ANNEXURE

. -A
TECHNICAL SPECIIFICATION

F OR

220 KV CABLES & 220 KV ACCESSORIES

220 kV Cable & Accessories Technical Specifications

1. SUPPLY OF 220 KV CABLE & ACCESSORIES

1.1 GENERAL SCOPE

1.1.1 Scope:Design,Manufacturing,testing,supply,transportation,insurance,loading,un
loading of 220 kV cables & Accessories at purchaser’s store/site

1.1.2 Bidder has to carry out design for complete underground 220 kV cable system

1.1.3 The cable and accessories furnished under this specification shall conform to
the standards specified in these specifications

1.1.4 The design and workmanship shall be in accordance with the best engineering
practice to ensure satisfactory performance and service life of the cable and
accessories. The supplier shall ensure compatibility of fittings and joints if
procured from other vendors.

1.1.5 The Bidder shall furnish the required instruction manuals as also the detailed
drawings for the cross linked polyethylene. The Bidder shall also supply the
Soft copy of manual at the time of detailed engineering

1.1.6 The Bdder shall submit the Pre -qualification Tests as well as Type Test reports
of cable system (Cable system consists of cable and end terminations) as per
IEC-62067 from accredited international laboratory (accredited by the national
accreditation body of country where laboratory is located) to establish about
its technical capability manufacturing such class and/or joints and terminations

1.1.7 The Owner reserves the right to re-conduct type tests or any of the test as
considered necessary.

1.1.8 Unless brought out clearly, the Bidder shall be deemed to conform to this
specification carefully. All deviations from this specification shall be brought
out in the schedule of deviations. Any deviation between the specifications and
catalogues or the bid offered if not clearly brought out in the schedule of
deviations will not be considered as valid deviation.

1.1.9 The Bidder shall furnish the following information:-

a. Name of manufacturer & country of manufacturer.

b. Standing of firm as manufacturer of 220kV and higher

voltage cables and accessories.

c. Description of cables of similar capacity to that quoted,

supplied, and installed during the last five years with the
name of the parties/buyers to whom supplies were made,
size of cable, date of installation and performance certificate
thereafter.

d. Details of testing facilities at manufacturer’s works.

e. Whether manufacturer has technical collaboration with

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220 kV Cable & Accessories Technical Specifications

another firm, if so, details regarding the same.

1.2CODES & STANDARDS

IEC 60183 Guide to the selection of high voltage cables.

IEC 60287 Calculation of continuous current rating of cables (100% load factor)

IEC 60332 Tests on electric cables under fire conditions.

Cable connections for gas insulated metal enclosed switchgear for
IEC 60859
rated voltages of 72.5 KV and above.
IEC 60885 Electrical test methods for electric cables
IEC-60228 Conductor for insulated cables

Power cable with extruded insulation and their accessories for rated
IEC-62067
voltage above 150 kV up to 500kV- Test methods and requirements

Calculation of thermally permissible short circuit currents,

IEC 60949
considering of non-adiabatic heating effect.

Test methods for insulation sheaths of electric cables and cards

IEC 60540
(elastomeric and thermoplastic components).

IEC-60811 Test methods for Insulation & sheaths of electric cable & cords
IEC 60229 Tests on cable over sheaths
IEC 60230 Impulse tests on cables and their accessories
IEC 60270 Partial discharge measurements
Cable Connections for Gas-Insulated Metal-Enclosed Switchgear for
IEC 859
Rated Voltages of 72.5 kV and Above
IEC-60840 Tests for Power cables with extruded Insulation
IEEE 404-1993 Joint for use with solid dielectric cables
IEEE -48 – 1996 Standard test procedures for HV – AC cable terminations.
Sheath bonding methods for single conductor cables and the
IEEE – Std 575
calculation of induced voltages and currents in cable sheaths.
BS 5468 XLPE insulation of electric cables
BS 801 Composition of lead and lead alloy sheaths of electric cables.
IS 5216 Guide for safety procedures and practices in electrical works
Specification for extruded insulation power cables and their
AEIC CS9
accessories rated above 46 kV through 345 kV
CIGRE Technical
Insulation Co-ordination for HV AC Underground cable systems
Brochure 189
CIGRE Technical
Special Bonding of High Voltage Power Cables
Brochure 283
CIGRE Technical
High-Voltage On-Site Testing with Partial Discharge Measurement
Brochure 502
CIGRE Technical A Guide for Rating Calculations of Insulated Cables

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220 kV Cable & Accessories Technical Specifications

Brochure 640
Standard for Extruded insulation power cables rated above 46
ICEA S-108-720
through 500 kV ac
IEC 60038 IEC standard voltages
IEC 60060 High-voltage test techniques
IEC 60228 Conductors of Insulated Cables
Selection and dimensioning of high-voltage insulators intended for
IEC 60815-1 use in polluted conditions - Part 1: Definitions, information and
general
Selection and dimensioning of high-voltage insulators intended for
IEC 60815-2 use in polluted conditions - Part 2: Ceramic and glass insulators for
AC System
Selection and dimensioning of high-voltage insulators intended for
IEC 60815-3
use in polluted conditions - Part 3: Polymer insulators for AC systems
IEC 60853 Calculation of the Cyclic and Emergency Current Ratings of Cables
Calculation of thermally permissible short-circuit currents,
IEC 60949
considering non-adiabatic heating effects
Short-circuit temperature limits of electric cables with rated
IEC 61443
voltages above 30 kV (Um = 36kV)
IEC 61463 Bushings – Seismic Qualifications
IEC 61914 Cable cleats for electrical installations
IEEE Guide for Partial Discharge Testing of Shielded Power Cable
IEEE 400.3
Systems in a Field Environment
IEEE 693 IEEE Recommended Practice for Seismic Design of Substations

