Cable Trays Tec Spec Chap D

8/8/2019 Cable Trays Tec Spec Chap D

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CHAPTER – D

TECHNICAL SPECIFICATION FOR FRLS POWER CABLE, CABLETRAYS 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 andforwarding of (a) power cables (b) perforated cable trays complete in allrespects along with their supporting/fixing arrangements (c) laying & fixing ofcable trays on supporting system, earthing of cable trays and laying ofvarious 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 thespecification.

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

2.01.03 Storage including insurance and preservation at site till installation andhanding 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 linewith cable boxes/suitable cable termination end, testing and commissioningof 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 overheadstructure near Main Access Tunnel of Power House at EL-1061 m atJhakri through main access tunnel as per Schedule of requirementappended at Annexure-E-A.

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

2.02 STANDARDS AND REGULATIONS

2.02.01 All materials in cables shall comply with applicable provisions of the latesteditions of relevant Indian Standards, Indian Electricity Rules, IndianElectricity 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 otherinternationally 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. Whenthe equipment conforms to any other standards, salient points of differencebetween the standards adopted and those prescribed in this specificationshall be clearly brought out in the tender and a copy of the applicablestandards(s) in English language shall also be enclosed by the supplier withthe tender.

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

1. IS-694 PVC insulated cables for working voltagesupto and including 1100V.

2. IS-1554 (Part-I) PVC insulated (heavy duty) electric cablesfor working voltages upto and including1100V.

3. IS-1554 (Part-II) PVC insulated (heavy duty) electric cables

for working voltages from 3.3kV upto andincluding 11kV.4. IS-3961 Recommended current ratings for cables5. 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 andincluding 33kV rating.

12. IS-12943 Brass glands for PVC cables.

13. IS-10418 Drums for electric cables.

14. IS-10810 (Part 0 to63) Method of test for cables.

15. IS-6474 Polyethylene insulation and sheath ofelectric cables.

16. IS-5819 Recommended short circuit ratings of highvoltage PVC cables.

17. IEC-60502 Power Cables with extruded insulation &their accessories for rated voltages 1kV to30 kV

18. IEC-540 & 540A Test methods for insulation and sheaths ofelectric cables and cord.

19. IEC-60332 Test on electric cables under fireconditions.

20. IEC-60754 Test on gases evolved during combustion



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of electric cables.21. IEC Hand Book for

Temperature IndexCable in fire regarding temperature IndexChapter-6.

22. IEC-10333 Cable joints and terminations23. 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(22 kV)

Three core95 mm2

AluminumConductor

UnarmoredCable

(b) L.T.Power cables Single core AluminumConductor

UnarmoredCable

2.03.02 Type of Cable:

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

2.03.03 Conductor:

The material for conductor for HT power cables shall consist of plainaluminum of H4 grade having tensile strength above 150 N/mm.sq. The

cable conductor shall be made from stranded aluminum wire to formcompacted circular conductors having resistance within the limits specified inrelevant IEC/Indian Standard. The minimum number of strands in theconductor shall not be less than the appropriate minimum numbers specifiedin the relevant standard.

2.03.04 Conductor (Shield):

The conductor shall have non-metallic semi-conducting shield which shallensure perfectly smooth profile and avoid stress concentration. Theconductor 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 thespecified system voltage. The manufacturing process shall ensure thatinsulation shall be free from voids. The insulation shall withstand mechanicaland 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 ofhigh 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-metallicsemi-conducting shield shall be put over the insulation. The insulation shieldshall be extruded in the same operation as the conductor shield and theinsulation by triple extrusion process.

2.03.07 Cable screening:

An aluminum screening shall be provided on top of the insulation shield incase of XLPE cable.

