Page 1 of 11
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Revision 0
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
TELECOM DIRECTORATE
SCHEDULE OF TECHNICAL REQUIREMENT (STR)
FOR
COMPOSITE CABLE (OFC + QUAD)
Research Designs and Standards Organisation
Manak Nagar, Lucknow – 226011
Page 2 of 11
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Revision 0
COMPOSITE (OPTICAL AND QUAD) UNDER GROUND ARMOURED CABLE
SPECIFICATION NO. RDSO/SPN/TC/50-2007 (REV.-4)
I.
SCOPE:
The Schedule of Technical Requirement covers machinery & plants, testing equipments and
quality assurance plan required for manufacturing of Composite Cable (OFC+QUAD) as per
RDSO specification No. RDSO/SPN/50/2007 Revision 4.0 or latest.
Vendor shall also comply norms issued by RDSO time to time in this connection and other
relevant laws of the country.
This STR shall be applicable to all vendors applying for registration.
II.
ESSENTIAL MACHINERY & PLANT REQUIRED FOR PRODUCTION:
S. N.
1.0
Description
Qty.
Required.
Insulation/extrusion
line
for
production
of
high
quality
telecommunication core with solid
polythene insulation provided with:
- Conductor pre heater
- Polythene Drying Unit with
air blast
- On line dia Controller
preferably XY axis to ensure
uniform
thickness
of
insulation eccentricity in the
core & dia over insulated
conductor & on line spark
Tester (0-15 KV AC) with
numeric fault counter to
monitor the number of spark
over faults occurring during
continuous extrusion of
cores.
- High
Precision
Temp.
Controller Digital Display for
Controlling each zone of
extruder
- Cooling trough of the length
01
Qty.
Available
Make &
Sr. No.
Year of
Installation
Remarks
Page 3 of 11
2.0
3.0
4.0
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
of 25 meters (minimum)
made up of stainless steel
material or any other
suitable material to avoid
rusting. Rusting may affect
the quality of polythene
insulation
resulting
contamination of foreign
particles over the surface of
insulation
- D.C. Drive take up, with
proper
tension
arrangements
Quadding machine to make star
quad of polythene insulated copper
conductor with built in high
frequency Spark Tester, tension
control Mechanism to maintain
uniform tension through out bobbin
length, Digital display of quad Lay
length.
Fully Computer controlled UV
curable Fibre Colouring Line with
automatic control of UV intensity,
Static Charge removal. Machine to
be installed and operated in
Temperature controlled and dust
free environment.
Fully Computer controlled Tubing /
Secondary coating line comprising
of:
- 12F
Driven
Tension
Controlled Pay-offs
- Jelly Filling System Fully
synchronized
with
Line
Speed
- Compound De-Humidifier
- Cooling Trough (25 Meters
long) with hot water section,
over length capstan and
cold water section.
- On-line Dual Axis Diameter
Measuring Unit
- Lump
&
Neck-down
01
01
01
Revision 0
Page 4 of 11
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Detector
Exit Capstan/ caterpillar
Dual
Take-up
with
automatic Changeover.
Fully Computer controlled SZ
stranding line comprising of:
- Strength member Payoff
- Double wheel entry capstan
- Strength Member tension
monitoring and Control
- 8 Nos. Loose tube/ Quad
Driven pay off with tension
Control system (2 nos. of
loose tubes & 6 nos. of
copper quads)
- SZ stranding unit with Lay
control and synchronisation
with line speed
- Dual counter rotating cross
binder head
- Torsion Blocker
- Pressurised Jelly Filling
arrangement
- Helical
Polyester
tape
Applicator
- Dual Wheel Capstan /
Caterpillar
- Motorised Take up
Inner Polyethylene sheathing Line
with 65 mm or higher extruder
having provision of:
- Pay-off
- Poly-Al Application system
with Pay-offs, Accumulator,
tension control, forming
bench, glue applicator
- Jelly Flooding Arrangement
- Compound Pre-heater
- Extruder & Crosshead with
PID
Temperature
Controllers
- Cooling trough of length of
25 meters (minimum) and
made up of stainless steel
-
5.0
6.0
01
01
Revision 0
Page 5 of 11
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
body.
