Insulated Cables

Mayank Goyal
Assistant Professor
Department of Electrical Engineering
Introduction
• Electric power can be transmitted or distributed either by overhead system
or by underground cables.
• The underground cables have several advantages such as less liable to
damage through storms or lightning, low maintenance cost, less chances of
faults, smaller voltage drop and better general appearance.
• However, their major drawback is that they have greater installation cost
and introduce insulation problems at high voltages compared with the
equivalent overhead system.
• For this reason, underground cables are employed where it is impracticable
to use overhead lines. Such locations may be thickly populated areas where
municipal authorities prohibit overhead lines for reasons of safety, or
around plants and substations or where maintenance conditions do not
permit the use of overhead construction.
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• An underground cable essentially consists of one or more conductors
covered with suitable insulation and surrounded by a protecting
cover.

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Construction of Cables

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The various parts of cable are:
• Cores or Conductors. A cable may have one or more than one core
(conductor) depending upon the type of service for which it is
intended. For example, the 3-conductor cable shown is used for 3-
phase service. The conductors are made of tinned copper or
aluminium and are usually stranded in order to provide flexibility to
the cable.
• Insulation. Each core or conductor is provided with a suitable
thickness of insulation, the thickness of layer depending upon the
voltage to be withstood by the cable. The commonly used materials
for insulation are impregnated paper, varnished cambric or rubber
mineral compound.

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• Metallic sheath. In order to protect the cable from moisture, gases or
other damaging liquids (acids or alkalies) in the soil and atmosphere,
a metallic sheath of lead or aluminium is provided over the insulation.
• Bedding. Over the metallic sheath is applied a layer of bedding which
consists of a fibrous material like jute or hessian tape. The purpose of
bedding is to protect the metallic sheath against corrosion and from
mechanical injury due to armouring.
• Armouring. Over the bedding, armouring is provided which consists
of one or two layers of galvanised steel wire or steel tape. Its purpose
is to protect the cable from mechanical injury while laying it and
during the course of handling. Armouring may not be done in the
case of some cables.
• Serving. In order to protect armouring from atmospheric conditions,
a layer of fibrous material (like jute) similar to bedding is provided
over the armouring.

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Insulating Materials for Cables
• The proper choice of insulating material for cables is of considerable
importance. In general, the insulating materials used in cables should have
the following properties :
• High insulation resistance to avoid leakage current.
• High dielectric strength to avoid electrical breakdown of the cable.
• High mechanical strength to withstand the mechanical handling of cables.
• Non-hygroscopic i.e., it should not absorb moisture from air or soil. The moisture
tends to decrease the insulation resistance and hastens the breakdown of the cable.
• Non-inflammable.
• Low cost.
• Unaffected by acids and alkalies to avoid any chemical action.
• The principal insulating materials used in cables are rubber, vulcanised
India rubber, impregnated paper, varnished cambric and polyvinyl chloride.

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• Rubber: Rubber may be obtained from milky
sap of tropical trees or it may be produced
from oil products. It has relative permittivity
varying between 2 and 3, dielectric strength is
about 30 kV/mm and resistivity of insulation
is 1017Ω cm. Although pure rubber has
reasonably high insulating properties, it
suffers form some major drawbacks viz.,
readily absorbs moisture, maximum safe
temperature is low (about 38oC), soft and
liable to damage due to rough handling and
ages when exposed to light. Therefore, pure
rubber cannot be used as an insulating
material.

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• Vulcanized India Rubber (V.I.R.): It is prepared by
mixing pure rubber with mineral matter such as zine
oxide, red lead etc., and 3 to 5% of sulphur. The
compound so formed is rolled into thin sheets and cut
into strips. The rubber compound is then applied to
the conductor and is heated to a temperature of
about 150ºC. The whole process is called
vulcanization and the product obtained is known as
vulcanized India rubber.
Vulcanized India rubber has greater mechanical
strength, durability and wear resistant property than
pure rubber. Its main drawback is that sulphur reacts
very quickly with copper and for this reason, cables
using VIR insulation have tinned copper conductor. The
VIR insulation is generally used for low and moderate
voltage cables.