2.03.08 Sheath:

(a) Inner Sheath: In case of cables consisting of two or more coresinner sheath suitable to withstand the site conditions and thedesired temperature shall be provided on the individual core

and then surrounded by common covering applied either byextrusion or wrapping of a filling material containingthermoplastic material. It shall be of adequate thickness andapplied by continuous process to produce a sheath ofconsistent quality free from all defects. PVC sheath shall beextruded. The circularity of the cable should be maintained.

(b) Outer Sheath: This is extruded over the armour for armouredcables and cover the inner sheath for unarmoured cables. Itshall be specially formulated heat resistant black PVCcompound conforming to the requirement of type ST2 of

IS:5831-1984, extruded to form the outer sheath. The cableshould also offer a specially formulated Flame Retardant LowSmoke compound (FRLS) for outer sheath. Suitable additivesbe added to prevent attack by rodents and termites. All servingmust be given anti-termite treatment. The thickness of thesheaths shall be as per relevant standards.

2.04 CONSTRUCTION:

2.04.01 Cables shall have suitable fillers laid up with the conductor to provide asubstantially circular cross section before the sheath is applied. Fillers shall

be suitable for the temperature of the cable and compatible with theinsulating material. The material shall be of the best quality andworkmanship should be neat and clean and of highest grade. The fillers andsheath material be non-hygroscopic. All materials shall be new, unused andof the finest quality.

2.05 TESTS:

2.05.01 Test during manufacture:

During the manufacture of cables, manufacturer’s standard tests shall beperformed and copies of test certificate from the independent test houseshall 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 acceptancetests shall be performed strictly as per applicable standard specifications andcopies of tests certificates shall be furnished.

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

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

2.05.02.04 The purchaser reserves the right to witness all tests and the supplier shallprovide all facilities, to the purchaser in this regard and shall inform thepurchaser sufficiently in advance to enable the purchaser to depute hisrepresentative 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. Thetest method, condition of test and test requirement shall comply with thosegiven under the type tests. Apart from these conductor examination, check ofdimensions 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 onXLPE and PVC insulated power.

1. Tensile test2. Wrapping test3. Conductor resistance4. Partial discharge test5. Dielectric power factor test

6. Bending test followed by partial discharge test7. Heating cycle test followed by partial discharge test8. Test for thickness of insulation and sheath9. Tensile strength and elongation test for insulation and sheath10. Ageing test for insulation and sheath11. Loss of mass tests for insulation and sheath12. Shrinkage Test for Insulation and Sheath13. Hot Deformation Test for Insulation and Sheath14. Cold Bend Test (up to 6mm.sq.) size15. Cold Impact Test for Insulation and Sheath16. Heat Shock Test for Insulation and Sheath17. Thermal Stability Test for Insulation and Sheath18. Test for Bleeding and Blooming of pigments for PVC Insulation &

Sheath



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19. Fire Resistance Test20. Measurement of Insulation Resistance21. Impulse withstands Test.

2.05.04.02 Sequence of electric tests shall be as per the relevant Indian/Internationalstandards. The Bidder shall submit the sequence of tests for the approval ofthe purchaser before conducting the tests. A copy of the adopted standardshall also be supplied.

2.05.04.03 The cables covered under this specification shall be subject to abovementioned tests alongwith any other test specifically required for thematerial. The cables other than PVC insulation shall be subjected to tests asper the respective IS/International Standards.

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

bid.

i) Accelerated water absorption test for insulationii) Di-electric Testiii) Oxygen Index Testiv) Temperature Index Testv) Flammability Testvi) Acid Gas Generation Testvii) Smoke Generation Testviii) Test for Rodent and Termite Repulsion

Test details is to be given by the manufacturer. The numbering of cores ofthe cables shall be prominent and indelible and shall be checked after thevarious physical tests such as ageing test, heating cycle test, bleeding andblooming 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 oncables similar to the cables covered herein by an Independent Agencyapproved by Govt./NABL (National Accreditation Board for Laboratories)shall be acceptable in lieu of the type tests. However, type test certificatesfrom the collaborators shall not be acceptable.

