Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 1 of 11

LOW VOLTAGE POWER & CONTROL CABLES

Project Document No: G3IR-1050-65-SP-9020

Unit: Discipline: Document Type:

General Electrical Specification

Document Title:

SPECIFICATION FOR LOW VOLTAGE POWER & CONTROL CABLES.

ISSUED FOR DESIGN

02 Aug 2012

1 0 Revision

30-Jul-12 18-Jul-12 Date

Re-Issued for Design (RFQ) Issued for RFQ Purpose

RR HS Prepared By

NG NG Checked By

VP VP Fluor BASF

Approved By

G3IR-1050-65-SP-9020

Page 1 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 2 of 11

LOW VOLTAGE POWER & CONTROL CABLES

Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 Date Description

18-Jul-12

Issued for RFQ

30-Jul-12

General Revision

G3IR-1050-65-SP-9020

Page 2 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 3 of 11

LOW VOLTAGE POWER & CONTROL CABLES

TABLE OF CONTENTS

1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

GENERAL .................................................................................................................................................. 4 Scope......................................................................................................................................................... 4 References ................................................................................................................................................ 4 Service Conditions................................................................................................................................... 5 TECHNICAL REQUIREMENTS ................................................................................................................ 5 General Requirement ............................................................................................................................... 5 Conductors ............................................................................................................................................... 6 Insulation................................................................................................................................................... 6 Fillers ......................................................................................................................................................... 6 Inner Sheath.............................................................................................................................................. 6 Armouring ................................................................................................................................................. 7 Outer Sheath............................................................................................................................................. 7 Core Identification.................................................................................................................................... 8 Equipment Identification ......................................................................................................................... 8

2.10 Cable Drums ............................................................................................................................................. 9 3.0 4.0 TEST AND INSPECTION .......................................................................................................................... 9 DRAWINGS AND DOCUMENTS ............................................................................................................ 11

G3IR-1050-65-SP-9020

Page 3 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 4 of 11

LOW VOLTAGE POWER & CONTROL CABLES

1.0

GENERAL 1.1 Scope This specification is intended to cover design, engineering, manufacture, inspection and testing at manufacturers works, packing, loading, forwarding, transport and delivery to site of flame retardant XLPE insulated LV power cables and PVC insulated control cables. 1.2 References 1.2.1 The LV Power and control cable shall conform to the latest editions of following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for Purchase, unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, as a minimum, Work included in this specification shall conform to the applicable provisions of these publications: PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V. Cross linked polyethylene insulated PVC sheathed cables for working voltages up to and including 1100V. Recommended current ratings for cables Low carbon galvanized steel wires, formed wires and tapes for armouring of cables PVC insulation and sheath of electrical cables. Conductors for insulated electrical cables and flexible cords. Specification for drums for electric cables. Methods of tests for cables. Standard test method for density of smoke from the burning or decomposition of plastics. Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics. Test on gases evolved during combustion of electric cables. Standard for type test of Class IE Electric Cables. Tests on Electric cables under fire conditions. Part-3 : Tests on bunched wires or cables (category -B) 1.2.2 In case of any contradiction between various referred standards/specification/data sheets and statutory regulations, it shall be brought to the notice of Client for IEC-60754 (Part-I) IEEE-383 IEC 60332 ASTM-D-2863 IS : 5831 IS : 8130 IS : 10418 IS : 10810 ASTM-D 2843 IS : 3961 IS : 3975 IS:7098 (Part -I) IS :1554 - I

G3IR-1050-65-SP-9020

Page 4 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 5 of 11

LOW VOLTAGE POWER & CONTROL CABLES

resolution, before taking a decision. Generally the following order of priority shall govern : 1.2.3 Statutory regulations BASF Guidelines Data Sheets This specification Codes and standards

The Manufacturer shall inform/consult the owner / consultant in case there is a conflict among the above documents.

1.3

Service Conditions 1.3.1 The cable shall be designed for a design ambient temperature of +45C and an altitude not exceeding 1000 meters above mean sea level. The cables shall be suitable for operating continuously at the rated capacity as specified in relevant I.S. code under the above ambient conditions without exceeding the permissible temperature rise and without any detrimental effect on any part. 1.3.2 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground buried installation with chances of flooding by water.

2.0

TECHNICAL REQUIREMENTS 2.1 General Requirement 2.1.1 Cables shall be flame retardant, low smoke (FRLS) type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification. 2.1.2 LV Power cable shall be 1.1 kV XLPE insulated power cables, PVC inner-sheathed (as applicable), armoured, PVC outer-sheathed conforming to IS: 7098. (Part-I). 2.1.3 Control Cables shall be 1.1KV Grade, multicore, PVC insulated, PVC inner-sheathed, armoured PVC outer-sheathed conforming to IS: 1554. (Part-I). 2.1.4 Earthing cables shall be single core, unarmoured, aluminium conductors with overall PVC insulation (1.1kV grade). PVC compound shall conform to the requirements of type ST-l compound as per IS: 5831. 2.1.5 Bidder shall have to furnish the minimum length of cable per drum for each type of cable with bid. 2.1.6 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over the declared value in the technical data sheets.