1.3 DESIGN CONSIDERATION:

a) The cable shall be suitable for buried installation with uncontrolled back
filling. The cable shall withstand all mechanical and thermal stresses, which
are likely to occur during its normal steady state and transient operation
conditions.

b) The metallic screen shall be designed to withstand earth fault current liable
to occur in the system during conductor to ground fault

c) The thermal resistivity of the soil is not exceeding 120 deg.C cm/watt.

d) The cable shall be designed to have a minimum useful life of not less than
forty years.

e) Each cable length shall be provided with a pulling socket pulling eye, which
shall be fitted to pulling end. The pulling socket eye end shall be able to take
the pulling tension of as per standard. along with factor of safety of 1.25.
The supplier shall confirm whether the cable can take this pulling load.

f) The outer sheath of the cable shall be given adequate chemical treatment in
order to protect itself from rodent and termite attack.

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220 kV Cable & Accessories Technical Specifications

g) The conductor shall be clean, uniform in size and shape, smooth and free from
harmful effects.

CURRENT RATING:
a. The bidder shall furnish the continuous current ratings in ground, in air, in pipes
and in ducts at the maximum conductor temperature of 90 deg.C with reference
to the ambient site conditions on the guidelines of relevant latest IEC.

b. Any additional data, other than furnished under climatic conditions and operating
conditions may be suitably assumed. The ratings shall be for trefoil / Horizontal
for 220 KV double circuits. When the sheaths are single point bonded and both
ends bonded or cross bonded (without exceeding the stipulated induced voltage
undue high circulating currents).

c. The current ratings shall be for single circuit/double circuit in operation.

d. The bidder shall also furnish technical information on de-rating factors for various
types of installation conditions in trefoil and flat (viz., depth of laying, varying
ground temperatures, cables in ducts / pipes, cable spacing, circuit spacing,
varying soil thermal resistivity etc.) shall be furnished by the bidder.

e. Bidder shall submit draft design reports for their proposed cable system with their
bids and that the final versions of the design reports be submitted after contract
award.

1.3.1 SYSTEM DESIGN CRITERIA

1 Rated system voltage 220 KV
2 Highest system voltage 245 KV
Impulses withstand voltage 1.2/50
3 microseconds 1050 KV Peak
wave of positive/negative polarity
4 System Frequency (% Variation) 50 Hz (+/- 5)
5 No. of phase per circuit 3
6 No of cores Single
7 System Earthing Solidly Grounded
One-minute power frequency withstand
8 460 KV
Voltage
9 Rated short time current 40 kA for 1 sec.
Duration of fault current & variation in
10 40 KA for 1 Second ,50 HZ +/- 5%
frequency
12 Conductor size 1200 sq.mm
13 Conductor Material Plain annealed Copper
Power frequency with stand voltage for
14 318 kV (rms)
30 min.
15 Daily load factor 1
16 System neutral Effectively grounded

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220 kV Cable & Accessories Technical Specifications

1.4 CABLE DESIGN FEATURES

The cable shall be manufactured by “Triple head”

extrusion process, in a clean room environment. The
conductor screen, Insulation & Insulation screen shall
ALL be extruded in A COMMON HEAD i.e. SINGLE ONE
TIME PROCESS to ensure homogeneity and reduction of
1 Manufacturing process
voids, in the insulation and the screening
System of the cable, whereby enhancing the life of the
cable. The cable shall be manufactured by “DRY CURED”
& “Dry Cooled” process.

Conductor
Single core conductor consist of Milliken construction
(Maximum conductor
2 shall be comprising of 5 segmental, compacted circular
temperature at rated
0 copper wire in accordance with IEC 60228 (class 2)
current = 90 C )
Preferably shall be achieved by water swellable yarn /
Longitudinal and radial
3 fibers / tape in the Interstices / strands / layer of the
water sealing of conductor
conductor.
Semi conducting separator Semi-conducting separator tapes shall be applied over
4 tape (As per Manufacturer’s the conductor, suitable for continuous operating
Standard) conductor temperature of 90 deg C.
Triple- extruded XLPE
Insulation system consisting
of:

Conductor screen The conductor screen shall consist of extruded layer of

thermosetting black semi conducting compound & All
the requirement shall be as per IEC 62067

Insulation Screen Triple extruded XLPE insulation. Triple extruded XLPE

(Non- metallic). insulation having minimum thickness 23 mm &
5
nominal thickness (25mm) shall be in line with IEC
62067 recommendations.

