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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