Basic Training Course Cables & Joints Electrical

VOCATIONAL TRAINING CENTRE

BASIC TRAINING PROGRAM

Electrical

MODULE E- 9

Cables

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1. General

Cables form an important part of any installation but, because they are static,
and in normal service are very reliable, they do not always receive the attention
that they deserve.

There are three categories of cables associated with industrial installations -

power cables, control cables, and special cables for, for example,
communications and data transmission circuits. It is the first two categories
which are described in this chapter. A power cable contains one, two, three or
four cores each consisting of a copper conductor surrounded by insulating
material; a control cable usually has many cores and is known as a 'multicore'
cable. Aluminium is sometimes used as a conductor material; although its
conductivity is less than that of copper, it is somewhat cheaper. Corrosion
problems, however, preclude its use on Shell installations, particularly offshore.

2 Power Cables

Cables are designed for both high voltage and low-voltage transmission of
power. Though the general construction is similar in both cases, high-voltage
cables have thicker insulation and usually have smaller conductors, since low-
voltage cables carrying bulk power handle the heavier Currents. ‫مهم‬

2.1 General Construction

A power cable is made up of one, two, three or four insulated conductors

enclosed in a bedding‫ حشو‬. For mechanical protection, wire armouring‫تسليح‬
is wrapped around the bedding, and a coloured outer protective sheath,
usually of PVC, is extruded over the armouring, as shown in Figure 1, Each
insulated conductor is known as a ‘core',

Fig.1
Three Core Power Cable

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2.2 Conductors

The size of the copper conductor forming one of the cores of a cable is
expressed in square millimeters (mm2), and the current rating of the
cable is dependent upon the cross-sectional area of each core. The very
smallest cables have conductors consisting of only one strand of copper;
larger cables however have stranded conductors consisting of many
individual strands or wires laid up together; this gives flexibility, allowing
the cable to be bent more readily during installation. To achieve a circular
conductor, the number of strands follows a particular progression: 3, 7,
19, 37, 61, 127 etc, the diameter of each strand being chosen to achieve
the desired cross-sectional area of tile whole conductor.

As seen in Figure 2, 3-core and 4-core cables in the larger sizes have
conductors with the strands laid up in a segmental formation; this
achieves a better space factor and reduces the overall diameter of the
cable. It also reduces the inductance of the cable due to decreased
spacing between phases.

Fig.2
Segmental Cores

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Standard conductor sizes range from I.5mm2 to 400mm2 for 2-core, 3-

core and 4-core cables, and from 50mm2 to I000mm2 for single-core
cables.

2.3 Insulation, Covering and Stress Relief

Natural rubber or oil-impregnated paper is no longer used for the

insulation of cables up to 3810/6600V; synthetic‫ صناعى‬materials are now
used. For high-vo1tage cables the insulation is ethylene propylene rubber
(EPR) and for low-voltage cables it is polyvinyl chloride (PVC). EPR has
good electrical properties and is resistant to heat and chemicals; it is
suitable for a conductor temperature up to 85oC. PVC is a thermoplastic
material, therefore care must be taken not to overheat it; it is suitable
for conductor temperatures up to 70°C. PVC insulated cables should not
be laid when the temperature is less than 0oC because it becomes brittle
and is liable to crack.

High-voltage cables have an earthed metallic screen over the insulation of

each core. This screen consists of a lapped copper tape or metallic foil,
and its purpose is to control the electric field within the insulation and
thus the voltage gradient across it, as shown in Figure 3. Also, it avoids
any interaction of the electric stresses due to the voltages on different
phase conductors within the same cable.

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Fig.3
Voltage Gradient Across High Voltage Cable Insulation

Core insulation may be coloured red, yellow, blue and black to identify the
three phases and neutral. Twin cores are coloured red and black. Single-
core cables are identified by coloured PVC tape applied to the outer
sheath.

2.4 Cable Stress Relief

The copper screen is often terminated in a 'stress cone', which may be

seen in Figure 7. This is to spread the electric stress which would
otherwise tend to concentrate where the screen is cut off at a cable end
and could lead to breakdown. This is further discussed in para. 6.4

2.5 Bedding

The bedding consists of a layer of PVC extruded over the core insulation
as a base for the armouring.

2.6 Armouring

Mechanical protection of the cable is provided by a single layer of wire

strands laid over the bedding. Steel wire is used for 3-core or 4-core
cables, but single-core cables have aluminium wire armouring. With 3-core
or 4-core cables the vector sum of the currents in the conductors is
zero, and there is virtually no resultant magnetic flux. This is not so
however for a single-core cable, where eddy-current heating would occur
if a magnetic material were used for the armouring. Armouring is
described as Steel Wire Armoured (SWA) or Aluminium Wire Armoured
(AWA).

