Amendment No 1

D e s i g n, en g ineerin g , manufacture or Works,

p

rocure, assembly, testin g at Manufacturin g

acka g in g into

ro p erly sized units and s h i pp in g , trans p ort, delivery to site,

r e c e i p t, unloadin g , handlin g and stora g e at site, erection, testin g and commissionin g and p erformance testin g of 400/220 kV GIS substation at Hinjewadi District Pune. Addendum to T e c h n i c a l S p ecification for 220 kV EHV Cable under Volume I GENERAL TECHNICAL TERMS AND CONDITIONS FOR 400/220 KV GIS HINJEWADI SUBSTATION S p ec No: MSETCL/TR. PR ./TKC-I/400KV HINJEWADI Tender N o : MSETCL/CO/Tr Proj/Contracts/TKC-I/400KV Hinjewadi (GIS)/ T-1 102

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MAHARASHTRA STATE ELECTRICITY TRANSMISION CO. LTD. 400/220KV G IS H INJ EWADI SUBSTATION

V O L U M E I I T e c h n i c a l S pe c i f i c a t i o n

ANNEXURE-II I TECHNICAL SPECIFICATION OF EHV CABLE AND ACCESSORIES

1.0

General Re q uirements:

1.1 This section covers the re q uirements in respect of 220/245 KV Cross Linked Poly Ethylene (XLPE) cables. The route length of cable per run (7.0 KM) indicated is tentative and may
q

vary

on

carrying out detailed route survey. The bidder is re uired to carry out detailed route survey and work out the complete Bill of materials before making the offer. Unit rates of all major items like cable, end terminations, straight joints, etc. and also of all minor accessories
q

that

may

be

re q uired

for

the

completion of the work shall be

uoted for billing

q

purpose. In case there be any variation in the final with reference to the the offer, no price applicable.
q

uantity be

uantity as per the Bill of materials of implication on this account shall

1.2 Cables shall be laid buried in ground. There shall be three single core cables per circuit. Contractor shall be responsible for detailed route survey, design, manufacturing, testing and delivery of cable and associated accessories to site, testing of cables at site, digging of cable trenches, laying of cables in trenches, back filling of trenches, installation/erection of joints and termination, testing of feeder after installation and comissioning.

1.3 The cables shall be installed by direct burial at an approximate depth of 1.2 M below ground level unless otherwise necessary due to topographical conditions enroute.

1.4 Cable end shall be terminated with suitable terminations at the Gas Insulated Switchgear at both ends, covered in packageA.

Page 1 of 20

1.5 Cable joints shall be suitable for underground-buried installation with uncontrolled backfill
q

and

chances

of

flooding

by

water.

Cable joints shall have ade uate mechanical protection features. 1.6 The contractor shall make all the cable laying arrangement on his own. However, the owner shall be responsible for arranging clearance/permission from Govt. authorities / Private owners for digging of trenches/cutting of roads or any such work as may be re q uired for installation of cables and accessories. All other expenses, including compensation, if any is payable, shall be borne by the contractor.

1.7 The bidder shall decide the number of normal joints as also other accessories and the scheme of cross bonding for the cable so as to achieve the optimum current carrying capacity of the cables. 2.0 Technical Re q uirements for Cable : The cable for 220KV system shall meet the technical particulars indicated in Annexure ________________(i). 2.1 2.1.1 Manufacturing Process: The manufacturing process shall be designed to eliminate irregularities like protrusions, voids and contaminations, etc to ensure the long term reliability of the cable. 2.1.2 Raw materials used for manufacture of cable shall be of highest
q

uality

and

it The dust

should materials proof

meet shall

manufacturer's be clean Material and

material packed in by

specification. moisture and

packings.

received

manufacturer should be checked/tested to ensure that it meets material specification. 2.1.3 Loading of the extruder in the manufacturing plant shall be

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performed

in

entirely shall be

closed avoided The

and by use

dust use of

proof of a

environment. enclosed like

Contamination material

fully

handling

system.

special

means

pressurized air, etc for transport of granules shall, as far as practicable, be avoided. 2.1.4 All the three layers screen) (conductor shall be screen, extruded XLPE in insulation and

insulation

one

simultaneous

triple extrusion process through common triple cross head. The extruders and triple cross head shall be designed to

prevent stagnation of materials to eliminate hot spots and ensure smoothness of the conductor screen and core screen

surfaces.

