rahul kumar summer traning.pdf

8/21/2019 rahul kumar summer traning.pdf

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METHOD OF TEST FOR

CABLESAMITY UNIVERSITY RAJASTHAN

RAHUL KUMAR

B.TECH(EEE)

VTHSEMESTER


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DECLARATION

I, Rahul Kumar, Enrolment No A20424612012, student of B.Tech Electrical and Electronics

(2012-2016) at Raicon Labs Pvt. Ltd. Sonepat hereby declare that the Summer Training Report

on Cable and Electrical Accessoriesis an original work and the same has not been submitted

to any other Institute for the award of any other degree.


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ACKNOWLEDGEMENT

I take this opportunity to thank all those who have been instrumental in completion of my

training. Words could never be enough to express my true regards to all those who helped me

in completing this project. I cannot in full measure, reciprocate the kindness shown and

contribution made by various persons in this endeavour of mine. I shall always remember them

with gratitude and sincerity. First of all I would like to take the opportunity to thank Mr.

Dheeraj Tahan, Quality Manager, And Mr. Awadhesh kumar singh, Technical Manager,

Raicon Labs Private Ldt. for giving me the opportunity to undergo my summer internship in

their company.

I would forever be indebted to my Project Guide Mr.Neeraj Upadhyay, Lab In charge,

Raicon Labs Pvt. Ltd. for his guidance and support throughout the course of my project. The

Inputs provided by him have been invaluable for the completion of my Project.

I feel deep sense of gratitude towards Mr. Naveen , Lab In charge, thenentire Staff in Lab

anomy internal Project, Raicon Labs Pvt Ltd for assisting me throughout the project.

Also like to thank all my RLPL senior and batch mates who helped me time and again.

Rahul Kumar


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I. ABSTRACT

The Bureau of Indian Standards has formed some basic test that acts as

constraints in maintaining the quality of products. The Methods of Test forCables are routine test that are performed by the manufacturer to keep a

quality check and for safety measure.

These tests are mentioned in the IS:10810 of BIS and comprises total 54 test

methods for electrical cables.

The IS:10810 (Part 0 (General)) has the basic format and common

terminology used in the IS test following it. The standard value for cable as

per the tests has been mentioned in the IS:5831-1984.


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ContentsCompany Introduction ............................................................................................................... 7

LABORATORY WORK ................................................................................................................ 12

1. Polyvinyl Chloride Compound (PVC)................................................................................. 13

2. Type of Compound ........................................................................................................... 13

3. Type Tests ......................................................................................................................... 13

4. Acceptance Tests .............................................................................................................. 13

5. Routine Tests .................................................................................................................... 13

6. Rated Voltage ................................................................................................................... 14

7. Nominal Value .................................................................................................................. 14

General Notes on Tests ............................................................................................................ 14

CONDUCTOR ............................................................................................................................ 15

a. Material ............................................................................................................................ 15

b. Electrical Resistance ......................................................................................................... 15

INSULATION ............................................................................................................................. 15

a. Material ............................................................................................................................ 15

b. Application to the Conductor ........................................................................................... 16

i. Thickness .......................................................................................................................... 16

ii. Mechanical Properties before and after Ageing .............................................................. 16

FILLER ....................................................................................................................................... 16

a. Material ............................................................................................................................ 16

SHEATH .................................................................................................................................... 17

a) Material ............................................................................................................................ 17

TEST PERFMORMED UNDER IS:10810 ..................................................................................... 18

IS:10810 (Part 1) ...................................................................................................................... 18

Scope ........................................................................................................................................ 18

Significance .............................................................................................................................. 18

Terminology ............................................................................................................................. 18

a. Gauge Length .................................................................................................................... 18

b. Elongation at Break .......................................................................................................... 19

2. Apparatus ......................................................................................................................... 19

Material .................................................................................................................................... 19

Test Specimen .......................................................................................................................... 20


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Conditioning ............................................................................................................................. 20

1. Scope ................................................................................................................................ 20

2. Significance ....................................................................................................................... 20

3. Terminology ...................................................................................................................... 20

