TECHNICAL SPECIFICATION FOR 2.

5sqmm ARMOURED PVC INSULATED

AND SHEATHED 1.1kV GRADE COPPER CONDUCTOR (ISI MARKED) WITH
IMPROVED FIRE PERFORMANCE CONTROL CABLE AGAINST
NIT NO: EPC-II/28/2014-15
GENERAL
1.

SCOPE:
This specification covers requirements and tests for 2.5sqmm Control Cable
1.1kV grade, armoured, multi-core PVC insulated and sheathed cables with
improved fire performance, Category C2 (FR-LSH, Flame Retardant cables with
reduced halogen evolution and smoke) conforming to IS: 1554(Part-I):1988 with
latest amendments and ISI marked as per the details given below. The cables
covered in this standard are suitable for use where the combination of ambient
temperature and temperature rise due to load results in conductor temperature not
exceeding 85 degC under normal continuous operation and 160 degC under Short
Circuit condition.

2.

STANDARDS AND REGULATIONS:

The materials shall conform in all respects to the relevant Indian/International
Standards, with latest amendments thereof unless otherwise specified herein.
Some of them are listed below as:
i. IS-1554 (Part-I) PVC insulated heavy duty Cables.
ii. IS-8130-Conductors for PVC insulated Cables.
iii. IS-3961 (Part-II) - Recommended current ratings for Cables.
iv. IS-5831-PVC insulated and sheath of Electric Cable.
v. Other relevant standards for screening.

3.

CLIMATIC AND ISOCERAUNIC CONDITIONS:

3.1

The climatic conditions at site under which the material shall operate Satisfactory
are as follows;
a) Maximum ambient air temperature (C):
b) Minimum ambient air temperature (C):
c) Maximum daily average ambient air temperature (C):
d) Maximum Yearly average ambient temperature (C):
e) Height above Sea Level (m):

3.2

50
-20
40
22
2000 m

The material offered shall be suitable for continuous operation at the full rated
capacity under the above conditions.

Page 1 of 1

TECHNICAL REQUIREMENTS
4.

COPPER CONDUCTOR
The conductor shall be made from high conductivity copper rods complying with
IS: 613-1964 amended up to date. The conductor shall consist of plain annealed
high conductivity copper of circular cross section. The conductor shall be as per
IS: 8130-1984 amended up to date. The flexibility of solid conductor shall be of
Class-1.

5.

INSULATION
The insulation shall be of PVC compound applied by extrusion conforming to the
requirement of Type-C as per IS 5831- 1984 amended up to date. The nominal
thickness of the insulation shall be 0.9 mm and the tolerance on the thickness of
insulation shall be as per IS: 1554 (Part-1): 1988 amended up to date. The
insulation shall be heat resistant for maximum rated conductor temperature 85
deg C intended for cables with rated voltages upto & including 1100 volts.

6.

INNER SHEATH AND FILLER

The inner sheath and filler shall conform to IS: 1554(Part-I): 1988 amended up to
date and shall be of Thermoplastic material. The thermoplastic material used shall
not be harder than PVC used for insulation and outer sheath. The material shall be
chosen to be compatible with temperature ratings of the cable and shall have no
deleterious effect on any other component of the cable. The thickness of the inner
sheath shall be as per IS: 1554(Part-1): 1988 amended up to date. The laid up
cores shall be provided with an inner sheath applied either by extrusion or by
wrapping. It shall be ensured that the shape is as circular as possible.

7.

ARMOURING
The Armouring shall be of Galvanised round steel wire or Galvanized steel strips.
The material for armouring shall be selected as per the calculated diameter below
armouring. Where the calculated diameter below armouring does not exceed
13mm the armour shall consist of galvanized round steel wires. Where the
calculated diameter below armouring is greater than 13 mm, the armour shall
consist of either galvanized round steel wires or galvanized formed steel wires
(strips) and shall comply with the requirements of IS:1554(Part-1):1988 and
IS: 3975-1999 amended up to date. Armouring shall be applied over the inner
sheath. The armour wires/strips shall be applied as closely as possible. The
direction of lay of the armour shall be left hand. For double wire/strip armoured
cables, this requirement shall apply to the inner layer of wires/strips. The outer
layer shall, except in special cases, be applied in the reverse direction to the inner
layer and there shall be a separator of suitable non-hygroscopic material, such as,
plastic tape, bituminized cotton tape, bituminized hessian tape, rubber tape, proof
tape, etc, between the layers of armour wires/strips. A binder tape may be
provided on the armour. The dimensions of galvanized steel wires/strips shall be
as per table below. The tolerance on nominal dimensions shall be as per IS:39751999. However, for formed steel wires the tolerance shall be as per IS:1554(Part1)-1988 with latest amendments.
Page 2 of 2

Dimensions of Armour-Round Wires and Strips

(All dimensions in mm)
Calculated Diameter under
Armour
(Ref IS: 10462(Part-1): 1983
Up to and
including
For all diameters in excess of 13
or

Nominal
Thickness of Steel
Strip

Nominal
Diameter of
Round Wire

0.8

0.8
0.8

1.4
1.6
2.0

Over

13
25

8.

