DETAILED TECHNICAL SPECIFICATION FOR INSTRUMENT CABLES

DETAILED TECHNICAL SPECIFICATION

FOR

INSTRUMENT CABLES

TS-I02

CONTROLLED COPY UN-CONTROLLED COPY

00 16.06.2017 First issue GS PG SSR

REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

DOCUMENT NO.

NO. OF SHEETS (including cover

sheet)

TS-I02

6

1910

Text Box

FOR CONTROL & SIGNAL CABLE

AVANT-GARDE

DETAILED TECHNICAL SPECIFICATION FOR INSTRUMENT CABLES

DOC. NO. TS-I02 REV NO. 00 DATE: 04.07.2017 PAGE NO. 2 of 6

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TABLE OF CONTENTS

1.0 Scope of Work ................................................................................................................................ 3

2.0 Scope of Supply .............................................................................................................................. 3

3.0 Scope of Services ............................................................................................................................ 3

4.0 Technical Specification .................................................................................................................. 3

5.0 Inspection and Testing ................................................................................................................... 5

6.0 Drawings & Documents to be Submitted ..................................................................................... 6

6.1 Drawings & Documents to be submitted along with the offer ............................................... 6 6.2 Drawings & Documents to be submitted after award of contract ......................................... 6

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1.0 Scope of Work

1.1 The scope of work covered in this specification includes design,

engineering, procurement, manufacture, shop testing and inspection,

packing and forwarding, transportation, supply, unloading, handling at

site, erection, cleaning, testing, commissioning, trial operation, final

painting and performance testing of all instrumentation cables specified.

1.2 The scope shall include all necessary work and supply of all items

whether mentioned in these specifications or not, but which are necessary

for the satisfactory, reliable and safe operation and maintenance of the

plant and equipment required for achieving guaranteed performance of the

plant. Any items, device or material even if not included during the

tender stage but found necessary for the safe and satisfactory functioning

of the units shall be supplied, erected and commissioned by the BIDDER / SUPPLIER.

2.0 Scope of Supply

2.1 Supply of instrumentation cables, signal cables and control cables as

specified / as required.

3.0 Scope of Services

3.1 Laying of all Instrumentation cables from field instruments, Motorized

valves and all other panels supplied by BIDDER / SUPPLIER to

PURCHASER’s DCS marshalling rack.

4.0 Technical Specification 4.1 General

4.1.1 All cables shall have PVC insulated primary insulation of 85 °C PVC.

Inner and outer jacket shall be 90 °C PVC and shall be fire retardant low

smoke type with Antirodent properties. Oxygen index of PVC shall be

over 30% and temperature index shall be over 250 °C. Insulation grade

shall be 1100 V and shall meet insulation resistance, voltage and spark test

requirements as per BS EN 50288-7.

4.1.2 The cables shall be twisted and armoured. Armour over inner jacket shall

be galvanized steel wire only.

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4.1.3 Inner jacket and outer jacket colour of the cables shall be black. Outer

jacket colour of the signal cable, control cable shall be light blue and grey

respectively.

4.1.4 The completed cable maximum DC resistance of the conductor shall be

12.3ohm/Km at 20 °C for 1.0 Sq.mm conductor. The mutual capacitance

of the pair or adjacent core shall not exceed 250 pF/m at a frequency of

1 KHz. The capacitance between any core and screen shall not exceed

400 pF/m. L/R ratio of adjacent cores shall not exceed 40 microhenry/ohm

for cables with 1.0 Sq.mm. The drain wire resistance including shield

shall not exceed 30 ohm/Km. Running length of the cable shall be printed

atleast at every meter interval.

4.2 Signal Cables (Pair/Triad):

The single pair/triad and multi pair/triad cables shall be of 1.0 Sq. mm

conductor size, made of electrolytic annealed tinned copper conductor of 7

strands with each strand of 0.43-mm diameter. All signal cables shall be

shielded. Multi pair cables shall be both individually and overall shielded.

Shield shall be aluminium backed Mylar/Polyester tape bonded together

with the metallic side down, helically applied with either side having 25%

overlap and 100% coverage. The minimum shield thickness shall be 0.05

mm. The drain wire shall be provided for both individual pair and over all

shields and shall be 0.5 Sq.mm multi stranded bare tinned annealed copper

conductor. The drain wire shall be in continuous contact with aluminium

side of the shield. Pair identification shall be blue and white. Triad

identification shall be blue, white and brown.