On line spark tester (0-15
KV AC) with numeric fault
counter
- Caterpillar with Pneumatic
belt tension control
- Motorised Take-up
Aluminium
Wire
screening
machine comprising of:
- Pay-off
- Min 30 Pay-offs for Al. wire
- Taping Head
- Motorised Take up.
Steel tape armouring machine
consisting of :
- Pay-off
- Double Tangential Taping
Heads
- Butt Welding Machine
- Caterpillar with Pneumatic
belt tension control
- Motorised Take up
Intermediate/Outer Sheathing Line
with 80mm or higher extruder
having provision of:
- Pay-off
- Compound Pre-heater
- Extruder & Crosshead with
PID
Temperature
Controllers
- Cooling trough of length of
25 feet (minimum) and
made up of stainless steel
body.
- On line spark tester (0-15
KV AC) with numeric fault
counter
- Caterpillar with Pneumatic
belt tension
- Motorised Take up
Rewinding machine consisting of:
- Pay-off
- Sequential Meter Marking
Unit
-
7.0
8.0
9.0
10.0
01
01
01
01
Revision 0
Page 6 of 11
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Spark tester (0-15 KV AC)
with numeric fault counter
- Motorised Take up
Work Shop consisting of following
Machines
- Lathe
- Drilling
- Grinding
- Welding machines
D.G. set (heavy duty) of 100 KVA
minimum capacity.
Revision 0
-
11.0
12.0
01 Each
01
III. ESSENTIAL TESTING REQUIRED FOR QUALITY ASSURANCE:
S. N.
1
2
3
4
5
Description
Qty.
Required.
Tensile testing machines with
ranges as given below, (each with
3 sub ranges) to test copper wire,
rods, steel tapes, laminates & Al
wires etc.:i)
Tensile testing machine
0 to 200 N
ii)
Tensile testing machine
0 to 500 N
iii)
Tensile testing machine
0 to 10000N
Vernier calipers, least count
0.01mm with digital display.
Micrometer – least count 0.001
mm with digital display
Apparatus for determining melt
flow index (extrusion plasto meter
with
digital temp indication,
thermostatic control, accuracy
0.1°C.
Analytical monopan balance to
weigh to an accuracy of 0.1 mg.
01
01
01
01
01
Qty.
Available
Make &
Sr. No.
Year of
Installation
Remarks
Page 7 of 11
6
7
8
9
10
11
12
13
14
15
17
18
19
20
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Apparatus for environmental stress
cracking test to ASTM-1693
(Blanking die, Jig, specimen,
holders,
test
tubes,
corks,
aluminium foil, test tube rack,
bending clamps and transfer tools
constant temperature, bath range
0 to 1000 C with thermostatic
controlled heating system, inbuilt
digital temperature. Meter, hour
meter and sealing arrangement.
Facilities for Dip Test for
galvanization;
Two nos. of Air circulating ovens
with controls to maintain the
setting within ±2°C. Temp range 0
to 200 °C with PID control digital
display. Hour meter with sealing
arrangement to monitor tests
timings.
01
Environmental/
cold
chamber
(Minimum).
Apparatus for stability test of filling
compound (water bath range, for
monitoring
temperature,
hour
meter for recording test duration.
Scaling arrangement may also be
made for sealing.
Flash Point Apparatus
Drop Point Apparatus
Cone penetrometer
Ball point digital micrometers-least
count 0.001mm
Set up for water penetration test
(separate room required for
conducting tests).
Double Kelvin’s bridge.
01
Test set up for resistance to
compression test.
Multi meter Analog/Digital
Calibration Box for CR,IR and
Capacitance etc.
