CABLE

Item:-Checklist for 3.3kV Cu XLPE single core Cables FRLS

Checklist of FAT AS PER STANDARD IEC 60502-2(2005) & GTP
Sr.
no
.

Type of
test

Description

Acceptance
norms

Procedure

1.

Physica
l

Cross
section
area of
metallic
screen

Nom.8 sq.mm

2.

Physica
l

Thickness
of
insulation

Nom.2.0 mm

3.

Physica
l

Thickness
of outer
sheath

Min. 1.9 mm

N*0.78548*d2 Where
N = no. of wire &
d=nom. Dia of wire,
Physical
measurement of
diameter to calculate
the area
Physical
measurement of
thickness of
Insulation
Physical
measurement of
thickness of
Insulation

4.

Physica
l

Measureme
nt of
overall dia.
of cable

Approx. 34
mm

5.

Physica
l

(a)Conduct
or material

Annealed
Plane Copper.

(b)conduct
or shape

Stranded
Compacted
Circular

6.

Physica
l

Length
check
Rewinding
Method

The cable
length should
not be vary
from the
offered length
of the drum
-There
should be
finish of the
cable i.e. no
joint ,no
puncture etc.

Physical
measurement of
diameter of cable

Could
not
be
measured directly as
conductors
were
compacted. The test
report for the time of
manufacturing taken
from
the
quality
department
One complete drum
taken from the
offered lot. The full
drum to be rewind
into another empty
drum with the help of
measuring roller. The
cable to be rolled by
passing from the
hand

Sample
on which
test
conducte
d

Remarks

para of
10 of
IEC6050
2-2& GTP

para of
17.5. of
IEC6050
2-2& GTP
para of
14.3. of
IEC
605022& GTP
para of
17.8 of
IEC
605022& GTP
IEC
60228&
GTP

in the cable
Min. 30 at
room
temperature

7.

Physica
l

Oxygen
index test
on outer
sheath

The test sample

positioned vertically
in a glass chimney
and an oxygen
environment is
established with a
flow from the bottom
of the chimney the
top edgeof the test
sample is ignited and
the oxygen
concentration in the
flow is decreased
until the flame is no
longer supported.

ASTM D2863&
GTP

8.

Physica
l

Min.260C

9.

Physica
l

Temperatur
e index test
on outer
sheath
Acid gas
generation
test on
outer
sheath

Max.20%

The test Sample

inserted into quartz
glass tube and put
on a combustion
boat and 200 ML of
the solution
measured into a
conical flask and
chemical liquids is
used to
conglomeration and
coating of the silver
halide that is formed
by the reaction.

IEC
60754
part-1

10
.

Physica
l

Smoke
emission
test

Max. smoke
density rating
50%
(After vendor
approval)

Turn on the all

apparatus the
pressure of propane
adjust 276Kpa.
Warning-do not fail to
light the burner
immediately set the
temp. composition
adjust the lamp
control to 0% light
absorption lay the
test specimen flat on
the screen set the
time is zero .shut off
the exhaust blower
close the
smoke chamber door
.if in a hood shutoff

ASTM D2843

ASTM D2863

the hood fan close

the hood door within
50mm.of the bottom
of the hood. Record
the % light absorbed
at 15 second interval
continue 4 min.
11
.

Physica
l

Flammabilit
y test on
finished
cable

The length of
specimen is
600mm.position for
IEC 60332-1 of the
specimen is vertical
& position of the
flame 45 to vertical
specimen the test.
Duration of flaming is
480 second.
For IEC 60332-3 Cat
A the length of the
specimen is 3.5 m
and the number of
samples is 4 and the
charred portion
should not have
reached a height
exceeding 2.5 m
above the bottom
edge of the burner.

IEC
60332-1
IEC
60332-3
Cat-A

12
.

Physica
l

Conductor
screening

Visual examination
and physical
measurement.

7.1 Para
of IEC
60502-2

Visual examination
and physical
measurement.

As per
Para 12.7
of
IEC6050
2-1 &GTP

Visual examination
and physical
measurement.

As per
GTP

(a) material

13
.

14
.

Physica
l

Physica
l

Semiconducting
tape followed
by extruded
semiconducting
compound

Armouring
Material

Double
Aluminium
Tape

Nominal
thickness
Metallic
screen

0.5mm
Helically
applied plain
copper wires
(with gap)
followed by
an open helix

plain copper
tape.
Max.
0.0754/km

15
.

Electric
al

DC
resistance
test of
conductor
at 20C

16
.

Electric
al

Partial
Discharge
test

Sensitivity
should be less
than 5 PC

17
.

Electric
al

Capacitanc
e Test

Max. 0.76
mF/Km

18
.

Electric
al

High
Voltage
Test 4 Hrs

This test is done at

20C. Temperature
maintains 20C at
least 12h before the
test in case of doubt
as to whether the
conductor
temperature is the
same as the room
temp. the resistance
shall be measured
after the cable has
been in the test room
for 24h
Req-the DC
resistance of the
each conductor at
20C shall be not
exceeding the given
max value.
Test voltage shall be
raised gradually to
and held at 2u0 for
10 second and than
gradually reduced to
1.73 u0

Para 16.2
of
IEC6050
2 part(II)

The capacitance
should be measured
between conductor
and metallic sheath.

Para of
10.10 of
IEC
60840
&GTP

Test voltage shall be

raised gradually to
and held at 2u0 for
10 second and than
gradually reduced to
1.73 u0

para
of17.9
of IEC60502-2

Para of
18.1.4 of
IEC
60502-2

2) Type Test reports

(I) Electrical Type Test Reports as per QAP and IEC 60502-2 on
(II)Physical and Mechanical Type Test report as per QAP and IEC 60502-2 on

3) Stage Inspection Certificates

I) Copper Rod
II) Semiconducting Tape
III) Semiconducting Compound
IV) XLPE Compound
V) Copper Tape
VI) Glass Fibre Tape
VII) Aluminium Tape
VIII) FRLS PVC compound

4) Raw Material Test Certificates

(I)Conductor
(II)Semi conducting tape
(III)Inner Semiconducting tape
(IV) Insulation
(V)Outer Semiconducting tape
(VI)Copper wire
(VII)Copper Tape
(VIII)Inner Sheath
(IX)Glass Fibre Tape
(X)Aluminium Tape
(XI)Outer Sheath
5) Calibration status and Calibration certificates:
Physical and Chemical Equipments
Name of Instrument
1
2
3
4
5

Dial Vernire Caliper

Micrometer Pointed
Dial Thickness Gauge
Tensile Tester
Tensile Tester

6
7

8
9
10
11
12

Profile projector
Hot set oven
Digital Temp. Controller
Digital Timer
Digital Timer
Weight Box
Profile Projector
Oxygen Index/Temperature Index test apparatus as per ASTM D 2863
Halogen Acid gas Test
Smoke density Chamber ASTM D2843
Flammability Test (IEC-60332-3 Cat. A)
Air Flow meter Range 100 to 1500 L.P.H.
Air Flow meter Range 0 to 150 L.P.M.

Electrical Instruments
1
2
3
4
5

Digital kV Meter (AC) Q003659

Digital Micro OHM Meter Q004805
P D Calibrator Q000803
Digital kV Meter (AC) Q003656 & 3657
Glass Thermometer Q-002745

*All test, otherwise mentioned should be above 5C to 35C As per para15.1 of

IEC60502-2
These are above the guiding list and not complete.
Other parameters should be check as per approved GTP & IEC specification