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2.7 Outer Sheath

The outer sheath of extruded PVC protects the armouring and the cable
against moisture and generally provides an overall protective covering.

High-voltage cables are identified by outer sheaths coloured red; a black

sheath indicates a low-voltage cable (see also para. 7)

2.8 Selection of Power Cables

The following considerations are taken into account when selecting a

power cable for a particular application:

(a) The System Voltage and Method of Earthing

A low-voltage system usually has a solidly earthed neutral so

that the line-to-earth voltage cannot rise higher than (line
volts) ÷ √ 3. However, cables for low-voltage use are
insulated for 600V rms score to earth and 1000V rms core
to core.
High-voltage cables used in Shell installations are rated
1900/3300V or 3810/6600V or 6600/11000V, phase/line. In
selecting the voltage grade of cable, the highest voltage to
earth must be allowed for. For example, on a normal 6.6kV
unearthed system, a line conductor can achieve almost 6.6kV
to earth under earth-fault conditions, To withstand this, a
cable insulated for 6600/11000V must therefore be used.

(b) The Normal Current of the Cable

The conductors within a cable have resistance, and

therefore /2 R heating occurs when currents pass through
them, The maximum permissible temperature of the cable
depends upon the material of the insulation, and a conductor
size must be chosen so that this temperature is not
exceeded. Tables giving the continuous current-carrying
capacities of different cables are given in manufacturers'
literature and in the Regulations for the Electrical
Equipment of Buildings published by the Institution of
Electrical Engineers.

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The temperature of a cable depends not only on the rate of

heat input due to the passage of load current but also on the
rate at which the heat can be carried away. When using the
tables of current ratings it is important to note whether
they refer to cables laid in the ground laid in ducts or laid in
air. De-rating may be necessary if a number of cables are
run in close proximity to each other.

Another consideration in selecting a cable is the voltage (IR)

drop from the source of supply to the load. A drop of 1V in a
440V circuit is of little consequence, but it is a significant
percentage when the circuit operates at 24V,

(c) Abnormal Currents in the Cable

One abnormal condition is a sustained overload; a cable must

be protected so that an overload cannot persist long enough
to cause damage to the insulation by overheating. For
example, for PVC cables laid in air, the overload must not be
greater than 1.5 times the continuous maximum rated
current and must not persist for longer than four hours.

Another abnormal condition is when a cable has to carry a

through short-circuit current. In this case the temperature
of the conductor may be allowed to rise to a higher value,
say 150°C, for the short interval between the onset of the
fault and its disconnection. The short-circuit current that a
given cable can withstand depends upon the speed with which
the protection operates. For example, a PVC cable having
conductors of 185mm2 has the following short-circuit
ratings:
46kA for 0.2s
20.3kA for 1.0s
11.7kA for 3.0s

The 0.2s rating would be suitable for use with fuse

protection, but where relay-operated circuit breakers are
concerned, a longer time rating would be necessary. Again,
tables of short-circuit ratings are available in
manufacturers' literature.

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3 Control Cables

Control cables usually have conductors either 1.50mm2 or 2.50mm2 in cross-

section. The insulation, bedding and outer sheath are of PVC, and they are steel
wire armoured. Multicore cables are available having 2, 3, 4, 7, 12, 19 and 27
cores, each core being identified by a number on the insulation. The outer
sheath of control cables is coloured green.

4 Mineral Insulated Cables

Mineral-insulated (MI) cables are used where the integrity‫ سالمه‬of a circuit is of
great importance. They are particularly resistant to fire and are used in
circuits, such as communications or emergency lighting, which must continue
operational as long as possible after fire has broken out. They are also very
robust and resistant to mechanical damage.

Fig.4
Mineral Insulated Two Core Cable

MI cables are constructed by assembling the single-strand conductor or

conductors inside a seamless‫ غير مجعد‬copper tube. After threading a number of
'tablets' of magnesium oxide insulating material onto the conductors, the whole
assembly - conductors, insulation and copper tube - is drawn down through a
series of dies until the magnesium oxide is crushed to a powder and the whole
cable is solid. The final appearance is as in Figure 4.
After annealing‫ يلدن‬to make the cable more flexible, an outer sheath of PVC is
applied.

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MI cables are available in single-core from 1 mm2 to l50mm2, in 2-core, 3-core

and 4-core from 1mm2 to 25mm2, and in 7-core from 1 mm2 to 4mm2.

Special jointing techniques and materials must be used for terminating MI

cables, and great care must be taken to seal‫ يسد‬the cable ends against the entry
of moisture.

