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4) PVC Insulated Draft amendment-1

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INDIAN RAILWAY STANDARD SPECIFICATION

FOR
PVC INSULATED,UNDERGROUND,UNSCREEED CABLE FOR RAILWAY
SIGNALLING
(Tentative)

Serial No. IRS:S63-2014(Rev.4)

DRAFT AMENDMENT- 1

Number of pages-12

SIGNAL DIRECTORATE
RESEARCH, DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

MANAK NAGAR

LUCKNOW – 226011

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DOCUMENT DATA SHEET

Revision 4.0
Designation
Amendment 1
IRS:S-63/2014

Title of Document

Cross Linked Polyethylene (XLPE) Insulated,PVC

Sheathed, Underground, Unscreened Power
&SignallingCable for Railway

Authors: See Document Control Sheet

Signed by:
Name: P.K.Varma
Designation: Director / Signal, RDSO

Approved By RDSO

Name: Shri Mahesh Mangal

Designation: Sr.Executive Director / Signal, RDSO

Abstract
This document defines Cross Linked Polyethylene (XLPE) Insulated, PVC Sheathed,
Underground, Unscreened Power & Signalling Cable Specification.

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Document control Sheet

Designation Organization Function Level

Director/Signal RDSO Member Prepare

Sr.ED/ED/Signal RDSO - Approval

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REVISIONS AND AMENDMENTS:

Version Chapter/ Amendment Effective date

Annexure

IRS: S 63/1983 - FIRST ISSUE 1983

IRS: S 63/1988 - Revision 1 1988

IRS: S 63/1989 - Revision 2 1989

IRS: S 63/1989 - Amendment 1 Sept 1993

IRS: S 63/1989 - Amendment 2 Sept. 1996

IRS: S 63/1989 - Amendment 3 Sept. 1998

IRS: S 63/1989 - Amendment 4 Oct. 1999

IRS: S 63/1989 - Amendment 5 Sept. 2002

IRS: S 63/1989 - Amendment 6 Jan 2006

IRS: S 63/2007 - Revision 3 June 2007

(inclusive of all previously issued
amendments and policy letters)
IRS: S 63/2007 - Clause 5.10.4, 5.13.2 & 5.13.3 November 2007
(Revision 3 Amdt.1) modified.

IRS: S 63/2007 - New clause 5.4 (i) added and May 2009
(Revision 3 Amdt.2) Clause 5.6.1,& 5.11.1 modified.

IRS: S 63/2007 - Table 10 (i) and Table 10 (ii) 30.04.2012

(Revision 3 Amdt.3) modified

IRS: S 63/2014 - Revision 4 30.07.2014

(inclusive of all previously issued
amendments

IRS: S 63/2014 - Draft amendment- 1 to IRS: S 00.00.2014

63/2014 (Rev.4)

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DRAFT AMENDMENT NO. 1

To
Specification no. IRS S 63:2014 Rev. 4
PVC insulated underground, unscreened cable for Railway Signalling

This draft amendment is issued for utilising Cross linked Polyethylene (XLPE) material as an
insulation material in place of PVC, in Cables used for Railway Signalling covered by the
mentioned specification.
The relevant paragraphs of the specification where the amendment applies are mentioned
below:
INSULATION:

3.2.7 The insulation material can alternatively be of cross linked polyethylene (XLPE) conforming
to the requirement given as follows

Properties of XLPE insulation

Sl. No. Property Requirement
1 2 3
(i) Tensile strength, 150 Kg/cm2 ,(Min.)
(ii) Elongation at break 200%, (Min.)
(iii) Ageing in air oven
a) Treatment: Temperature
135 ± 3ºC
Duration
168 hours
b) Tensile strength variation
±25%
c) Elongation variation
±25%
(iv) Hot set
a) Treatment: Temperature
200 ± 3ºC
Time under load
15 minutes
Mechanical stress
20N/ cm2
b) Elongation under load
175%,(max)
c) Permanent elongation (set)
15%, (max)
after cooling
(v) Shrinkage
a) Treatment: Temperature
130 ± 3ºC
Duration
1 hour
b) Shrinkage
2%, (max)
(vi) Water absorption (gravimetric)
a) Treatment: Temperature 85 ± 2ºC
Duration 14 days
b) Water absorbed 1 mg/cm2, (max)
(vii) Volume resistivity:
a) At 27oC 1 x 1014 ohm-cm, (min)
o
b) At 90 C 1 x 1012ohm-cm, (min)
(viii) High Voltage test No breakdown
(ix) Insulation Resistance test 5,000Meg-ohm/km (min) for power cable
10,000Meg-ohm/km(min) for signalling cable
(x) Water Immersion test No breakdown

