall be sufficient in order to accommodate all
the power D.C. cables indicated in the specification for cables. However, the
approximate quantity of different trays have been given under clause 2.21,
which can be ensured by the bidder by visiting the site before filling the
tender.

2.18 EARTHING:

The perforated cable trays along with their supporting arrangements shall be
properly earthed by the supplier with nut and bolts from the earthing risers
provided by purchaser, generally in the vicinity of the tray routing. The
earthing shall be as per latest I.E. rules and IS/IEC recommendation. The
size of earth connection shall be such that its conductance should be more
than the conductance of 14 sq.mm. copper conductor cross section.

2.19 CO-ORDINATION WITH OTHER CONTRACTOR

During the execution of this contract, other contractor shall also be working
in the Pump House and Sub-Station. The supplier shall, therefore, co-
ordinate with other contractors to avoid any dispute with other contractor
during execution of this contract.

2.20 FABRICATION OF TRAYS

All fabrication of trays shall be in accordance with IS:800 and as per the
approved drawings unless otherwise specified.

All material shall be straight and if necessary before being worked, shall be
straightened and/or flattened by pressure unless required to be of curvilinear
form and shall be free from twists.

Before cutting the steel, measurement should be done by appropriate gauge

and according to the drawing.

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 Shearing or flame cutting may be used provided the resulting edge shall be
reasonably clean and straight. Sheared members shall be free from
distortion at sheared edges, when gas cutting is adopted, the flame cut edge
shall be machined to a depth of 3 to 5mm.

The welding and the welded work shall generally conform to IS:816 &
IS:9595. Unless otherwise specified.

The welding surfaces shall be smooth, uniform & free from fins, tears,
notches or any other defect which may adversely affect welding and shall be
free of loose scale, slag, rust, grease, paint moisture of any other foreign
material.

The welding procedure shall be so arranged that the distortion and

shrinkage stresses are reduced to a minimum and that the welds meet the
requirement of quality.

2.21 SCHEDULE OF REQUIREMENT OF PERFORATED TRAYS

The schedule of requirement of trays shall be calculated from the drawings

and can vary ±15% as per site requirement.

Description Trays of 300 mm size

Transformer Hall & Power House 3000 m
etc.

2.22 SUBMISSION OF DRAWINGS AND DOCUMENTS:

2.22.1 Submission alongwith Tender:

Based on the specification write up and specification drawings the contractor

shall submit the following drawings/documents and information with the
tender:-

a) Drawings showing dimensional details and constructional features of all

components including the following:-

i) Cable trays and accessories

ii) Typical supporting arrangements in various locations

iii) Typical cable trays layout arrangement (showing typical

bends,, T-offs, branching, reducers, coupler etc.)

iv) Typical dimensional details of glands and lugs for various

sizes/types

v) Typical drawings for control and 415V and 22 kV termination

and jointing showing splicing, glanding, lugs, screen/armour
earthing etc.

b) Descriptive literature, catalogues, giving design features and

manufacturing details.
14
 c) Installation and maintenance instructions.

d) Evidence of type tests and special tests conducted on similar type of

equipment/component.

2.21.2 Submission during contract:

2.21.2.1 Within 60 days of the placement of order the contractor shall furnish at least
7 sets of documents showing the following for approval.

i) Make, dimensional details and technical specification and

catalogues of the various components such as glands, lugs,
ferrules, sleeves etc. Typical samples of items like ferrules, glands,
lugs, cable lugs shall also be given.

ii) Write up erection procedure for cable trays, cable laying and
termination including site testing of cables.

iii) Cable routing diagrams

2.21.2.2 15 days after the approval of above documents, 7 copies of

drawings/documents shall be submitted.

2.21.2.3 Based on the layout/foundation drawings of Sub-Station and other sites

which shall be handed over to the successful bidder during detailed
engineering, the contractor shall prepare and submit seven sets of erection
drawings for cable facilities showing various cross section of cable, tray
facilities, cable tray number, supporting arrangement, plan, elevations etc.
for various areas of sub-station. The drawings shall be approved by SJVNL
and erection of cable facility at site shall be done according to these
drawings any modification at site, if required, shall be marked upon these
drawings and sketches/revised drawings got approved from the site/project
authorities.