2.05.05 Acceptance Test:

i) Tensile Testii) Wrapping Testiii) Conductor Resistance Testiv) Test for thickness of Insulation and Sheathv) Partial discharge testvi) HV Testvii) Insulation resistance test



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2.05.06 Optional Test:

The purchaser reserves the right to conduct the following tests at anadditional cost, if considered necessary. The supplier shall furnish the pricefor conducting these tests separately.

i) Fire Resistance Testii) Flammability Testiii) Cold Bend Testiv) Cold Impact Test

2.06 PARAMETERS:

1. Type of cable FRLS XLPE Cables, PCC cables2. 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 ofcables

10%

6. Short circuit conditionsa) Currentb) Duration

H.T. L.T12.5kA 50 kA3 Sec. 1 Sec

2.07 CABLE PARTICULARS:

Full technical details and descriptive literature shall be furnished indicatingthe construction details, standard applicable for the components of the cableand current ratings of the cables in air and ground. De-rating factors to be

considered for the ambient temperature, ground temperature and groundingof cable in air and ground shall be furnished. The certificates for the typetests conducted on cables similar to the cables covered herein shall besubmitted along with the tender.

2.08 CURRENT RATINGS:

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

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

2.08.03 The current rating shall be based on maximum conductor temperaturedepending 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 temperatureof –5 deg.C to 45 deg.C.

2.10 OPERATION:

2.10.01 Cables shall be capable of satisfactory operation under a power supplysystem 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 withchances of flooding by water.

2.10.03 Cables shall have heat and moisture resistance properties. These shall be oftype 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 theAnnexure-I i.e. Schedule of Requirement.

2.11.02 The quantity is approximate and can be changed at the time of placing theorder 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 heavyconstruction. The wood used for construction of the drum shall be properlyseasoned, sound and free from defects and wood preservative shall beapplied 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 duringtransportation, handling and storage. The cut ends of the cable shall besealed by means of non hygroscopic sealing material.

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

i) Reference to this Indian standardii) Manufacturer’s name, brand or trade markiii) Type of cable and voltage gradeiv) No. of coresv) Nominal cross-sectional area of conductorvi) Cable codevii) Length of cable on drumviii) No. of lengths on reel, drum or coil (if more than one)ix) Gross weightx) Country of manufacturexi) Year of manufacturexii) 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 IndianStandards.

2.14.02 The cables shall carry the manufacturer’s name or trade mark and the wordidentified through out its length. The manufacturer’s data shall include thename, the cable size, voltage rating together with any other informationwhich the manufacturer considers appropriate. This identification endorsedor 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 becomplete responsibility of the bidder for laying, fixing, straight jointing in caseof 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 terminationshall be made with solder less crimping type and tinned copper lugs whichfirmly grip the conductor. Insulated sleeves shall be provided at all the wirestermination. Engraved core identification plastic ferrules marked tocorrespond with Cable No./Wire No. shall be fitted at both ends of eachcable, Ferrules shall fit tightly on the wire and shall not fall off when thewire/cable is disconnected from the terminal blocks. Number 6 & 9 shallhave different markings for ferrules purposes. Necessary cable no./wire no.shall be marked/tagged (or the standard practice adopted) on the cable atthe different locations for easy identifications during maintenance. Powercables having more number of cables per phase shall be laid in trefoil

formation or shall be laid as per standard practice adopted for laying. Cableslaid in horizontal cable trays as well as on vertical ladders shall be fixed atadequate number of places to hold the cable firmly. Bidder should submit acomplete write up regarding laying, fixing and termination of the cable forapproval before starting of the work. Any mechanical damage to the cablesresulting in discarding of the cables shall be replaced by the bidder free ofcost.

2.15.02 The LT cables and D.C. cables which are not under the scope of supplywill be lifted from centre store of SJVNL located at Jhakri. It will beresponsibility of the bidder to lift the cables from centre store Jhakri

and transport to site including loading & un-loading and utilizing atworks.