01
01
02
01
01
01
01
01
01
01
01
01
Revision 0
Page 8 of 11
21
22
23
24
25
26
27
28
29
30
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Stamping die (for cutting dumbbell
and other type of samples)
Digital/Analog Thermometer (duly
calibrated)
Digital/Analog stop watch.
Traveling
Microscope/Profile
Projector for checking eccentricity /
circularity of core.
Ageing oven range 0 to 200 deg. C
with Digital temperature controller
& pressure monitoring facility. Hour
meter (with sealing arrangement)
Cold Bend test apparatus (cold
chamber as mentioned in cold
bend test)
Hardness Tester (Shore-D)
Fully
Automatic
Computer
Controlled
Cable
Testing
Equipment for the following tests:
- Conductor Resistance
- Resistance Unbalance
- Digital capacitance meter
range 0.01µF to 1000 µF in
three range ± 1 % of the
reading.
- Capacitance
unbalance
meter for measurement of
capacitance pair to pair &
pair
to
ground
with
adequate range & digital
display.
- Attenuation Measurement at
0.8 kHz, 5 kHz & 150 kHz.
- ELFEXT
and
NEXT
Measurement at 0.8 kHz, 5
kHz & 150 kHz.
- Characteristic
impedance
test set up (0-20 K Ohm) in
three ranges, test frequency
0.8 kHz& 5 KHz.
AC High voltage tester 0-10 KV
(10 mA capacity)
Digital million meg ohm meter
range 1 Megohm to 109 Megohm
01
01
01
01
01
01
01
01
01
Revision 0
Page 9 of 11
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
in six ranges, DC test voltage, 100
Volt to 500 Volt ± 2% with one
minute timer.
Set up for reduction factor test as
per VDE spec.
Standard to check calibration of
Test equipment.
DSC Instruments
Carbon black content test set up
for
black
Sheathing/Jacketing
Compound
Carbon black dispersion test set
up for black
Sheathing/Jacketing Compound
Fibre Optic Analyser suitable for
measuring spectral attenuation
from 1200 nm to 1625 nm, MFD at
1310 & 1550 nm, and Fibre Cut-off
Wavelength
Fibre
Geometry Analyser
–
Suitable for measuring diameter of
core, clad and primary coating,
non-circularity and cocentricity
error
Optical
Time
Domain
Reflectometer (OTDR) – Suitable
for measuring Attenuation at 1310,
1550 & 1625 nm wavelength
Chromatic Dispersion Test Setup
suitable for measuring CD from
1200 nm to 1625 nm, zero
dispersion
wavelength,
zero
dispersion slope
Fiber Strain Measurement System
Fusion Splicer, suitable for splicing
SM Fibre
Polarisation Mode Test Setup
suitable for measuring PMD at
1310, 1550 nm wavelength
Crush Test Setup
Tensile Test Setup
Torsion Test Setup
Repeated Bend Test Setup
Cable Bend Test Setup
01
01
01
01
01
01
01
02
01
01
01
01
01
01
01
01
01
Revision 0
Page 10 of 11
48
49
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Abrasion Test Setup
Walk-in Type Climatic Chamber (40°c to + 85°c)
01
01
Revision 0
Page 11 of 11
IV.
Effective from
01.01.2007
STR
for
Composite RDSO/SPN/TC/50/2007
Cable (OFC+Quad)
Rev. 4.0
Revision 0
PROCESS FLOW CHART - FOR COMPOSITE (OPTICAL & QUAD) UNDER GROUND
ARMOURED CABLES
ROD BREAK DOWN
INTERMEDIATE WIRE
DRAWING
FIBRE COLOURING
SECONDARY LOOSE
TUBE
INSULATION
TUBE
QUADDING
S-Z STRANDING &
JELLY FILLING
SHEATHING
SCREENING &
PROTECTION
INTERMEDIATE
SHEATH
ARMOURING
FINAL SHEATH
REWINDING &
MARKING
FINAL TESTING
DESPATCH