2.21.2.4 The contractor shall furnish 1 (one) reproducible and 7 (seven) prints each of
the “As Built” drawings of cable facilities to customer for information and
record. While doing cable laying as per the cable schedules the contractor
shall write down/enter the actual route followed by him. This shall be entered
on two spare sets of cable schedules and returned to the customer (1 set
each)

15
 ANNEXURE-D-I

SCHEDULE OF REQUIREMENT FOR FRLS POWER CABLES

Sr. No. Description Qty. Unit Price Total

Ex-works/m Amount
1. 22kV Aluminum Conductor
unarmored FRLS, XLPE
Power Cable:

i) 3-C 95 mm2 1200 m

2 1.1 kV Grade, Aluminum 10800 m

Conductor unarmored FRLS
PVC Cable for L.T System.
1)1C 400 mm2
2. Cable trays 300 mm wide 3000 m
and accessories

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company

16
 ANNEXURE-D-II

SCHEDULE FOR ERECTION, TESTING & COMMISSIONING OF POWER & D.C.

CABLE,TRAYS AND CABLING

Sr. No. Description Qty. Rate Total cost

1. Erection/site assembly of supporting Meter Per 100
system for cable trays, i/c erection of meter run
cable trays on supporting system
including anchor bolts washer etc. for
typical supporting arrangement per
100 mtr. run.
2. Laying, fixing, termination including Meter Per meter
lugging ferruling providing cable
glands etc. as per Clause No. 2.15 of
the specification and complete testing
and commissioning of different sizes
of the power cables as per given in
the schedule of requirement
Annexure-D-A.
3. Laying, fixing, termination including Meter Per meter
lugging ferruling providing cable
glands etc. as per Clause No. 2.15 of
the specification and complete testing
and commissioning of different sizes
of the LT and DC cables as per given
in the schedule of requirement
Annexure-D-B .

Optional item (not to be evaluated)

Bidder should quote unit rate of glands etc. of each size of any addition/deletion of work.

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company

17
 Annexure-D-A

22kV XLPE/FRLS CABLE REQUIREMENT

Sr.No. From To Type of Size (mm2) Length

Cable (Meters)
1. 22kV over head Transformer hall XLPE 3 Core 95 mm2 1200
structures (near crown up to 24 kV unarmoured
portal of main incoming panel
access tunnel) and then outgoing
panel to HV
bushing of 2.5
MVA Transformer
at EL-1062 m.
2. From DG incomer LT Panel incomer FRLS cable 1C400 mm2 10800
panel at Pot Head DG panel at EL-
Yard 1062 m

Note:- The quantity of 22 kV & LT cable is tentative and can vary ±15% as per site
conditions.

18
 Annexure-D-B

LT, DC CABLES TO BE LIFTED FROM JHAKRI STORE FOR THE PURPOSE OF

LAYING, TERMINATION ETC.:

A: LT CABLES

Sr.No. Description of Cable Size Length

1. Al – 3 ½ PVC FRLS Cable 35mm2 1300 mtr.
2. Al – 3 ½ PVC 150 mm2 50 mtr.
3. Al – 3 ½ PVC 300 mm2 1250 mtr.
4. Al – 1C 300 mm PVC 300 mm2 4200 mtr.

B: DC CABLES:

Sr.No. Description of Cable Size Length

1. Cu, 2c, PVC 16mm2 300 mtr.
2. Cu, 2c, PVC 25 mm2 100 mtr.

Note:- The quantity of LT and DC cables to be lifted from Jhakri Store is tentative and can
vary ±15% as per site conditions.

19
 SCHEDULE–D-III

SCHEDULE OF TECHNICAL DEVIATIONS

Sl. Vol. Clause No. Page Deviation/ Variation Extra price to be paid in
No. No. No. case deviation is required
to be withdrawn by the
bidder

Bidder’s Guarantee:

We guarantee that the above deviations in no way shall adversely affect the
performance and other requirements of the equipment stipulated in the specifications.

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company
20
 SCHEDULE-D-IV

SCHEDULE OF TECHNICAL DATA PARTICULARS OF POWER CABLE

A. POWER CABLE 22 kV

1.0 General:

1.1 Manufacturer’s name and

address
1.2 Location of factory

2.0 Cable Wire

2.1 Type and size of cable

2.2 Standard applicable

2.3 Voltage rating

2.4 Permissible variation in voltage

frequency and combined voltage
and frequency
2.5 Suitable for earthed/unearthed
system
2.6 No. of cores

3.0 Conductor and its hardness

3.1 Standard applicable

3.2 Material copper/aluminium/grade

3.3 Nominal cross-sectional area

3.4 Form of conductor

circular/shaped
3.5 No. of strands

3.6 Nominal dia of each strand

21
3.7 Whether strands are tinned or
not
3.8 Temperature co-efficient of
resistance at 20 deg.C.
4.0 Conductor Screen

4.1 Standard applicable

4.2 Material

4.3 Minimum thickness

4.4 Whether extruded

5.0 Insulation

5.1 Standard applicable

5.2 Material (mention type)

5.3 Minimum average thickness

5.4 Tolerance on the smallest of the

measured values of thickness of
insulation

5.5 Dia of core over insulation

5.6 (a) Minimum volume resistivity at

27 deg. C.