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• Impregnated paper: It consists of chemically pulped
paper made from wood chippings and impregnated
with some compound such as paraffinic or
napthenic material. This type of insulation has
almost superseded the rubber insulation. It is
because it has the advantages of low cost, low
capacitance, high dielectric strength and high
insulation resistance. The only disadvantage is that
paper is hygroscopic and even if it is impregnated
with suitable compound, it absorbs moisture and
thus lowers the insulation resistance of the cable.
For this reason, paper insulated cables are always
provided with some protective covering and are
never left unsealed.

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• Varnished cambric: It is a cotton cloth
impregnated and coated with varnish. This
type of insulation is also known as empire
tape. The cambric is lapped on to the
conductor in the form of a tape and its
surfaces are coated with petroleum jelly
compound to allow for the sliding of one
turn over another as the cable is bent. As
the varnished cambric is hygroscopic,
therefore, such cables are always provided
with metallic sheath. Its dielectric strength
is about 4 kV/mm and permittivity is 2.5 to
3.8.

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• Polyvinyl chloride (PVC): This insulating material is
a synthetic compound. It is obtained from the
polymerisation of acetylene and is in the form of
white powder. For obtaining this material as a
cable insulation, it is compounded with certain
materials known as plasticizers which are liquids
with high boiling point. The plasticizer forms a gel
and renders the material plastic over the desired
range of temperature.
• Polyvinyl chloride has high insulation resistance,
good dielectric strength and mechanical toughness
over a wide range of temperatures. It is inert to
oxygen and almost inert to many alkalies and acids.
Therefore, this type of insulation is preferred over
VIR in extreme environmental conditions such as in
cement factory or chemical factory. As the
mechanical properties (i.e., elasticity etc.) of PVC
are not so good as those of rubber, therefore, PVC
insulated cables are generally used for low and
medium domestic lights and power installations.
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Classification of Cables
The classification of Underground cables can be done on the basis of
several criteria. Various aspects are taken into account while
classification and these include:
• Number of conductors in the cable
• Voltage rating of the cable
• Construction of cable

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Classification Based Upon Number Of
Conductors in the Cable
• A cable may have one or more than one core
depending upon the type of service for which
it is intended. It may be
(i) single-core Single – Core Cable

(ii) two-core
(iii) three-core
(iv) four-core etc.
• For a 3-phase service, either 3-single-core
cables or three-core cable can be used
depending upon the operating voltage and
load demand.
Three – Core Cable
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Classification Based Upon Voltage Rating of the Cable
• Low tension cables: maximum voltage upto 1000 V (1 kV)
• High tension cables: maximum voltage upto 11 kV.
• Super tension cables: maximum voltage upto 33 kV.
• Extra high tension cables: maximum voltage upto 66 kV.
• Extra super voltage cables: These are used for applications
with voltage requirement above 132 kV.

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Classification Based Upon Construction of the Cable
• In practice, underground cables are generally required to deliver 3-
phase power. For the purpose, either three-core cable or three single
core cables may be used. For voltages upto 66 kV, 3-core cable (i.e.,
multi-core construction) is preferred due to economic reasons.
However, for voltages beyond 66 kV, 3-core-cables become too large
and unwieldy and, therefore, single-core cables are used.
• The following types of cables are generally used for 3-phase service :
• Belted cables — upto 11 kV
• Screened cables — from 22 kV to 66 kV
• Pressure cables — beyond 66 kV.

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 1. Belted Cables
• Figure shows the constructional details of a
3-core belted cable.
• The cores are insulated from each other by
layers of impregnated paper. Another layer of
impregnated paper tape, called paper belt is
wound round the grouped insulated cores.
The gap between the insulated cores is filled
with fibrous insulating material (jute etc.) so
as to give circular cross-section to the cable.
• The cores are generally stranded and may be
of noncircular shape to make better use of
available space. The belt is covered with lead
sheath to protect the cable against ingress of
moisture and mechanical injury.

