CABLE TERMINOLOGY

SBEE Heavy Duty Cables :

a) Letters used in Type Designations :

A = Appearing as a first letter denotes Aluminium Conductor.

Y = (PVC) Insulation or (PVC) Sheath depending on the position in which it appears.

2X = (Cross-linked Polyethylene) Insulation.

W = Round Steel Wire Armouring.

WW = Double Round Steel Wire Armouring.

F = Formed Steel Wire (Strip) Armouring.

FF = Double Formed Steel Wire (Strip) Armouring.

C = Metallic Screening (Usually of Copper).

CE = Metallic Screening (usually of Copper) over each individual core.

Gb = Holding Helix Tape (of Steel)

Wa = Aluminium Round Wire & Aluminium Formed Wire (Strip) Fa Armouring

b) Type Designations :

AYY Aluminium Conductor, Insulated, Outer Sheathed Heavy Duty Cables.

AYWY Aluminium Conductor, Insulated, Galvanised Round Steel Wire Armoured and Outer
Sheathed Heavy Duty Cables.

AYFY Aluminium Conductor, Insulated, Galvanised Flat Steel Wire (Strip) Armoured and Outer
Sheathed Heavy Duty Cable.
CABLE TERMINOLOGY

AYCY Aluminium Conductor, Insulated, Metallic Screened and Outer Sheathed Heavy Duty
Cable.

A2XCY Aluminium Conductor, TROPOTHEN-X Insulated, Metallic Screened and TROPODUR

Outer Sheathed Heavy Duty Cable.

AYCEFY Aluminium Conductor, Insulated, individual core metallic screened, Flat steel Wire
(strip) Armoured and Outer Sheathed Heavy duty Cable.

A2XCEFY Aluminium Conductor Insulated, individual cores metallic screened, Flat Steel Wire
(Strip) Armoured and Outer Sheathed Heavy Duty Cable.

NOTE : If the first letter A is dropped in the above designations (i.e. YY, YWY, YFY etc.) they will
denote corresponding types with Copper Conductors.

YWWGby…(Mining) Copper Conductor Insulated, double round wire armoured and Outer
Sheathed Heavy Duty Mining Cable.

YFFGby…(Mining) Copper Conductor Insulated, double flat wire (strip) armoured and Outer
Sheathed Heavy Duty Mining Cable.

Paper Cables :

a) Letters used in Type Designations :

A = Appearing as a first letter denotes Aluminium Conductor.

P = Paper Insulation

L = Lead Sheath

Ly = Lead Alloy Sheath

CABLE TERMINOLOGY

S = Lapped bedding or serving of compounded fibrous materials (when it comes below

armouring in armoured cables, it is known as bedding).

Y = Extruded PVC Bedding or Serving.

T = Double steel tape armouring.

Tg = Double steel tape armouring galvanised.

W = Single round steel wire armouring.

WW = Double round steel wire armouring.

F = Single formed steel wire (strip) armouring.

FF = Double formed steel wire (strip) armouring.

b) Type Designations:

APLS Aluminium Conductor, Paper Insulated, Lead Sheathed and Served Cable.

APLyS Aluminium Conductor, Paper Insulated, Lead Alloy Sheathed and Served Cable.

APLy Aluminium Conductor, Paper Insulated, Lead Sheathed and overall PVC Sheath protected
Cable.

APLyY Aluminium Conductor, Paper Insulated, Lead Alloy Sheathed and overall PVC Sheath
protected Cable.

APLSTS Aluminium Conductor, Paper Insulated, Lead Sheathed, double steel tape armoured and
served Cable.

APLySTS Aluminium Conductor, Paper Insulated, Lead Alloy Sheathed, double steel tape
armoured and overall PVC Sheath protected cable.

NOTE :
CABLE TERMINOLOGY

1. If the first letter A is dropped in the above designations (i.e. PLS, PLSTS, PLSTY, etc) they
will denote the corresponding types with Copper Conductors.

2. If the cable is armoured with round steel wire armouring or formed steel wire (strip)
armouring replace T in above by W or F respectively e.g. APLSWS, APLSFS, etc.