(b) Minimum volume resistivity at

70 deg.C.

5.7 Colour scheme of identification of

cores
5.8 Average dielectric strength

5.9 Suitability with regard to moisture

ozone, acid, oil and alkaline
surroundings

6.0 Insulator Screen

22
6.1 Standard applicable

6.2 Whether extruded semi-

conducting screen is applied
6.3 Material of the semi-conducting
screen
6.4 Thickness of the semi-conducting
screen
6.5 Whether extruded under triple
extrusion process
6.6 Whether copper type screening
is applied
6.7 Thickness of the copper tape

6.8 For braided screen material and

dia of screen wire and min.
percentage coverage

7.0 Inner Sheath

7.1 Standard applicable

7.2 Material thickness of inner

sheath
7.3 Whether extruded

7.4 Minimum thickness of inner

sheath
7.5 Calculated diameter over
stranded cores of the cables
7.6 Whether the inner sheath and the
filling material are suitable for the
operating temperature of the
cable

8.0 Outer Sheath/Overall Covering

8.1 Standard applicable

8.2 Material (mention type if any)

8.3 Whether extruded

23
8.4 Minimum average thickness

8.5 Tolerance on the smallest of the

measured values of thickness of
outer sheath
8.6 Calculated dia. Under the sheath

8.7 Whether anti-termite treatment

has been given in the outer
sheath
8.8 Whether flame retardant low
smoke compound added in outer
sheath

9.0 Electrical Properties

9.1 Conductor resistance at 20 deg.
C. per km.
9.2 Maximum permissible conductor
temperature:

a) Under continuous full load

b) Under transient conditions
9.3 Loss tangent at normal frequency

9.4 Reactance at 50 C/S per km.

9.5 Capacitance at 50 C/S per km.

9.6 Current ratings

9.6.1 In air (continuous)

9.6.2 In duct (continuous)

9.6.3 Reference ambient temperature

of the above
9.6.4 Short circuit current rating for 1
sec. duration
9.7 Derating factors

9.7.1 For an ambient temperature of

50 deg.C.
9.7.2 For grouping of 6 to 9 cables in
cable trench/cable rack trays and
in 4 to 6 tiers for different
24
 spacings and also touching each
other

10.0 Mechanical Data

10.1 Overall dia of the cable

10.2 Dia of the cable under the sheath

10.3 Diameter under armouring

10.4 Diameter over the stranded cores

10.5 Wight of cable per km.

10.6 Drum length

10.7 Tolerance on drum length

10.8 Total weight of the drum

10.9 Dimension of the drum

10.10 Recommended minimum

installation radius
10.11 Maximum safe pulling force

10.12 Whether identification as per

clause 2.14 of the specification is
being provided
10.13 Whether packing has been done
as per clause 2.13 of the
specification

B. CABLE TRAYS
1.0 General

1.1 Manufacturer’s name and

address

1.2 Location of factory

1.3 Type and size of

a) Trays

25
1.4 Standard applicable

1.5 Thickness

a) Trays
b) Supports
c) Brackets

1.6 Earthing system

1.7 Weight per 100 m

a) Trays
b) Supports
c) Brackets

1.8 Distance between parallel

Layer of trays

1.9 Galvanisation of:

a) Trays
b) Nuts & Bolts

1.10 Painting of support system

1.11 Supporting arrangement system

2.0 Cable Clamps

2.1 Material

2.2 Type

2.3 Thickness

3.0 Cable Termination Kit

3.1 Manufacturer

3.2 Applicable standard

3.3 AC withstand voltage (ph/Ground

& time duration) (kV)
3.4 Partial Discharge at 1.1
ph/ground volt (Pc)
3.5 Impulse withstand 1.2/50 us (kV)

26
3.6 Short circuit current 1 sec (KA)

3.7 Dynamic Short Circuit withstand

(kV)
3.8 Type test report for above tests
plus for humidity and salt-fog
tests furnished (Yes/No)
3.9 Kit particulars:

a) Material of tubling/
moulded part
b) Method of stress control
c) Method of environmental
seal
d) List of items included in
the kit furnished (Yes/No)