5 Method of Specifying Cables

There is a 'shorthand' method used to describe the construction of any cable,

using abbreviations to indicate the nature of the various materials. For example,
a low-voltage cable might be described as:

(Reference) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Abbreviation 0.6/1kV STR CU/PVC/PVC/SWA/PVC/HO2/HCL
3-core, l50mm2

Interpreted this means:

1 0.6kV line to earth

2 1kV line to line
3 Stranded conductor
4 Copper conductor
5 PVC conductor insulation
6 PVC bedding
7 Steel wire armoured
8 PVC outer sheath
9 (see below)
10

Another example is:

6.6/11kV STR CU/EPR/SCR/PVC/AWA/PVC/HO2/HCL

1-core, 630mm2

Where EPR indicates ethylene propylene conductor insulation

SCR indicates screened
AWA indicates aluminium wire armoured.

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The last two items (9 and 10) indicate the flammability and the toxicity of the
synthetic materials used in the cable. HO2 indicates that a high level of oxygen
is required to sustain‫ يعزز‬combustion: in the case of the Shell specification this
means more than 30% oxygen in the atmosphere. HCL denotes 'Hydrochloric
Level' showing that, when the synthetic materials burn, they produce
hydrochloric acid gas (HCI) which is highly poisonous and very corrosive.

In particular PVC, when burnt, releases large quantities of HCI and also
produces dense black smoke; for example, a 1m Iength of cable containing, say,
6kg of PVC can completely black out a room 1000m3 in site within five minutes of
the fire starting.

6 Installation

6.1 Cable Runs

Cables may be laid discretely in the ground, run in ducts or clamped to

cable trays; the third method is the most common in offshore
installations. Each cable must be identified at each end, using a marker
bearing the cable number.

There is a practical limit to the conductor size which can be run as a 3-

core or 4-core cable - it becomes too stiff and heavy to handle. A 3-
phase circuit is then run as three (or four) single-core cables. To minimise
the electromechanical forces between the cables under short-circuit
conditions, and to avoid eddy-current heating in nearby steelwork due to
magnetic fields set up by load currents, the three single-core cables
comprising the three phases of a 3-phase circuit are always run clamped
in 'Trefoil' formation, as shown in Figure 5.

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Fig.5
Single Core Cables Laid in Trefoil

At any instant in time the net magnetic flux outside the group of cables
due to the three line currents in them approximates to zero because of
the symmetrical cable Iayout.

Heavy current cable runs, such as the low-voltage connections from a

transformer, may consist of up to four single-core cables in parallel per
phase; all 12 cables are run bunched into four 3-phase sets, each set laid
in trefoil. In the case of 4-wire systems the neutral conductor needs a
smaller cross-sectional area than that of the phase conductors and may be
met by one or more smaller single-core cables in parallel.

6.2 Cable Terminations

A power cable is terminated in an air-insulated cable box in offshore

installations; it enters the box through a compression gland which grips
the wire armouring and seals the entry of the cable. The outer sheath,
armouring and bedding of the cable are stripped back, enabling the cores
to be spread to match up with the fixed bushing terminals, and the
insulation is removed to expose the conductors. Such a cable box is often
referred to as a 'trifurcating box'.

In some high-voltage onshore installations, especially outdoor ones, the

cable box may be filled with compound, a tar-like substance which is
poured in hot and then sets hard to exclude moisture. It can only be
removed by heating.

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Fig.6
Low Voltage Cable Termination

Conductors are terminated either with lugs bolted to the fixed bushing stems
as shown in Figure 6 or, for heavier currents, with cylindrical ferrules which are
clamped into terminal blocks. In either case the terminations are crimped onto
the conductors using either hand or hydraulic crimping tools. To make a good
connection it is vital that the lug or ferrule is the correct size for the
particular conductor and that the correct die is used in the crimping tool.

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Fig.7
High Voltage Cable Termination

Special measures must be adopted, when screened high-voltage cables are

terminated, to prevent a concentrated electric field being developed where the
copper screening tape is cut back; this strong electric field could lead to the
insulation at that point being so overstressed that a breakdown occurs. Special
stress cones are fitted which are bonded to the screening tape; they control
the electric stress and reduce the resulting voltage gradients to a safe value.
This arrangement is shown in Figure -7.

6.3 Single-core Cables

The conductor of a single-core cable and its surrounding metallic armouring act
as a current transformer having a 1:1 turns ratio; load current passing through
the conductor produces a magnetic flux which, linking with the wires of the
armouring, induces an emf in them. If a circuit is provided between the
armouring at one end of the cable and at the other, a current flows in the
armouring which, if sufficiently large, causes heating. This is shown in Figure
8(a).

