Specification No. RDSO/2010/EM/SPEC/0000, Rev. ‘0

Page 1 of 15 Effective From ---- Specification No. RDSO/2010/EM/SPEC/----- Rev. ‘0’

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Checked By Verified By

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

lR;eso t;rs

Draft Technical Specification

For

Manufacture and Supply of Modular based Cable and Pipe

Sealing System with Adjustable Layer

Specification No. RDSO/2010/EM/SPEC/0000, Rev. ‘0’ ( -------- 2010)

ISSUED BY

ELECTRICAL ENERGY MANAGEMENT DIRECTORATE RESEARCH DESIGNS & STANDARDS ORGANIZATION

MANAKNAGAR, LUCKNOW - 226 011 S No.

Amendment Revision Reason No. Date No. Date

1. - - ‘0’ - First Issue Approved by Executive Director (EEM)


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I N D E X

Clause No.

Description Page No.

1.0 Background 3

2.0 Objective 3

3.0 Scope 4

4.0 Climatic Condition 4

5.0 Standards 5

6.0 Cable & Pipe Sealing System Specification

5

7.0 Schedule of Tests 9

8.0 Drawing 14

9.0 Infringement of patent rights 14

10.0 Sampling of Cable 14


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1.0 Background:

A number of failures and losses are caused by water leakage, fire, and rodent entry into substations, buildings, shelters, control rooms and control Panels. Improper sealing also results in increased cooling load in Air conditioned control room and ultimately leads to power loss. The failures are mainly caused due to:-

1. Damage and cutting of cables due to entry of rodents. 2. Water and dust entry. 3. Overheating of cables due to very less spacing between

the cables. 4. Loss of power occurs due to the cooling loss in an AC

room because of improper sealing.

Currently, local putty or rubber grommet is used to seal the system, if at all. Such type of sealing arrangement only lasts for a short time. At present, globally all the companies have started to use the proper Modular based Cable and Pipe Sealing System with adjustable layer with following features:

1. Protection against Energy/Power Loss in the form of leakages in AC rooms.

2. Water protection according to IP54, IP66 and IP67 ratings.

3. Protection from rodents such as rats, snakes, lizards, etc.

4. Possibility for future capacity expansion 5. Area efficient cable penetration to minimize heat

induction 6. Fire stopper and gas proof. 7. Applicable for retrofit during operation of site

2.0 Objectives:

Foolproof sealing system is a pre-requisite for providing protection against Fire, Water, Energy/Power Loss, Humidity, Temperature Variations, Pull Tension and Rodents, wherever cables are entering in to the Electrical sub-station, Control Room, SCADA Room, Electrical Equipments, Cabinets, Power and UPS Room, Transformers, Buildings and Power equipments.


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The objective of this specification is to define the sealing which shall offer the aforesaid sealing protection and also save on power leakages occurring due to cooling loss in air-conditioned spaces.

The specification lays down the acceptance tests and type tests to be carried out on the sealing system with EPDM rubber modules with adjustable layers and the internal test results of the materials to be submitted by the supplier.

3.0 Scope:

Scope of this specification is to define the Modular based Cable and Pipe Sealing System with adjustable layer. The Cable and Pipe Sealing System must be fire resistant and should be smoke-, gas- and water-tight.

4.0 Climatic Condition:

The climatic conditions specified in this clause are average conditions; any specific conditions specified in the tender documents shall override these.

Atmospheric temperature

(a) Max. Ambient temperature 50°C (b) Max. daily average ambient temp. 40°C (c) Max. soil temp. at cable depth 35°C (d) Minimum temperature: - 5°C

(-10°C in J&K area. Also snowfall in certain areas during winter season)

Humidity 100% saturation during rainy season. Reference site conditions:

i) Ambient Temp

50° C

ii) Humidity 100%

iii) Altitude 1,000m (2,000 m in J & K area) above mean sea level.

iv) Rainfall: Very heavy in certain areas.

v) Atmosphere during hot weather

Extremely dusty and desert terrain in certain areas. The dust concentration in air may reach a high value of 1.6 mg/m³. In many iron ore


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and coalmine areas, the dust concentration is very high affecting the filter and air ventilation system.

vi) Pollution level

Humid and salt laden atmosphere with maximum pH value of 8.5, sulphate of 7mg per liter, max. concentration of chlorine 6 mg per liter and maximum conductivity of 130 micro siemens/cm.

vii) Wind speed High wind speed in certain areas, with wind pressure reaching 150kg/m².

