1 Cable –

1.1 Cable related points-

1.2 Classification by operating voltage—
Low voltage (LV) less than 1000 volts
Medium voltage (MV; between 1000 volts (1 kV)
distribution) and 69 kV,
High voltage 69 KV to 138 KV
Extra high voltage (EHV; from 345 kV, up to about 800
transmission) kV
Ultra high voltage (UHV) higher than 800 kV.

1.3 Cable Schedule

is a document containing list of instrument cable. This document
Cable schedule
shows cable as well as gland required by each instrument or connection. The
information of the cable schedule shall consists:

 Cable Number
 Cable Type / Specification
 Cable Size
 Cable Length
 Source and destination termination description
 Cable gland type and size for each incoming cable

1.4 Types Of Conductors Used In

Overhead Power Lines--
A good conductor should have the following properties:

 high electrical conductivity

 high tensile strength in order to withstand mechanical stresses
 relatively lower cost without compromising much of other properties
 lower weight per unit volume
 aluminium has replaced copper because of the much lower cost and lighter weight of the aluminium
conductor compared with a copper conductor of the same resistance.
 1. AAC : All Aluminium Conductor
2. AAAC : All Aluminium Alloy Conductor

 These conductors are made from aluminium alloy 6201 which is a high strength Aluminium-
Magnesium-Silicon alloy.
 This alloy conductor offers good electrical conductivity (about 52.5% IACS) with better
mechanical strength.
 AAAC may be used for distribution purposes. However, it is not usually preferred for
transmission.

3. ACSR : Aluminium Conductor, Steel Reinforced

4. ACAR : Aluminium Conductor, Alloy Reinforced

1.4.1 AAC : All Aluminium Conductor

 It is made up of strands of EC grade or Electrical Conductor grade aluminium.
 AAC conductor has conductivity about 61% IACS (International Annealed Copper Standard).
 Despite having a good conductivity, because of its relatively poor strength, AAC has limited use in
transmission and rural distribution lines.
 AAC can be seen in urban areas for distribution where spans are usually short but higher
conductivity is required.

1.4.2 AAAC : All Aluminium Alloy Conductor

 AAAC conductors can be employed in coastal areas because of their excellent corrosion resistance

1.4.3 ACSR : Aluminium Conductor, Steel Reinforced

 ACSR consists of a solid or stranded steel core with one or more layers of high purity aluminium
(aluminium 1350) wires wrapped in spiral.
 The core wires may be zinc coated (galvanized) steel or aluminium coated (aluminized) steel.
 The central steel core provides additional mechanical strength and, hence, sag is significantly less
than all other aluminium conductors
 ASCR conductors are very widely used for all transmission and distribution purposes.

1.4.4 Aluminium Conductor, Alloy Reinforced

 ACAR conductor is formed by wrapping strands of high purity aluminium (aluminium 1350) on high strength
Aluminum-Magnesium-Silicon alloy (6201 aluminium alloy) core.
 ACAR has better electrical as well as mechanical properties than equivalent ACSR conductors

1.5 Types Of system Used In Overhead

Power Lines-
1.5.1 Bundled Conductors
 Transmission at extra high voltages (say above 220 kV) poses some problems such as significant corona loss
and excessive interference with nearby communication lines when only one conductor per phase is used.
 EHV level, the electric field gradient at the surface of a single conductor is high enough which causes corona
loss and interference problems.
 The electric field gradient can be reduced significantly by employing two or more conductors per phase in
close proximity.
 Two or more conductors per phase are connected at intervals by spacers and are called as bundled
conductors
1.6 Type of underground cables
The underground cables are classified in two ways; by the voltage capacity, or by the construction

1.6.1 By voltage
LT cables: Low-tension cables with a maximum capacity of 1000 V
HT Cables: High-tension cables with a maximum of 11KV
ST cables: Super-tension cables with a rating of between 22 KV and 33 KV
EHT cables: Extra high-tension cables with a rating of between 33 KV and 66 KV
Extra super voltage cables: with maximum voltage ratings beyond 132 KV

1.6.2 By Construction
Belted cables: Maximum voltage of 11KVA
Screened cables: Maximum voltage of 66 KVA(There are two types of screened cables; the H type
and the S.L type.)
Pressure cables: Maximum voltage of more than 66KVA

these reasons, the underground cables are mostly used for transmitting up to 33KV
1.7 type of ground cable –
1.7.1 xlpe cable-
1.7.1.1 Testing of xlpe cable-
1.8 Construction of Power Cable

There are various parts of a cable to be taken care of during construction.