2.15.03 Cable Tags:

After pulling, cables shall be provided with identification tags consisting of1.5mm thick aluminium strips of size 30x60mm on which cable numbersshall be die-punched. The tags shall be tied to the cables with non-corrosivewire. 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.



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b) Within the distances of 1 to 2 meters on either side of crossing of anywall, floor, fire stop or other barrier in cable galleries/trenches etc.One meter distance to be kept so that cable tags do not getconcealed during lost/disturbed fire sealing, re-plastering, etc.

c) At the field end termination before entry to the terminal box/junctionbox/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 executiondrawings/physical measurements, physical measurements shall be made bythe

contractor in the presence of the representative of the purchaser.

The measurements of cable laying shall be made on the basis of lengthactually laid from the lug to lug including that of loops provided and laidaccordingly.

All the leftover surplus, scrap and serviceable cable pieces anddrums/spools/reels out of the cable quantities shall be returned by thecontractor 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 sizewise and category-wise to the owner’s stores/yard. All such cable shall carryan aluminium sheet metal tag indicating the size, and type of cable, cable ofserviceable lengths being returned to the stores in drums shall have theirfree ends sealed and the balance lengths on the drums shall be noted. Thisshall 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 cableschedule for the cables covered under this specification which shallincorporate the details of termination markings and route etc. in consultationwith 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 andcommissioning of cabling system being installed by him. It shall be overallresponsibility of the contractor to arrange and complete all activities incomplete co-ordination with equipment commissioning agency keeping inview the overall commissioning programme. The contractor shall submit acheck list for testing and commissioning and the activities shall be carriedout in accordance with the check list.

2.15.05.02 Testing and electric measurement of cable installations shall conform toIS:1255.



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2.15.05.03 Prior to installation, cables shall be tested for

a) Continuity of conductorsb) Insulation resistance between conductor and earthc) Insulation resistance between the conductors

2.15.05.04 After installation each cable shall be tested for

a) Insulation resistance between conductorsb) Insulation resistance between the conductors and earthc) Absence of cross phasingd) Firmness of terminations

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

2.15.05.06 The contractor shall have to bring all testing equipment/instruments insufficient numbers. All instruments shall be calibrated to the satisfaction ofthe purchaser before actual testing and tests to be conducted by qualifiedexperienced personnel.

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

2.16 CABLE TRAYS:

The hot dipped galvanized perforated cable trays and their fittings shallconform to the Indian Standards or their latest amended editions orequivalent International Standard. The bidder shall specify in the bid towhich 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 least400N per 1000 mm ladder length for 200 mm wide tray. The trays shall befabricated 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 shallbe hot dip galvanized according to BS-729-1971 or equivalent standardsuitable 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 persquare meter surface with a approximate thickness of 80 micron. The zinccoating shall be smooth, clean and uniform thickness and free from defectslike ash and dross inclusions, bare patches, black spots, pimples, lumpiness,rust stains, blisters etc. The galvanizing shall not adversely affect themechanical properties of the coated material, the quality of the coating will



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be established by tests as per IS-2633. All manufacturing process includingpunching, cutting, bending and welding of perforated cable trays shall becompleted and burrs shall be removed before the application ofgalvanization process is applied. Zinc conforming to at least Grade Zn 98 asspecified 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 thehelp of coupler plates by nuts and bolts. The coupler plate and nuts andbolts shall also be properly hot dip galvanized, where the bends of the traysare required at site the same shall be supplied by the bidder without anyextra 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 thesame shall be cut at site and joined by nuts and bolts with the help ofcoupler plates.

