TECHNICAL SPECIFICATIONS FOR EHV 110kV Power Cables

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Tender No. PFCCL/18-19/ET/1KLP, NSIP& TLPAnnex- 3TECHNICAL SPECIFICATIONS FOREHV 110kV Power CablesPage 1 of 20

Tender No. PFCCL/18-19/ET/1KLP, NSIP& TLPContentsEHV 110kV Cables. 51.1.12.EHV cables . 5Governing Specifications . 62.1 Standards . 62.2 Abbreviations. 73.Technical Requirement. 73.1 Conductor . 73.2 Conductor screen . 73.3 Insulation . 83.4 Insulation Screen . 83.5 Water swellable Tape . 83.6 Metallic Sheath . 93.7 Bedding Tape . 93.8 Outer Sheath . 94.Additional Requirement . 94.1 CABLE ACCESSORIES AND BONDING. 104.2 Atmospheric and Climatic Conditions . 115.Maintenance & Life . 116.Special Condition . 117.TESTING . 117.1 All type tests to be conducted as per IEC 62067, IEC60840 (latest) . 117.2 Change in BOM . 127.3 Type Tests. 137.4 Submission of Performance Certificates . 147.5 Type Test Results . 147.6 Details of ‘Make of Cables/Accessories . 147.7 Rejection of Type Test Report . 147.8 Type Test Reports . 14Page 2 of 20

Tender No. PFCCL/18-19/ET/1KLP, NSIP& TLP7.9 ROUTINE TESTS. 147.9.1General . 157.9.2Partial discharge test . 157.9.3Voltage test . 157.9.4Electrical test on over sheath of the cable . 167.10Acceptance tests. 167.10.1General . 167.10.2Frequency of tests . 177.10.3Repetition of tests . 177.10.4Conductor examination . 177.10.5Measurement of electrical resistance of conductor and metallic screen . 177.10.6Additional Acceptance Tests . 187.10.7Short Circuit Test . 187.10.8TEST CERTIFICATES . 187.11RESPONSIBILITY OF CONTRACTOR FOR DELIVERY/SUPPLY . 19Page 3 of 20

Tender No. PFCCL/18-19/ET/11.KLP, NSIP& TLPEHV 110KV CABLESThis specification defines the objectives, guidelines and requirements for Supply, Laying,Testing and Commissioning of Extra High Voltage Cables (110kV) consisting of: 1.17 runs (including 1 spare) of 110KV Underground Cable for route length of approx.570m at Pariyaram, Near Chalakudy 110KV Substation between the Coordinates - T111 (GPS 10.31597, 76.38891) to T 113 (10.31816, 76.38516) including allassociated materials and accessories. Cable end Termination along with support structures for terminating 110 kV DoubleCircuit Cable at both end of Substations as per bid price schedule (BPS). Supply of Single Phase Link Box without SVL with earth bond cable suitable for110KV XLPE Cable 110kV Surge Arrestor Polymer (Silicon Rubber)mounting in Tower Heavy Duty Non Magnetic materials Aluminium cast cable bracket / clamp withprotective sleeve inside with all fixing materials like fasteners etc. suitable for 110kV630 sq.mm Cable, Cable Trays etc. as per Bill of Quantities. The XLPE cable and its accessories shall be complete with all fittings andcomponents necessary for the satisfactory performance and ease of maintenance.with all accessories suitable forEHV cablesDetailed description and its applicationThis specification defines the objectives, guidelines and requirements for Supply,laying, testing and commissioning of High Voltage Cables for use at any locations asrequired.The details of transformer installed capacities with overload capacities shall befurnished in tabular form depending at the time of necessity for communicating theapproximate current cable capacity requirement to the contractor. The cable sizes shallalso be worked out according to the rated capacity.Power Supply characteristics shall be as per latest applicable Indian grid standardsnotified by Central Electricity Authority (CEA), India, as amended from time to time.The reference characteristics of the network are tabulated as under:Rated voltage (rms)Maximum voltage (rms)110/ kV123 kVPage 4 of 20