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3.2.7.1
Applicable for power cable only Applicable for Signalling Cable only
The value of insulation resistance of each The value of insulation resistance of each
core shall not be less than 5000Meg- core shall not be less 10,000Meg-ohm/km
ohm/km at ambient temp. at ambient temp.

3.2.7.2 The average thickness of the insulation shall not be less than the nominal value t1 as
specified in Table 11.

5.2. TYPE TESTS :

5.2.2 Following tests under type tests are included for XLPE insulation in addition to tests
mentioned under Cl. 5.2.

Applicable for power cable only Applicable for Signalling Cable only
The following shall constitute type tests The following shall constitute type tests
(i) Tensile strength & % (i) Tensile strength & % elongation before
elongation before ageing (Cl:5.10.1.2)
ageing(Cl:5.10.1.2) (ii)% variation in Tensile strength &
(ii) % variation in Tensile strength Elongation after ageing (Cl:5.10.1.2)
& elongation after ageing (iii)Hot Set test (Cl:5.10.13)
(Cl:5.10.1.2) (iv) Shrinkage test (Cl:5.10.2.2)
(iii) Hot Set test (Cl:5.10.13) (v) Water absorption (gravimetric) Test
(iv) Shrinkage test (Cl:5.10.2.2) (Cl:5.10.14)
(v) Water absorption (gravimetric) (vi)High Voltage test (Cl:5.10.15)
test(Cl:5.10.14) (vii) Insulation Resistance test
(vi) High Voltage test (Cl:5.10.15) (Cl:5.10.16)
(vii) Insulation Resistance test (viii) Water Immersion test (Cl:5.10.17)
(Cl:5.10.16)
(viii) Water Immersion test (ix) Volume Resistivity test (Cl:5.10.18)
(Cl:5.10.17)
(ix) Volume Resistivity test
(Cl:5.10.18)

5.2.3Following tests under type tests mentioned in Cl:5.2. are not to be carried out on XLPE
insulation.
Applicable for power cable only Applicable for Signalling Cable only
(i) Tensile strength and (i) Tensile strength and
elongation at break elongation at break
before and after ageing before and after ageing
( 5.10.1)(i) ( 5.10.1)(ii)
(ii) Hot Deformation test (ii) Hot Deformation test
(5.10.3) (5.10.3)
(iii) Loss of Mass test (iii) Loss of Mass test
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(5.10.4) (5.10.4)
(iv) Colour Fastness to (iv) Colour Fastness to Day-
Day-Light Light Exposure(5.10.5)
Exposure(5.10.5) (v) Colour Fastness To
(v) Colour Fastness To Water (5.10.6)
Water (5.10.6) (vi) Bleeding and Blooming
(vi) Bleeding and test (5.10.7)
Blooming test (5.10.7) (vii) Cold Bend test (5.10.8)
(vii) Cold Bend test (5.10.8) (viii) Heat Shock test (5.10.10)
(viii) Heat Shock test (ix) Thermal Stability test
(5.10.10) (5.10.11)
(ix) Thermal Stability test
(5.10.11) (x) Specific Gravity test
(x) Specific Gravity test (5.10.12)
(5.10.12)

5.3. ACCEPTANCE TESTS

5.3.4 Following tests under acceptance tests are included for XLPE insulation in addition to tests
mentioned under Cl. 5.3.

