Vol - III Technical Specification (Electrical) l1

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DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

TECHNICAL SPECIFICATION, CHAPTER 2
Document
No:
KSLPEIRR-1501-EE-TS-01
R0
Contents
Volume III (Technical specification for Electrical Items)
2.5.0 HV LV & Control Cables...................................................................................

2.5.1 Codes and standards...........................................................................................
2.5.2 Specification Requirement Schedule for HV and LV Power and Control
Cables..............................................................................................................................
2.5.3 Cable Selection and Sizing.................................................................................
2.5.4 Construction Feature..........................................................................................
2.5.5 Tests......................................................................................................................
2.6.0 Earthing & Lightning Protection System.........................................................
2.6.1 Codes and standards...........................................................................................
2.6.2 System Concept and Design Criteria................................................................
2.6.3 Lightning protection system...............................................................................12
2.5.0 HV LV & Control Cables

2.5.1 Codes and standards
All materials in cables shall be designed, manufactured and tested in accordance
with the
Latest applicable Indian Standards (IS) /IEC except where modified and/or
supplemented by
This is a proprietary document of Kirloskar Brothers Limited, Pune INDIA

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This specification.
Materials in cables conforming to any other standard, which ensures equal or better
quality, may be accepted. In such case, copies of the English version of the
standard adopted shall be submitted along with the bid.
1. IEC: 502
Power cables with extruded insulation & their accessories
for rated
Voltages of 1kV to 36kV
2.
IEC:540 &540A
Test methods for insulation & sheaths of electric cables &
cords
3.
4.
5.
IEC:332
IEC: 754
ASTM-D-2843
or
Test on electric cables under fire conditions

Test on gases evolved during combustion of electric cables
Standard test method for density of smoke from burning
Decomposition of plastics.
2.5.2 Specification Requirement Schedule for HV and LV Power and

Control Cables
Sr.
Parameter
Description
No.
HV Power Cables 33000V Grade
1
33000 grade 900 C rating heavy duty XLPE power cable suitable for use in
non effectively earthed system conforming to following requirement and in
line with IS 7098, IS-8130, IS-5831 and IS-3975.
1.1
Conductor
Stranded and compacted aluminum conductor of grade
H2 and class 2 for all sizes, generally conforming to
IS:8130
1.2
Conductor
Extruded semi conducting compound.
Screen
1.3
Insulation
Extruded cross linked polyethylene (XLPE)
1.4
Insulation
Screen
1.5
1.6
Core
Identification
Inner Sheath
1.7
Armour
Extruded semi conducting compound with a layer of

non magnetic metallic tape. For single core armored
cables, the armoring shall constitute the metallic part of
screening. The semi conducting tape shall be easily
strippable.
By colored strips applied on (For three core cables)
cores or by numerals.
Extruded PVC compound conforming to type ST2 of IS:
5831 for three core cables. Single core cables shall have
no inner sheath. Filler material shall also be of type ST2
PVC.
Galvanized single round steel wire armor for twin and
multicore cables.

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Non magnetic hard drawn aluminium single round wire

conforming to H4 grade for single core cables.
1.8
Overall Sheath
Extruded FRLS PVC compound conforming to type ST2
of IS: 5831.
L.T. Power Cables 1100 V Grade
2
2.1
2.2
2.3
2.4
2.5
1100 V grade, 850 C/ 900 C rating, heavy duty, HR PVC/XLPE power cable
conforming to following requirement and in line with IS 1554, IS 5831, IS
8130 and IS 3975.
Conductor
Stranded and compacted plain aluminium of grade H2
and class 2/stranded, high conductivity annealed plain
copper as per Annexure, generally conforming to IS:
8130.
Insulation
Extruded HR PVC compound conforming to type C of IS:
5831 or XLPE.
Inner Sheath
5831 for multicore cable. Single core cables shall have
no inner sheath.
Armour
Galvanized single round steel wire armour for twin and
multicore cables.
Non magnetic hard drawn aluminium single round wire
conforming to H4 grade for single core cables.
Overall Sheath
of IS:5831.
Control Cables 1100 V Grade

3.0
3.1
3.2
3.3
3.4
3.5
1100 V grade, 700 C rating, PVC Control cable conforming to following

requirement and in line with IS-1554, IS-8130, IS-5831 and IS-3975.
Conductor
Stranded, non compacted and circular, high
conductivity annealed plain copper, generally
conforming to IS: 8130.
Insulation
Extruded PVC compound conforming to type A of IS:
5831.
Inner sheath
5831 for multicore cables. Single core cables shall have
no inner sheath.
Armour
Galvanised single round steel wire for twin and
multicore cables.
Overall sheath
of IS: 5831.
HR
Heat Resistant
FRLS
Flame Retardant Low Smoke
2.5.3 Cable Selection and Sizing

In cable sizing the following are to be taken into consideration.
(a) Short circuit current and duration
(b) Continuous current.