3. If the cable is armoured with double round steel wire armouring or double formed steel
wire (strip) armouring replace T by WW or FF respectively e.g. APLSWWS, APLSFFS, etc.

4. If the cable is armoured with galvanised double steel tape, replace T by Tg e.g. APLSTgS.

5. In the case of H type cable with common Lead Sheath, add suffix (screened) e.g. APLSTS
(screened) APLSTY (screened) etc.

6. In the case of HSL type cable with separately Lead Sheathed cores, add suffix (screened
SL) e.g. APLSTS (screened SL), APLSTY (screened SL) etc.

For completely specifying the cable, the type designation is to be followed by indication of
number of cores, nominal cross-section of conductor, construction of conductor and voltage
rating of cable as shown in the following examples :

1. AYY 3 1/2 x 50/25 sm 0.65/1.1 kV

2. AYFY 3 x 185sm 3.8/6.6 kV (E)

3. AYCY 1 x 400 rm 6.35/11 kV (E)

4. AYCEFY 3 x 240 rm/v 6.35/11 kV (E)

5. A2XCEFY 3 x 300 rm/v 12.7/22 kV (E)

6. YWWGbY 3 x 16 rm/12 (Mining) 0.65/1.1 kV

7. YFFGbY 3 x 70 sm/35 (Mining) 1.9/3.3 kV

8. APLS 1 x 630 rm 3.8/6.6 kV (E)

CABLE TERMINOLOGY

9. APLySWY 3 x 240 sm 6.35/11 kV (E)

10. APLSTS 3 x 400 sm 11 kV (UE)

11. APLSTS (Screened) 3 x 150 sm 12.7/22 kV (E)

12. APLSTgY (Screened) 3 x 300 rm 19/33 kV (E)

NOTE :

i. The nominal cross-section of conductors indicated are in sq.mm.

ii. In Item (1) the cross-section indicated as ' 50/25 ' mean that the main conductors are of
nominal cross-section 50 sq.mm. and the neutral conductor is of nominal cross-section
25 sq.mm.

iii. The construction of conductor is indicated as follows :

re : circular, solid conductor

rm : circular, multiwire stranded conductor

rm/v : circular, compact multiwire stranded conductor

sm : shaped, multiwire stranded conductor

In Items (6) and (7) the examples Mining Cables the figures ' 16 rm/12 ' & ' 70 sm/35 ' denote
that the nominal cross-section of conductor is 16 sq.mm. (circular, multiwire stranded), 70
sq.mm. (shaped, multi-wire stranded) and the minimum effective cross-sections of armouring
are equivalent to 12 sq.mm. of copper* and 35 sq.mm. of copper* respectively.

(*or Aluminium in case of Aluminium conductor Mining cables)

CABLE TERMINOLOGY

Rubber Cable :

For Cables other than Ship Wiring :

Constituent Code Letter

Aluminium Conductor A
Elastomer (Rubber) Insulation R
Copper wire braiding or helical screening of
C
Copper wires
Semi-conducting extruded Screening over &
Cg
below Insulation
Copper wire braiding or helical screening of
CE @
Copper wires on individual cores
Glass Fibre Yarn braiding C
Textile Braiding B
Synthetic Yarn Braiding S
Textile Braiding on individual cores BE @
Synthetic Yarn Braiding on individual cores SE @
Steel round wire armouring W
Double steel round wire armouring WW
Steel strip armouring F
Double steel strip armouring FF
Non-magnetic round wire armouring Wa
Non-magnetic strip armouring Fa
Steel wire braiding Wb
Steel wire pliable armouring Wp
Elastomer (Rubber) Outer Sheath R
PVC Outer Sheath Y

Normal flexible conductor is denoted as 'rf' & special (as per client requirement) flexible
conductor is denoted as "rff". When the conductor material is Copper no Code Letter is
requried for conductor @ In case only some of the cores are individually screened/braided the
number of such cores shall be indicated as suffix to the Code Letter e.g. CE4, BE4, etc

For Ship Wiring Cables :

CABLE TERMINOLOGY

Constituent Code Letter

Ship Wiring Cable (Marine use) M
Elastomer (Rubber) Insulation G
Braiding of Steel/Copper/Annealed Tinned
C
Copper
Elastomer (Rubber) Outer Sheath G
PVC Outer Sheath Y

NOTE :

Material of braiding shall be indicated in brackets at the end as follows :

Plain Copper (CU) and Annealed Tinned Copper (ATC)

Examples for the above code letters :

1) Annealed tinned Copper flexible conductor of nominal cross-section 25Sqmm insulated with
Rubber Compound, provided with Copper wire braiding on individual cores, for cores stranded
together, inner sheathed, provided with steel wire braiding and overall sheathed with Rubber
compound.