Apparatus ................................................................................................................................. 21

a. Tensile Testing Machine ................................................................................................... 21

b. Plane Faced Micrometer .................................................................................................. 21

c. Suitable Scale .................................................................................................................... 21

d. Weighing Balance ............................................................................................................. 21

4. Material ............................................................................................................................ 21

Test Specimen .......................................................................................................................... 21

5. Conditioning ..................................................................................................................... 21

IS:10810 (Part 3) ...................................................................................................................... 21

CONCLUSION ............................................................................................................................ 28

REFERENCES ............................................................................................................................. 29


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Table Of FigureFigure 1 Raicon labs pvt ltd ........................................................................................................ 7

Figure 2 Eletrical & Mechanical Scope ....................................................................................... 8

Figure 3 Electrical & Mechanical Testing ................................................................................... 9

Figure 4 Cable Code ................................................................................................................. 17Figure 5 Preferred arrangement of marking............................................................................ 17

Figure 6 Tensile Testing Machine ............................................................................................ 19

Figure 7 Plane Faced Micrometer ............................................................................................ 19

Figure 8 STANDARD DUMB-BELL TEST PIECE ........................................................................ 24

Figure 9 SMALL DUMB-BELL TEST PIECE ............................................................................... 24


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Company Introduction

Figure 1Raicon labs pvt ltd

FIG. 1

I would like to take this opportunity of briefly introducing M/s. RAICON LABS PVT.

LTD. as a well-established organization serving varied fields of Engineering. The

organization provides its services in,

Geo-Technical/Soil Investigation.

Quality analysis & Material Testing. ( Civil, Mechanical, Chemical, Electrical )

Non-destructive analysis of structures. ( UPV, Rebar Location, Corrosion analysis,

R-Hammer)

Pile Integrity Testing.

Rebaring & Retrofitting.

Concrete cutting & Core drilling.

Raicon Labs Pvt Ltd. was established in 2010, at 140-HSIIDC, Rai Industrial Estate,

Haryana and developedincorporating various testing machines and Equipment.

The name and business strength that has been earned by our organization today, is due to

the professionally equipped and able staff, who have a varied experience of Project


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executions & Material analysis, good knowledge of serving the customers to their

satisfaction. This is further enhanced by the innovative ideas of the management, who

strive from time to time in creating awareness and keeping the company at par to the latest

development of today's world. The laboratory carries out different tests on building

materials, metals, alloys, water, environmental pollutants, cables, switches, conduit pipes

etc. The lab incorporates, as well, a workshop for the preparation of standard test

specimens special rooms for concrete casting, curing, and carrying out some standard

tests are also available in the premises of the building. The technical staff of the

laboratory includes highly qualified persons having relevant experience in the relative

fields which cooperate for serving the field of testing work. The Raicon is currently

serving various govt. & private Organization in their scientific activities & plays a

pioneering role in the QA/QC of construction work using its up-to-date facilities.

Our Lab is accredited by:

National Accreditation Board for Testing & Calibration Laboratories (NABL),

Department of Science and Technology, Govt. of India.

ISO 9001:2008.

NABL - Under Process

Figure 2Eletrical & Mechanical Scope

Fig 2


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Figure 3 Electrical & Mechanical Testing

Fig 3

Table 1 Testing Facilities

1 ELECTRICAL

I Electric wire/Cable, PVC insulated

a) Conductor resistance

b) Tensile test for aluminium conductor

c) Anneling test for copper conductor

d) High voltage test (AC)

e) High voltage test (DC)

f) Wrapping test for Aluminium conductor

g) Flammability test

h) Thickness of insulation

i) Insulation resistance & volume restivity

j) Loss of mass

k) Ageing in air oven

l) Tensile strength and elongation at break of insulation

m) Shrinkage test

n) Hot deformation test


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o) Heat shock

p) Cold bend test

q) Cold impact test

ii) MS Conduit pipe

a) Dimensions checking

b) Bending test at room temp.

c) Bending test at low temp.