The insulation screen shall consist of extruded layer of

black thermosetting semi-conducting layer. The
minimum & average thickness shall be in line with IEC
62067 recommendations
Make of Compound for
Insulation & Inner / outer Borealis / Dow Chemicals only
Semi-conducting compound
 Semi conducting water swellable tapes shall be
applied over the insulating screen
Inner Longitudinal and radial
6  Selection of Swelling height, time, weight, &
water sealing
volume resistivity of tape shall be justified by
technical calculation / documents
7. Metal screening (If required Metallic screen shall consist of concentric layers of

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220 kV Cable & Accessories Technical Specifications

to meet short circuit rating) annealed copper wires followed by copper tape binder
applied in helical form
 Semi conducting water swellable tapes shall be
Outer Longitudinal and applied over the metallic screen
radial water sealing bedding  Selection of Swelling height, time, weight, & volume
7
(applicable only If metallic resistivity of tape shall be justified by technical
screen is provided) calculation / documents
 (Extruded Corrugated Aluminium/ Welded
Corrugated Aluminium/ copper tape & copper wire +
8 Metallic sheath
Extruded Lead alloy Type” E”) with anticorrosive of
high viscosity bituminous coating.

The outer sheath (with termite repellant, anti-rodent,

U/V resistant & Free from chlorinated paraffin,
resistant to sulphides found in the ground) shall
consist of extruded black colored HDPE. The Nominal
thickness (5.0 mm) at any point & minimum thickness
9 Outer Sheath
shall be in line with IEC recommendations.

c) Outer HDPE sheath (PE-7 grade)

d) Extruded Semi conductive layer on outer sheath
shall be considered (Thickness of extruded layer
shall be 0.3 mm minimum)

The cable shall be suitable to carry continuously rated

10 Cable Rating
load current on 220 KV, single circuit, without exceeding
the maximum conductor temperature of 90 deg. C.
b) The current rating shall be calculated based on the
following:
i) Soil thermal resistivity – 1.20 deg.C Mtr / Watt
ii) Ambient temperature – 45 deg C
iii) Ground temperature 30 deg C.
iv) Trefoil formation
v) As per the type of bonding recommended by the
vendor
vi) depth of laying 2000 mm
viii) Any other additional requirement for cable laying, if
necessary, can be recommended for AEML
Economic drum length is to be determined by the
vendor. However, for bidding purpose the drum length of
the cable shall be considered as @ 500 M.
11 Drum Length
Exact length shall be confirmed at later stage after
confirmation by contractor of route length + cable
required for terminations and joints.
Manufacturer shall be required to take prior approval
from Engineering and Procurement for any short length
12 Short length of cables
supply.
Manufacturer shall not be allowed to put two cable

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220 kV Cable & Accessories Technical Specifications

pieces of different short lengths in same cable drum.

The extruded outer sheath shall be embossed with
Sequential length marking at interval of every-one
meter. The outer sheath shall also be embossed with
(minimum as described below:
a) Voltage designation
b) Type of construction / cable code
c) Nominal cross-sectional area of conductor &
Embossing on cable outer
13 material
sheath/Jacket (HDPE)
d) Manufacturers name & trademark
e) Name of buyer (AEML)
f) Month & year of manufacturing
g) P.O. No. & Date
h) Batch No. or Lot No. or Drum no. (For traceability
purpose, in case of any future issues / problem in
cable)
The following information shall be marked on the
drum:

a. Trade name or trademark; if any

b. Manufacturer's & Buyer’s name

c. Cable construction

d. No. of Core & Cross-sectional area of the

conductor of the cable

e. Type of cable and voltage for which it is

suitable

f. Length of the cable on the drum, Cable

length initial reading & end reading shall be
14 Drum identification label marked on drum. Cable starting end shall be
taken out from winding to read this drum
reading with proper sealing to protect
against external damage. The ‘Start’ end
meter marking and “Finish” end meter
marking and the drum lengths shall be
printed on the drum flange along with other
markings.

g. Direction of rotation of drum (an arrow)

and Purchase order number with date and
SAP item code

h. Month & Year of Manufacturing

i.Port of Destination

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220 kV Cable & Accessories Technical Specifications

j. Drum Serial no.

k. Size of drum (Diameter of drum & Width)

l.Gross weight of the drum

15 Cable Accessories General technical requirements:

a. The terminations offered in response to this

specification shall be manufactured and tested as
per IEC 62067 standards.

b. All terminations shall have the same or better

electrical and mechanical withstand capabilities
than the main cable. All terminations shall be
suitable for tropical conditions and shall be
provided with adequate mechanical protection
against environmental conditions such as moisture
ingress and UV radiation where exposed to direct
sunlight but not limited to etc.

c. Each termination kit shall be accompanied with

set of installation instructions. The instructions
shall be sequential and well detailed with
dimensions and graphics, illustrating the
assembling of each component of the accessory
onto the cable.

d. Separate to the working instructions a detailed

dimensional drawing of the longitudinal cross
section of each accessory offered must be
provided. The drawing shall include all necessary
details of the construction to complete the
joint/termination including the identification of
each component of the accessory into a list of
components.

e. The main insulation units for electrical field

stress control units of. The unit shall be factory
tested according to IEC 62067. Heat shrink and/or
tape type joints/terminations are not acceptable.

f. All materials as well as installation techniques of

terminations shall be compatible with the relevant
cable material.

g. All terminations design shall allow to carry out

periodical cable sheath testing without
220 kV Outdoor termination disassembling of the accessory.