The Type Designation shall be RCEWbR 4 x 25 rf

2) Annealed tinned Copper (2.5 sq.mm) flexible conductor, insulated with silicon rubber, overall
braided with Glass Fibre Yarn and varnished cable. The type designation shall be RG 1 x 2.5 rf.

3) Annealed tinned copper flexible conductor of nominal cross-section 2.5 sq.mm insulated
with Rubber Compound, 2 cores provided with protective screen of annealed tinned Copper
wire braiding, 2 screened cores and 14 un-screened cores laid up together in one layer, inner
sheathed, provided with annealed tinned Copper wire braiding and overall sheathed with
Rubber Compound with reinforcement of Synthetic Yarn Braid.

The Type Designation shall be RCE2CSR (14 + 2) x 2.5rf

4) Stranded conductor of annealed tinned Copper of nominal cross-section 2.5 sq.mm,

insulated with Rubber Compound, 3 cores stranded together, inner sheathed, provided with
CABLE TERMINOLOGY

plain Copper/annealed tinned copper/steel wire braiding and overall sheathed with
Rubber/PVC Compound.

The Type Designation shall be :

With Plain Copper Wire : MGCG (Cu) 3 x 2.5 rm

Braiding : MGCY (Cu) 3 x 2.5 rm

With annealed tinned : MGCG (ATC) 3 x 2.5 rm Copper Wire braiding : MGCY (ATC) 3 x 2.5 rm

CABLE GLOSSARY

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Ampacity: Current carrying capacity of a cable is known as its ampacity.

This property is unique for each wire/ cable & is influenced by

• Conductor material, number of conductors & cross- sectional area

• Thermal conductivity & Thickness of insulation

• Ambient temperature

• Ability of construction to dissipate heat after installation

Armouring (Or Armour): A metal covering usually applied in the form of tape or wire, intended
to protect a cable from mechanical damage.

ABCDEFGHIJKLMNOPQRSTUVWXYZ
CABLE TERMINOLOGY

Bobbins: Metal spools used for taking up drawn wire and subsequently used for payoff
packages in cabling and stranding equipment

Braid : A fiberous or metallic group of filaments interwoven in cylindrical form to form a

covering over one or more wires.

Braider: a machine used to apply a woven fiberous or metallic braid over a cable.

Braiding: The plaited protective covering of a cable.

Barrier Joint

: A cable joint between two mass-impregnated cables in which the impregnating compound in
each cable is separated from that in the other.

Bedding (of an armoured cable): A layer or layers of material applied to a cable beneath the
armour.

Bunched Stranding : A term applied to a number of wires twisted together in one direction in
one operation without any regard to their geometric arrangement.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Cable: An assembly of one or more conductors, ether solid or stranded, each covered with a
layer of insulating material throughout its length, the whole being provided with a common
protective covering.

Cable Filler : A material used in a multiple-core conductor cable to occupy space and thus round
up the cable, sometimes used to accomplish conductor spacing.

Cable Terminal Box: A box fitted at the end of a cable in order to facilitate the connection, and
sometimes the quick disconnection of other conductors.

Calculated Effective Sectional Area: The area of a solid conductor of the same resistivity and
having the same resistance as that of any equal length of the conductor. In the case of a split
conductor cable, the calculated effective area is the sum of the cross sections of each of the
two or more sections into which the conductor is divided.
CABLE TERMINOLOGY

Compacting : Compact stranding, are conductor constructions that can add little more ampacity
into a tight space.

Conductor: A body or substance, which offers a low resistance to the passage of an electric
current.