d) Compression test

e) Collapse test

f) Impact test

g) Resistance to burning

h) Electrical characteristics

i) Insulation resistance

j) Resistance to heat test

iii) Switch

a) Marking

b) Resistance to ageing

c) Electrical strength

d) Insulation resistance

e) Temperature rise test

f) Making and breaking capacity

g) Normal operation

h) Mechanical strength

i) Checking of dimensions

j) Protection against electric shock

k) Provision for earthing

l) Terminals

m) Resistance to heat

n) Screw, current carrying parts and connections

o) Creepage and clearance distances

p) Resistance to abnormal heat and fire

q) Resistance to rusting

iv) Socket & Plug

a) Marking

b) Resistance to ageing, to harmful injures of water

c) Electrical strength

d) Insulation resistance

e) Temperature rise test

f) Making and breaking capacity

g) Normal operation

h) Mechanical strength

i) Checking of dimensions


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j) Protection against electric shock

k) Provision for earthing

l) Terminals

m) Resistance to heat

n) Screw, current carrying parts and connections

o) Creep age and clearance distances

p) Resistance to abnormal heat and fire

q) Resistance to rusting

r) Force necessary to withdraw the plug


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LABORATORY WORKIn the broad field of Electrical Engineering, various equipment and systems are used to

cater to the application for Electrical power generation, transmission, distribution,

control, instrumentation, Communication and domestic application. Each one of the

products/ equipment requires a wide variety of tests and hence a need of specialized

testing facility.

The field of Electrical Testing covers tests of an essentially electrical nature performed

on instruments, equipment, appliances, components and materials. This document sets out the

specific criteria requirements for an electrical testing laboratory, in addition to the general

requirements of ISO/ IEC 17025: 2005. The document also guides the laboratory to write the

Scope of Accreditation. Instrument accuracy limits for various parameters and ranges have

been indicated. Also various tests where the laboratories can participate in Proficiency Testing

have been listed in the field of Electrical Testing the tests have been classified into Product

wise grouping e.g. Circuit breaker, Isolator, MCB etc. from Switchgear equipment group.

However certain specialized tests, which are performed on a wide range of equipment,

have been grouped Test Facility wise e.g. High voltage, EMI/ EMC testing etc.

2.1 IS: 10810 (Part 0)

A large number of Indian Standards have been published covering the requirement of

electric cables. In order to avoid repetition and to bring uniformity, this standard has been

brought out to consolidate methods for various tests at one place.

This standard is being issued in different parts, each part dealing with a particular test, indetail. The idea is that, besides the consolidation of details at one place, the option should

be open to the users of different standards to procure whatever parts are relevant to their

activities. The format and main clauses are listed below, have been kept the same in all

parts (except Part 0 'General ) for the sake of uniformity and to avoid the possibility of

missing any details:


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2.1.1Format

1. Scope

2.

Significance

3. Terminology

4.

Apparatus

5.

Material

6. Test Specimen

7. Conditioning

8. Procedure

9.

Tabulation of Observations

10.Calculations

11.Report

2.1.2Terminology

In addition to those given In IS: 1885(Part 32)-1971 'Electrotechnical

vocabulary: Part 32 Cable, conductors and accessories for electrical supply', the following

definitions shall apply. Additional definition wherever applicable are given in Individual parts.

1. Polyvinyl Chloride Compound (PVC) Combination of materials suitably

selected, proportioned and treated, of which the characteristic constituent is the

plastomer polyvinyl chloride or one of its copolymers. The same term also designates

compounds containing both polyvinyl chloride and certain of its polymers.

2. Type of CompoundThe category in which a compound is placed according to

its properties, as determined by specific tests. The type designation is not directly

related to the composition of the compound.

3. Type TestsTests required to be made before supplying a type of cable covered by

this standard on a general commercial basis in order to demonstrate satisfactory

performance characteristics to meet the intended application. These tests are of such a

nature that, after they have been made, they need not be repeated unless changes are

made in the cable materials or design or manufacturing process, which might change

the performance characteristics.

4. Acceptance TestsTests carried out on samples taken out from a lot for the

purpose of acceptance of lot.

5. Routine Tests Tests conducted by manufacturer on all finished lengths to

demonstrate the integrity of the cable.