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(c) Installation conditions.

(d) Voltage drop under normal running and starting condition.
For HT Cable sizing SC current of 25 KA for 0.3s shall be considered.
Apart from above, consideration shall also be given to limit the cable to some
standard sizes instead of using too many types.
The standard cable sizes, capacities, derating factors, etc. as given in IS will be
generally followed.
(a) For breaker protected circuits minimum size will be determined by short circuit
rating.
(b) For motor circuits the selection of size will be made ensuring that the cable shall
withstand a short circuit fault directly following a second hot start.
For fuse protected circuit, the conductor size will depend on full load current subject
to voltage drop not exceeding 3%. For practical purposes, the minimum size chosen
is as below:
(a) Aluminium : 10 sq. mm.
(b) Copper : 2.5 sq. mm.
All drives of small rating where terminations with Aluminium cables are not feasible,
shall have
copper cable
All control cables shall be 2.5 sq. mm. copper cables
Multicore control cables will generally have spare conductor (s) in accordance with
the following chart:
Conductors required
1 or 2
3 or 4
5 or 6
7 to 10
11 to 14
Cables
1-2Core or 3Core
1-5Core
1-7Core
1-12Core
1-16Core
Separate cables for each type of following services / functions as applicable shall be
used for each feeder. One multicore cable using different services shall not be
acceptable.
(a) Power.
(b) Control, interlock and indication.
(c) Metering and measuring.
(d) Alarm and annunciation.

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(e) C.T. Cables.

(f) V.T. Cables.
2.5.4 Construction Feature
The cables shall be suitable for laying on racks, in ducts, trenches, GI conduits and
under ground (buried) installation with chances of flooding with water.
For continuous operation at specified rating, maximum conductor temperature shall
be limited to the permissible value as per relevant standard and / or this
specification.
The insulation and sheath materials shall be resistant to oil, acid and alkali and
shall be tough enough to withstand thermal, electrical and mechanical stresses
during handling.
All HV cables shall be armoured. Armouring shall be single flat/round strip of
galvanised steel for multicore cables and aluminium for single core cable. For EHV
power cable the armouring shall be of non-ferrous flat strip metal.
The outer sheath shall have flame retardant low smoke (FRLS) characteristics and
shall meet the requirements of additional tests specified for this purpose. Core
identification for multicore cable shall be provided by colour coding. Allowable
tolerance in the overall diameter of cable shall be +/- 2mm above the declared
values in technical data sheets.
Within buildings, cables shall be installed on cable trays or racking in a manner that
shall prevent the cable being damaged, and to minimise the occurrence and spread
of fire. When installed outdoors all cable trays will be provided with covers. These
shall provide suitable mechanical and solar protection. Power cables shall be
adequately clamped to prevent movement under short-circuit conditions. Single
core cables shall be clamped in trefoil formation. Duplicated circuits, such as
cables that service main distribution switchboards and those cables forming part of
emergency/high integrity circuits shall follow different routes or be separated as far
as is practicable.
Separation shall be achieved by laying cables neatly on trays. 11 kV cables,
415/230 V power cables, and control cables shall be separated from each other. 11
kV cables shall be placed at the top of the cable routes and in single layers only.
415/230 V cables shall be placed in the next lower levels and control cables placed
at the lowest levels. 415/230 V and control cables may be laid to a maximum of two
layers.

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All cables external to buildings shall be laid in PVC Conduit or on trays or racks
within reinforced concrete trenches. Direct burial of cables in the ground shall not
be permitted unless specifically approved when they shall be of the armoured type
or mechanically protected in an approved manner. All cable racking/trays shall be
bonded to the earthing system.
Drum length and tolerance
The cables shall be supplied in wooden/metal drums, each containing minimum 500
meters length for power cables and 1000 meters for control cables. Allowable
tolerance on individual drum length is 5%.
Non-standard length
Owner may accept non standard lengths up to 5% of the total ordered quantity.
However, the
Contractor will be required to obtain Owner's approval before packing the cables on
drums. Non standard lengths shall not be less than 100 meters in any case.
Joints and terminations
Materials of construction for a joint/termination shall perfectly match with the
dielectric chemical and physical characteristics of the associated cables. The
material and design concepts shall incorporate a high degree of operating
compatibility between the cable and joints. The protective outer covering (jacket)
used on the joints/terminations shall have the same qualities as that of the cable
outer sheath in terms of ambient/operating temperature withstand capability and
resistance to hazardous environments and corrosive elements. Special provision of
protection shall have to be made considering coastal location of site.
The other mandatory accessories viz., ferrules, cable ties, clamps, cable markers,
sand, bricks, etc shall be supplied.
Cable identification
Cable identification shall be provided by embossing the following on the outer
sheath:
(a) Manufacturer's name or trade mark
(b) Voltage grade
(c) Year of manufacture
(d) Type of insulation, e.g. HR85 for HR PVC etc.
(e) Type of outer sheath e.g. "FRLS" etc.
(f) ISI marks