2.1.5 The cross linking, curing and cooling shall be carried out in one operation and shall be a dry curing and cooling process under high pressure to eliminate the formation of voids in the insulation and contaminants in the dielectric. 2.1.6 Process conditions speed such etc. as curing be and cooling temperatures, during

production

shall

closely

monitored

manufacture to ensure a good degree of cross linking through the whole insulation. 2.1.7 XLPE extrusion by Vertical extrusion line or Mitsubishi Dainichi Continuous Vulcanising (MDCV) process will be preferred to ensure circularity and concentricity of the extruded layers around the conductor. However, Continuous

Catenary Vulcanising (CCV) process is also acceptable. 2.2 2.2.1 Constructional Details: The cable shall be made of stranded, compacted and segmented Electrolytic grade copper conductor, taped with semi con-

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ducting tape. Conductor screening shall be with extruded semi-conducting thermosetting compound layer. The cable shall be insulated with completely dry cured XLPE insulation. Insulation screening for non-metallic part shall be with extruded semi-conducting thermosetting compound layer. Taping with semi-conducting water swellable tape shall be provided for longitudinal water sealing. Screening for metallic part shall be with extruded corrugated Aluminium or overall extruded black Medium Density Poly Ethylene (MDPE) OR PVC, OR lead alloy E sheathed in combination with bedding of semiconducting tape(s) . Armouring shall be with annealed copper wire screen and taped with open helix copper tape binder, if re q uired, followed by suitable non-metallic tape binder and over all extruded black, Medium Density Poly Ethylene (MDPE) or PVC sheath.

2.2.2 The conductor shall be stranded/segmented round copper conductor complying the re q uirement of flexibility class-2 of IEC-228. The wires shall be of annealed high conductivity copper. The grade and
q

uality of the copper used for the conductor shall

be not less than the International Annealed Copper Standard (IACS) of 100%, with purity of the order of 99.99%.

2.2.3

The

conductor

screen

shall

consist

of

an

extruded

layer

of

thermosetting semi-conducting compound and shall be continuous and cover the whole surface of the conductor. The screen shall be firmly bonded to XLPE insulation. The minimum

thickness of conductor screen shall be 1.0 mm. A non-hy-

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groscopic semi-conducting tape shall be applied to the conductor under extruded layer. The outer surface of the conductor screen shall be circular and free from irregularities. 2.2.4 The insulation shall be cross-linked polyethylene (XLPE). The insulation material shall comply with the re q uirement of TableIV of IEC 840. The insulation shall be applied by extrusion and vulcanized to form a compact homogeneous body free from micro voids and contaminants. The eccentricity of insulation shall not be more than 10%. 2.2.5 The insulation screen shall consist of an extruded layer of thermosetting semi-conducting compound and shall be continuous and cover the whole surface area of insulation . It

shall be firmly bonded to the insulation. The minimum thickness of insulation screen shall be 0.8 mm. The ovality of the core shall not be more than 5%. 2.2.6 The under-sheath water barrier shall consist of a semi-

conducting moisture swelling layer covering the whole surface area of the insulation screen. The barrier shall restrict longitudinal water penetration under the metallic

sheath. The minimum thickness of water swellable tape shall be 0.3 mm. 2.2.7 The metallic sheath shall be of extruded corrugated Aluminium sheath or lead alloy E, having composition as per IS 692. The metallic sheath shall be extruded using a continuous screw press and shall be free from all extrusion defects. The nominal thickness of metallic sheath shall be as per the recommendation of IEC 502. Metallic sheath, together with copper screen (if re q uired) shall be able to withstand

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short circuit current of 40 KA for a duration of three second.