2.17.04 i) The perforated cable trays shall be supported on the solid supporting

arrangement made from channel of minimum size 100x50mm andangle iron of size 50x50x6mm thick angle approximately at a distanceof 0.1 to 1.2m center to center either from ground/wall or ceiling.However, the supporting system shall be designed by bidder suitableto bear the uniform load of 400N per 1000mm ladder length for300mm wide tray. The calculations in respect of this design shall besupplied by the successful bidder during design stage. M.S. angle ironbrackets shall be further supported/anchored either to wall orceiling/ground as per the site requirement. The brackets andsupporting system shall be painted with two coats of zinc chromateprimer 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, thenecessary angle iron side support should be provided by the bidder.

iii) The provision for fixing of brackets support system of vertical side ofapproach tunnel should be made by the bidder for fixing thesupporting system. However, bidder is requested to visit the sitebefore 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 thetools/tackles, including welding machines etc. for the manufacturing ofthese cable supports.

2.17.05 The depth of trays shall be 30 mm and thickness 2 mm (min.) with width of200 mm. Necessary standards equal and unequal 90 deg. Bends, tees andcross connections shall also be designed properly as per site requirement.

2.17.06 The free vertical distance between parallel perforated trays/racks/laddershall be at least 250mm and the perforated trays shall be 50mm away fromthe walls. The trays shall be fixed to the brackets with proper nuts and boltssystem.



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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 inproper shape.

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

2.17.09 The supporting brackets/fixing bolts size shall be so calculated that thedesign 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 possiblethe 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 allthe power D.C. cables indicated in the specification for cables. However, theapproximate quantity of different trays have been given under clause 2.21,which can be ensured by the bidder by visiting the site before filling thetender.

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 risersprovided by purchaser, generally in the vicinity of the tray routing. Theearthing shall be as per latest I.E. rules and IS/IEC recommendation. Thesize of earth connection shall be such that its conductance should be morethan 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 workingin 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 theapproved drawings unless otherwise specified.

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

Before cutting the steel, measurement should be done by appropriate gaugeand according to the drawing.



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Shearing or flame cutting may be used provided the resulting edge shall bereasonably clean and straight. Sheared members shall be free fromdistortion at sheared edges, when gas cutting is adopted, the flame cut edgeshall 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 befree of loose scale, slag, rust, grease, paint moisture of any other foreignmaterial.

The welding procedure shall be so arranged that the distortion andshrinkage stresses are reduced to a minimum and that the welds meet therequirement of quality.

2.21 SCHEDULE OF REQUIREMENT OF PERFORATED TRAYS

The schedule of requirement of trays shall be calculated from the drawingsand can vary ±15% as per site requirement.

Description Trays of 300 mm sizeTransformer Hall & Power Houseetc.

3000 m

2.22 SUBMISSION OF DRAWINGS AND DOCUMENTS:

2.22.1 Submission alongwith Tender:

Based on the specification write up and specification drawings the contractorshall submit the following drawings/documents and information with thetender:-

a) Drawings showing dimensional details and constructional features of allcomponents including the following:-

i) Cable trays and accessories

ii) Typical supporting arrangements in various locations

iii) Typical cable trays layout arrangement (showing typicalbends,, T-offs, branching, reducers, coupler etc.)

iv) Typical dimensional details of glands and lugs for varioussizes/types

v) Typical drawings for control and 415V and 22 kV terminationand jointing showing splicing, glanding, lugs, screen/armourearthing etc.

b) Descriptive literature, catalogues, giving design features andmanufacturing details.



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c) Installation and maintenance instructions.

d) Evidence of type tests and special tests conducted on similar type ofequipment/component.

2.21.2 Submission during contract:

2.21.2.1 Within 60 days of the placement of order the contractor shall furnish at least7 sets of documents showing the following for approval.

i) Make, dimensional details and technical specification andcatalogues 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 ofdrawings/documents shall be submitted.