Applicable for power cable only Applicable for Signalling Cable only
The following shall constitute acceptance The following shall constitute acceptance
tests tests
(i) Tensile strength & % (i) Tensile strength & % elongation before
elongation before ageing ageing (Cl:5.10.1.2)
(Cl:5.10.1.2) (ii)% variation in Tensile strength &
(ii) % variation in Tensile Elongation after ageing (Cl:5.10.1.2)
strength & elongation after (iii)Hot Set test (Cl:5.10.13)
ageing (Cl:5.10.1.2) (iv) Shrinkage test (Cl:5.10.2.2)
(iii) Hot Set test (Cl:5.10.13) (v) Water absorption (gravimetric)
(iv) Shrinkage test (Cl:5.10.2.2) Test(Cl:5.10.14)
(v) Water absorption (vi)High Voltage test (Cl:5.10.15)
(gravimetric)test(Cl:5.10.14) (vii)Insulation Resistance test
(vi) High Voltage test (Cl:5.10.16)
(Cl:5.10.15) (viii)Water Immersion test (Cl:5.10.17)
(vii) Insulation Resistance test (ix) Volume Resistivity test (Cl:5.10.18)
(Cl:5.10.16)
(viii) Water Immersion test
(Cl:5.10.17)
(ix) Volume Resistivity test
(Cl:5.10.18)

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5.3.5 Following tests under acceptance tests mentioned in Cl:5.3. are not to be carried out on
XLPE insulation.
Applicable for power cable only Applicable for Signalling Cable only
(i) Tensile strength and elongation (i) Tensile strength and elongation at
at break before and after ageing break before and after ageing (
( 5.10.1)(i) 5.10.1)(ii)
(ii) Specific Gravity test (5.10.12) (ii) Loss of Mass test (5.10.4)
(iii)Thermal Stability test (5.10.11)
(iv) Specific Gravity test (5.10.12)

5.4. ROUTINE TESTS

5.4.1 Following tests under routine tests are additionallyincluded for XLPE insulation
(i) High Voltage test (Cl:5.10.15) all drums
(ii) Insulation Resistance test (Cl:5.10.16) all cores
(iii) Volume Resistivity test(Cl:5.10.18)- 4% of drums on all cores
(iv) T.S. and percentage elongation of insulation(Cl:5.10.1.2)
100% upto 10 cores,10+50% of the core in excess of 10 (specimen shall
cover all colours).
(v) Hot Set test(Cl:5.10.13)- 10% of drums covering each colour

The routine test shall be conducted on total drums offered for inspection

5.10.1 TENSILE STRENGTH AND ELONGATION

5.10.1.1 Tensile strength and elongation at break(For PVC insulation & Sheath)(for
power&Signalling cable) - This test shall be conducted in accordance with IS: 10810
(Part -7). The material shall fulfil the requirements indicated below:

Insulation Inner &

Outer
Sheath
a) Before Ageing:
1) Min. Tensile strength, kg / cm2 150 150
2) Min. elongation percentage 150 200
b) After ageing in air oven at 80 ± 2ºC for 168 hours:
1) Min. tensile strength kg / cm2 150 150
2) Min. elongation percentage 150 200

The maximum variation after ageing shall be within ± 20% of the values obtained before ageing.
For tests before and after ageing, samples shall be from the same drum in case of sheaths, and
from the same core in case of insulation.
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5.10.1.2 Tensile strength and elongation (For XLPE insulation) (For Power & Signalling
cable): The materialshall fulfil the requirements indicated below:

Requirement
--------------------
a) Before Ageing :

1) Min. Tensile strength, Kg/cm2 150

2) Min. elongation percentage 200
b) After ageing in air oven at 135 ± 3ºC, the maximum variation after ageing shall be
within ± 25% of the values obtained before ageing.

5.10.2 SHRINKAGE TEST

5.10.2.1 For PVC Insulation & sheath

This test shall be conducted in accordance with IS: 10810 (Part- 12). The insulation or
sheath shrinkage shall not exceed 2% of the original length. During the test no cracks
shall occur in the insulation or sheath.

5.10.2.2 For XLPE Insulation

This test shall be conducted in accordance with IS: 10810 (Part- 12)-1984.Test
temperature shall be 130±3Oc. The shrinkage shall not exceed 2% of the original
length. During the test no cracks shall occur in the insulation.

5.10.13 HOT SET TEST

The test shall be conducted on insulation in accordance with IS: 10810 (Part-30).
Specified values shall be as per Cl: 3.2.7 (iv).