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6. Rated VoltageThe rated voltage of a cable is the reference voltage for which

the cable is designed and which serves to define the electrical tests. The rated voltage

is expresses by the combination of two values Vo /Vexpressed in volts: Vo being the

rms value between any insulated conductor and the earth. V being the rms value

between any two-phase conductors of multicore cable or of a system of single core

cables. In an alternating current system, the rated voltage of a cable shall be at least

equal to the nominal voltage of the system for which it is intended. This condition apply

both to the value Vo and to the value V. In direct current system the nominal voltage

of the systems shall not be higher than 1.5 times the rated voltage of the cable.

7. Nominal ValueThe value by which a quantity is designated and which is often

used in tables. Usually, in this standard, nominal values give rise to values to be checked

by measurements taking into account specified tolerances.

General Notes on Tests

1. These methods of tests have been, primarily laid down for electric cable.

However, these methods may also be used, with or without modification,

for testing other types of cable ( such as, telecommunication cables),

cable joints and terminals, If referred to in the individual product

specification.

2. Full test conditions (such as temperatures, durations and voltage) and full

test requirements are not specified in this standard. It Is intended to

specify such detail in the standard dealing with the relevant type of cable

or Its component.

3. The details given in this standard may be modified by the relevant product

standard to suit the needs of a particular type of cable. In case of any

deviation between this standard and the individual product standard, the

provisions of latter shall apply.

2.1.4 GENERAL REQUIREMENTS


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CONDUCTOR

a. Material-The conductors shall consist of annealed, bare or tinned of

high conductivity copper wires complying with Class 1 or Class 2 or

Class 5 as per IS 8130. The conductor shall be composed of aluminium

wires complying to IS 8130. A separator tape made of suitable material

may be applied over conductor at the discretion of the manufacturer. The

aluminium conductors shall be of Class 1 or Class 2 as per IS 8130 for

sizes up to and including 10 mm2and stranded type as per Class 2 of IS

8130 for the sizes above 10 mm.

b. Electrical Resistance -The resistance of each conductor at 20C

shall be in accordance with the requirements of IS 8130 for the given class

of conductor. Compliance shall be checked by the test given in Table 1,

Sl No. (i) (a). The classes of the conductors relevant to the various types

of cables are given in Section 2 and Section 3. Conductors of cables for

fixed installations shall be circular solid, circular stranded or compacted

circular/ shaped stranded conductors. Nominal cross-sectional area of

conductor of cables covered in this standard are given in respective tables.

In case of tinned copper conductor, the persulphate test shall be conducted

as per IS 8130 and as per IS 10810 (Part 4).

INSULATION

a. Material-The insulation shall be of polyvinyl chloride compound of

the type specified for each type of cable (see also Section 2 and Section

3):

i.

Type ACables for fixed installation

ii. Type CHeat-resistant cables (HR)

iii. Type DFlexible cables and cords

The PVC shall conform to IS 5831. The test requirements for this compound

are as per IS 5831 and as mentioned in the respective sections. The single core

unsheathed cables (see Section 2) with fire performance for category FR and

FR-LSH, the insulation shall satisfy the relevant special FR/FR-LSH properties.

In case of sheathed cables with fire performance for category FR and FR-LSH(see Section 3), the insulation need not be with FR/FR-LSH properties.


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b. Application to the Conductor-The insulation shall be so

applied that it fits closely on the conductor. It shall be possible to remove

it without damage to the insulation itself, to the conductor or to the tin

coating, if any. Compliance shall be checked by inspection and by

manual test.

i. Thickness-The mean value of the thickness of insulation shall

be not less than the specified value for each type and size of cable

shown in the relevant tables given in Section 2 and Section 3.

The smallest of the measured values of thickness of insulation (ti

) shall not fall below the nominal value (ti) specified in the

relevant table by more than (0.1 mm+0.1 ti ).

ii. Mechanical Properties before and after Ageing-

The insulation shall have adequate mechanical strength and

elasticity within the temperature limits to which it may be

exposed in normal use. The compliance shall be checked by

carrying out tensile strength and elongation test, for respective

type of PVC, as per Table 1 of IS 5831. The applicable test

values shall be obtained from Table 1 of IS 5831, for appropriate

type of PVC.