The power cable mainly consists of

1. Conductor
2. Insulation
3. LAY for Multicore cables only
4. Bedding
5. Beading/Armouring (if required)
6. Outer Sheath

Parts of Cable:

1. Conductor (For LV/MV/HT Cables)

2. Conductor Screen (For MV/HT Cables)
3. Filler & Binding Tapes (For LV/MV/HT Cables)
4. Insulation (For LV/MV/HT Cables)
5. Insulation Screen (For MV/HT Cables)
6. Separation Tape (For MV/HT Cables)
7. Bedding (Inner Sheath)
8. Metallic Sheen (For MV/HT Cables)
9. Armor (For LV/MV/HT Cables)
10. Outer Sheath (For LV/MV/HT Cables)
11. Water Blocking Tapes –Optional (For MV/HT Cables)
12. Insulation Tapes–Optional (For MV/HT Cables)

1.8.1 Conductor
 Conductors are the only power carrying path in a power cable.
  Conductors are of different materials. Mainly in cable industry we use
copper (ATC, ABC) and aluminium conductors for power cables.
 There are different types of conductor as Class 1: solid, Class 2
stranded, Class 5 flexible, Class 6 Extra flexible (Mostly used for cords
and welding) etc.

1.8.2 Insulation
The insulation provided on each conductor of a cable by mainly PVC (Poly
Vinyl Cloride), XLPE (Crosslinked Polyethyelene), RUBBER (Various Types
of Rubber). Insulating material is based on operating temperature

Maximum Operating
nsulation Material
Temperature

PVC TYPE A 75oC

PVC TYPE B 85oC

PVC TYPE C 85oC

XLPE 90oC

RUBBER – EPR IE-1 90oC

RUBBER – EPR IE-2, EPR IE-3, EPR 150oC

IE-4, SILICON IE-5

1.8.3 Beading (Inner Sheath)

 This portion of the cable is also known as inner sheath. Mostly it is
used in Multi core cables. It works as binder for insulated conductors
together in multi-core power cables and provides bedding to
armour/braid
 This portion of the cable is mainly made of PVC( PVC ST-1, PVC ST-
2 ), RUBBER (CSP SE-3, CSP SE-4 and PCP SE-3, PCP SE-4, HOFR
SE-3 HOFR SE-4, HD HOFR SE-3 ETC)

1.8.4 Armouring
 There are mainly G.I. WIRE ARMOURING, G.I. STEEL STRIP armouring. It is done by placing G.I. WIREs, GI or
STEEL STRIPs one by one on inner sheath.
 Armouring is a process which is done mainly for providing earthing shield to the current
carrying conductors as well as it is also used for earthing purpose of the cable for safety.
 When there is any insulation failure in the conductor, the fault current gets enough paths to flow through
the armour if it is properly earthed.
 Providing extra mechanical protection and strength to cable is an important added advantage of armouring
 n MINING CABLES it is done for conductance
1.8.5 Outer Sheath
This is outermost cover of the cable normally made of PVC (Poly Vinyl Chloride), RUBBER (Various
Types of Rubber) and often the same material as the bedding. It is provided over the armour for
overall mechanical, weather, chemical and electrical protection. Outer sheath is protection offered
to cable not much electrically but more mechanically

Max
Materi
Advantages Disadvantages Operating
al
Temperature

70oC for
Highest dielectric general
Cheap, Durable, losses, Melts at high purpose 85oC
PVC
Widely available temperatures, for heat
Contains halogens resisting
purpose

Lowest dielectric Highly sensitive to

losses, High water treeing,
PE
initial dielectric Material breaks down
strength at high temperatures