2.2.8 A copper wire screen may be included over the lead alloy E sheath to allow passage for the re q uired earth fault current. A semiconducting wire screen provided binder tape tape/ . An the may bedding copper be shall wire be applied under the copper also be metallic to open helix also copper binder screen. over the tape may non copper

over

Suitable

applied

screen

prevent the penetration of the outer sheath in to the screen. There need not be any copper wire screen for Aluminum sheath construction.

2.2.9

The outer sheath shall consist of an extruded layer of black, high density polyethylene or PVC type ST2 as per IEC502. The nominal thickness of outer sheath shall not be less than the value calculated as per the recommendation of IEC 502. The outer sheath shall be of sufficient hardness to discourage termite attack. A conductive layer shall also be provided over the outer sheath surface to test the integrity of cable from time to time.

2.3 2.3.1

Marking on Outer sheath : The following (minimum) particulars shall be marked on cable outer sheath at suitable regular intervals: a)Manufacturer's name and / or trade name b)Voltage grade viz, 220KV (nominal) c)Cable size (no. of core X conductor cross section) d)Year of manufacture e)Purchaser's name i.e. MSETCL. 2.3.2 The spacing between the end of one set of marking and the beginning of the next on the legend shall not exceed 150

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mm.

Besides

above,

progressive

se q uential

marking

of

length

shall also be provided at every one metre, which shall be clear and legible and shall be in contrast colour.

2.4

Sealing and Drumming:

2.4.1 Immediately after the tests at the works, both ends of every length of cable shall be sealed by means of heat shrinkable end caps. 2.4.2 Cables shall be wound on metallic drums. All the drums shall be arranged to take a round spindle and be logged with strong closely fitting wooden battens so as to prevent damage to the cable. 2.4.3 Each drum shall bear an identification number permanently

stenciled or branded on the outside of the flange. Particulars of the cable i.e. voltage grade, type of insulation, conductor size, length, gross weight, net weight, direction of rolling and name of manufacturer, year of manufacture, Name of owner and contract reference etc.

shall be clearly marked on one flange of the drum.

2.4.4

Stranded length of cable per drum shall not exceed 500 metres. A tolerance of +/- 3% will be permissible on standard drum length. Exact drum length be shall decided be by finalized joint after award of

contract, contract.

which

shall

route

survey

with

purchaser's engineer and contractor's engineer after award of

Cable Accessories : Joints : The dielectric design of the joint shall be optimised. The electric stress distribution along the interface between the

Page of 20

insulator and the cable shall take into account the dimensions of the joint and the cable and the dielectric permittivity of the insulation. The material of insulator shall

have good thermo-mechanical behaviour. 3.1.2 The materials used in the assembly of the joint shall be

compatible with the material of the insulator and the cable insulation. 3.1.3 The conductor shall The be connected by means of the of an approved shall

arrangement.

tensile

strength

connector

meet the re q uirements of the copper conductor. 3.1.4 The joints shall rubber shall be of with of a all premoulded one-piece stress construction. factory This design

comprise joint,

tested element

synthetic provided

management

during the moulding process in the factory. 3.2 Outdoor Terminations:

3.2.1 The terminations shall be suitable for outdoor installation in heavily polluted atmosphere having porcelain/composite

insulator. It should be resistant to UV (ultra violet) exposure. The termination stress control shall be by means of

elastomeric stress cone. 3.2.2 The stress cone design shall inhibit possible mechanical stress and deformation of the cable insulation surface during

operation and be also capable of accommodating minor radial and longitudinal movement without detriment to the

elastomeric stresses in the insulation shield. 4.0 4.1 Tests for Cables and accessories : Tests for cables:

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All the type, routine and acceptance (special) tests as per IEC 840 shall be carried out.