To control these circulating currents insulated cable gland adapters are used
whereby the body of the gland, and consequently the wire armouring of the
cable, is electrically isolated from the earthed gland plate of the cable box by a
layer of insulation. Figure 8(b) shows a 3-phase circuit run with single-core
cables using insulated cable glands. To control the voltage of the armouring it
must be bonded to earth; this is done by deliberately bridging the gland
insulation using bonding links. The armouring can be bonded in one of two ways.
In Figure 2.8{a) it is bonded at both ends of the cable run (shown in red); the
emf induced in the armouring causes currents (IA) to circulate in the armouring
which in heavy current circuits may lead to an undesirable temperature rise in
the armouring. Alternatively, the armouring may be bonded at one end only as in
Figure 2.8(b); there is no circuit for current to flow, but a voltage (EA) is
developed across the gland insulation at the unbonded end. Where one end of
the circuit is in a hazardous area, it is customary to bond this end so that any
arcing that may occur due to emfs induced in the armouring can only take place
in the non-hazardous area.

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There is one other magnetic problem associated with single-core cables: where
such cables enter a cable box or pass through partitions the conductors must
pass through holes in the gland plate. If these plates are made of a magnetic
material such as steel, the magnetic fields due to the load currents in the
conductors induce eddy currents in the gland plate which may cause it to
become very hot. For terminating or passing a.c. circuits using single-core
cables, gland plates of non-magnetic material must be used.

Fig. 8
Insulated Cable Glands

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6.4 Control Cables

Control cables are also terminated using compression glands. The sheathing and
armouring are stripped back to leave tails of the required length. Each core is
identified using plastic ferrules bearing the wire number, and terminated using a
crimped connector. The cores are either laced up into suitable runs using plastic
cable ties, or secured to cable racks within a control panel.

7 Outer Sheath Colours

Standard colours are used in Shell installations to identify the system to which
the various cables belong; they are:

Red : High-voltage system

Black : Low-voltage system
Green : Control and instrumentation system,
Orange : Fire and gas detection and telecommunications systems.
Blue : Intrinsically safe systems.
Yellow : Thermocouple circuits,

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Types of Cables

PILC Paper Insulated, Lead Alloy E sheathed

PILCPVC Paper insulated, Lead Alloy E sheathed,

PVC Oversheath
PILCSWAS Paper insulated, lead alloy E sheathed,
single wire armoured, bitumen
PILCSWAPVC impregnated, hessian/jute
Paper insulated, lead alloy served.
E sheathed,
double steel tape armoured, PVC
PILCDTAPVC Oversheath
Paper insulated, lead alloy E sheathed,
double steel tape armoured, PVC
PVCSWAS Oversheath
PVC Insulated, single wire armoured,
bitumen impregnated hessian/jute
PVCSWAPVC served
PVC insulated, single wire armoured,
PVC Oversheath
PVCLCSWAS PVC Insulated, lead alloy E sheathed,
single wire armoured, bitumen
PVCLCDTAS impregnated,
PVC insulated,hessian/jute
lead alloy served
E sheathed,
double steel tape armoured, bitumen
PVCLCSWAPVC impregnated hessian/jute
PVC insulated, lead alloy served
E sheathed,
single wire armoured, PVC Oversheath
MICC Mineral insulated, copper covered

MICCPVC Mineral insulated, copper covered, PVC

Oversheath
EPRCSPGWBCSP EPR insulated, CSP sheathed, galv.
Steel wire braids armoured, CSP
XLPESWAPVC Oversheath.
XLPE insulated, single wire armoured,
PVC Oversheath.
Notes
1. The lead sheath is required for elastomer and PVC cables to prevent
radial ingress of petroleum based solvents which might permeate through
PVC and cause deterioration of insulating materials and might enter and
pass along stranded conductors into equipment terminations.

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2. The PVC Oversheath is required as a protection against corrosive

conditions which could attack the steel wire armour or lead sheath.
Certain conditions may require other types of compounds.

Abbreviations

PVC POLYVINYL CHLORIDE

SWA SINGLE WIRE ARMOUR
CPE CROSS LINKED CHLORINATED POLYETHYLENE
CSP CHLOROSULPHONATED POLYETHYLENE
EPR ETHYLENE PROPYLENE RUBBER
HCI HYDROGEN CHLORIDE
HOFR CHLOROSULPHONATED POLYETHYLENE OR
CHLORINATED POLYETHYLENE COMPOUND (HEAT, OIL,
RESISTANT AND FLAME RETARDANT)
Si SILICON RUBBER
FR SPECIALLY FIRE RESISTANT
M MARINE
XLPE CROSS LINKED POLYETHYLENE

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