TECHNICAL SPECIFICATIONS
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TECHNICAL SPECIFICATIONS FOR
LOW VOLTAGE CABLE JOINT BOXES & ARMOUR
BONDING COMPONENTS/ACCESSORIES
1. SCOPE
This specification is for design, manufacture, testing low voltage cable
joint boxes & armour bonding components/ accessories
2. PARTICULARS OF SYSTEM
The following are the particulars of the systems in which the equipment
shall operate:-
a) The incoming supply shall be at full load, 380 volt, 3-phase and neutral at
a frequency of 50 Hz with the neutral point of the system solidly earthed. The
symmetrical fault rating of the Low Voltage network shall be 40kA for 1 second.
b) The working voltage of the system does not normally exceed 10 percent above
the nominal voltage.
c) All apparatus and materials to be supplied must be suitable for operation
in the following site conditions:
Altitude .... Sea level
Maximum ambient temperature .... 48 degree Centigrade
Maximum Humidity .... 100%
3. DESIGN, MANUFACTURE & STANDARDIZATION
3.1 General:
All apparatus and materials supplied and all works carried out, shall
comply in all respects with the requirements of this Tender, and such
regulations, which may be in force. This particularly applies to the guarding of
plant and apparatus.
Except where modified by this specification, equipment and materials shall
be in accordance with latest editions of relevant IEC (International Electro
technical Commission) or relevant BS (British Standard).
The tenderer shall specify when tendering, the standards with which his
offer complies.
Quality Control activity of the Manufacturer should conform to ISO 9000-
9004.
As an alternative to IEC or BS Specification, the Tenderers may quote for
materials in accordance with their National Standard. In such case differences
between IEC or BS Specification and their National Standard should be clearly
indicated by the Tenderers in his offer and one copy of the National Standard in
English language should be attached with the offer.
When IEC/BS or ISO Recommendations or National Standards are referred to,
the Edition shall be that of current at the date of Tender, together with any
Amendments issued to that date.
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The Contract Works shall be designed to facilitate inspections, cleaning
and repairs and for operation in which continuity of service is the first
consideration. All apparatus shall be designed to ensure satisfactory
operation under the atmospheric conditions prevailing at the sites and under
such sudden variations of load and voltage as may be met under working
conditions on the system and short-circuits, including those due to faulty
synchronizing, within the rating of the apparatus.
The design shall incorporate every reasonable precaution and provision for
the safety of all those concerned in the operation and maintenance of the
Contract Works and of associated works supplied under other contract.
All material used shall be new and of the best quality and of the class
most suitable of working under the conditions specified and shall withstand
various temperature and atmospheric conditions arising under working
conditions without distortion or deterioration of the setting up of undue
stresses in any part, and also without affecting the strength and suitability
of the various parts of the work which they have to perform.
3.2 Drawings/Catalogues/Instruction Manual:
The Contractor shall provide drawings, catalogues/instruction manual.
3.3 Testing:
The Contractor shall carry out the tests stated in 'INSPECTIONS &
TESTS' .
One sample joint of each size/type will be assembled and subjected to
following tests:-
1) A.C. high voltage test at 3.5 kV for 5 minutes.
2) Insulation resistance test.
3) Impact test.
4) A.C. high voltage test at 3.5 kV for 5 minutes (after Impact test).
5) Insulation resistance test (after impact test).
Detail of Impact Test
The joint should be placed on a hard bare floor. A wedge shaped block of 4
kgs having a right angle with a 2 mm radius impacting edge should be
dropped freely 6 times from a height of 2 metres on the joint specimen, so
that the impacting edge is horizontal and at right angle to the axis of
the joint. The drops should be distributed over the length of joint and
effect of test will be observed.
4. LOW VOLTAGE CABLE JOINT BOXES
4.1 The joint boxes should be suitable for XLPE/SWA/PVC, 4 core, armoured
cables according to BS.5467 or equivalent IEC specification.