1. For terminations
2. For splices

4.0 Cable lugs

4.1 Make

4.2 Type

4.3 Material

4.4 Applicable Standard

5.0 Cable Glands

5.1 Make

5.2 Type

5.3 Material

5.4 Surface Treatment

6.0 Fire Sealing System

6.1 Type

27
6.2 Make

6.3 Material of fire stop

6.4 Pressure withstand capacity of

fire stop system
6.5 Weight of fire stop assembly

6.6 Shelf life of fire stop material

6.7 Life of fire stop assembly

Note:-

1. Bidder can supply above information for different types of cables.

28
 SCHEDULE-D-V

SCHEDULE OF TRANSPORTAITON WEIGHTS & DELIVERY PERIOD

Sr.No. Item Qty. Shipping weights Total Delivery date of

Tones/Units length components

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company

29
 SCHEDULE-D-VI

SCHEDULE OF STANDARDS & CODES APPLICABLE FOR MATERIALS

COMPONENTS, MANUFATURE, ASSEMBLY, TESITNG, INSTALLATION &
COMMISSIONING OF POWER CABLES, TRAYS ETC.

Sr.No. Subject/Title Standard/Code Other Remarks

1. Material
2. Components
3. Manufacture
4. Assembly
5. Testing
6. Installation (laying, fixing and
connecting)
7. Commissioning

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company

30
 SJVN Manufacturer Name & Manufacturing/Field Quality Project : Nathpa Jhakri Hydro
Shimla Address Plan Electric Project
Item QP No.
Rev. Ref. No.
No.
Sub-system Dated Supplier:
P
Sr. No. Component Characteri Class Type of Quantum of Reference Acceptan Format Agency Remarks
& operation stics Check check Document ce Norms of record
M C S

31
LEGEND FOR SJVN DOC. NO.
USE

MANUFACTURER CONTRACT M : MANUFACTURER

/SUB- C : CONTRACTOR
CONTRACTOR S : SJVN
INDICATE “P” PERFORM & VERIFIED BY QC
DEPT “W” WITNESS AND “V” VERIFICATION

REVIEWED BY
SIGNATURE
NAME & SIGN OF APPROVING
AUTHORITY & SEAL
SCHEDULE-D-VII
 SCHEDULE-D-VIII

SCHEDULE OF DELIVERY & COMPLETION PERIOD

Sl. No. Activity Period in days from
the date of issue of
LOI / LOA
1. Submission of general layout ,fixing arrangement drawings &
design for approval of SJVNL
2. Approval of above by SJVNL
3. Order placement for bought out items (if any) by contractor
4. Opening of site office at Jhakri by contractor
5. Submission of cable schedule and remaining construction
drawings and commencement of supplies
6. Inspection of:
i) 24 KV Switchgear
ii) Sub-Station Transformer
iii) 415 V ACDB/DG Set panel
iv) Cable, Cable Tray & earthing
v) Fire fighting arrangement

7. Commencement of despatch of supplies of :

i) 24 KV Switchgear
ii) Sub-Station Transformer
iii) 415 V ACDB/DG Set panel
iv) Cable, Cable Tray & earthing
v) Fire fighting arrangement

8. Completion of receipt of material at Jhakri site

i) 24 KV Switchgear
ii) Sub-Station Transformer
iii) 415 V ACDB/DG Set panel
iv) Cable, Cable Tray & earthing
v) Fire fighting arrangement

9. Commencement of erection activities at site

i) 24 KV Switchgear
ii) Sub-Station Transformer
iii) 415 V ACDB/DG Set panel
iv) Cable, Cable Tray & earthing
v) Fire fighting arrangement

10. Completion of erection

i) 24 KV Switchgear
ii) Sub-Station Transformer
iii) 415 V ACDB/DG Set panel
iv) Cable, Cable Tray & earthing
v) Fire fighting arrangement

11. Testing, commissioning & taking over *

*The period should not be more than 150 days.

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company

32
 SCHEDULE-D-IX

RECOMMENDED SPARES

Sr. No. Particulars/Description Qty. Remarks

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company
33
 SCHEDULE-D-X

SCHEDULE FOR SUBMISSION OF DRAWINGS

Sr. No. Name of the Drawings When to be submitted (to be given

in days after receipt of order)

Date: Signature of bidder

Name:
Place: Status:
Whether authorized attorney
of tendering company
Name of tendering Company
34