4.1.1

Routine Tests: The following routine tests shall be carried out on each manufactured length. a)Partial discharge test b)Voltage test c)DC voltage test on outer sheath d)Conductor resistance test

4.1.2

Special (Acceptance) Tests: The following tests shall be made on samples taken to repre sent batches. For the tests in items (b) and (g) below,

complete drum length of cable shall be used. a)Conductor examination b)Measurement of electrical resistance of conductor c)Measurement of thickness of insulation and non metallic sheath. d)Measurement of thickness of metallic sheath e)Measurement of overall cable diameter f)Hot set test for XLPE insulation g)Measurement of capacitance 4.1.3 Fre q uenc y of Tests: The above special (acceptance) tests shall be made on one

length from each manufacturing series of the same type and size of cable, but shall be limited to not more than 10% of the number of lengths in any contract, rounded to upper

unity.

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4.1.4

T y pe Tests: The offered type of EHV cable should have been successfully type tested in following internationally accredited laboratories. (1) (2) (3) (4) (5) (6) (7) (8) Central Power Research Institute, India CESI, Italy KEEMA, Holland F.G.H. , Germany CERL, UK EDS, France HydroQuebec, Canada Any other Reputed accredited Laboratories from US or EUROPE.

The type tests shall be carried out by the manufacturer on cables exactly as specified in IEC - 840 before the dispatch of cable from contractor's works. If the cables are already tested, it will be at the sole discretion of the purchaser whether to waive the type test or ask for repetition of all or some specific tests. Contractor shall
q

uote

type

test

charges for individual test in his bid.

The following tests shall be included in the type tests: A)Electrical Tests : a)Bending test followed by Partial discharge test b)Tan delta measurement c)Heating cycle voltage test followed by partial discharge measurement d)Impulse withstand test followed by a power fre q uency voltage test. B)Test on Cable components : a)Check for cable construction b)Resistivity of semi conducting layers c)Test for determining the mechanical properties of insulation before and after ageing

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d)

Test for determining the mechanical properties of non-metallic sheath before and after ageing Ageing tests on pieces of complete cable to check compatibility of materials f) Pressure test at high temperature on sheath g) h) i) Hot spot test on XLPE insulation Carbon black content of PE sheath Shrinkage test on XLPE insulation

e)

j)

Longitudinal water penetration test for water tightness between core and metallic sheath

4.1.5

Tests at site after installation: Pre-commissioning tests on site, which shall be performed by the successful bidder, shall include the following : a)DC voltage test on outer sheath at 10KV (DC) for one

minute between metallic sheath/screen and external conducting surface. b)Conductor resistance of each complete circuit. c)On completion of cable laying and jointing work, the

complete installation shall be checked with a DC voltage of 3 U applied for 15 minutes. d)AC test voltage for 24 Hrs with the phase to earth voltage of the system (U ) . This is alternative to DC voltage test as per (c) above. 4.2 Tests for Accessories: All the relevant type tests, routine tests and acceptance

tests shall be carried out on the accessories. However, type tests would be waived if the manufacturer furnishes a copy of type test report carried out at an independent laboratory.

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5.0

Installation/La y ing of cables: The successful bidder shall carry out all activities con-

nected with the laying and installation of the XLPE power cables and completion of the work for which the project is intended and to the full satisfaction of the purchaser. 5.1 Scope: The successful bidder shall carry out detailed route survey, propose the re q uired method of cable laying directly

buried, cables in ducts/HDPE pipes at road crossings, excavation of trenches and construction of joint bays as per

re q uirement of the field conditions. The scope also includes supply of all re q uisite labour, tools and materials like

sand, bricks, pipes, joint marker and route markers and all other consumables re q uired for the completion of work.