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4.2 Each joint box should be complete with the following:
a) One outer plastic box (in two halves) complete with resin pouring holes
with lids, flange edge fixings, foam strip and seals etc.
b) 4 Nos. Insulating sheets of size 175 mm x 140 mm x 1.5 mm thick.
c) 5 metre compounded hessian tape.
d) Mixing vessel.
e) Sufficient quantity of resin, hardener and filler (if applicable).
f) One pair plastic gloves.
g) Shearing head type Mechanical Connectors.
h) Jointing instructions.
i) Any other accessories necessary as per the Tenderer's design.
4.3 Plastic shells of each joint along with all accessories (except compound)
shall be packed in a preliminary card board carton. Such card board
cartons shall be braced onto pallet type bases. Each pallet shall contain
between 50 to 75 primary cartons.
4.4 The cable compound i.e. resin, hardener, filler (if applicable) shall be
supplied in 2 to 4 Nos. cans/tins/bags each.
Cans/tins/bags, whatever used should be robust to eliminate the
possibility of leakage during transportation/storage.
Cans/tins/bags containing hardener/resin and filler (if applicable) for
one No. joint shall be further packed in a primary card board carton. Such
card board cartons shall be braced on pallet type bases. Each pallet shall
contain such No. of cartons that no damage occurs to the cartons in the
bottom row due to weight of cartons on the upper rows.
Shelf life of the compound offered for joints should be at least 24 months
from date of Delivery. The cans/tins/bags containing Resin and Hardener
should be separately labeled and it should contain the manufacturing date
and shelf life expiry date.
Tenderer shall attach specification/catalogue/test certificates for cable
compound offered indicating shelf life of compound.
4.5 Joint boxes should comply with minimum dimensional requirements as under:
ITEM 1 ITEM 2
DETAILS
BRANCH JOINT BRANCH JOINT
FOR 185 SQ. MM CABLE FOR 300 SQ. MM CABLE
a) Length of Joint Box 830 mm 1000 mm
b) Minimum internal
dimensions 200 mm 250 mm
across a cross section
(eg.
height/width etc.)
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The minimum internal dimension across a cross section of the joint should
be available at least for 75% of the length of the joints and depth of the
joint case should sufficient for transposing of cables.
4.6 Marking
Plastic shells (both halves) of joint boxes shall be indelibly embossed
with the following legends:
Manufacturer's Name
Year of Manufacture
DEWA Contract No.
Height of Embossing characters shall not be less than 5 mm.
Embossing shall be made along the length of joint box on both halves of
moulds.
4.7 The design of lid/lids for compound filling opening shall be such that it
fits tightly over the opening provided.
5. ARMOUR BONDING COMPONENTS
5.1 Copper Conductor:
The material used for manufacture of conductors shall be high conductivity
copper with purity, electrical and mechanical properties as specified in
BS 2874.
All copper used shall be of 99.9% purity of the international standard.
95 sq. mm conductor for armour bonding kits shall be PVC insulated,
green/yellow colour coded, plain soft drawn high conductivity electrolytic
copper stranded conductor to BS 6360 (latest edition). The length of each
conductor shall be suitable for the joint box with which it is to be used
and both ends of the conductor will be provided with crimped sockets.
5.2 Crimping type Sockets
Tinned, pressed electrolytic copper tubular, solderless crimping type
lugs/sockets suitable for terminating copper stranded conductor of size
95 sq. mm/50 sq. mm.
Stud holes should be suitable to the dia of the galvanized iron clamps.
5.3 Back up rings/Worm drive clips/G.I. clamps for fixing
Armour Bonding Conductor
Accessories for fixing armour bonding conductor shall be suitable for
cable sizes specified. All cables shall be low tension 4 core cables with
shaped solid/ stranded, annealed, aluminium/copper conductor, XLPE
insulated, extruded PVC sheathed, armoured with a single layer of
galvanized steel wires and black PVC sheathed overall suitable for
600/1000 V working pressure manufactured in accordance with BS 5467 or
relevant IEC regulations.
All material used shall be of the best quality and of a kind most suited
to the working conditions specified. They shall satisfactorily withstand
without undue stress, distortion and corrosion, operational climatic and
atmospheric conditions prevailing at site.