Continuous Vulcanisation (CV) : A continuous, in-line process whereby a wire has an extruded
covering applied, is then passed through a tube containing such temperature and pressures as
are necessary to complete vulcanisation.

Control Cable : A multi-conductor cable made for operating in control or signal circuits, usually
flexible, relatively small in size, and with relatively small current rating.

Core: Assembly comprising a conductor and its own insulation.

Corona Discharge: A phenomenon called corona discharge may occur in high voltage
transmission line , resulting in formation of ozone, a highly reactive form of oxygen, and in
ionisation of oxygen in the surrounding air. The insulation may be attacked by ozone and by
corona

Corona partial discharge may also occur in a void within insulation system where the voltage
gradient is sufficiently high.

Cross-Sectional Area: The sum of the cross-sectional area of the component wires of the
conductor of a cable, the cross sectional area of each wire being measured perpendicular to its
individual axis.

Current Carrying Capacity: The current a conductor of a given size is capable of carrying safely
without exceeding its own temperature limitations, at a defined set of conditions.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Direction of Lay: Defined as “right-hand” or “Left-hand” these terms have the same meaning as
specified for screw threads. It is said to be “right-handed” if, when assembled with a fixed
mating thread and twisted in a clockwise direction, it moves away from the operator; and “left-
handed” if, when assembled with a fixed mating thread and twisted in a clockwise direction, it
approaches the operator. The right-hand lay is also know as Z-lay and left hand lay as S-Lay.
CABLE TERMINOLOGY

Distributor: The portion of any underground cable with which a service line is, or is intended to
be, immediately connected.

Dividing Box: A box fitted to one end of a two, three, four core or multicore cable for
termination.

Dielectric : A material with good electric insulating characteristics, insulating medium.

Dielectric Constant : A term used to define the degree of insulating characteristics possessed by
a dielectric.

Typical Values of Dielectric Constant

Material Dielectric Constant

PVC 3.4 - 8.0
EPR 2.5 - 3.5
PE 2.5 - 2.6
XLPE 2.3 - 6.0

Drain wires : A number of small gauge bare wires applied concentrically about the insulation
shield of a high voltage cable for the purpose of a fault current return path.

Drawing : The process of reducing a cylindrical rod or wire to a desired diameter by pulling the
wire through a die or series of dies thus stretching the wire.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

EPR : Ethylene Propylene Rubber

Extrusion : The application of a semi-solid plastic or rubber material by forcing it on a wire

passing through the extruder in a continuous fashion.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Feeder: A line, which supplies a point of distribution network without being tapped at any
intermediate point.
CABLE TERMINOLOGY

Fillers (of a cable): The material used to fill the interstices between the cores of a two-, three-
four-core or multicore cable.

Fully-Impregnated Insulation: Mass-impregnated insulation where no attempt has been made

to remove free compound after impregnation.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Galvanisation : A coating of some metal part (usually steel or iron) with zinc by dipping or
electroplating.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Insulation : A non-conductive material usually surrounding or separating two or more

conductive materials.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Jacket : A covering put around an insulated conductor for the purpose of protection and/or
resistance.

Properties of Jacketing Material

Units PVC PE

Continuous Service Temperature of deg. C 70 75

conductors
Installation Temperature (min) deg. C -10 -40
Tensile Strength (min) PSI 1500 1400
Elongation (min) % 100 350
Specific Gravity - 1.43 0.93
CABLE TERMINOLOGY

Joint Box: A box to protect the insulation of a cable from air or moisture at a cable joint.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Lay : The distance taken to complete one revolution of helically laid strand of wire around a
central core.

Lay Direction : A simple means of determining the direction of lay is that- when looking along a
strand, the individual wires disappear in the forward direction to the left, the strand is said to
left handed and if to the right, right handed.

Lay Ratio: The ratio of the axial length of complete turn of the helix formed by the core of a
cable or the wire of a stranded conductor, to the mean diameter of the helix.

Length of lay(LAY): The axial lenth of one complete turn of the helix formed by the core in the
case of a cable, or of the wire in the case of a stranded conductor.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Mass-Impregnated and Drained Insulation: Mass- impregnated insulation from which free
impregnation compound is removed by draining at a temperature in excess of the maximum
working temperature.