4.3 Control Cables:

The control cable shall be 1.5 Sq.mm conductor size made of electrolytic

annealed tinned copper conductor of 7 strands with each strand of 0.53-

mm diameter. The control cable shall be over all shielded. Shield shall be

aluminium backed Mylar/Polyester type. Each core shall be identified by

colour or by number at regular intervals. 4.4 K type Compensating cables:

The conductor material for K type compensating cable is Chromel (+) and

Alumel (-). Diameter of wire shall be 0.81 mm (20 AWG). The insulation

material shall be extruded HR PVC type C of IS:5831. The colour

identification for cable shall be Yellow and red. The taping material shall

be Polyester tape with thickness 0.023 mm (Min) of 25% Overlap and

100% coverage. The inner sheath material shall be PVC type ST2 of

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IS:5831. The colour of the inner sheath shall be black. The outer sheath

material shall be extruded FR PVC type ST2 of IS:5831 and the colour of

the outer sheath shall be yellow. The conductor resistance (max) shall be

1995 Ohm /km at 20 Deg C. The insulation resistance (min) shall be 100

MOhm/km. Oxygen index of PVC shall be over 30% and temperature

index shall be over 250 Deg C as per ASTMD 2863.

4.5 Type of cables

4.5.1 Instrumentation signal cables shall be considered for all analog input and

output signals, Instrumentation control cables shall be considered for all

digital input and output signals.

4.5.2 Size of the instrument signal cable shall be as below

� Branch cable:

4-20mA - 1P x 1.0 sqmm

T/C - 1P x 20 AWS

RTD - 1T x 1.0 Sqmm

� Main cable:

4-20mA - 12P x 1.0 sqmm or 6P x 1.0 Sqmm.

T/C - 12P x 20 AWS or 6P x 12 AWS

RTD - 6T x 1.0 Sqmm or 10T x 1.0 Sqmm

4.5.3 Size of the instrument control cable shall be as below

� Branch cable:

DI/DO - 2C x 1.5 sqmm

� Main cable:

DI/DO - 12C x 1.5 sqmm or 24C x 1.5 Sqmm

5.0 Inspection and Testing

5.1 Inspection and testing cables shall be carried in two major test procedures

as indicated below

Physical test

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Electrical test

5.1.1 Physical test

Physical test involves measurements of size, thickness of the various parts

of the cables. Size of the conductor & armour wire, diameter of each core

and over all cable shall be checked. Similarly thickness of insulation, outer

sheath, and inner sheath shall be tested. Checking of numbering on core /

pair and marking on outer sheath shall be the part of physical test

5.1.2 Electrical test

The following shall be tested during to ensure the parameters as specified

in the approved documents

- Resistance of Conductor & insulation,

- capacitance & inductance values

- Tensile strength of core and sheath,

- Elongation of core and sheath.

In addition to the above high voltage test and heat shock test shall be

carried out.

6.0 Drawings & Documents to be Submitted

6.1 Drawings & Documents to be submitted along with the offer

6.1.1 NIL

6.2 Drawings & Documents to be submitted after award of contract

6.2.1 Quality Assurance plan for cables

6.2.2 Instrument Cable Schedule

DETAILED TECHNICAL SPECIFICATION

FOR

HT & LT CABLES

TS-E13

CONTROLLED COPY UN-CONTROLLED COPY

00 12.06.2017 First issue JP SSR SSR

REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

DOCUMENT NO.

NO. OF SHEETS

(including cover sheet)

TS-E13

7

1910

Text Box

FOR POWER CABLE 3C X 2.5 Sq.mm 3C x 6 Sq.mm

AVANT-GARDE

DETAILED TECHNICAL SPECIFICATION FOR HT & LT CABLES

DOC. NO. TS-E13

REV NO. 00

DATE 12.06.2017

PAGE NO. 2 of 7

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TABLE OF CONTENTS

1.0 Standards 3 2.0 General Construction 3 3.0 PVC Cables 3 4.0 LT XLPE Cables 4 5.0 HT XLPE Cables 4 6.0 Testing 5 7.0 Packing and Marking 6 8.0 Drawings & Documents to be submitted 6

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1.0 Standards

1.1 The design, manufacture and testing of cables shall comply with the

latest issue of the standards mentioned in the Design Basis.