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220 kV Cable & Accessories Technical Specifications

a) Outdoor termination: Outdoor termination with

resin-glass fiber tube equipped with silicone sheds
(composite type) including connecting single/twin
AAAC conductor or Al. tube). Outdoor type
terminations / housing shall be suitable for hot line
washing with Insulator creepage distance of 8500
mm minimum.
b) The termination shall be suitable for installation
in vertical or in inclined position up to 45" on
transmission line (T/L) Towers. For this purpose
and to reduce weight on T/L towers, the insulator
housing shall be of Polymer type suitable to
exposure to the full solar UV radiation. The base
of the termination shall be insulated from
supporting steelwork by mounting upon pedestal
type insulators
c) The insulator housing shall be dry type or be filled
with high viscosity cold pouring compound.
Compounds to be heated during installation are
not allowed. The termination construction must
allow the thermal expansion of the cable
insulation. For this purpose, the stress cone units
must be made of flexible silicone rubber to allow
the radial expansion of the cable insulation at all
operation conditions
d) The termination contact top bolt shall provide a
sliding system allowing the axial movement of the
cable conductor thus avoiding cable bending In
the termination insulator housing. The
termination conductor connector shall be of
compression type or bolted type. The cable
manufacturer and/or contractor will liaise fully

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220 kV Cable & Accessories Technical Specifications

with the accessory manufacturer in the definition

of the necessary base of the termination as well
as necessary outer diameter at the top of the
connector of in order to ensure that the cable
terminations will interface correctly with the
support structure and connection to the
Transmission line
e) Outdoor terminations shall be self supporting and
suitable of installing in areas with heavy industrial
pollution, tropical or near coastal areas.
Therefore, the insulators creepage distance must
be min.8500 mm suitable for pollution class E
according to IEC 60815 The corresponding
specific creepage distance of the insulator shall
be measured over the r.m.s. value of the phase to
ground maximal system voltage.
f) Vendor need to consider the support
arrangement for cable in their scope
g) Vendor shall ensure the compatibility of joint
accessories with cables

220 kV GIS/Transformer end Terminations:

220 kV GIS/Transformer a) It shall be preferred to have the accessories

end Terminations
manufactured by the Cable manufacturer
itself.
b) All the Cable accessories must be of Type
tested quality. Certificates are to be submitted
along with the bids.
c) The GIS termination shall be dry type but
dimensions shall be matched with oil filled
type terminations (As per IEC 62271-209
standard recommendation)

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220 kV Cable & Accessories Technical Specifications

d) The Transformer end termination shall be dry

type, but dimensions shall be matched with oil
filled type. Transformer end terminations shall
be As per DIN EN 50299 requirements
(Standard for Oil immersed cable connection
Assemblies)
e) Stress cone shall be pre-moulded type no
painted or coated type control unit is
acceptable
f) Material of stress cone shall be “silicone
rubber” only
g) Overall dimension of the GIS / transformer side
termination shall be achieved as per IEC
standard preferably without using any
extension adaptor
h) The design of Cable terminations at the 220 KV
GIS/Transformer side shall be coordinated by
vendor with design of the 220 KV GIS
Switchgear or Transformer manufacturer
respectively
i) It shall be preferred to have the accessories
manufactured by the Cable manufacturer
itself.
j) Vendor need to consider the support
arrangement for cable in their scope
k) Vendor shall ensure the compatibility of
accessories with cables
l) Accessories shall be universal type suitable to
use in any type of GIS (SF6 gas)
m) Heat shrink and / or tape type terminations
are not acceptable

220 kV Cable Joints (Insulated & Straight Through):

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220 kV Cable & Accessories Technical Specifications

a) It shall be preferred to have the accessories

manufactured by the Cable manufacturer
itself
b) Material of stress cone (Premoulded single
piece design joint body) shall be “silicone
rubber” only
220 kV Cable Joints
c) Joints shall have same electrical /mechanical
& thermal properties as like cable
d) Longitudinal & Radial water blocking is
required for joints. This requirement is same
as cable
e) Outer protection of Joints shall be suitable
for underground installation in polluted water
conditions
f) All the joints shall be type & PQ tested
according to IEC-62067, Annexure-G
g) Joint body shall be encased with copper
metallic enclosure.
h) Insulator provided in insulated joint shall
withstand 10 kV DC voltage during testing
i) Vendor shall ensure the compatibility of joint
accessories with cables
j) Heat shrink and / or tape type joints are not
acceptable

1.5 Quality Assurance

Vendor Quality plan To be submitted for purchaser’s approval

Inspection point To be mutually indentified and agreed in quality plan

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220 kV Cable & Accessories Technical Specifications

1.6 Inspection & Testing

All the routine tests shall be carried out in line with relevant
Routine test
1 IEC -62067 standards with latest amendments

The cable & Accessories must be of “type tested”

quality.

Type test report shall be submitted for the type, size

and rating of the cable & accessories offered, along
with the bid.