Tender No. PFCCL/18-19/ET/1KLP, NSIP& TLPFrequencyNeutralShort circuit current50 HzSolidly earthed31.5kA for 1 secCurrent rating for cables shall be determined taking into consideration the followinginstallation methods as applicable: Buried in GroundIn the tunnelsOn brackets in the trenchesInside Ducts / Pipes or TrenchlessPipes And on the following as per designdata: 2.temperature correctionsoil thermal resistivitylaying depth in groundtype of laying in cable spacingcable grouping factor etcGOVERNING SPECIFICATIONSThe details and specifications applicable to the 110 kV cables are as under:The cables shall be of 1x630 sqmm 64/110kV grade for 110kV. The cable shall besingle core, stranded circular Aluminum conductor, XLPE insulated, corrugatedAluminum or Corrugated Copper sheathed suited for rated fault current and short circuitpower, outer covering HDPE sheath and overall graphite coated, conforming to IEC60840 for 110kV. Multiple runs of cables to be provided as per current carryingcapacity.2.1StandardsThe EHV Cables shall satisfy the requirements given below and shall also comply withstandards in force when the cables are manufactured, particularly which are in thefollowing table. (Unless otherwise stipulated in the specifications, the latest version ofthe following Standards shall be applicable).S. No. Specification No.1.IEC 60840 latest2.IEC: 62067 latest3.IEC : 60228 – latestTitle of SpecificationPower cables with extruded insulation and theiraccessories for rated voltage above 30 kV andup to 150 kV- Test Methods & requirements.Power Cables with extruded insulation and theiraccessories for rated voltages above 150kV.Conductors for insulated cables.Page 5 of 20

Tender No. PFCCL/18-19/ET/14.IEC: 60502–2-latestApplicable clauseonly5.IEC 60840 latest6.IEC: 62067 latest7.IEC 60230 latest.IEC 60853-2 latest.8.2.23.4.17.IEC 60811 latest.8.IEC 60885 – Part 3latest.KLP, NSIP& TLPCross linked polyethylene insulated Thermoplasticsheathed cables.Power cables with extruded insulation and theiraccessories for rated voltage above 30 kV andup to 150 kV- Test Methods & requirements.Power Cables with extruded insulation and theiraccessories for rated voltages above 150kV.Impulse test on cables & their accessories.Calculation of the cyclic and emergency currentrating of cables. Part 2: Cyclic rating of cablesgreater than 18/30 (36) kV and emergencyratings for cables of all voltagesCommon test methods for insulating andsheathing material of electrical cables.Electrical test methods for electric cables. Part 3:Testmethodsforpartialdischargemeasurements on lengths of extruded powercablesAbbreviations IEC – International Electro technical Council ASTM- American Society for Testing and Materials IS- Indian Standard TSS – Traction Sub Station ASS – Auxiliary Sub Station RSS – Receiving Sub Station TR- XLPE – Track Resistant- Cross Linked Poly Ethylene FRLS – Fire Retardant Low Smoke FRLSZH – Fire Retardant Low Smoke Zero Halogen ACTM – AC Traction ManualTECHNICAL REQUIREMENTThe various Constructional features required for the EHV cables are as under:ConductorThe Conductor shall be of Aluminium with a cross section of 630 sqmm. Theconstruction shall be reverse concentric stranded Aluminium, compressed conductor.The Manufacturer shall indicate the following details: Number of wiresDiameter of wiresPage 6 of 20