Does not melt but

thermal expansion
Low dielectric
occurs, Medium
losses, Improved
sensitivity to water
XLPE material 90oC
treeing (although
properties at high
some XLPE polymers
temperatures
are water-tree
resistant)

Increased
flexibility,
Reduced thermal Medium-High
expansion dielectric losses,
EPR 90oC
(relative to Requires inorganic
XLPE), Low filler / additive
sensitivity to
water treeing

High weight, High

Low-Medium cost,
dielectric losses, Requires hydraulic
Paper Not harmed by pressure / pumps for
70oC
/ Oil DC testing, insulating fluid,
Known history of Difficult to repair,
reliability Degrades with
moisture
1.8.6 Beading(it is type of armouring)-in instrument
cable

ANNEALED TINNED COPPER WIRE, NYLON BRAID, COTTON BRAID are

mainly used for this purpose. Braiding is the process which gives high
mechanical protection to cable and also used for earthing purpose.
Significance of braiding is it is more flexible in comparison to armouring.

1.8.7 Screen (to prevent interference)- in

instrumentation cable
Screen is constructed from aluminized polyester film/tape which provide
protection from external interference. The aluminum tape is spirally wrapped
with 25% overlap to guarantee 100% coverage of cable element including in
bending area. Screen also consists of copper drain wire of which shall be
electrically in contact with the screen along the cable.

 twisted wire shall have minimum of six crossover per foot. Eight crossover
per foot is a typical specification

1.9 Thermoset vs. Thermoplastic

Thermoset-XL . Thermoplastic
During the curing process, polymer Thermoplastic materials consist of chains
chains are cross-linked with other of molecules that separate when heat is
molecules. This is why thermoset applied. This molecular construction
materials are also known as cross-linked gives thermoplastics the ability to melt
materials and remold time and time again.
Once cured, thermoset materials are
irreversibly molded
thermosets are great solutions for high- hermoplastics, they will burn when
temperature applications or for circuits at excessive heat is applied because their
risk for overload. High-temperature melting point is simply too high to reach.
ratings make them more likely to function The materials degrade and decompose
if an application overheats suddenly. before they can reach temperatures high
enough to melt.

1.10 Industrial detail of cable—

Cross-Linked Polyethylene XLPE
Ethylene-Propylene Rubber EPR
Polyvinyl Chloride PVC
Polyethylene PE

1.10.1 Low voltage cabel kei—

1.10.2 EHV cable—

1.10.3 Rubber cable—

1.11 insulation levels—
The insulation of the cable must be able to withstand the voltage stresses experienced during normal and abnormal
operating conditions

1.11.1 100% level:

Cables in this category may be applied where the system is provided with relay protection which normally clears
ground faults within 1 minute This category is usually referred to as the grounded systems

1.11.2 133% level-

Cables in this category may be applied where the system is provided with relay protection which normally
clears ground faults within 1 hour This category is usually referred to as the low resistance
grounded, or ungrounded systems.

1.11.3 173% level-

Cables in this category may be applied where the time needed to de-energize the ground fault
is indefinite This level is recommended for ungrounded and for resonant grounded systems.
The current capacity that the cable needs to carry is determined by the load it serves

1.12 Technical parameter of HT cable

1.13 Technical parameter of LT cable--
1.14 CHECKLIST FOR CABLE INQUIRY
1.14.1 Commercial information

1.14.2 Technical information

1.14.3 tests
1.14.4 Installation data

acc
1.14.5 accessories

1.15 Installation point of cable

1.15.1 Under ground –
1. The minimum width of trench for laying single cable shall be 350 mm
2. There shall be a clearance of at least 150 mm between axis of the end cables and the
sides of the trench.
3. The trench shall then be provided with a layer of clean, dry sand cushion of not less than 75mm.

4. The LT cable shall be laid at a depth of not less than 750 mm. HT cables shall be laid at a depth
of 1000mmm.
5. The minimum safe bending radius for all types of PVC and XLPE cables shall be
taken as 12 times and 15 time the overall diameter of the cables respectively.
6. At joints and termination, the bending radius of individual cores of a multi core cable shall not be
less than 15 times its overall diameter.
 7. Where available space is
restricted, LV/MV cable shall be laid above HV cables.
8. Where cables cross one another, the cable of higher voltage shall be laid at a lower
level than the cable of lower voltage
9. Power and communication cables shall as far as possible co\ross at right angles.