All type tests shall be carried out in accordance with

relevant IEC -62067 standards and in accordance with
2 Type test the sequence prescribed.
Type tests must have carried out from following
international
laboratories
 KEMA, Holland
 EDF, France
 Hydro-Quebec, Canada
 CESI, Italy
 CPRI, Bangalore
 IPH Germany
 FGH Italy
The supplier shall submit prequalification test report for
220 kV cable & accessories as per IEC 62067 for AEML
acceptance
PQ tests must have carried out from following international
laboratories
Prequalification Test  KEMA, Holland
3
 EDF, France
 Hydro-Quebec, Canada
 CESI, Italy
 CPRI, Bangalore
 IPH Germany
 FGH Italy
Acceptance / Special
Tests including test All the tests in line with relevant IEC standards like IEC-
4
after installation at 62067 IEC 60840, IEC 60540 with latest amendments
site
The buyer reserves the right to witness all Incoming, In-
process & Final tests specified on completed cables.
The buyer reserves the right to inspect cables at the
5 Inspection Seller’s works at any time prior dispatch, to verify
compliance with the specifications
In-process and final inspection call intimation shall be
given in advance to purchaser.

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220 kV Cable & Accessories Technical Specifications

Three sets of complete test certificates shall be submitted

5 Test certificates
along with the dispatch documents.

1.7 SHIPPING, HANDLING & SITE SUPPORTING

The cable shall be wound on non-returnable steel drums of

suitable size and packed (with steel covering of suitable size for
protection of cables) conforming to International Standards.
Packing Cable shall have seaworthy packing in case cables are
dispatched by shipping lines.
Steel Stand shall be provided for each Cable Drum for firm
holding & restrictions from rolling on the Ground.
The seller shall be responsible for any transit damage due to
Transit damage
improper packing.
The ‘Start’ end meter marking and “Finish” end meter marking
and the drum lengths shall be printed on the drum flange along
with other markings.

Pulling eye & sealing of A cable pulling eye shall be provided at “Finish” end of cable on
Cable ends each drum. Suitable fillings/putty shall be used for sealing gap
between outer sheath and pulling eye. Heat shrinkable sleeves
on the pulling eye shall also be provided. The “Start” end of the
cable shall be sealed with Polyurethane compound with PVC cap
and hot melt adhesive lined heat shrinkable end cap.

1.8 ELECTRICAL TESTS AFTER INSTALLATION

Tests on new installation shall be carried out when the installation of the cable
system has been completed. Following tests will be carried out & offered Cable &
accessories shall withstand installation tests as per IEC:

a. DC voltage tests of the over sheath with voltage level and duration specified
in clause 5 of IEC 60229_2007. The voltage shall be applied between each
metal sheath or metal screen and the ground.

b. Alternatively, a voltage of Uo may be applied for 24 hrs. (Soak test)

c. Note: All site testing and commissioning shall be witnessed by the AEML. No
site testing shall occur until the AEML-Representative has accepted the
submitted commissioning and test plan.

1.9 PACKING & STORAGE OF ACCESSORIES MATERIAL

The storage temperature of all products shall be mentioned along with the
product catalogue. The wooden packing material shall meet the ISPM 15
Standard. The wooden pallets must be waterproof having anti rodent & anti
termite properties.

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220 kV Cable & Accessories Technical Specifications

 Boxes with insulators for storage of less than one year shall meet Class D and
for longer storage time they shall meet Class B.
 Drums and cans with liquid Silicone oil shall meet Class B for long-time storage
& for short-time storage and during installation procedures they shall meet
Class D.
 All other boxes of high voltage accessories shall meet Class C for storage,
unless otherwise stated.

Classes of the ISPM 15 Standard are as follows:

Class A: Electrical/electronic goods and instruments, which are particularly

sensitive to ambient
Factors and must be protected against:
a) Temperatures above or below the prescribed limits
b) Sudden changes in temperature
c) Relative humidity and vapors
d) Stacking pressure and mechanical damage
e) Contamination with dust, dirt, rain, snow or salt spray

Class B: Goods not particularly sensitive to ambient influences but need to be

protected against:
a) Extreme temperatures
b) Relative humidity and vapors
c) Stacking pressure and mechanical damage
d) Air pollution

Class C: Goods relatively insensitive to ambient factors but need to be protected

against:
a) Rain, snow, salt spray
b) Stacking pressure and mechanical damages

Class D: Goods to be protected against direct weathering and mechanical damage.

Class E: Goods insensitive to ambient climatic or meteorological factors and need

only to
be protected against mechanical damage.

The following pictograms shall appear at wooden pallets, boxes, cans or semi
finished products
Packed into plastic bags. The meaning of each pictogram is described in the
following
table:

Transit damage: The seller shall be responsible for any transit damage due to
improper packing.

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220 kV Cable & Accessories Technical Specifications

Equipment identification label: The following information shall be marked on the

Package:

a. Trade name or trademark; if any

b. Manufacturer's & Buyer’s name

c. Type of cable sq.mm and voltage for which it is suitable

d. Month & Year of Manufacturing

e. Port of Destination

f. Equipment Serial no.

g. Gross weight of Package

1.10 STORAGE CONDITIONS & GUIDELINES:

Parts or materials of high voltage accessories may have different storage

durations and conditions. The storage durations shall be listed in the tables.
Expiry and production date shall be labeled at the packaging of the relevant
parts and materials.
Having maximum shelf life of components in accessories kit shall be preferred
on priority during evaluation of vendor.