G3IR-1050-65-SP-9020

Page 5 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 6 of 11

LOW VOLTAGE POWER & CONTROL CABLES

2.1.7

In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable

2.2

Conductors 2.2.1 2.2.2 The conductors shall comply with the requirements of IS: 8130. LV power cables shall be of stranded copper conductors up to 16 mm2 and stranded Aluminium conductors above 16 mm2. 2.2.3 Control cables shall be of annealed high conductivity stranded copper round conductors. 2.2.4 Aluminium conductor used in power cables shall have tensile strength of minimum 100 N/ mm2. 2.2.5 The conductors shall be solid for conductor of nominal area up to and including 1.5mm2 and stranded beyond 1.5 mm2. 2.2.6 Conductors of nominal area less than 16 mm2 shall be circular only. Conductors of nominal area 16 mm2 and above may be circular or shaped as per IS 8130. Cables with reduced neutral conductor shall have sizes as per Table 1 of IS 1554 (Part-I).

2.3

Insulation 2.3.1 XLPE insulation shall be suitable for a continuous conductor temperature of 90 Deg.C and short circuit conductor temperature of 250 Deg.C. 2.3.2 PVC insulation shall be suitable for continuous conductor temperature of 70 Deg.C and short circuit conductor temperature of 160 Deg.C.

2.4

Fillers 2.4.1 The cables shall have suitable fillers wherever required, laid up with conductors to provide substantially circular cross section before the inner sheath is applied. 2.4.2 Fillers between the cores shall not stick to insulation and inner sheath.

2.5

Inner Sheath 2.5.1 2.5.2 The PVC inner sheath shall be applied over the laid up cores by extrusion. Inner sheath shall conform to the requirements of type ST 2 compound of IS: 5831 for LV Power cable and type ST 1 compound of IS: 5831 for LV control cable. 2.5.3 All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS: 5831.

G3IR-1050-65-SP-9020

Page 6 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 7 of 11

LOW VOLTAGE POWER & CONTROL CABLES

2.6

Armouring 2.6.1 2.6.2 For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanized steel as follows: Calculated nominal dia of cable under armour i) ii) iii) iv) v) vi) 2.6.3 Upto 13 mm Above 13 & upto 25mm Above 25 & upto 40 mm Above 40 & upto 55mm Above 55 & upto 70 mm Above 70mm 1.4mm dia GS wire 0.8 mm thick GS formed wire / 1.6 mm dia GS wire 0.8mm thick GS formed wire / 2.0mm dia GS wire 1.4 mm thick GS formed wire /2.5mm dia GS wire 1.4mm thick GS formed wire / 3.15mm dia GS wire 1.4 mm thick GS formed wire / 4.0 mm dia GS wire Size and Type of armour

Aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum resistivity of 0.028264 ohm mm2 per meter at 20OC. The size of aluminium wires/formed wires for armouring shall be same as indicated above for galvanized steel.

2.6.4

The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. The minimum area of coverage of armouring shall be 90%.

2.6.5

The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of G.S. wire/formed wire.

2.7

Outer Sheath 2.7.1 The outer sheath of the cables shall be FRLS, black in colour and applied by extrusion over the armouring. It shall be of PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831 for LV power cable and Type ST 1 compound of IS: 5831 for LV control cable. The minimum thickness of outer sheath for armoured cables shall be as per IS: 7098 (Part-2). 2.7.2 FRLS PVC compound for outer sheaths of all the cables shall meet the following performance requirements and cables shall pass these test. The critical oxygen index value shall be minimum 29 at room temperature and the temperature index value shall be minimum 250C at oxygen index of 21 when tested as per IS-10810 (part-58). The maximum total acid gas generation as determined by titration shall be less than 20% by weight, when tested as per IEC 754-1.

G3IR-1050-65-SP-9020

Page 7 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 8 of 11

LOW VOLTAGE POWER & CONTROL CABLES

The maximum smoke density rating expressed in percentage light absorption at any point on the curve during testing period shall not exceed 60% when tested as per ASTM-D-2843-77.

The cables shall pass the hydrolytic stability and ultraviolet test as per DIN 53387. The measured values of ultimate and ultraviolet test as per elongation after the test shall not be less than 60% of that measured before the test.

The finished cables shall pass the flammability test as per IEC-332-1 and IEC-383. In addition it shall also pass flammability test as per class F3 of Swedish Standard S5-424-1475.

2.8

Core Identification 2.8.1 Cores of the cables shall be identified by colouring of insulation. Colour scheme shall be adopted as per requirement given in IS 1554 / 7098. 2.8.2 Colour coding shall be acceptable for all cables upto 5 cores. Cables with more than 5 cores shall have printed numerals on each core. 2.8.3 Core numbers with a minimum letter size of 3mm shall be printed serially on each core of the control cable at intervals of not more than 200 mm. 2.8.4 Core numbers with a minimum letter size of 2 mm shall be printed serially on each core of the instrumentation cable at intervals of not more than 200 mm and each core shall be colour coded as per IEC-189 Part-2. 2.8.5 Earthing conductor shall be coloured green.