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• The belted type construction is suitable only for low and medium
voltages as the electrostatic stresses developed in the cables for these
voltages are more or less radial i.e., across the insulation. However,
for high voltages (beyond 22 kV), the tangential stresses also become
important. These stresses act along the layers of paper insulation. As
the insulation resistance of paper is quite small along the layers,
therefore, tangential stresses set up leakage current along the layers
of paper insulation. The leakage current causes local heating,
resulting in the risk of breakdown of insulation at any moment.

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2. Screened Cables
• In order to overcome the difficulty of leakage current in belted cables,
screened cables are used where leakage currents are conducted to
earth through metallic screens.
• These cables are meant for use upto 33 kV.
• Two principal types of screened cables are H - type cables and S.L.
type cables.

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• H – Type Cables

• This type of cable was first designed by H. Hochstadter and hence the
name.
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• Figure shows the constructional details of a typical 3-core, H-type
cable.
• The three cores are individually insulated with paper and then
covered by a metallic screen / cover. These metallic covers are
perforated. As a result, such construction allows the three metallic
screens to touch each other. These three metallic covers are then
grouped together in a metallic tape usually made of copper. A lead
sheath surrounds this construction. The metallic covers and the
sheath are grounded.
• The obvious advantage is the electric stresses are radial, not
tangential and hence of lesser magnitudes. Also, the metallic covers
improve the heat dissipation.

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• S.L. (Separate Lead) Type Cables

• It is similar to the H - type cables, with the difference that each of the three
cores has its own lead sheath. With this provision, the need for the overall
sheath used previously is eliminated. The advantage of such a construction is
that the chances of a core-to-core breakdown are greatly minimized. Also, the
flexibility of the cable is improved.
• The limitations are severe.
• Such construction is limited for voltages up to 66kV only.
• The individual sheaths are thinner, and if there are constructional defects,
moisture may enter the cable and reduce its dielectric strength.
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3. Pressure Cables
• For voltages beyond 66 kV, solid type cables are unreliable because
there is a danger of breakdown of insulation due to the presence of
voids. When the operating voltages are greater than 66 kV, pressure
cables are used. In such cables, voids are eliminated by increasing
the pressure of compound and for this reason they are called
pressure cables.
• Two types of pressure cables viz oil-filled cables and gas pressure
cables are commonly used.

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• Oil – Filled Cables
• Oil is circulated under suitable pressure through ducts provided for
such purpose. This oil supply and pressure are maintained through
reservoirs kept at proper distances. The oil used is the same that is
employed for impregnation of paper insulators.
• Oil under pressure compresses the layers of paper insulation and is
forced into any voids that may have formed between the layers. Due
to the elimination of voids, oil-filled cables can be used for higher
voltages, the range being from 66 kV upto 230 kV.
• Oil-filled cables are of three types viz., single-core conductor
channel, single-core sheath channel and three-core filler-space
channels.

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 Oil – Filled Cables

Single-Core Conductor Channel Single-Core Sheath Channel Three-Core Filler-Space Channels

Oil Filled Cable Oil Filled Cable Oil Filled Cable

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• The oil-filled cables have three principal advantages.
• Firstly, formation of voids and ionization are avoided.
• Secondly, allowable temperature range and dielectric strength are increased.
• Thirdly, if there is leakage, the defect in the lead sheath is at once indicated
and the possibility of earth faults is decreased.
• However, their major disadvantages are the high initial cost and
complicated system of laying.