Storage conditions of silicone rubber parts (stress cones and joint bodies) &
Silicone oil shall be specifically mentioned:

Maximum storage time & production date/ expiry date shall be specifically
mentioned for each component in kit content as per following format:

Maximum Expiry
Material Description Storage time / date /
Shelf life Production
date

Guidance for safe and correct handling of packed accessories shall be

specifically mentioned.

1.11 SPECIAL STORAGE PACKING

Special packing for silicone rubber parts (stress cones and joint bodies):

Single piece silicone rubber stress cones used in terminations and silicone
rubber/EPDM used for terminations shall have a maximum storage life ( At least

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220 kV Cable & Accessories Technical Specifications

10 years). The material shall be able to store significantly for longer period ( At
least 10 years). The influence of moisture on the silicone rubber part during the
storage time must be considered during packing of material.

It is very important that, these silicone rubber parts of spare accessory kit shall
be packed in a special bag ( Vacuum packing in Bag), allowing to store them for
longer period starting from the date of production. At time of dispatch from
factory, each spare accessories kits shall be packed in a separate case. This
packing is suggested in view of ease in future utilization.

1.12 PACKING FOR SILICONE OIL

The closed cans and drums with silicone oil must be protected against rain with
a watertight cover.

1.13 DEVIATION

Deviation from this specification shall be stated in writing in reference to the

specification clause / GTP / Drawing & description of alternative offer. In
absence of such statements requirements of specifications shall met without
exception.

1.14 MANDATORY SPARES SHALL BE SUPPLIED BY BIDDER

Sr.No. Description Qty UOM

220KV 1/c 1200 sq.mm copper conductor, XLPE
insulated, Copper wire & copper tape + extruded Lead
1 (Type E) /Extruded Corrugated Aluminium/Welded 500 mts
Corrugated Aluminium metallic sheath with HDPE
outer Jacket
2 220 kV Cross bonding joints (Pre-moulded type) 2 sets
3 220KV GIS termination 1 sets
4 220KV straight through joints ((Pre-moulded type) 1 sets
5 Link BoX-3 Phase with SVL 1 Nos
6 Link BoX-3 Phase (Direct) 1 Nos
7 Link BoX-1 Phase (Direct) 1 Nos
8 OFC (48 C Single mode) cable 500 Mts
9 DTS (6F MM+6F SM) OFC cable 500 Mts
10 Electronic Ball Markers 15 Nos

1.15 SYSTEM SPARES REPORT

The Contractor shall provide a System Spares Report describing:

a. Recommendations for spare parts, tools, and equipment, based on a life

cycle strategy document and statistical failure rates.

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220 kV Cable & Accessories Technical Specifications

b. Cable lengths to be replaced as a result of each cable failure, identification

of long lead-time items, expectations for deliveries for replacements and
shelf life limitations.
c. A lifecycle strategy document showing failure rates, number of units
installed, criticality, and a list of “life-cycle spares” that should be obtained
by the Owner prior to the end of their production cycle.
d. Replacement plan for shelf life expiry of spares.
e. Spare parts shall be available on site at the moment installations work starts.
f. The Contractor shall advise the Owner regarding any special tools
recommended for use with the spare materials, as well as maintenance
requirements for the spare items, such as shelf life of jointing materials, etc.
g. Spares with shelf lives that expire during the warranty period of the cable
system shall be replenished free of cost to the Owner.
h. Spares with shelf lives that expire during the period of the Maintenance
Service Contract beyond the warranty period shall be identified and unit
rates provided for these items.
i. The Contractor shall ensure that additional spares are available for purchase
for a minimum of 15 years after commissioning of the cable system. If spares
provided for this project become obsolete, the Contractor shall provide the
Owner with a minimum of 2 years notice prior to stoppage of manufacturing
of the given equipment so the Owner may purchase additional spares if
required.
j. The Contractor shall provide a complete list of recommended spares for
equipment supplied under this Contract to assist with meeting the
guaranteed availability requirements. These spares shall include the
mandatory spares identified above as well as the additional spares identified
by the Cable Contractor as necessary to meet the performance guarantees.
The Contractor shall also prepare lists of additional spares which they
recommend should be purchased for use to the end of design life but are not
necessarily needed to achieve the guaranteed reliability and availability. The
Owner may elect to purchase any or all these additional spares at any time
up to the end of the warranty period at the quoted price.

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220 kV Cable & Accessories Technical Specifications

k. The Contractor shall replace all spares consumed or damaged before or

during installation and commissioning.
l. All equipment supplied for use as spares shall be interchangeable with, and
of the same or better material, workmanship, and design as the
corresponding parts of the original equipment.
m. The Contractor shall maintain a data base of all spare parts. Prior to the
delivery of spares, the Contractor shall submit a consolidated list of spare
parts with quantities, estimated weight, and volume. The shelf life of each
spare part shall be identified.
n. Each spare part shall be identified with a unique bar-coded label that is
linked to the spare parts inventory list.
o. All spare equipment shall be stored according to the Contractors
requirements

1.16 DELIVERY SCHEDULE.

16.1 Delivery start date ………………shall be as per Purchase order

16.2 Delivery end date ………………shall be as per Purchase order
16.3 Material dispatch clearance date ………………shall be as per Purchase order.