2.21.2.3 Based on the layout/foundation drawings of Sub-Station and other siteswhich shall be handed over to the successful bidder during detailedengineering, the contractor shall prepare and submit seven sets of erectiondrawings 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 SJVNLand erection of cable facility at site shall be done according to thesedrawings any modification at site, if required, shall be marked upon thesedrawings and sketches/revised drawings got approved from the site/projectauthorities.

2.21.2.4 The contractor shall furnish 1 (one) reproducible and 7 (seven) prints each ofthe “As Built” drawings of cable facilities to customer for information andrecord. While doing cable laying as per the cable schedules the contractorshall 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 seteach)



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ANNEXURE-D-I

SCHEDULE OF REQUIREMENT FOR FRLS POWER CABLES

Sr. No. Description Qty. Unit PriceEx-works/m

TotalAmount

1. 22kV Aluminum Conductorunarmored FRLS, XLPEPower Cable:

i) 3-C 95 mm2 1200 m

2 1.1 kV Grade, AluminumConductor unarmored FRLSPVC Cable for L.T System.1)1C 400 mm2

10800 m

2. Cable trays 300 mm wide

and accessories

3000 m

Date: Signature of bidderName:

Place: Status:

Whether authorized attorneyof tendering companyName of tendering Company



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ANNEXURE-D-II

SCHEDULE FOR ERECTION, TESTING & COMMISSIONING OF POWER & D.C.CABLE,TRAYS AND CABLING

Sr. No. Description Qty. Rate Total cost1. Erection/site assembly of supportingsystem for cable trays, i/c erection ofcable trays on supporting systemincluding anchor bolts washer etc. fortypical supporting arrangement per100 mtr. run.

Meter Per 100meter run

2. Laying, fixing, termination includinglugging ferruling providing cableglands etc. as per Clause No. 2.15 ofthe specification and complete testing

and commissioning of different sizesof the power cables as per given inthe schedule of requirementAnnexure-D-A.

Meter Per meter

3. Laying, fixing, termination includinglugging ferruling providing cableglands etc. as per Clause No. 2.15 ofthe specification and complete testingand commissioning of different sizesof the LT and DC cables as per givenin the schedule of requirement

Annexure-D-B .

Meter Per meter

Optional item (not to be evaluated)

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


Place: Status:




18

Annexure-D-A

22kV XLPE/FRLS CABLE REQUIREMENT

Sr.No. From To Type ofCable

Size (mm2) Length(Meters)

1. 22kV over headstructures (nearportal of mainaccess tunnel)

Transformer hallcrown up to 24 kVincoming paneland then outgoingpanel to HVbushing of 2.5MVA Transformerat EL-1062 m.

XLPE 3 Coreunarmoured

95 mm2 1200

2. From DG incomerpanel at Pot HeadYard

LT Panel incomerDG panel at EL-1062 m

FRLS cable 1C400 mm2 10800

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



19

Annexure-D-B

LT, DC CABLES TO BE LIFTED FROM JHAKRI STORE FOR THE PURPOSE OFLAYING, TERMINATION ETC.:

A: LT CABLES

Sr.No. Description of Cable Size Length1. 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 Length1. 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.



20

SCHEDULE–D-III

SCHEDULE OF TECHNICAL DEVIATIONS

Sl.No.

Vol.No.

Clause No. PageNo.

Deviation/ Variation Extra price to be paid incase deviation is requiredto be withdrawn by thebidder

Bidder’s Guarantee:

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


Place: Status:Whether authorized attorneyof tendering companyName of tendering Company



21

SCHEDULE-D-IV

SCHEDULE OF TECHNICAL DATA PARTICULARS OF POWER CABLE

A. POWER CABLE 22 kV

1.0 General:

1.1 Manufacturer’s name andaddress

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 voltagefrequency and combined voltage

and frequency2.5 Suitable for earthed/unearthed

system

2.6 No. of cores

3.0 Conductor and its hardness


3.2 Material copper/aluminium/grade

3.3 Nominal cross-sectional area

3.4 Form of conductorcircular/shaped

3.5 No. of strands

3.6 Nominal dia of each strand



22

3.7 Whether strands are tinned ornot

3.8 Temperature co-efficient ofresistance at 20 deg.C.

4.0 Conductor Screen


4.2 Material

4.3 Minimum thickness

4.4 Whether extruded

5.0 Insulation


5.2 Material (mention type)

5.3 Minimum average thickness

5.4 Tolerance on the smallest of themeasured values of thickness ofinsulation

5.5 Dia of core over insulation

5.6 (a) Minimum volume resistivity at27 deg. C.