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(g) Nominal cross sectional area of the conductor & no of cores

(h) Sequential marking
(i) Owners identification mark .
Packing and transport
Cables shall be supplied in non-returnable drums. The drums shall be of heavy
construction. All wooden parts shall be manufactured from seasoned wood. All
ferrous parts used shall be treated with suitable rust preventive finish or coating to
avoid rusting during transit or storage. Wooden cable drum shall be treated by
immersing in copper-nitrate solution.
The ends of each length shall be sealed before shipment. Heat shrinkable cable cap
shall be used for this purpose. A label shall be securely attached to each end of the
reel indicating the Purchaser's order number, Owners identification mark, length,
type, voltage grade, conductor size and number of cores of the cable. A tag
containing the same information shall be attached to the leadings end of the cable
inside. An arrow and necessary instructions shall be marked on the drum indicating
the direction in which it should be rolled. Drum numbers are to be indicated on the
cable drums.
2.5.5 Tests
Shop tests
The Cables shall be subject to shop tests in accordance relevant IS/IEC standards to
prove the design and general qualities of the Cables as below:
(a) Routine tests on each drum of cables.
(b) Acceptance tests on drums chosen at random for acceptance of the lot.
(c) Type tests on each type of cable, inclusive of measurement of armor DC
resistance of
power cables.
Additional Tests
Following additional acceptance tests shall also be performed on each type of
cables having outer sheath with improved fire performance (category C1, Type
FR/ Category C2, Type FRLSH)
(a) Oxygen index test (for both C1 & C2)
The Oxygen index shall not be less than 29
(b) Temperature Index Test (for both C1 & C2)
The measured value of temperature index shall be 21 at a temperature of 250C

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(c) Flame Retardance test on single cable and on bunched cables (for both C1 &
C2)
After the test, there should be no visible damages on the test specimen within
300mm from
its upper end. After burning has ceased, the cables should be wiped clean and the
charred or affected portion should not have reached a height exceeding 2.5 meter
above the bottom edge of the burner, measured at the front and rear of the cable
assembly.
(d) Halogen acid gas evolution test (for category C2).
The level of HCL evolved shall not exceed 20 per cent by weight
(e) Smoke density test (for category C2)
The cables shall meet the requirements of light transmission of minimum 40% after
the test.
(f) Test for rodent & termite repulsion property
The test shall be carried out to note the presence of rodent and termite repelling
chemical in
PVC compound. Normal procedure is that a few chippings of the PVC compound are
slowly
ignited in a porcelain dish or crucible in a muffle furnace at about 600C. The
resulting
ignited ash is boiled with a little ammonium acetate solution (10%). A drop of
aqueous
sodium sulphide solution is placed on a thick filter paper and it is allowed to soak.
The spot
is touched with a drop of above extract. A black spot indicates the presence of antitermite
& rodent compound.
Test witness
Tests shall be performed in presence of Owners representative if so desired by the
Owner. The Contractor shall give at least thirty (30) days' advance notice of the
date when the tests are to be carried out.
Test certificates
(a) Certified reports of all the tests carried out at the works shall be furnished for
approval of the Owner.

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(b) Test reports shall be completed with all details and shall also contain IS specified
limit
Values, wherever applicable, to facilitate review.
(c) The cables shall be dispatched from works only after receipt of Owner's written
approval of the test reports.
2.6.0 Earthing & Lightning Protection System

2.6.1 Codes and standards
IS: 2309
Code of Practice for the protection of building and allied structures
against
lightning.
IS: 2629
recommended practice for hot dip galvanizing of iron & steel
IS: 2633
Method for testing uniformity of coating on zinc coated articles.
IS: 3043
Code of practice for Earthing
IEEE: 80
IEEE guide for safety in AC substation grounding
IEEE: 142
Grounding of Industrial & commercial power systems
2.6.2 System Concept and Design Criteria

(i) Objectives
(a) Provide safety to personnel from contact of dangerous potential caused by
ground fault.
(b) Ensure sufficient grounding current for effective relaying.
(c) Stabilize circuit potential with respect to ground.