13
25
40

OUTER SHEATH
The Outer sheath shall be of PVC compound conforming to the requirements of
Type ST-2 as per IS: 5831-1984 with latest amendments. The outer sheath shall
be applied by extrusion over the armouring. The outer sheath shall be so applied
that it fits closely over armouring. It should be possible to remove it without
damage to the inner sheath. The colour of the outer sheath shall be black. The
thickness of the outer sheath shall not be less than the minimum value specified as
per table below:
Thickness of Outer Sheath
(All dimensions in mm)
Calculated Diameter under the Outer
Sheath
(Ref IS: 10462(Part-1): 1983
Over

Up to and including

15
25

15
25
35

Minimum Thickness of
Outer Sheath
1.24
1.40
1.56

All other characteristics and the tolerance for thickness of Outer Sheath shall be
as per IS: 1554 (part -I) of 1988 amended up to date.
9.

LAYING UP OF CORE
The cores shall be laid up together with suitable lay. The outer most layer shall
have right hand lay and the successive layers shall be laid with opposite lay. The
interstices shall be filled with non-hygroscopic material.

Page 3 of 3

10.

CORE IDENTIFICATION
Cores shall be identified by different colouring of PVC insulation by adopting the
following Scheme:
a) 1 Core: red, black, yellow, blue or natural (non-pigmented);
b) 2 Cores: red and black;
c) 3 Cores: red, yellow and blue;
d) 4 Cores: red, yellow, blue and black;
e) 5 Cores: red, yellow, blue, black and grey;
f) 6 Cores and above: Two adjacent cores (counting and direction core) in
each layer, blue and yellow, remaining cores grey.

11.

TESTS
The tests on the 1.1kV Control Cable shall be performed in accordance with
IS:1554:(Part-I)-1988, IS:8130-1984, IS:5831-1984 & IS:10810-1984 amended
up-to-date as mentioned below:

11.1

TYPE TESTS
The following shall constitute the type tests:
a) Tests on conductor:
1) Annealing test.
2) Conductor resistance test
b) Test for round steel wire/formed steel wire (strip) armour
1) Dimensions
2) Physical tests on round/formed wire:
i)
Tensile Strength
ii)
Elongation at break
iii)
Torsion test for round wires
iv)
Winding test for formed wires
v)
Uniformity of zinc coating
vi)
Mass of zinc coating
vii)
Resistivity
c) Test for thickness of insulation and sheath
d) Physical tests for insulation and outer sheath:
1) Tensile strength and elongation at break
2) Ageing in air oven
3) Shrinkage test
4) Hot deformation
5) Loss of mass in air oven
6) Heat shock test
7) Thermal stability
e) Insulation resistance test
f) High voltage test (water immersion test)
g) High voltage test at room temperature
h) Flammability test
i) Oxygen Index test
j) Flame retardance test
k) Test for specific optical density of smoke
l) Smoke Density
Page 4 of 4

m) Test for halogen acid gas evolution

n) Temperature Index.
11.2

ACCEPTANCE TESTS
The following shall constitute the acceptance tests:
a) Annealing test
b) Conductor resistance test
c) Test for thickness of insulation and sheath
d) Tensile strength and elongation at break of insulation and sheath
e) Insulation resistance test
f) High voltage test at room temperature.
g) Oxygen Index test
h) Flame retardance test
i) Test for specific optical density of smoke
j) Smoke Density
k) Test for halogen acid gas evolution
The sampling plan for acceptance tests shall be as per IS: 1554(Part-1):1988.

11.3

ROUTINE TESTS (To be conducted on all finished cable lengths).

The following shall constitute the routine tests:
a) Conductor resistance test
b) High voltage test at room temperature

11.4

SPECIAL TESTS
The following shall constitute the special tests:
a) Cold bend test
b) Cold impact test

11.5

TYPE TEST CERTIFICATE: The Suppliers are advised to submit the certified photocopy of Type Test
Certificates in respect of all the type tests indicated in Clause 11.1 above,
from any of the NABL accredited laboratories approved by Govt. of India
such as CPRI/ERDA/ERTL etc, for the offered materials required as per
tender. The suppliers shall confirm that they will supply the material exactly
for the design for which type tests have been conducted. The above type test
certificates should not be more than five years old from the date of opening
of tender. The offers which are submitted without the type test certificates
shall invariably be rejected.

11.6

All the tests and inspection shall be made at the place of manufacturer unless
otherwise specifically agreed upon by the manufacturer and purchaser at the time
of purchase. The manufacturer shall offer all reasonable facilities to the
purchaser, without charges to satisfy him that the material is being furnished in
accordance with the specification. In order to ensure that quality of raw materials
used during manufacturing of PVC Cables is as per the requirement of relevant
IS, the inspecting officer shall check the quality of raw material, obtain necessary
invoices in proof that raw materials used are of desired quality.
Page 5 of 5

The purchaser has the right to have any or all type / acceptance tests carried out
by an independent NABL Accredited agency whenever there is dispute regarding
the quality of supply. In case the material fails to pass the test as per specification,
the testing charges along with the other charges which were actually incurred for
arranging the testing through independent agency shall be recovered from the
supplier. In addition to this, action as deemed fit, may be taken against the
Supplier.
12.