5.2

Route Surve y : The successful contractor shall make a detailed survey of the cable route after the award of contract, to decide the re q uirements of the following. Cable delivery length per drum Location of joint bay positions Quantity of joints re q uired Design of cable ducts/trench for road crossing and drainage crossing, etc.

5.3

Location of joint ba y s : The location of joint bays should be carefully decided to

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avoid traffic hazards, collection of sub-soil water and any possibility of flooding due to storm waters. The joint bays should be of sufficient dimensions to accommodate staggered joints, having brick walls & PCC base. Joints would be kept on a sand bedding of 100 mm. The joint bays located should be easily accessible for inspection and testing. 5.4 5.4.1 Installation of underground cables: Cable installation shall be carried out as per IS:1255 and other applicable standards. 5.4.2 Cable drum shall be unloaded, handled and stored in an approved manner on hard and well drained surface so that they must not sink. In no case shall the drum be stored flat i.e. with

flange horizontal. Rolling of drums shall be avoided as far as possible. on For unreeling jacks of on cables, wheels. the All drum shall be

mounted

suitable

or

possible care

shall be taken during unreeling and laying to avoid damage due to twist, kink or sharp bends.

5.4.3

Bending radii for cables shall be as per manufacturer's recommendations. Manufacturer's instructions shall be

strictly adhered to and necessary conducting medium shall be provided over the cable outer sheath for checking the

healthiness of outer sheath.

5.4.4

Cable

trenches,

as

for

as

possible,

shall

be

constructed

for

directly buried cables. Construction of trench for cable shall also include excavation, preparation of sieved sand bedding, riddled soil cover, supply and installation and compacting, of concrete and protective covers, back filling supply

installation of route marker and joint marker.

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Back filling shall be by the material excavated. However bigger stones and pieces of rock, etc shall be removed.

5.4.5 Cables shall be laid in flat/trefoil formation subject to the owner's axial approval. to In case of flat formation, between the minimum cables

(centre

centre)

spacing

adjacent

shall be twice the outer diameter of the cable(2D). 5.4.6 The cables shall be covered by well compacted sand of approx 100 mm thickness after laying on a sand cushion of 100 mm, for protection against damage. Concrete protective covers (RCC slabs) shall be installed/provided directly over the compacted sand over the cable surface. RCC slabs shall sufficiently cover the width of all the cables and will have the dimensions of approximately 300 mm x 300 mm x 50 mm. 5.4.7 The cable jointing and termination work shall be carried out by experienced cable jointer who shall have ade q uate experience in jointing and termination of 220KV or higher voltage grade XLPE cables.

5.4.8

Bidder

shall

carry

out

the

earthing

of

sheath/screen

at

both

ends of termination using insulated sheath bonding (Earthing) cable of re q uired size. The sheath/screen shall be bonded to the earth station through disconnecting type link boxes.

6.0

Cables re q uired under the GIS Package

6.1 For connection between the GIS & ICT and between GIS and overhead lines, GIS duct is preferred. However, alternatively the bidder may propose XLPE cable of 400KV/220KV class and appropriate current carrying capacity. At existing Hinjewadi

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cable shall not be

protection (inter trip)

II substation also GIS duct is preferred for connection between the GIS and the existing main bus. In case 220KV cable is proposed by the bidder for this purpose, the same shall be of appropriate current rating. 6.2 Wherever XLPE cable is proposed, the contractor shall submit design calculations supporting the ade q uacy of the size of cable proposed. Only after the size of cable is approved by the owner shall the contractor procure the cable. The cable termination for connecting to the overhead line/ICT/existing bus shall be suitable for outdoor installation in heavily polluted atmosphere and shall be made completely weather proof through the cable sealing ends. The cable termination at GIS end shall be finalized in co-ordination with the GIS supplier/manufacturer. Relevant drawings shall be got approved from the MSETCL. The arrangement for supporting the cable end terminations at the non-GIS end shall also be subject to MSETCLs approval.