FILLER

a. Material-The fillers shall be composed of one of the following or of

any combination of the following:

a) A compound based on unvulcanized rubber or plastics; or

b) Natural or synthetic textiles; or

c) Paper; or

d) PVC

When the filler is composed of unvulcanized rubber, there shall be no

harmful interactions between its constituents and the insulation and/or

the sheath.The filler material shall be suitable for operating temperature

of the cable and compatible with other components of the cable. This

shall not be harder than the PVC used for insulation and sheath.


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SHEATH

a) Material-The sheath shall be polyvinyl chloride compound of the

type specified for each type of cable (see also Section 3) as given

below:

a) Type ST1cables for fixed installations

b) Type ST2cables sheathed with 85C HRPVC compound

c) Type ST3flexible cables

The PVC shall conform to IS 5831. Test requirements for these

compounds are as per Table 2 of IS 5831. For the cables with fire

performance category FR and FR-LSH, sheathing compound shall

satisfy the relevant special FR/FR-LSH properties (Table 2).

Table 2Cable code

Figure 4 Cable Code

Figure 5Preferred arrangement of marking


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TEST PERFMORMED UNDER IS:10810

Annealing test for Wires Used as conductors (Part 1)

Tensile Test for Aluminium Wires (Part 2)

Wrapping Test of Conductors (Part 3)

Conductor Resistance Test (Part 5)

Thickness of Thermoplastic and Elastomeric Insulation and Sheath (Part 6)

Breaking Strength and Elongation at Break for Impregnated Paper

insulation (part 8)

Loss of Mass Test (Part 10)

Thermal Ageing Test (Part 11)

Shrinkage Test (Part 12)

IS:10810 (Part 1)

Scope

a.

Covers method for determining the elongation properties of

annealed copper wires, aluminium wires for welding cables

and solidal conductors used in electric cables.

Significance

b.

As the conductor of a cable is subjected to twisting andbending, it is necessary that it should be flexible enough to

take any desired bend without breaking. This test takes into

consideration the extent of work hardening which may be

caused during the stranding and laying up process.

Terminology

a.

Gauge Length- Original length of that portion of the test

specimen over which strain or change of length is

determined.


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b. Elongation at Break- Increase in gauge length of a tension

test specimen, measured after fracture, within the gauge

length, expressed as a percentage of the original

gauge length.

2.

Apparatus

a.Tensile Testing Machineas shown in Fig 5

b.Plane Faced MicrometerLeast count 0.01 mm.

c. Suitable ScaleLeast count 0.01mm

Figure 6 Tensile Testing Machine

Figure 7 Plane Faced Micrometer

Material

No other material than the test specimen is required.


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Test Specimen

The gauge length for measurement of elongation of

wire shall be 250 mm. The total length of the specimen shall

be at least equal to gauge length plus the length of the wire

required for the full use of grips employed. The specimen

shall be straightened by hand, if necessary and the gauge

marks shall be scribed lightly with dividers or drawn with

ink, as preferred.

Conditioning

No conditioning is required

2.4 IS:10810 (Part 2)

1. ScopeCovers method to determine tensile strength of aluminium

wires used for conductors of electric cables.

2. Significance This test is performed on conductor material to

determine the strength of the material when subjected to tensile

stress. Since cable conductors to be pulled from one end alongtrenches are subjected to considerable force during pulling as well

as manufacture, it is necessary to ensure that the conductor material

has adequate tensile strength

3. Terminology

a. Guage length- The original length of that portion of the

specimen over which strain or change of length is determined.

b. Breaking Load The load at which the Jest specimen

fractures.


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Apparatus

a. Tensile Testing Machine Automatic, having capacity to

meet the requirement of this test and shall have the rate ofseparation of jaws as specified in 8.3. The grips shall be such as

to firmly hold the test specimen.

b. Plane Faced MicrometerLeast count 0.01 mm.

c. Suitable ScaleLeast count 1 mm.

d. Weighing BalanceSensitivity 0.01 g.

4. MaterialNo material other than the test specimen is required.

Test Specimen

a.

The gauge length shall be 250 mm. The total length of the

specimen shall be at least equal to gauge length plus the length

of the wire required for the full use of grips employed.

b.Number of SpecimensOne.

5. ConditioningNo pre-conditioning is required

IS:10810 (Part 3)


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2.6 IS:10810 (Part 5 )


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2.7 IS:10810(Part 7)

1. Scope-Covers the method to determine the tensile strength and elongation

at break of thermoplastic and elastomeric insulation and sheath of electric

cables.