Mass-Impregnated Insulation: Insulation in which the paper tapes are applied un-impregnated,
the complete insulation being subsequently dried and impregnated with compound as a whole.

Mass-Impregnated Non-Draining Insulation- Insulation in which the impregnating compound

has a sufficiently high viscosity at maximum working temperature to preclude migration of
compound or the draining of compound under service conditions.

Mean Diameter of a wire: The mean of two measurements taken at right angels at the same
cross sections.

Mains, Underground: All underground cables used for the transmission and distribution of
electrical energy and includes feeders, distributors and pilot cables.
CABLE TERMINOLOGY

Messenger : A bare cable used for its strength characteristics to support power conductors and
insulated power cables. A messenger can be used as a conductor, partial conductor, or non-
conductor.

Milliken conductors : With alternating current there is a tendency for more of the current to
be carried on the outside of the conductor than in the centre (skin effect), and to overcome this
problem the larger sizes of conductor are frequently of Milliken construction. Such conductors
are formed from several individual sector shapes (usually four for power cables). A thin paper
or other suitable insulation is applied over alternate sectors. There is insufficient economic
advantage to use this construction below 1000 mm2 but Milliken design may also be used to
obtain increased conductor flexibility.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Neutral Conductor : In multiphase circuits the conductor used to carry unbalanced current and
in single phase systems the conductor used for a return current path.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Oxygen Index : It is the minimum of oxygen in an oxygen -nitrogen mixture in which the
material will burn(air contains 21 % oxygen) .

In the oxygen index test, temperature is approximately maintained at room temperature.

In actual practice during fire the extent of burning may be significantly influenced by the actual
temperature involved. In order to overcome this, the oxygen index is measures over a range of
temperature. From the results, a temperature index is obtained by extrapolation. As the
relationship is non-linear, extrapolation results are not accurate.

A more valid method is maintaining the oxygen concentration at 21% and varying the
temperature, the temperature index being recorded as the minimum temperature at which a
material will support combustion following its burning.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Pay-off : The process of feeding a cable or wire from a bobbin, reel, or other packages. Also a
device used for paying out wire or cable into a piece of equipment or machinery.
CABLE TERMINOLOGY

Pitch Circle Diameter : The diameter of a circle passing through the centre of the conductors in
any layer of a multi-conductor cable.

Proofed Tape : A tape applied to the insulation of rubber insulated cables and composed of
cotton cloth coated with the rubber compound.

Polyvinyl Chloride (PVC) Sheathing: A sheathing of PVC compound Used on an insulated cable
or flexible cord to form an outer protective covering so as to make the cable or cord reasonably
resistant to decay, mechanical abrasion, acids, alkalies and other corrosive materials.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Resistance : The property of an electric circuit which determines, for a given current, the rate at
which electric energy is converted into heat and has a value such that the current squared,
multiplied by the resistance gives the power

Rated Voltage : The voltage at which the cable is designed to operate. In the case of ac system,
the rated voltage means the voltage between phases.

Reinforcement (Against Internal Pressure): A covering consisting of metal tapes or strips or

wires used to enable the cable to withstand internal pressure.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Sealing, End (Sealing Box or Sealing Chamber) A box fitted to one end of a single core cable to
protect its insulation from air or moisture at the point where connection is made with another
conductor.

Service Line : A line connecting the consumer’s installation to the distributor.

Service of an armoured or metal sheathed cable: A layer or layers of material applied as a final

covering to the outside of a cable to protect it.

Sheath ( of a Cable) : A uniform and continuous covering used to protect the insulation,

especially against moisture, or to protect an inner metallic sheath or armour against corrosion.
CABLE TERMINOLOGY

Stop Joint: A cable joint between two pressure cables in which the fluid in each cable is

separated from that in the other cable by pressured resisting barrier.

Straight through joint: A cable joint connecting two cable together end to end.

Short Circuit Rating : It is required to determine cross sectional areas of conductor and screen
in respect of short circuit current

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Tee-Joint: A cable where a branch connection is made to a main cable.

Tough Rubber Sheathing: A sheathing used on an insulated cable to form an outher protective

covering of tough rubber. It is composed of rubber mixed with hardening substances and

suitably vulcanized to make it waterproof and reasonably resistant to deca y, mechanical

abrasion, acides, alkalies and other corrosive materials.