5.0 Standards:

The Cable and Pipe Sealing System shall conform to the following Indian Standards / International Standards as amended/revised till date unless stated otherwise, as applicable:

S. No. Specification

No. Description

1. IEC:60529 Protection from dust, water, humidity, and penetrating solid objects as per IP66, 67

2. UL 1479 Fire Tests of Through-penetration Firestops 3. BS 476/20 Fire Tests on Building Materials and

Structures: Method for Determination of the Fire Resistance of Elements of Construction (General Principles)

4. UL94 V0 Tests for Flammability of Plastic Materials for Parts in Devices and Appliances. Burning stops within 10 seconds on vertical specimen.

5. NF F 16-101, NF F 16-102

Low Smoke and Toxicity index.

6.0 Cable and Pipe Sealing System Specification: 6.1 General Arrangement:- Modular based cables sealing system

shall mainly consist of following sub-assemblies: a) Modules b) Frames (Metallic/ Non Metallic) c) Compression Unit (Separate or Integrated) d) Stay Plates (For rectangular frames)


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e) Lubricants &/ or Assembly Gel

6.2 Modules: Module diameter shall be adjustable by adding on or peeling off procedure so as to suit the cable outer diameter.

The modules shall consist of two halves for each cable, and each module shall be a length of 30 mm or 60 mm. The modules should be able to accommodate cables or pipes of diameter 3.5 to 99 sq mm, a range that encompasses the commonly used sizes. The spare modules may be supplied /with /without re-adjustable and reusable plug /wrap /core for sealing the cables for spare.

6.2.1 Specifications:

6.2.1.1 Composition: Low Smoke Index, Halogen free rubber compound based on Ethylene Propylene Diene Terpolymer (EPDM). The Material (EPDM rubber) of module with centre plug/wrap/core shall be fire resistant as per UL 1479 or BS 476/20 and ensure protection against Dust, Water, & penetrating solid objects as per IP54, IP66 and IP67 (IEC 60529). If no IP protection is mentioned during the tendering stage, then it shall be supplied with IP 67.

6.2.1.2 Adjustable Diameter Modules:-

Modules shall be of adjustable diameter so that by adding on or peeling off the layers, cables of different outer diameters can be accommodated. The spare modules may be supplied /with /without re adjustable and reusable plug /wrap /core for sealing the cables for spare.

6.2.1.3 Physical and chemical properties

(a) State: Solid (b) Odour: Rubber (c) Specific gravity: 1200-1600 kg/m3 (d) Temperature of Decomposition: - > +300°C


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(e) Solubility: Insoluble in water.

(f) Temperature Range: -60 to +80 Degree C.

(g) Certificates in respect of the following:

(i) Fire Protection:- Fire protection for more than 180 minutes as per UL 1479 or BS 476/20. Moreover it should also stop burning within 10 seconds on vertical specimen, no drips allowed as per UL94 V-0 or equivalent.

(ii) Environmental Sealing: Protection against Dust, Water and

penetrating solid objects: IP54, IP66 and IP67 (IEC 60529).

(iii) Temperature Variations (iv) Pull Tension (v) Protection against Rodents, tested by any NABL/

international laboratory 6.3 Frame:

The Frames should be available in different designs and materials. The depth of the frames shall be 30 mm and 60 mm as compatible with module size. The choice of frame shall depend primarily on the material used in the application area and the method of attachment. The frames can either be cast, bolted, welded, riveted or fitted into sleeves.

Material used for frames shall have good impact strength, Tensile strength and should withstand the temperature variations. Material used for the frame shall be as follows:- A) Metallic:- M.S galvanized, SS, Aluminium (for the application

required in concrete) B) Non-Metallic:- Nylon 6/6 with 30% GF (for the application

required in Puff Shelter)


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Frames for cable entry system

6.4 Compression Unit/ Wedge/Press wedge:

6.4.1. The Compression Unit (wedge/press wedge) is used in frames with a rectangular packing space for uniform compression of Cables, Pipes, Modules, and Stayplates. The compression unit should save valuable installation time both when it comes to installation and re-installation of the Modular based Cable and Pipe Sealing System with adjustable layer. When tightened/ loosened, the complete compression unit should compress/ decompress the wedge and compression unit/ press wedge.