IDENTIFICATION, PACKING AND MARKING

12.1

MANUFACTURERS IDENTIFICATION.
The manufacturer shall be identified throughout the length of the cable by
manufacturers name or trade-mark being indented, printed or embossed on the
cable. The indentation, printing or embossing shall be done only on the outer
sheath.

12.2

CABLE IDENTIFICATION
In order to distinguish these electric cables from telephone cables and signify
their flame retardance property, the word ELECTRIC and the letters FR-LSH
shall be indented, printed or embossed throughout the length of the cable. The
indentation, printing or embossing shall be done only on the outer sheath.

12.3

CABLE CODE
The Cable code sequence shall be as per IS:1554(Part-1):1988.

12.4

PACKING
The cable shall be wound on a drum of suitable size and packed. The ends of the
cable shall be sealed by means of non-hygroscopic sealing material.

12.5

MARKING
The cable shall carry the following information stenciled on the drum:
a) Reference to the relevant Indian Standard, for example, Ref IS: 1554
(Part 1)
b) Manufacturers name, brand name or trade-mark
c) Type of cable and voltage grade
d) Number of cores
e) Nominal cross-sectional area of the conductor;
f) Cable code
g) Length of the cable on the drum
h) Number of lengths on drum (if more than one)
i) Direction of rotation of drum (by means of an arrow)
j) Approximate gross mass
k) Running end of cable
l) Country of manufacture
m) Year of manufacture.

Page 6 of 6

12.6

BIS STANDARD MARK

The cable (drum) shall also be marked with the Standard Mark governed by the
provisions of the Bureau of Indian Standards Act, 1986 and the rules and
regulations made there under. The licence for the use of STANDARD MARK
shall be obtained from the Bureau of Indian Standards and shall be enclosed along
with the bid.

13.

SCHEDULE OF REQUIREMENT
Material Description

S.No
1
2
3
4
5
6

Control Cable 2.5sqmm FR-LSH

2-Core
4-Core
8-Core
10-Core
12-Core
16-Core

Sd/Asstt. Ex. Engineer

EPC-II, Srinagar

FOR
Jammu
(kms)
8.32
15.03
6.46
6.25
5.40
10.56

Sd/Purchase Officer
EPC-II, Srinagar

FOR
Srinagar
(kms)
5.90
11.90
4.50
10.75
2.70
9.30

Total
(kms)
14.22
26.93
10.96
17.00
8.10
19.86

Sd/Superintending Engineer
EPC-II, Srinagar

Page 7 of 7

ANNEXURE-A
GUARANTEED TECHNICAL PARTICULARS FOR 2.5sqmm ARMOURED PVC
INSULATED AND SHEATHED 1.1kV GRADE COPPER CONDUCTOR (ISI
MARKED) WITH IMPROVED FIRE PERFORMANCE CONTROL CABLE
AGAINST NIT NO: EPC-II/28/2014-15
(To be filled in by the tenderer/bidder)
S.No

Particulars

Name of Manufacturers

Standard applicable

Whether material offered is

having ISI mark.
Give ISI marking no. & its
validity period

Rated Voltage

Suitable for earthed or

unearthed system

Continuous current rating

when laid in air at an ambient
temp. 40C and for maximum
conductor temperature 85C.

Current carrying capacity

Short Circuit Amps (rms)

Duration of short circuit

Conductor temperature
allowed for Short Circuit

Conductor details

Material

Nominal cross section area

2-Core

4-Core

8-Core

10-Core

12-Core

Page 8 of 8

16-Core

Conductor resistance/Km at
20C

Insulation details

Composition and type

Thickness

Tolerance in thickness

10

Colour scheme for

identification

11

Inner sheath details

Material

Extruded/Wrapped

Calculated diameter over laid

up cores

Thickness

12

Armour

Type of armour

Nominal diameter over the

inner sheath

Nominal thickness of steel

strip/dia. Of wire

13

Outer sheath details

Material

Extruded, please confirm

Page 9 of 9

Calculated diameter under the

sheath

Thickness

Tolerance on thickness

14

Overall diameter of cable over

the outer sheath

15

Volume resistively at 27C

and 70C

16

Cable Drum

Dimensions of the drum

Approximate weight of Drum

Maximum length per drum

17

Net weight of cable (Kg/Km)

18

Cross Sectional area of copper

conductor in mm

19

Average Dia of above copper

conductor in mm

Sd/Asstt. Ex. Engineer

EPC-II, Srinagar

Sd/Purchase Officer
EPC-II, Srinagar

Sd/Superintending Engineer
EPC-II, Srinagar

Page 10 of 10