(b) Minimum volume resistivity at70 deg.C.

5.7 Colour scheme of identification ofcores

5.8 Average dielectric strength

5.9 Suitability with regard to moistureozone, acid, oil and alkalinesurroundings

6.0 Insulator Screen



23


6.2 Whether extruded semi-conducting screen is applied

6.3 Material of the semi-conducting

screen6.4 Thickness of the semi-conducting

screen

6.5 Whether extruded under tripleextrusion process

6.6 Whether copper type screeningis applied

6.7 Thickness of the copper tape

6.8 For braided screen material anddia of screen wire and min.percentage coverage

7.0 Inner Sheath


7.2 Material thickness of innersheath


7.4 Minimum thickness of innersheath

7.5 Calculated diameter overstranded cores of the cables

7.6 Whether the inner sheath and thefilling material are suitable for the

operating temperature of thecable

8.0 Outer Sheath/Overall Covering


8.2 Material (mention type if any)




24

8.4 Minimum average thickness

8.5 Tolerance on the smallest of themeasured values of thickness ofouter sheath

8.6 Calculated dia. Under the sheath

8.7 Whether anti-termite treatmenthas been given in the outersheath

8.8 Whether flame retardant lowsmoke compound added in outersheath

9.0 Electrical Properties

9.1 Conductor resistance at 20 deg.C. per km.

9.2 Maximum permissible conductortemperature:

a) Under continuous full loadb) 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 temperatureof the above

9.6.4 Short circuit current rating for 1sec. duration

9.7 Derating factors

9.7.1 For an ambient temperature of50 deg.C.

9.7.2 For grouping of 6 to 9 cables incable trench/cable rack trays andin 4 to 6 tiers for different



25

spacings and also touching eachother

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 minimuminstallation radius

10.11 Maximum safe pulling force

10.12 Whether identification as perclause 2.14 of the specification isbeing provided

10.13 Whether packing has been doneas per clause 2.13 of the

specification

B. CABLE TRAYS

1.0

1.1

1.2

1.3

General

Manufacturer’s name andaddress

Location of factory

Type and size of

a) Trays



26

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

2.0

2.1

2.2

2.3

Standard applicable

Thickness

a) Traysb) Supportsc) Brackets

Earthing system

Weight per 100 m

a) Traysb) Supportsc) Brackets

Distance between parallel

Layer of trays

Galvanisation of:

a) Traysb) Nuts & Bolts

Painting of support system

Supporting arrangement system

Cable Clamps

Material

Type

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 1.1ph/ground volt (Pc)

3.5 Impulse withstand 1.2/50 us (kV)



27

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-fogtests furnished (Yes/No)3.9 Kit particulars:

a) Material of tubling/ moulded part

b) Method of stress controlc) Method of environmental

seald) List of items included in

the kit furnished (Yes/No)

1. For terminations2. 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



28

6.2 Make

6.3 Material of fire stop

6.4 Pressure withstand capacity of

fire stop system6.5 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.



29

SCHEDULE-D-V

SCHEDULE OF TRANSPORTAITON WEIGHTS & DELIVERY PERIOD

Sr.No. Item Qty. Shipping weightsTones/Units Totallength Delivery date ofcomponents


Place: Status:




30

SCHEDULE-D-VI

SCHEDULE OF STANDARDS & CODES APPLICABLE FOR MATERIALSCOMPONENTS, MANUFATURE, ASSEMBLY, TESITNG, INSTALLATION &

COMMISSIONING OF POWER CABLES, TRAYS ETC.