Tender No. PFCCL/18-19/ET/1 KLP, NSIP& TLPQuality of AluminiumThickness and construction of sheath.The conductor shall be formed from Aluminium conductor according to class 2(compact circular stranded) complied with IEC 60228 latest publication.The maximum temperatures admissible for the conductor are as follow: Continuous serviceOverload conditionShort Circuit condition90ºC105ºC250ºC4.2Conductor screenA Conductor screen made of semiconducting compound shall be provided over theconductor, by extrusion. The extruded coat shall be continuous, with a constant meandepth, without bump, perfectly adhering to the insulation envelope. A semiconductingtape(s) shall be provided below the extruded semi-conducting conductor screen toprevent penetration of the compound into the underlying conductor. The electricresistivity of the conductor screen shall not be more than 5000 Ώ cm at 20ºC and notmore than 25000 Ώ cm at the working rated temperature.4.3InsulationThe Insulation envelope shall be of cross-linked polyethylene (TR-XLPE) insulationapplied by extrusion. The voltage gradient in the rated working conditions shall be-Equal to or less than 6 kV/mm at the level of internal semiconductorEqual to or less than 3 kV/mm at the level of external semiconductorThe mechanical characteristics shall be as follow:In delivery condition-minimal traction resistanceminimal elongation before breaking::12.5 Mpa200%After ageing of 168 h at 135 C-maximal variation of traction resistance:maximal variation of elongation before breaking :The isolating envelope shall comply with the hot conditionelongation test:-temperatureon load durationmechanical constraint:::Page 7 of 20 C15 minutes0.2 Mpa25%

Tender No. PFCCL/18-19/ET/1-maximal elongation on loadmaximal elongation after coolingKLP, NSIP& TLP::100%15%The insulation compound shall be of high quality, heat, moisture, ozone and coronaresistant. Track Resistant XLPE compound should be from reputed manufacturer e.g.Borealis Sweden or NUC Japan or equivalent with satisfactory service experience ofmore than 5 years. The Insulation shall be applied by triple extrusion and vulcanizedusing dry curing process to form a compact homogenous body free from micro voidsand contaminants. The insulation shall be suitable for operation in wet or dry locationsat conductor temperature not exceeding 90 deg. C for normal operation, and 250 deg.C for short circuit conditions4.4Insulation ScreenThe Insulation screening shall be applied direct upon the insulation and shall be of alayer of extruded semi conducting thermosetting compound firmly and totally bonded tothe insulation. Semi conducting compound should be from Borealis Sweden or NUCJapan or equivalent with satisfactory services.Minimum thickness of Insulation screen should be 0.8 mm. The conductor screen,insulation & insulation screen shall be extruded in a single process. (Triple extrusion)4.5Water swellable TapeThe tape shall be semi-conducting water swellable tape to be applied over theextruded insulation screening to block and prevent moisture propagation in alongitudinal direction. The semi-conducting tape shall be suitable for the operatingtemperature of the cable and compatible with the insulation.4.6Metallic SheathMetallic sheath shall be either of Corrugated Aluminum sheath or Copper sheath. Themetallic sheath shall be able to carry a short circuit current of 40/31.5/31.5/31.5kA for110 kV cables for1 seconds. The bidder shall be required to submit the calculation ofarea of aluminum or copper sheath in this support4.7Bedding TapeThe bedding shall be anti-corrosive layer of Bitumen compound.4.8Outer SheathThe outer sheath shall be extruded red/yellow/blue colour or similar as per phase,graphite coated high density polyethylene, type ST-7 confirming of requirement of IECspecifications and extruded continuously. The outer sheath should have embossing atevery one meter for Contractor Name, manufacturer name, GED, Voltage grade etc.Page 8 of 20

Tender No. PFCCL/18-19/ET/1KLP, NSIP& TLPThe Mechanical Characteristics shall be as follow:In delivery conditionminimal traction resistance:12.5 Mpaminimal elongation before breaking:300%After ageing of 240 h at 110 Ctraction resistance:minimum valuemaximum variation::12.5MPa25%Elongation before breaking:minimum valuemaximum variation::300%25%The variation is the difference between the medium value obtained after ageing andthe medium value without ageing, expressed in percentage of the last4.ADDITIONAL REQUIREMENTKSEBL may decide to visit the works of cable manufacturer to verify the manufacturingprocess mentioned. The Bidder along with the bid documents shall submit the detailsregarding cable construction, bill of material and the manufacturing process proposedto be adopted for the manufacturing of cables to be used in the project, along withQuality control measures adopted by the Manufacturer, to ensure:The values and tolerances are strictly as per IEC.The cable manufacturer exercises strict quality control measures, including stageinspections, routine inspections etc. to ensure conformity to standards.Periodical inspections of the Manufacturer work, manufacturing processes, InternalQuality control records of the manufacturer etc shall be carried out by the User(GED/Nominated agency), to ensure compliance to Quality standards.The client will deliver the supply, upon request, only after execution of in-plantinspection operations and satisfactory testing according to the technical requirementsimposed.The cables shall pass all the tests stipulated in the IEC rules in force on the dateof the order.The sleeves and the insulating materials used shall meet the guaranteerequirements imposed.The equipment shall be capable of withstanding intensive use without alteration,and of performing its duty even after extended idle period.Assembled Pulling eye shall have to be supplied with all cables.Page 9 of 20