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• Gas Pressure Cables

• The voltage required to set up ionization inside a void increases as the

pressure is increased. Therefore, if ordinary cable is subjected to a
sufficiently high pressure, the ionization can be altogether eliminated. At
the same time, the increased pressure produces radial compression
which tends to close any voids. This is the underlying principle of gas
pressure cables.
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• The triangular section reduces the weight and gives low thermal
resistance but the main reason for triangular shape is that the lead
sheath acts as a pressure membrane. The sheath is protected by a
thin metal tape.
• The cable is laid in a gas-tight steel pipe. The pipe is filled with dry
nitrogen gas at 12 to 15 atmospheres. The gas pressure produces
radial compression and closes the voids that may have formed
between the layers of paper insulation.
• Such cables can carry more load current and operate at higher
voltages than a normal cable. Moreover, maintenance cost is small
and the nitrogen gas helps in quenching any flame.
• However, it has the disadvantage that the overall cost is very high.

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Laying of Underground Cables
• Underground cables are, of course, meant to be installed or laid
under the ground. The reliability of underground cable network highly
depends upon proper laying of cables, quality of cable joints and
branch connections etc.
• There are three main methods of laying underground cables, which
are –
• Direct laying,
• Draw-in system and
• Solid system.

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 Direct Laying
• This method is the most popular as it is simple and cheap. The cables to be laid
using this method must have the serving of bituminized paper and hessian tape so
as to provide protection against corrosion and electrolysis.
• The direct laying procedure is as follows.
• A trench of about 1.5 meters deep and 45 cm wide is dug.
• Then the trench is covered with a 10 cm thick layer of fine sand.
• The cable is laid over the sand bed. The sand bed protects the
cable from the moisture from the ground.
• Then the laid cable is again covered with a layer of sand of
about 10 cm thick.
• When multiple cables are to be laid in the same trench, a
horizontal or verticle spacing of about 30 cm is provided to
reduce the effect of mutual heating. Spacing between the
cables also ensures a fault occurring on one cable does not
damage the adjacent cable.
• The trench is then covered with bricks and soil to protect the
cable from mechanical injury.
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• Advantages
• Simpler and cheaper than the other two methods
• Heat generated in cables is easily dissipated in
the ground.
• Disadvantages
• To install new cables for fulfilling an increased
load demand, completely new excavation has to
be done which costs as much as the new
installation.
• Alterations in the cable network are not easy.
• Maintenance cost is higher.
• Identifying the location of a fault is difficult.
• This method can not be used in congested areas
such as metro cities where excavation is too
expensive.

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 Draw – In System
• In this method, cast iron or concrete pipes or
ducts are laid underground with manholes at
suitable positions along the cable route. The
cables are then pulled into the pipes from the
manholes. Usually, an additional pipe/duct is
also provided along with the three cable
ducts for carrying relay protection
connections and pilot wires. Distance
between the manholes should be such that
pulling in the cables is easier.
• At corners or while changing the direction of
route, radius of the corners must be longer.
• The cables that are to be laid in this way need
not be armoured but must be provided with
the serving of hessian and jute in order to
protect them when being pulled.
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Advantages
• Repairs, additions or alterations to the cable network can be
easily made from manholes without re-excavation.
• In this method, as the cables need not be armoured, the
cable jointing procedure becomes simpler.
• Maintenance cost is quite lower.
• Fewer chances of fault occurrence due to the strong
mechanical protection provided by the system.
Disadvantages
• The initial cost is very high.
• Due to unfavourable conditions for dissipation of heat,
current carrying capacity of the cables is reduced.
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• This method of cable laying is suitable for congested areas where
excavation is expensive and inconvenient, for once the conduits have
been laid, repairs or alterations can be made without opening the
ground.
• This method is generally used for short length cable routes such as in
workshops, road crossings where frequent digging is costlier or
impossible.

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 Solid System
• In this method, the cable is laid into troughing
of cast iron, stoneware, asphalt or treated
wood. When the cable is laid into the position,
the troughing is filled with a bituminous of
asphaltic compound and then covered over.
Cables to be laid in this manner could be just
lead covered as the troughing provides a good
mechanical protection.
• This method is very rarely used nowadays as it
is more expensive and requires skilled labour
and favourable weather conditions. Due to
poor heat dissipation facilities, the current
carrying capacity of the cable is reduced.
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 Thank You

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