Sr.No. Subject/Title Standard/Code Other Remarks1. Material2. Components3. Manufacture4. Assembly5. Testing6. Installation (laying, fixing and

connecting)7. Commissioning


Place: Status:Whether authorized attorney

of tendering companyName of tendering Company



31

SCHEDULE-D-VII

R e m a r k s

S

C A g e n c y

M

P r o j e c t : N a t h p a J h a k r i H

y d r o

E l e c t r i c P r o j e c t

R e f . N o .

S u p p l i e r :

F o r m a t

o f r e c o r d

N A M E & S I G N O F A P P R O

V I N G

A U T H O R I T Y & S E A L

Q P N

o .

R e v . N o . D a t e d

A c c e p

t a n

c e N o

r m s

D O C .

N O .

R e f e r e n c e

D o c u m e n t

F O R S J V N

U S E

R E V I E W E D B Y

M a n u f a c t u r i n g / F i e l d Q u a l i t y

P l a n

I t e m

S u

b - s y s t e m

Q u a n t u m o f

c h e

c k

T y p e o f

C h e c k

C l a s s

M a n

u f a c t u r e r N a m e &

A d d

r e s s

C h a r a c t e r i

s t i c s

L E G

E N D

M : M

A N U F A C T U R E R

C : C

O N T R A C T O R

S : S

J V N

I N D I

C A T E “ P ” P E R F O R M & V E R I F I E D B Y Q C

D E P

T “ W ” W I T N E S S A N D “ V ” V E R I F I C A T I O N

C o m p o n e n t

& o p e r a t i o n

C O N T R A C T

S J V N

S h i m l a

S r . N o .

M A N U F A C T U R E R

/ S U B -

C O N T R A C T O R

S I G N A T

U R E



32

SCHEDULE-D-VIII

SCHEDULE OF DELIVERY & COMPLETION PERIODSl. No. Activity Period in days from

the date of issue ofLOI / LOA

1. Submission of general layout ,fixing arrangement drawings &design for approval of SJVNL

2. Approval of above by SJVNL3. Order placement for bought out items (if any) by contractor4. Opening of site office at Jhakri by contractor5. Submission of cable schedule and remaining construction

drawings and commencement of supplies6. Inspection of:

i) 24 KV Switchgearii) Sub-Station Transformeriii) 415 V ACDB/DG Set paneliv) Cable, Cable Tray & earthingv) Fire fighting arrangement

7. Commencement of despatch of supplies of :i) 24 KV Switchgearii) Sub-Station Transformeriii) 415 V ACDB/DG Set paneliv) Cable, Cable Tray & earthingv) Fire fighting arrangement

8. Completion of receipt of material at Jhakri sitei) 24 KV Switchgearii) Sub-Station Transformeriii) 415 V ACDB/DG Set paneliv) Cable, Cable Tray & earthingv) Fire fighting arrangement

9. Commencement of erection activities at sitei) 24 KV Switchgearii) Sub-Station Transformeriii) 415 V ACDB/DG Set paneliv) Cable, Cable Tray & earthingv) Fire fighting arrangement

10. Completion of erectioni) 24 KV Switchgearii) Sub-Station Transformeriii) 415 V ACDB/DG Set paneliv) Cable, Cable Tray & earthingv) Fire fighting arrangement

11. Testing, commissioning & taking over *

*The period should not be more than 150 days.


Place: Status:




33

SCHEDULE-D-IX

RECOMMENDED SPARES

Sr. No. Particulars/Description Qty. Remarks


Place: Status:Whether authorized attorneyof tendering companyName of tendering Company



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)


Place: Status:Whether authorized attorney

Documents

Cable Trays Tec Spec Chap D