6.4.2. For Round Type Seals, the Compression unit is integrated in the seal i.e. for round seal there should be built in compression unit and no separate compression unit should be required as in rectangular arrangements.

6.4.3 Material of wedge should be similar to that of modules i.e. Low Smoke Index, Halogen free rubber compound based on Ethylene-Propylene rubber (EPDM). The bolts shall be of galvanized steel.

6.5 Stay Plates:

6.5.1 To increase stability and to secure Mechanical anchorage within

the frame, Stay Plates should be placed between each row of blocks. Material of construction shall be SS316.

6.5.2 Dimensions: 120 millimeters and 60 millimeter (4.724" und

2.362") width or as compatible with frame. 6.5.3 Stay plates shall be of galvanized steel.


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6.6 Lubricants

6.6.1 Lubricants/ Assembly gel shall be used in all installations for IP 54 rating or more to assure the proper sealing performance.

7.0 Schedule of Tests

7.1.0 General 7.1.1 Only after all the designs and drawings have been approved and

clearance given to this effect by RDSO, the manufacturer shall take up manufacture of the prototype unit.

7.1.2 The contractor shall submit a detailed test plan, for approval of

RDSO, consisting of test procedures, schematic/circuit diagrams, items/parameters to be checked and values required as per specification for each of the tests and the number of days required to complete all the tests at one stretch. The schedule shall also indicate the venue of each of the tests.

7.1.3 The routine/acceptance/type tests to be carried out on the

Cable Sealing System, as part of above inspection are given below.

7.1.4 Prototype inspection shall be witnessed by RDSO as per the

approved test plan. RDSO reserves the right to witness the complete or part of the tests at their discretion.

7.1.5 During the process of type testing or even later, the

DG/EEM/RDSO, Lucknow, reserves the right to conduct any additional test(s), besides those specified in the test plan herein, on any equipment/item so as to test the equipment/item to his satisfaction.

7.1.6 The tests shall be conducted on the prototype Cable Sealing

System at the works of the manufacturer or at any NABL/Government approved test house or laboratory in the presence of authorized representative of DG/EEM/RDSO.


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Contractor shall submit the complete test report consisting of full details of the tests and test parameters.

7.1.7 On successful completion of the tests, prototype approval

certificate shall be issued. 7.1.8 Series manufacture shall start only after issue of prototype

approval by RDSO. Acceptance tests, as per the approved test plan, on the balance quantity shall be done by the authorized representative of the Indian Railways as per purchase order.

7.1.9 Six copies of the following test certificates shall be submitted to

the Purchaser for record:-

(i) Type test certificate as issued by RDSO.

(ii) Acceptance test certificate for complete lot.

(iii) Routine test certificates. 7.1.10 Test certificates shall be completed with all the results.

Purchaser’s approval shall be obtained before dispatch of Cable Sealing System.

7.1.11 Manufacturer shall advise the purchaser one month in

advance when the material shall be ready for inspection and tests, so that the latter’s representatives may be deputed to witness the test(s).

7.1.12 No material shall be shipped or dispatched until inspection

and tests to the satisfaction of purchaser have been completed. 7.1.13 Notwithstanding the successful completion of the tests as

above, the contractor shall be fully responsible for the satisfactory performance of the Cable Sealing System as per the specification, without any prejudice to any claim, right or privilege of the purchaser arising out of use of defective design, material or manufacturing by the contractor.

7.2 Tests:

Tests are to be carried out to prove conformity with the specification. These are intended to prove the general qualities and design of a given type Cable Sealing System. The test plan


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shall be got approved by RDSO before carrying out the test. Following tests shall be carried out on the cable as a minimum:

S No.

Name of Test Type Test

Routine Test

Acceptance Test

Test Method

1. Water Ingress Test

√ - - As per Clause No. 7.4.1

2. Pull Test √ - - As per Clause No. 7.4.2

3. Visual Examination

√ √ √ As per Clause No. 7.3.1

4. Dimensional Examination

√ √ √ As per Clause No. 7.3.2

5. Fire protection for 3 hrs*

√ - - As per UL1479/BS 476-20

6. The Burning stops within 10 seconds on vertical specimen, no drips allowed*

√ - - As per UL94 V-0 or equivalent.