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Tenderer shall submit detailed drawings for each of the accessories
showing material used etc.
Galvanized iron clamp for fixing armour bonding conductor of size
95/50 sq. mm shall be complete with flanges, nuts, bolts washer etc.
If tenderer's design for accessories for fixing armour bonding conductor
is different, he shall submit the detailed drawing showing all accessories
& fixing arrangement.
5.4 Flexible Copper Braid
The material used for manufacture of copper braid shall be high
conductivity copper with purity, electrical and mechanical properties as
specified in BS 2874.
All copper used shall be 99.9% purity of international standard.
Size/cross sectional area of copper braid shall be equivalent to
95 sq. mm and shall be supplied in catch weight coils. Each coil shall not
have copper braid of length more than 25 metres.
Each item of armour Bonding components/accessories shall be packed
separately in sound cardboard packs. Each pack will be provided with a
label to indicate the specification of the accessories packed in and their
respective quantity.
5.5 T E S T S:
All material/equipment shall be inspected/tested in accordance with
relevant IEC/BS. standards as applicable to determine whether the
materials and apparatus comply with specification or not.
Certificates of all tests shall be provided to the Company in triplicate.
TEST CERTIFICATES:
Tenderers must submit copies of test certificates for tests carried out on
the equipment offered. Copy of such certificates must be submitted by the
tenderer with their offer for similar equipment manufactured/supplied
elsewhere in the past.
GENERAL
Copies of test certificate for the tests carried out shall be submitted
with despatch documents of each consignment.
6. ACCESSORIES
SHEARING TYPE MECHANICAL CONNECTORS
6.1 CONSTRUCTION
Compatibility of Materials
a) All materials used in the construction of cable joint accessories shall
be suitable for use with cast resin filled joints. The materials used
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shall be such that no deterious effect are caused to the component parts
of the joint or the resin when they come into contact with one another.
b) Mechanical Connectors shall be constructed of suitable materials that
are compatible with the conductor metals they are intended to connect. The
connector design and material shall be of sufficient strength to impart
the appropriate mechanical loading to overcome the effects of contact
resistance.
c) The design shall also ensure that allowance is made for contraction and
expansion of the joint due to thermal cycling whilst maintaining the
mechanical stress below the level at which creep of the conductor material
would occur.
d) The means of controlling the amount of torque required to make the
connection shall be such that it is not reliant on the
operator's/jointer's expertise.
6.2 Cable Types
The joint accessories shall be suitable for use with four core, XLPE
insulated, PVC sheathed, steel wire armoured, PVC sheathed, overall cables
600/1000 volt grade manufactured in accordance with BS.5467. The types of
conductor required to be joined are stranded/solid aluminium conductor
from 25 sq.mm to 300 sq.mm or stranded copper conductor.
6.3 Connection of Dissimilar Metals
The design of connector shall incorporate such features so that jointing
of aluminium and copper can be carried out without any electrolytic
reaction taking place.
6.4 Design and Approval
The design and construction of conductor connections shall meet the
requirements of BS.4579. Tenderers are required to submit copies of test
reports which demonstrate that the equipment being offered meets with this
specifications.
6.5 Drawings & Samples
The tenderer shall provide drawings, samples, catalogues etc. of the items
offered by them in their offer.
All drawings, catalogues and samples shall be submitted by the Contractor
at his expense and shall become the property of the Authority.
6.6 Testing
All relevant tests pertaining to Mechanical Connector should be carried
out. Tenderer will be required to submit 4 sets of Test Certificates for
such tests carried out with each consignment. They should also indicate
standard to which tests are carried out and enclose full description of
each test.
The tenderer shall submit along with his offer one copy of Test
Certificate for similar product manufactured in the past.
6.7 Packing & Despatch
The Connector shall be supplied in card board box packs. Each cardboard
box shall not contain more than 100 Nos. Connectors. Number/Size/Type of
Connectors packed in a card box should be indicated on the outside of the
box. These card boxes should be duly strapped to provide adequaste safety
for shipment/despatch.
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FAW: NM
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