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(ii) Grounding design

The grounding design shall be done in accordance with the consideration of the off
shore location of the seawater intake and outfall system All electrical equipment,
non current carrying metal parts, structures, building steel, lightning protection
system, generator/transformer neutrals will be connected to ground grid. The
minimum conductor section shall be determined on the basis of ground fault
current. The section shall be increased by an allowance to account for the effects of
corrosion loss over the design life of 30 years taking into account of coastal region
site. The ground grid mesh shall be designed to keep the touch and step voltages
within safe limits as per
recommendation of IEEE 80.
(iii) Above ground connections
(a) Galvanized steel flats shall be used for all connections above earth. Sizing shall
be
decided during detailed engineering stage.
(b) Inside building, ground conductors will be run for each floor supported on
building steel
and/or cable trays. These ground conductors in turn will be connected to the station
ground
grid through riser (at least two) coming up along building columns/cable shafts.
(c) Two separate and distinct ground connections will be provided for each electrical
equipment in compliance with I.E. Rules.
(d) All connections above ground will be welded type except connection to
equipment/structures which shall be bolted type with appropriate washers.
(iv) Equipment ground lead
Equipment ground connections shall be sized to carry the available ground fault
current.
Considerations shall also be given to mechanical ruggedness of the connections
and to limit the number of sizes.
Entire erection of grounding work shall be carried out in such a way as to be
capable of withstanding the intended services of carrying full short circuit level
currents to ground mat without any damage/deformation.

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The sizes of earthing conductors for various electrical equipments shall be as

below:
Sr No.
Equipment
1.
Main earth grid
2.
33kV/11kV
switchgear/equipmen
t 415V switchgear
33KV/11KV
Transformer
HT Motor
3.
4.
5.
6.
7.
8.
9.
10.
11.
LT motors 3.7kW to
15kW
LT motor up to 3.7
kW
Power transformer
Neutral
Control panel &
control desk
Push button station /
JunctionBox
Columns, structures,
cable
trays and busduct
enclosures
Crane, rails, rail
tracks & other noncurrent carrying
metal parts
Earth
conductor
buried in earth
40 mm dia.MS
rod
---
Earth conductor above

ground level & in built-up
trenches
50x10mm MS flat
---
50x6mm GS flat
---
50x6mm GS flat
---
16 Sq.mm Stranded GI wire
---
---
50 x 6mm CU flat
---
25 x 3 mm GS flat
---
---
50x6mm GS flat
50x6mm GS flat
25x6mm GS flat
(V) Ground Electrode

Ground electrodes sizing shall be determined based on the calculations but shall be
at least 40 mm diameter and 3 metre long galvanized M.S. rod. These are to be
fabricated and driven into the ground by the side of mat conductor. All connections
to the conductors shall be done by arc welding process.
(VI) Risers
Risers are required for connecting the equipment and structures with the ground
mat. These will be at least 40 mm diameter G.I M.S. rod laid from ground mat to

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above ground level properly clamped or supported along the outer edge of the
concrete foundation. Connection to the ground mat shall be done by arc welding
and the other end is to be kept free at least 300 mm above grade level/concrete
floor level unless otherwise shown.
(VII) Column Grounding
All columns are required to be grounded by 40 mm dia M.S. rod from ground mat.
Laying, supporting along with foundation, connecting at ground mat are within the
scope of this specification. At least 300 mm length of the above rods shall be left
free above the grade level/concrete floor level for connection with columns.
(VIII) Galvanising
The galvanising shall be uniform, clean, smooth, continuous and free from acid
spots. Should the galvanising of the samples be found defective, the entire batch of
steel has to be regalvanised, at Bidder's cost. The amount of zinc deposit shall not
be less than 610 grams per square metre of surface area and in addition, the
thickness of the zinc deposit at any spot whatsoever shall not be less than 75
microns. The Owner reserves the right to measure the thickness of zinc deposit by
Elkometer or any other instrument and reject any component which shows
thickness of zinc at any location less than 75 microns.
The maximum fault current for 33kV system is to be considered as 25 kA for 1 sec.
2.6.3 Lightning protection system

(i) Objective
(a) Provide protection to structures from lightning strokes.
(b) Provide a low resistance-conducting path to lightning discharge.
Lightning protection shall be provided for Pump house House building and other
structures.
For metal structures which are electrically continuous down to the ground level, no
lightning
protection is required except adequate grounding connections.
(ii) System design