* Certificates shall be provided by the supplier at the time of testing.

7.3 Acceptance Tests:

Tests will be carried out on samples taken specifically from an offered lot for the purpose of acceptance of the lot. Following test shall be done to carry out the acceptance of the product.

7.3.1 Visual Examination:

The Cable Sealing System shall be examined physically for the workmanship and the design technology employed. It shall be checked for any flaws, defects and cracks visible to naked eye. Following examinations also to be done:-

7.3.1.1 Manufacturer’s Identity/Trademark & Dimensional Range:

Cable Sealing System shall be examined visually to check the manufacturer’s trademark. The location of the trademark on the system shall be matched with the concerned drawing of system. Each module shall be visually checked for the range of diameters


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of cables it can hold and shall be verified by checking the printing or marking of dimensional range mentioned on each module.

7.3.1.2 Compression of System:

The Cable Sealing System shall be examined visually to check the proper compression of modules. The rays of light shall not come through the system/ modules.

7.3.1.3 System configuration:

The Cable Sealing System shall be examined visually to check configuration of modules with frame/system. Configuration shall be verified with concerned drawing and BOM of system.

7.3.2 Dimensional Test:

7.3.2.1 Objective: To check the manufacturing of Cable Sealing System. 7.3.2.2 Method:

Each Module is printed or marked with dimensional range showing the minimum and maximum cable diameters it can hold. The Module shall be verified by placing the cables of size falling under that dimensional range.

7.3.2.3 Refer the Drawing of the subjected Cable Transit System to check the dimension of the system

7.4 Type Test:

Type Tests are carried out to prove conformity with the specification. These are intended to prove the general qualities and design of a given type of Cable Sealing System. The type tests shall be carried out once in three years or earlier at the discretion of the inspecting authority. Following shall constitute the type tests

(i) Water Ingress Test (ii) Pull Test

7.4.1 Water Ingress Test: 7.4.1.1 Objective: To determine the water tightness of the Cable

Transit System when subjected to spray of water.


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7.4.1.2 Test Equipment: A holding arrangement/fixture of

sufficient dimension to house the Cable Transit System. 7.4.1.3 Initial Examination: The Cable Sealing System shall be

assembled with all its components like modules, stay plates, wedge, etc. and a continuous cable passing through its any module.

7.4.1.4 Conditioning: The Cable Sealing System in its assembled

condition shall be secured at holding arrangement / fixture. The water shall be sprayed with a pressure of 12.5 l/min and the distance between nozzle and test item shall be 2.5m to 3.0 m. at normal room temperature. This test shall meet the requirement as per IEC 60529.

7.4.1.5 Duration: The test is to be done for a duration of 3 min in

all directions. 7.4.1.6 Final Examination: The Cable Sealing System shall be

examined externally for any abnormality. The Cable Sealing System shall be visually examined at other side of system for any ingress of water.

7.4.1.7 Acceptance: The Cable Sealing System will be declared to

have passed the water ingress test in case there is no water vapour present on other side of the transit system.

7.4.2 Pull Test:

7.4.2.1 Objective: To check the strength and holding of the cable by module inside the Cable Sealing System.

7.4.2.2 Test Equipment: A holding arrangement / fixture of sufficient dimension to house the Cable Sealing System.

7.4.2.3 Method: The Cable Sealing System should be assembled with a long length of cable so that it can be pulled to the required force of 80N to check the strength of module inside the Transit System.

7.4.2.4 Acceptance: The Cable Sealing System will be declared to have passed the pull test in case there is no movement of cables or modules.


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8.0 Drawing:

The manufacturer shall supply relevant drawing and literature with the material for each type of module along with its arrangement consisting of frames, stay plates, etc.

9.0 Infringement of patent rights:

Indian Railways shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, use of similar components in the design and development of this item and any other factor not mentioned herein which may cause such a dispute. The entire responsibility to settle any such disputes/matters lies with the manufacturer/ supplier.

10.0 Sampling of Cable:

Sampling plan for carrying out acceptance tests shall be as per the recommendations of Appendix “A” of IS: 7098 (Part-11)-1985 and tested from each lot for ascertaining the conformity of the lot to the requirements of the specification.


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Typical Pictures of Installation

For Room/ Building Entry

For Cabinet Entry

Documents

Specification No. RDSO/2010/EM/SPEC/0000, Rev. ‘0