2. Significance - During the process of manufacture and during installation

electric cables are unavoidably subjected to mechanical stresses; particularly

bending. Thermoplastic or elastomeric insulation and/or sheath in the cable

are also subjected to these stresses and strains. This test is carried out to

ensure that the insulation and/or sheath have requisite tensile strength and

elongation to withstand the same.

3. Terminologya. Gauge Length -The original length of that portion of the specimen

over which strain or change of length is determined.

b. Elongation at Break - The increase in gauge length of a tensile test

specimen measured at the moment of break and expressed as a percentage

of the original gauge length.

c. Breaking Load - The load at which the test specimen breaks.

d. Tensile Strength at Break- Tensile strength is computed from the

measurements of breaking load and cross-sectional area of the test specimen.

4. Apparatus

a. Die - The shape and dimensions of dumb-bell punching die for

preparing dumb-bell test specimens shall be as shown in Fig.7 and 8. The

die shall be sharp and free from nicks in order to prevent ragged edges on

the specimens.


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Figure 8 STANDARD DUMB-BELL TEST PIECE

Figure 9 SMALL DUMB-BELL TEST PIECE

2.8 . TEST REQUIREMENTS

According to the IS 5831 the insulation and sheath shall satisfy the testrequirements stated in Tables 3 and 4 respectively, to the extent

specified in the relevant cable standard. Type A general purpose

insulation for maximum rated conductor temperature 70C intendedfor cables with rated voltages up to and including 3.3/3.3 kv. Type


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B General purpose insulation for maximum rated conductor temperatureintended for cables with rated voltages above 3.3/3.3 kv.Type C Heatresisting insulation for maximum rated conductor temperature 85Cintended for cables with rated voltages up to and including 1 100 volts.

continue..


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continue..


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CONCLUSION

The IS Test pertaining to Methods of test for Cables as per the IS: 10810 have

been studied and performed. This test have a significant role in quality and safe

standards of electrical wires.

This IS comprises various test for standardizing the wire material in terms of

Elongation, Tensile stress, Resistance, Sheath covering, Loss of Mass due to

heating, High Voltage test and many other parameter.

These parameters reveal if any of electrical circuits or equipment can be

overloaded, any potential electric shock risk and fire hazards, identify any

defective electrical work and highlight any lack of earthing or bonding.


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REFERENCES

1.http://raiconlabs.com/aboutus.html

2.http://www.bis.org.in/index.asp

3.https://law.resource.org/pub/in/bis/S5/is.10810.0.1984.pdf

4.https://law.resource.org/pub/in/bis/S05/is.5831.1984.pdf

5.https://law.resource.org/pub/in/bis/S05/is.694.2010.pdf

6.

https://law.resource.org/pub/in/bis/S5/is.1885.32.1993.pdf
http://raiconlabs.com/aboutus.htmlhttp://raiconlabs.com/aboutus.htmlhttp://www.bis.org.in/index.asphttp://www.bis.org.in/index.asphttps://law.resource.org/pub/in/bis/S5/is.10810.0.1984.pdfhttps://law.resource.org/pub/in/bis/S5/is.10810.0.1984.pdfhttps://law.resource.org/pub/in/bis/S05/is.5831.1984.pdfhttps://law.resource.org/pub/in/bis/S05/is.5831.1984.pdfhttps://law.resource.org/pub/in/bis/S05/is.694.2010.pdfhttps://law.resource.org/pub/in/bis/S05/is.694.2010.pdfhttps://law.resource.org/pub/in/bis/S5/is.1885.32.1993.pdfhttps://law.resource.org/pub/in/bis/S5/is.1885.32.1993.pdfhttps://law.resource.org/pub/in/bis/S5/is.1885.32.1993.pdfhttps://law.resource.org/pub/in/bis/S05/is.694.2010.pdfhttps://law.resource.org/pub/in/bis/S05/is.5831.1984.pdfhttps://law.resource.org/pub/in/bis/S5/is.10810.0.1984.pdfhttp://www.bis.org.in/index.asphttp://raiconlabs.com/aboutus.html

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