Tender No. PFCCL/18-19/ET/1KLP, NSIP& TLPSteel drum with steel packing shall have to be supplied4.1I.Cable Accessories and BondingStraight Through JointsThe straight through Joints should be Pre-moulded Type (for 110kV) of proventechnology and make, suitable for underground buried cables. The joint shouldcomprise of stress control sleeves, insulating sleeves and co-extruded dual wallTubing comprising of an insulating and semi-conducting layer. A mechanical connectorwith shear head bolts shall make the conductor connection. The product should betype tested as per IEC specifications.II.General Specifications:1.The product offered should be proven and should be in use in India for aminimum period of 5 years for the same voltage class. List of past supplies inIndia to be furnished. Performance certificates to be submitted along with theoffer.2.The product offered should have long (30 years) shelf life. Details of shelf life ofeach component shall be submitted with vendor proposal.3.Offers should be supported with type test certificates (not older than05years at the time of vendor approval) from CPRI/CESI/KEMA or accreditedtest laboratories as per IEC/IEEE specifications, failing which the offersshall be rejected.General Specifications for Joints and Terminations for 110kV Cablesa)The Terminations and Joints should be tested in accordance with both the IEEE404 as well IEC 60840/62067.b)Ease of Installation: The joint body should be a three-piece assembly to allow foreasy installation without the use of special tools and also to keep a firm control onthe positioning of the stress control cone etc.c)The termination body should be a composite housing with moulded siliconeshaded profile for the external leakage insulation.d)The joint and termination should employ mechanical connectors for which themanufacturer must have a minimum of 10 years of experience in the design,manufacturing and usage.e)The terminations should employ a positive sealing at the insulation end to preventmoisture etc from seeping into the cable.The Terminations and Straight Through Joints for 110 kV cables shall also be of Premoulded type suitable for 110kV (E) Grade of higher, single core 630 sq mm or higher,XLPE Insulated, Aluminium sheathed cable.Page 10 of 20

Tender No. PFCCL/18-19/ET/14.2KLP, NSIP& TLPAtmospheric and Climatic ConditionsThe entire equipment will be designed for operation in hot weather, according to theclimatic conditions defined in General Specifications.The equipment will be sturdy and properly treated against corrosion. This protectionshall be suited to the various environmental conditions encountered in the variousparts of the network.It must be noted that environmental conditions will be very severe during construction;these conditions shall not be the cause of any alteration of equipment or materialwhether already installed or simply stored.5.MAINTENANCE & LIFEThe cable should be designed for maintenance free best service life best in the industryand not less than 30 years for all types of installation & under prescribed environmentalconditions.6.SPECIAL CONDITIONThe manufacturer shall have laid down in-house selection process of the raw materialused and shall submit all details, if equivalent raw material is used wherever specified7.TESTING7.1Following type tests to be conducted as per IEC 62067, IEC 60840, ASTM &ASTM &another relevant IEC.S. No. Name of Type test1234CableBending test on the cable followed byinstal

IEC 60840 latest Power cables with extruded insulation and their accessories for rated voltage above 30 kV and up to 150 kV- Test Methods & requirements. 2. IEC: 62067 latest Power Cables with extruded insulation and their accessories for rated voltages above 150kV. 3. IEC : 60228 – latest Conductors for insulated cables.

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