5.10.14 WATER ABSORPTION TEST (GRAVIMETRIC)

The test shall be conducted in accordance with IS:10810 (Part-33).Specified values shall
be as per Cl: 3.2.7 (vi)

5.10.15 HIGH VOLTAGE TEST

This test shall be tested as per Cl:5.12 of IRS:S-63/2014 .

5.10.16 INSULATION RESISTANCE TEST

This test shall be tested as per Cl:5.13 of IRS:S-63/2014 .Specified values shall be as per
Cl:3.2.7.1

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5.10.17 WATER IMMERSION TEST

This test shall be tested as per Cl:5.14 of IRS:S-63/2014 .

5.10.18 VOLUME RESISTIVITY TEST

The test shall be conducted in accordance with IS: 10810 (Part-43) .Specified values
shall be as per Cl:3.2.7 (vii)

8.INFORMATION TO BE SUPPLIED BY THE PURCHASER

8.5.1 Type of insulation required(PVC or Cross Linked Polyethylene (XLPE))

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TABLE 11 - THICKNESS OF INSULATION

Nominal Thickness of insulation (tı) mm

Nominal Area of
Conductor(mm²) Single core (mm) Multi core(mm)
(1) (2) (3)
1.5 1.0 0.7
2.5 1.0 0.7
4 1.0 0.7
6 1.0 0.7
10 1.0 0.7
16 1.0 0.7
25 1.2 0.9
35 1.2 0.9
50 1.3 1.0

TABLE 12(i)
SAMPLING PLAN FOR ACCEPTANCE TEST
(CLAUSE 7,IRS:S-63/2014)
(Applicable for PowerCable only)

Following sampling plan is included for XLPE insulation in addition to sampling plan given in
Table 10 (i) of IRS:S-63/2014 Rev. 4

Sl. No. Tests Sample Size No. Of Test Pieces To Be Taken

(No. Of Drums) From Each Sample
(1) (2) (3) (4)
1. T.S. & % elongation of 10% subject to min. 2 100% upto 12 cores. 12+20% of
insulation (5.10.1.2) samples from each lot. the cores in excess of 12 (Specimen
shall cover all colours)

2. Ageing test of insulation 4%(out of 10% for Two samples of cores of each
(5.10.1.2) physical test) subject to colour from each sampled drum
min. 2 drums
3 Shrinkage test for insulation - do - One sample of core of each
(5.10.2.2) colourfrom each sampled drum.
4. Hot Set test 10% subject to min. 2 One sample of core of each colour
(CL:5.10.13) samples from each lot. from each sampled drum.(Min. 4
sample)
5. Water Absorption test -do- One sample of core of each colour
(CL:5.10.14) from each sampled drum.(Min. 3
sample)
6. Volume Resistivity 4% subject to minimum All cores.
test(CL:5.10.18) 2 drums.

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TABLE 12(ii)
SAMPLING PLAN FOR ACCEPTANCE TEST
(CLAUSE 7, IRS:S-63/2014)
(Applicable for Signalling Cable only)

Following sampling plan is included for XLPE insulation in addition to sampling plan given in
Table 10 (ii) of IRS:S-63/2014

Sl. No. Tests Sample Size No. Of Test Pieces To Be Taken

(No. Of Drums) From Each Sample
(1) (2) (3) (4)
1. T.S. & % elongation of 10% subject to min. 2 100% upto 12 cores. 12+20% of
insulation (5.10.1.2) samples from each lot. the cores in excess of 12 (Specimen
shall cover all colours)

2. Ageing test of insulation 4%(out of 10% for Two samples of cores of each
(5.10.1.2) physical test) subject to colour from each sampled drum
min. 2 drums
3 Shrinkage test for insulation - do - One sample of core of each colour
(5.10.2.2) from each sampled drum.
4. Hot Set test (CL:5.10.13) 10% subject to min. 2 One sample of core of each colour
samples from each lot. from each sampled drum.(Min. 4
sample)
5. Water Absorption test -do- One sample of core of each colour
(CL:5.10.14) from each sampled drum.(Min. 3
sample)
6. Volume Resistivity test 4% subject to minimum All cores.
(CL:5.10.18) 2 drums.

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