10. Where
power cables are laid in proximity to communication cables the horizontal and vertical
clearances shall not normally be less than 300 mm.
11. Approved GI cable markers shall be provided along the route of the cable at every
30 meters distance. (For underground cables).
12. Distance between two adjacent cables shall be kept equal to cable diameter and cables
shall be clamped properly to keep the cables in positions.
13.
14.
15.

1.15.2 Overhead

1.16 Normal- LT-Cable size calculation—

1.16.1 Theory –
Basic fact to consider –
All cable sizing methods more or less follow the same basic six step process:
1 Gathering data about the cable, its installation conditions, the load that it will carry, etc
2 Determine the minimum cable size based on continuous current carrying capacity
 3 consider the derating factor and calculate the size of cable (Cable derating amp should be
higher than full load current of load.)
4 Determine the minimum cable size based on voltage drop considerations
5 Determine the minimum cable size based on short circuit temperature rise
6 Determine the minimum cable size based on earth fault loop impedance
7 -No. of cable runs ≥ (Full load current / Cable derating current).
8 Select the cable based on the highest of the sizes calculated in above step

1.16.1.1 Step 1: Data Gathering

 Load Details
 Cable Construction
 Installation Conditions
 Derating factor –
 Temperature Correction Factor (K1) When Cable is in the Air
 Ground Temperature Correction Factor (K2)
 Thermal Resistance Correction Factor (K4) for Soil (When Thermal Resistance of Soil is known)
 Soil Correction Factor (K4) of Soil (When Thermal Resistance of Soil is not known)
 Cable Depth Correction Factor (K5)
 Cable Distance correction Factor (K6)
 Cable Grouping Factor (No of Tray Factor) (K7)

1.16.1.2 Step=2 Installed Current Ratings

International standards and manufacturers of cables will quote base current ratings of different types of cables

Cable Selection and Coordination with Protective Devices—

Feeder-

Motor
1.16.1.3 Step 3: Voltage Drop
 Current flow through the cable – the higher the current flow, the higher the voltage drop
 Impedance of the conductor – the larger the impedance, the higher the voltage drop
 Most cable manufacturers will quote a cable’s resistance and reactance in Ω/km


 Calculating Maximum Cable Length due to Voltage Drop –using above formula
1.16.1.4 Step 4: Short Circuit Temperature Rise
The initial conductor temperature is typically chosen to be the maximum operating temperature of the cable.

The final conductor temperature is typically chosen to be the limiting temperature of the insulation.

1.16.1.5 Step 5: Earth Fault Loop Impedance

1.16.1.6 Example-1
1.16.1.7 Example =2
 SIZE OF NUTERAL CONDUCTER SHOULD BE EQUAL TI (16 SQMM )
AFTER THEAT size may be reduced but it should fill the requirement of over
load and short circuit protection . if equal to phase conductor then it will
protected by phase protection
 In normal operating conditions the power
Factor of (ku) consumption of a load is sometimes less
than that indicated as its nominal power
maximum rating, a fairly common occurrence that
utilization justifies the application of an utilization
factor (ku) in the estimation of realistic
values.

In an industrial installation this factor may

be estimated on an average at 0.75 for
motors.
 It is a matter of common experience that
Diversity (ks) the simultaneous operation of all installed
loads of a given installation never occurs in
factor -
thus will practice, i.e. there is always some degree
Coincidence be of diversity and this fact is taken into
factor always ≤ account for estimating purposes by the use
1 of a factor (ks)
( IEC60050 )

1.17 Normal- HT-Cable size calculation—

1.18 Under ground Cable size calculation

–

1.19 Over head line Cable size calculation

1.20 Standard size of cable –
.50 .75,1,1.5,2.5

1.1 KV 1.1 kvlevel control 3.3 KV level

level
1.21 Formula-

1-

2-

3-