1.17 DRAWING AND DOCUMENTATION

For approval
Final after For
Description Along with offer for award of
approval information
contract
6 copies + 1
i) Detailed dimensional cross- sectional 3 Copies (Typical
4 copies soft copy in
drawing of the cable. drgs.)
CD
ii) Detailed Kit Content, Installation
6 copies + 1
Instruction Sheet, dimensional drawing 3 Copies (Typical
4 copies soft copy in
of Straight joint & Guaranteed drgs.)
CD
Technical Particular Sheet.
iii) Detailed Kit Content, Installation
6 copies + 1
Instruction Sheet, dimensional drawing & 3 Copies (Typical
4 copies soft copy in
Guaranteed Technical Sheet of End drgs.)
CD
termination arrangement.

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iv) Type test certificates of offered type

2 Copies 2 copies
and design of cables & accessories - 6 copies + 1
(Type
Type test report for the combination soft copy in
and sample
of cable with joints and terminations CD
Routine Test)
offered shall be submitted.
6 copies + 1
v) Acceptance test certificate for
4 copies soft copy in
complete lot of cable
CD
6 copies + 1
vi) Routine test certificate for each drum 4 copies soft copy in
CD
vii) Guaranteed technical particulars of 6 copies + 1
each type of cable (duly filled in, signed & 4 copies soft copy in
stamped copies) CD
viii) Experience detail to manufacture &
6 copies + 1
supply of 220 KV cables / meeting
1 COPY soft copy in
qualifying requirement of the
CD
specification
6 copies + 1
ix) Dimensional drawing for pulling eye. 3 Copies 4 copies soft copy in
CD
6 copies + 1
x) Rating factors details (Standard as well
3 Copies 4 copies soft copy in
as considered for AEML project)
CD
xi) Complete cable catalogue, manual,
6 copies + 1
instruction booklet on handling, pulling,
3 Copies soft copy in
laying, jointing, termination and testing
CD
of cable and accessories.
xii) Summary of Deviation from this
1 COPY
Specifications
6 copies + 1
xiii) Listing of Accessories included in the
3 Copies 3 Copies soft copy in
proposal
CD
6 copies + 1
xiv) Quality Assurance Plan 1 COPY 3 Copies soft copy in
CD
xv) Supply record of cables and cables
1 COPY
accessories (for the offered design)
xvi) List of mandatory / 6 copies + 1
recommended spares /special tools / test 1 COPY 3 Copies soft copy in
equipment etc CD

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220 kV Cable & Accessories Technical Specifications

xvii) Various Calculations like:

a) Continuous current rating
6 copies + 1
b) Thermal Short circuit rating for
3 Copies 4 copies soft copy in
conductor, metal sheath & screen
CD
c) Conductor skin effect loss at maximum
current rating

2. CABLE HANDLING & PULLING PROCEDURE:

This section describes general instructions to be observed during cable pulling work.
 Handling of Cable drum/cable

 At time of acceptance and prior to installation, the cable drum should be

thoroughly examined for any outside physical damage or damage to cable
end caps.
 This examination should also include lagging, drum flanges and drum
marking, tags and labels.
 While handling cables, necessary precautions shall be taken to prevent
damage to the cable. During loading and unloading of drums, every
precaution shall be taken not to drop the drum.
 Cable drums that are to be transported on trucks must be securely blocked
or anchored to prevent rolling.
 Whenever a cable is cut, the exposed end shall be sealed to protect from
rain, mist or dripping or splashed water by heat shrinkable caps.

 Before Cable Threading

 It shall be confirmed that 250 mm ducts where the cable is to be installed

are free from any foreign materials such as stones, nails and pieces of
concrete, asphalt, brick pieces, glass pieces, sharp edged objects etc.,
which may damage the cable. Such materials should be removed using duct
brushes before threading the cable. Any water inside the pulling pits/opening
pits/jointing pits should be pumped out completely.
 Road corner side opening pits must be checked thoroughly, to ensure that
the minimum bending radius of 20D of the cable is attained.