2.0 General Construction

2.1 The cables shall be brand new and in good condition. These shall be

suitable for laying in trays, trenches, ducts, conduits and underground

buried installation with uncontrolled backfill and possibility of

flooding by water. Extra PVC / Rubber end caps for each XLPE Cable

size shall be supplied.

2.2 All cables shall have sequence marking for length. Cables shall also have embossment at regular intervals for brand, voltage grade and size.

3.0 PVC Cables

3.1 All power / control cables for use on medium voltage systems shall be

heavy duty type, 1100 V grade with aluminium / copper conductor,

PVC insulated, inner sheathed, armoured and overall PVC sheathed.

3.2 The construction of the conductors shall be ‘stranded’ for all cables. Conductors of nominal area less than 16 Sq.mm shall be circular only.

Conductors of nominal area 16 Sq.mm and above may be circular or

shaped.

3.3 The core insulation shall be with PVC compound applied over the

conductor by extrusion and shall confirm to the requirement of Type

‘A’ compound of IS: 5831. Control cables having 5 core and above

shall be identified with prominent and indelible ‘Arabic Numerals’ on the outer surface of the insulation. Colour of the numbers shall be

white with a spacing of maximum 500 mm between two consecutive

numbers.

3.4 The inner sheath shall be applied over the laid-up cores by extrusion

and shall be of PVC confirming to the requirement of Type ST1 PVC

compound of IS:5831. The extruded inner sheath shall be of uniform

thickness of size not less than those specified in IS.

3.5 For multicore cables, the armouring shall be by single round

galvanized steel wires where the calculated diameter below armouring

does not exceed 13 mm and galvanized steel strips where this

dimension is greater than 13 mm.

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3.6 The outer sheath for the cables shall be applied by extrusion and shall

be PVC compound conforming to the requirement of type ST1

compound of IS: 5831. To protect the cables against rodent and

termite attack, suitable chemicals shall be added into the PVC

compound of the outer sheath.

4.0 LT XLPE Cables

4.1 All cables shall be of heavy duty type, 1100V grade with aluminium

conductor, XLPE insulated, inner sheathed, armoured and overall PVC

sheathed.

4.2 The construction of the conductors shall be ‘stranded’ for all cables. Conductors of nominal area less than 16 Sq.mm shall be circular only.

Conductors of nominal area 16 Sq.mm and above may be circular or

shaped.

4.3 The core insulation shall be with cross-linked polyethylene unfilled

insulating compound. It shall be free from void and shall withstand all

mechanical and thermal stresses under steady state and transient

operating conditions.

4.4 The inner sheath shall be applied over the laid up cores by extrusion

and shall conform to the requirement of Type ST2 compound of IS:

5831. The extruded inner sheath shall be of uniform thickness of size

not less than those specified in IS.

4.5 For multicore cables, the armouring shall be by single round

galvanized steel wires where the calculated diameter below armouring

does not exceed 13 mm and galvanized steel strips where this

dimension is greater than 13 mm.

4.6 The outer sheath for the cables shall be supplied by extrusion over the

armouring and shall be of PVC compound confirming to the

requirement of Type ST2 compound of IS: 5831. To protect cable

against rodent and termite attack, suitable chemicals shall be added

into the PVC compound of the outer sheath.

5.0 HT XLPE Cables

5.1 All cables shall be with Aluminium Conductor, XLPE insulated,

screened, sheathed, armoured and overall PVC sheathed. Insulation of

cables shall be of 11 kV, Unearthed (UE) grade & 33kV Earthed (E)

type.

5.2 The construction of the conductors shall be dry cured type, stranded

and compacted circular for all cables.

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5.3 The cables shall be provided with both conductor screening and

insulation screening. The conductors shall be provided with non-

metallic extruded semi-conducting shielding.

5.4 The core insulation shall be with cross-linked polyethylene unfilled

insulating compound. It shall be free from void and shall withstand all

mechanical and thermal stresses under steady state and transient

operating conditions and insulation shall be dry cured.

5.5 The insulation shielding shall consist of non-metallic extruded semi-

conducting compound in combination with a non-magnetic metallic

screening of copper. The insulation screen shall be strippable without

application of heat. The copper screen shall be capable of carrying the

single line to ground fault current of 1 kA for duration of one (1)

second, for three cores together.