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(a) Air termination network with down conductors and earthing electrodes will be
provided on
the basis of IS Code of Practice.
(b) Horizontal air termination shall be so laid out that no part of the roof will be
more than 9
meters from the nearest conductor.
(c) Shielding angle for one vertical air termination shall be 45o. For more than one
rod, shielding angle between the rods shall be taken as 60 o.
(d) Down conductors will run along the outer surfaces of the building and shall have
a test joint
about 1500 mm above ground.
(e) An earth electrode will be provided at the connection point of the down
conductor with the
station ground.
(f) Galvanized steel rods and flats will be generally used for air termination and
connections.
Lightning protection system shall be in strict accordance with standards as
mentioned in
Clause Lightning conductor shall be of 25x6mm GS strip when used above ground
level and
shall be connected through test link with earth electrode/earthing system.
Lightning system shall comprise of air terminations, down conductors, test links,
earth electrode etc. as per approved drawings.
(iii) Down Conductors
Down conductors shall be as short and straight as practicable and shall follow a
direct path to earth electrode.
Each down conductor shall be provided with a test link at 1000 mm above ground
level for testing. No connections other than the one direct to an earth electrode
shall be made below a test point. All joints in the down conductors shall be welded
type.
Down conductors shall be cleatted on outer side of building wall, at 750 mm
interval or welded to outside building columns at 1000 mm interval.

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Lightning conductor on roof shall not be directly cleatted on surface of roof.

Supporting blocks of PCC/insulating compound shall be used for conductor fixing at
an interval of 1500 mm.
All metallic structures within a vicinity of two meters of the conductors shall be
bonded to conductors of lightning protection system.
Lightning conductors shall not pass through or run inside GI Conduits.
Testing link shall be made of galvanized steel of size 25x 6mm.
(iv) Routine Test
a) Routine tests as per specification and applicable standards shall be carried out
on all equipments/items covered in the specification.
b)
Physical
&
dimensional
check
on
all
equipments
as
per
approved
drawings/standards.
HV/IR as applicable.
c) Check/measurement of thickness of paint/zinc coating/nickel-chrome plating as
per specification & applicable standard.
(V) Commissioning
The Contractor shall carry out the following commissioning tests and checks after
installation at site. In addition the Contractor shall carry out all other checks and
tests as recommended by the Manufacturers.
Earthing and Lightning protection system
1) Earth continuity checks.
2) Earth resistance of the complete system as well as sub-system.

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SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

2.5.0 HV LV & Control Cables...................................................................................

2.5.0 HV LV & Control Cables

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

Power cables with extruded insulation & their accessories

Test methods for insulation & sheaths of electric cables &

Test on electric cables under fire conditions

2.5.2 Specification Requirement Schedule for HV and LV Power and

Extruded cross linked polyethylene (XLPE)

Extruded semi conducting compound with a layer of

This is a proprietary document of Kirloskar Brothers Limited, Pune INDIA

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

Non magnetic hard drawn aluminium single round wire

Control Cables 1100 V Grade

1100 V grade, 700 C rating, PVC Control cable conforming to following

Flame Retardant Low Smoke

2.5.3 Cable Selection and Sizing

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DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

(c) Installation conditions.

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DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

(e) C.T. Cables.

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DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

(g) Nominal cross sectional area of the conductor & no of cores

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DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

2.6.0 Earthing & Lightning Protection System

recommended practice for hot dip galvanizing of iron & steel

Method for testing uniformity of coating on zinc coated articles.

Code of practice for Earthing

IEEE guide for safety in AC substation grounding

Grounding of Industrial & commercial power systems

2.6.2 System Concept and Design Criteria

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

(ii) Grounding design

This is a proprietary document of Kirloskar Brothers Limited, Pune INDIA

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

The sizes of earthing conductors for various electrical equipments shall be as

Main earth grid

Earth conductor above

16 Sq.mm Stranded GI wire

6 Sq.mm Stranded GI wire

6 Sq.mm Stranded GI wire

(V) Ground Electrode

This is a proprietary document of Kirloskar Brothers Limited, Pune INDIA

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

2.6.3 Lightning protection system

This is a proprietary document of Kirloskar Brothers Limited, Pune INDIA

SAED, RIVER VALLEY, NORTH SENEGAL

DOCUMENT -VOL. II ELECTRICAL EQUIPMENTS

This is a proprietary document of Kirloskar Brothers Limited, Pune INDIA