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220 kV Cable & Accessories Technical Specifications

 The drum should be mounted on appropriate capacity jack. For cable

threading, the cable drum shall be set at the opposite direction to the arrow
painted on the drum that indicates the direction of rolling during
transportation. The positioning of cable drums should be so chosen to
require the least pulling strength at the end of the cable path.
 Reliable communication between the drum, the head of the cable, on
curves, entrances to duct, intermediate post and the winch to be established
to effectively coordinate the work process. The equipment to be used should
be of proven reliability and should be thoroughly tested before cable
installation begins.
 Essential words or signals for the cable pulling, at least START and STOP,
are fixed and understood by all the associated staffs.
 The meeting prior to cable pulling is recommended to decide position of
watchmen with communicative equipment to guide cable pulling works.
Watchman shall be positioned at pulling chambers and at every corner.
 It shall be confirmed that cable drum, drum brake, winch, rollers, wire rope,
drum for wire rope and any other necessary tools / equipment have been
checked & set properly.
 Swivel shall be installed between wire rope and pulling eye to prevent the
cable from twisting. At the entrance to the cable trench a cable guiding and
bearer stand is positioned, over which the cable is taken off the cable drum
is pulled into the trench. The rollers that are inclined towards the center
ensure that the cable is fed centrally into the trench. The rule for curves in
the trench is that under no circumstances they should fall below the
minimum prescribed bending radius of the cable.
 The guiding rollers shall be placed before the cable drums for supporting the
initial cable lengths. The cable rollers in straight portions should be set at
pulling/opening pits meters to avoid the slack of the cable pulling. Whereas
the cable rollers in bend portions shall be set as close as possible, so as
cable is not subjected to the sidewall pressures.
 Enough numbers of corner cable rollers/bend rollers are positioned on the
curves in pulling/opening pits, to prevent cable sliding off. In field practice
anchor pins have proved ideal for anchoring the corner rollers.

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220 kV Cable & Accessories Technical Specifications

 Final check of ducts shall be carried out so as to eliminate the risks that may
damage the cable. Timbering / shuttering shall be provided securely prior to
cable pulling at positions (Opening pits) where trench may or is liable to
collapse.
 When the cable is pulled into shaft or inclined tunnel, sufficient capacity of
brake facilities shall be applied so that the cable may not slip down due to its
weight.

 During Cable Pulling

 Maximum pulling speed shall be 7 mtr / min. The pulling speed shall be
reduced at corners, inlets of duct, etc. where the smooth pulling may be
blocked. After confirming that no damage has occurred at these portions, the
pulling may proceed. Proactive measures shall be taken to eliminate the
cause of damages, if any.
 Maximum pulling tension should not exceed 1.5 tones. In case if site
condition necessitates to exceed, then site engineer shall discuss the site
situation with Project head and get it approved. Site Engineer shall keep a
record of pulling force control by electronic measuring system with printout
system KPR2000.
 Watch the cable on the cable rollers, especially at bend portions and
maintain sufficient clearance between existing services and the cable along
the whole cable route all the time during cable pulling.
 The cable pulling should be stopped immediately on finding any damage
and should not be resumed until the causes are removed.
 When the inner end of the cable on the cable drum is loosened during cable
pulling, it shall be tightened again to the cable drum.
 To avoid ingress of moisture, it must be observed by site engineer that the
end capping of the cables is not damaged. Cut pieces of the cables must be
capped immediately, before laying of the same is taken-up.
 Circuit Identification tags should also be attached at every entry point into
the premises and at the cable end termination.
 Phase Identification shall be ensured by providing nylon/acrylic flexible tape
of Red/Yellow /Blue color.

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220 kV Cable & Accessories Technical Specifications

 Electronic cable ball markers shall be tied at pulling and jointing chambers.
 Laying of 24 Core OFC Cable through 140 mm ducts & DTS cable along
with 220 kV cable shall be laid as per standards.
 The minimum safe bending radius for the XLPE cable shall be taken as 20 D
where ‘D’ is outer diameter of the cable. At joints and terminations, the
cable should never be bent so that the radius of the bend is less than 26
times the diameter over the insulation.
 The site Engineer shall ensure that desired minimum clearances is
maintained as follows:
Power cable to control cable : 0.2 mts.

Power cable to communication cable : 0.3 mts.

Power cable to gas/water main : 0.3 mts.

Power cable to power cable clearance : 2 D (D is external diameter of

Cable)

Circuit to Circuit clearance (Axial) : 0.7 mts according formation either

 After Cable Pulling

 The outlook of the cable shall be checked whether the cable has been
damaged or not. The damage portion of cable shall be repaired as required.
If sheath fault requiring cable jointing, then entire cable length to be
replaced.
 After the cable pulling DC sheath test at 10kV for 1 minute shall be
conducted within 24 hrs to ensure that no damage has occurred to the cable
sheath during cable pulling. After completion of the test heat shrinkable end
caps to protect against ingress of water or any foreign particles, must
immediately seal the exposed area.
 The cable end shall be raised up higher than the maximum water level
expected. The integrity of sealing at the cable ends shall be confirmed to
prevent water or any moisture entering the cable. Repair work shall be
carried out if necessary.

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220 kV Cable & Accessories Technical Specifications

3. EARTHING OF SINGLE CORE CABLE

 Earthing shall be employed to prevent the flow of induced circulating current

through sheath and consequential derating of cables. To maintain the
sheath voltage to earth below permissible limit of @60 volts cross bonding
arrangement will be implemented.
 Metal sheath of the cable shall be bonded to the earthing system as per
relevant IEC standards
 AEML site engineer shall ensure that all metal pipes or conduits in which the
cables have been installed should be efficiently bonded and earthed.
Earthing and bonding should be done in accordance with IS 3043 code of
practice for earthing. The bidder to supply complete earthing materials
required.
 The earthing cables to be laid from cable jointing bay to link box and link box
to earth point

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