5.6 The conductor screen XLPE insulation and insulation screen shall all

be extruded in one operation by ‘Triple Extrusion’ process to ensure perfect bonding between the layers. The core identification shall be

coloured strips or by printed numerals.

5.7 The inner sheath shall be applied over the laid up cores by extrusion

and shall conform to the requirement of Type ST2 compound of IS:

5831. The extruded inner sheath shall be of uniform thickness of size

not less than 0.7 mm for all sizes of cables.

5.8 For multicore cables, the armouring shall be by galvanized steel strips

and armouring for single core cables shall be with hard-drawn

aluminium round wire of 2.5 mm diameter.

5.9 The outer sheath for the cables shall be supplied by extrusion over the

armouring and shall be of PVC compound confirming to the

requirement of Type ST2 compound of IS: 5831. To protect cable

against rodent and termite attack, suitable chemicals shall be added

into the PVC compound of the outer sheath.

6.0 Testing

6.1 The cables shall be tested and examined at the manufacturer's works.

All the materials employed in the manufacture of the cable shall be

subjected, both before and after manufacture of the cable, to

examination, testing and approval by PURCHASER /

CONSULTANT. Manufacturer shall furnish all necessary information

concerning the supply to the PURCHASER.

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6.2 After completion of manufacture of cables and prior to despatch,

cables shall be subjected to type, routine, acceptance and special tests

as detailed below. The test reports for all cables shall be got approved

from the PURCHASER / CONSULTANT before despatch of the

cables.

6.3 All routine tests as listed in standards mentioned in the Design Basis,

shall be carried out respectively for PVC cables and XLPE cables.

6.4 The inner and outer sheath of XLPE cables shall be subjected to all the

tests applicable for PVC cables. The test requirement for insulation

and sheath of PVC cables shall be as per latest revision of standards

mentioned in the Design Basis.

6.5 The SUPPLIER shall produce type test certificates as and when

demanded by the PURCHASER / CONSULTANT. These tests shall

also be conducted on mutually agreed terms, if insisted by the

PURCHASER / CONSULTANT.

7.0 Packing and Marking

7.1 Cable shall be despatched in wooden drum of suitable barrel diameter,

securely battened, with the take-off end fully protected against

mechanical damage. The wood used for construction of the drum shall

be properly seasoned, sound and free from defects. Wood

preservatives shall be applied to the entire drum.

7.2 On the flange of the drum, necessary information such as

manufacturer's name, type size voltage grade of cable, length of cable

in meters, drum No. cable code, ISI Certification mark, gross weight

etc., shall be printed. An arrow shall be printed on the drum with

suitable instruction to show the direction of rotation of the drum.

8.0 Drawings & Documents to be submitted

8.1 Drawings & Documents to be submitted along with offer

8.1.1 Bidder credentials as per the schedule

8.1.2 Schedule of deviation

8.1.3 Filled-in data sheets

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8.2 Drawings & Documents to be submitted after award of contract 8.2.1 Drawing & Document Submission Schedule

8.2.2 Bar Chart for the design, manufacture and delivery

8.2.3 Filled-in Technical Data Sheets

8.2.4 Quality Assurance Plan.

SR. NO. BaaN ID Cable Type Discription G. Total (Mtr)

1 CAB0001 1Px 1.0 Sq. mm Signal Cable 6000

2 CAB0002 1Tx 1.0 Sq. mm RTD Triad Cable 1000

3 CAB0003 1Px20AWG Thermocouple Cable 1300

4 CAB0004 2Cx1.5 Sq. mm Control Cable 3500

5 CAB0005 3Cx2.5 Sq. mm Power Cable 1300

6 CAB0006 2Px 1.0 Sq.mm Multipair Signal Cable 1000



9 CAB0009 9Cx1.5 Sq.mm Multicore Control Cable 7000



12 CAB0012 12Tx 1.0 Sq. mm Multicore RTD Cable 2000

13 CAB0013 12Px20 AWS Multipair Thermocouple Cable 300

14 CAB0014 3Cx6 Sq.mm Power Cable 400

15CAB0015

2 Pair x 0.20

Sqmm

Modbus Cable (Armoured) by DCS

supplier300

16 CAB0016 1C X 16 SQ MM EARTHING CABLE COPPER 500

CABLE ANNEXURE SHEET

DETAILED TECHNICAL SPECIFICATION FOR INSTRUMENT CABLES

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