2.9

Equipment Identification 2.9.1 All warning, identification and instruction labels shall be inscribed in both the English and local languages. 2.9.2 The individual cores of cables shall be coloured as per relevant IS. Where it is not possible to distinguish the cores by colour, coloured strip shall be applied on the cores or core nos. shall be marked on each core at regular intervals. 2.9.3 The outer sheath of all cables shall be embossed throughout the cable length at every one-meter at two sides with the following information. Manufacturers name Cable standard identification e.g. ISI Symbol. Year of manufacture Cable designation (cores, size, voltage grade, insulation) Running meter markings A legend FRLS at every 5 meter to indicate that the cable is Fire Retardant Low Smoke type.

G3IR-1050-65-SP-9020

Page 8 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 9 of 11

LOW VOLTAGE POWER & CONTROL CABLES

2.9.4

The embossing shall be progressive, automatic, in line and marking shall be legible and indelible.

2.10

Cable Drums 2.10.1 Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS : 10418. 2.10.2 A label shall be securely attached to the end of the reel indicating the customers order number, length of cable and size of conductor. All the details as per relevant IS shall be printed on each Cable reeling drum. Each drum shall carry minimum manufacturer's name, purchaser's name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum 2.10.3 A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. 2.10.4 Cables shall be supplied in specified drum lengths during order. Where no such indication is given, standard drum lengths may be offered. 2.10.5 A tolerance of 2 % shall be permissible for each drum. However, overall tolerance on each size of cable shall be limited to 2%. Offers with short / non-standard lengths are liable for rejection. If non-standard drum lengths are specified in the data sheet, the same shall be supplied.

3.0

TEST AND INSPECTION A) All equipments to be supplied shall be of type tested quality. The supplier shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last five years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by owner. B) In case the supplier is not able to submit report of the type test(s) conducted within last five years from the date of bid opening, or in case the type test report(s) are not found to be

G3IR-1050-65-SP-9020

Page 9 of 11

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 10 of 11

LOW VOLTAGE POWER & CONTROL CABLES

meeting the specification requirements, the supplier shall conduct all such tests under this contract, free of cost to the Owner and submit the reports for approval. C) Type Tests for LV Power Cable The reports for the following type tests shall be submitted on one size each of XLPE LVPower cables : S.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.(a) 11.(b) 12 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
G3IR-1050-65-SP-9020

Type Test For Conductor Annealing test Tensile test Wrapping test Resistance test For Armour Wires/ Formed Wires Measurement of Dimensions Tensile Test Elongation test Torsion test Wrapping test Resistance test Mass of Zinc Coating test Uniformity of zinc coating Adhesion test For XLPE insulation & PVC Sheath Test for thickness

Remarks For copper conductor only. For aluminium conductor only. For aluminium conductor only.

For round wires only For aluminium wires/formed wires only For G.S. Formed wires /wires only. For G.S. Formed wires /wires only. For G.S. Formed wires /wires only.

Tensile strength & elongation tests before ageing and after ageing Ageing in air oven Loss of mass test Hot deformation test Heat shock test Shrinkage test Thermal stability test Hot set test Water absorption test Oxygen index test Smoke density test Acid gas generation test For completed cables Insulation resistance test (Volume resistivity method) High voltage test Flammability test as per clause Flammability test Flammability test as per IEC - 60332 Part-3 (Category -B)
Page 10 of 11

For PVC sheath only For PVC sheath only For PVC sheath only For PVC sheath only For XLPE insulation only For XLPE insulation only For outer sheath only For outer sheath only For outer sheath only

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9020 Date 30-Jul-12 Page 11 of 11

LOW VOLTAGE POWER & CONTROL CABLES

D)

Type Tests for LV Control Cable The reports for the following type tests shall be submitted on one size each of LT Control cables : S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9(a). 9(b). 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Type Test Remarks

For Conductor Annealing test Resistance test For Armour Wires / Formed Wires Measurement of Dimensions Tensile Test Elongation test Torsion test For round wire only Wrapping test Resistance test Mass of zinc Coating test For GS wires/formed wires only Uniformity of zinc coating For GS wires/formed wires only Adhesion test For GS wires/formed wires only For PVC insulation & PVC Sheath Test for thickness Tensile strength and elongation test before ageing and after ageing Ageing in air oven Loss of mass test For PVC insulation and sheath only Hot deformation test For PVC insulation and sheath only Heat shock test For PVC insulation and sheath only Shrinkage test Thermal stability test For PVC insulation and sheath only Oxygen index test For outer sheath only Smoke density test For outer sheath only Acid gas generation test For outer sheath only For completed cables Insulation resistance test(Volume resistivity method) High voltage test Flammability test as per clause Flammability test Flammability test as per IEC - 60332 Part-3 (Category-B)

E)

Flammability Test This test shall generally be carried out as per IEEE 383. The cable installation to be tested shall consist of as many cables as are necessary to give at least 10 kg of organic material per meter run.

4.0

DRAWINGS AND DOCUMENTS The Vendor shall furnish drawings in accordance with SDDC form, enclosed with the Bid.

G3IR-1050-65-SP-9020

Page 11 of 11