7.0 Optic Fibre/ADSS cable & Accessories. 7.1 Fibre Optic/ADSS cable is to be layed between 400KV Hinjewadi and Hinjewadi-II substation. This shall be layed in the same trench in which the 220KV XLPE cables are layed. The FO/ADSS cable shall be layed in suitable metal conduit/pipe for protection against mechanical damage. The cable shall be suitably protected from induced voltages from the 220KV XLPE cables. It shall be ensured that in the event of short circuits in the power cables leading to damage/bursting of the 7.2 XLPE cable, the ADSS/FO affected/damaged.

The FO/ADSS cable is meant for

purpose

and also for data transfer and communication. The number shall not be less than four (4) but the actual

of
q

fibres

re uirement shall be worked out by the contractor and the same shall be submitted to the owner (MSETCL) for approval.

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7.3 All interfacing devices associated with the FO/ADSS cable for the smooth shall and be reliable brought the communication, out IEDs in at shall the 400KV offer data transfer and Since IEC inter the 61850 trip shall be included in the scope and the details thereof bid documents. are cable FO protection/control compliant Hinjewadi the

bidder

interface

accessories accordingly.

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Annexure (i) Technical Particulers 220KV XLPE POWER CABLE (MANUFACTURED BY RCP) (Radiant Curing process ) Technical particulars for 220KV XLPE power cable. 1) CONDUCTOR : Material Type Size Max. DC resistance at 20 DC * App.AC resistance at 90 DC * E.C.grade plain copper Standard, compacted and segmented. Single core, 1000 sq.mm. 0.0175 Ohm/Km 0.0236 Ohm/Km

2) CONDUCTOR SCREENING : i) i) Type and material Resistivity of semiconducting screen. Extruded semiconducting compound. s h a l not exceed 1000 ohm.m

3) INSULATION : i) Type and material - Extruded h i gh purity XLPE satisfying requirements of Table-2 of IS 7098 (Part 3) : 1993
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i)

Dielectric power factor at rated voltage

S h a l be in line with IS 7098, pa r t I / IEC60840

4)_INSULATION SCREEING : i) Non-metalic part : a)

Type and material Extruded semiconducting compound.

b)

Resistivity of semi-

S h a l not exceed 500 Ohm m conducting screen. (Extrusion of conductor, insulation and insulation screen in one single operation to ensure perfect bonding without any surface irregularities in the boundary layers). i) Water blocking tape : (for longitudinal water sealing) a) Material Semiconducting non-woven water barrier tape. Extruded corrosion resistant lead aloy E sheath / extruded Corrugated aluminium sheath.
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Metalic part (for radial water sealing and Metal_ sheath) : a) Type and material

5) Armour : i) Material i) Type

Annealed copper wire

- Applied helicaly over PVC

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bedding & covered with open helix tape, folowed by suitable binder taping. 6) OUTER SHEATH : i) Type and material Extruded PVC compound of type ST2 220 Coated with suitable 220/root 3 conducting material. 245

i)

Surface treatment

se to neutral7) VOLTAGE GRADE : ge for equipment between conductors/phases(in KV) (in KV) H i ghest volta 190 ge for 30 minutes(in kV) 1.2/50 micro sec.lightning impulse withstand voltage (in K d volta 8) e after im RATING : ithstand voltagCURRENT pulse test (in KV) 1050 (Peak) 190

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Rated continuous current : a) Flat formation in ground and cross bonding. b) Trefoil formation in 10% 40 kA for 3

i)

Sec.

143 5 Pcoulomb

9) Maximum alowable temp. for Cable and accessories : i) During continuous operation at rated f u l load current the maximum temp. of the cond.shal not exceed. The cond.temp.after SC shal not exceed. 90 DC *

i)

250 DC *

i) Emergency overloading temp.- 130 DC * for three hours. Note : DC * stands for (temperature) in Degree Celsius.

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