Trifurcating Joint: A box connecting a three core cable to three single core cables.

Temperature Index: Temperature index is the temperature at which oxygen index becomes 21.

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Waterproof Servicing: A layer or waterproof material applied to the exterior of an armoured or

lead sheathed cable.

Wire: Composed of a conducting material, uniform in diameter and circular in cross section.

Useful Electrical Formulae for Determining Amperes, Horsepower, Kilowatts and

CABLE TERMINOLOGY

Kilovolts Amperes
Alternative Current
To find Direct Current
Single Phase Three Phase
Amperes when Horsepower is HP x 746 HP x 746 HP x 746
known E x Eff E x Eff x PF 1.73 x E xEff x PF
Amperes when Kilowatts is KW x 1000 KW x 1000 KW x 1000
known E E x PF 1.73 x E x PF
Amperes when Kilovolt is KVA x 1000 KVA x 1000 KVA x 1000
known E E 1.73 x E
IxE I x E x PF I x E x 1.73 x PF
Kilowatts
1000 1000 1000
IxE IxE I x E x 1.73
Kilovolt Amperes
1000 1000 1000
I x E x Eff I x E x Eff x PF I x E x 1.73 x Eff x PF
Horsepower(output)
746 746 746

Notes :

I = Amperes
E = Phase to phase volts
Eff = Efficiency expressed as decimal (95% = 0.95)
PF = Power factor expresses as decimal (85% = 0.85)
KW = Kilowatts
KVA = Kilovolt Amperes
HP = Horsepower

COMMON CONVERSION FACTORS

To Convert Into Multiply By
Atm pressure Kilogram/sq.cm 1.0332
Centimeters Inches 0.3937
CABLE TERMINOLOGY

Centimeters Millimeters 10
Horsepower (electric) Watts 746
Inches Centimeters 2.54
Inches Millimeters 25.4
Kilogram Force Newton 9.80665
Kilogram/sq.cm Kilopascal 98.0665
Kilopascal Kilogram/sq.cm 0.010197
Kilowatts Megawatts 0.001
Megawatts Kilowatts 1000
Millimeters Centimeters 0.1
Millimeters Inches 0.03937
Newton force Kilogram 0.10197
Square Inches Square Millimeters 645.16
Square Millimeters Square Inches 1.550 x 10 -3
Watts Horsepower (electric) 1.340 x 10 -3
CABLE TERMINOLOGY

CABLES

1. What are different elements of a Cable?

2. Basic about cable components & constructional details
3. What are the type designations of cable?
4. Nomenclature of the cables
5. What are different cable types and categories?
6. Comparison of XLPE cables with PVC cables
7. What is screening in cable and why it is required?
8. What is FRLS H cable?
9. What are the general Packing practices followed?

• Conductor

Conductor is a current carrying element made up of Aluminium or Copper with a specific

cross section for the assigned rating, having resistance / km within certain specified limits.

• Electrical Insulation (dielectric)

Insulation is provided over the conductors to electrically isolate them from one another.
Various types of insulating materials used are : PVC, XLPE (Cross Linked Polyethylene),
Rubber, Impregnated Paper, etc.

An insulated conductor is termed as Core. A cable may have one or more cores. In a multiple
core cable , the cores are helically stranded together.
In twin, three & multi-core cables, the cores are laid up together with a suitable lay; the
outer most layer has right-hand lay and the successive layers are laid with opposite lay
direction.

• Inner sheath (bedding)

Cables with stranded cores are provided with Inner Sheath applied either by extrusion or by
CABLE TERMINOLOGY

wrapping. It is ensured that the shape is as circular as possible. Inner Sheath is so applied
that it fits closely on the laid up cores & it should be possible to remove it without damage
to the insulation. Thickness of Inner Sheath is specified in relevant standard and is based on
calculated diameter over laid-up cores.

• Armour

A wire, strip or a tape applied helically over the cable, to protect the cable from penetration
by sharp objects, crushing forces, and damage from rodents or boring insects, is termed as
Armour.
Armour is applied over the insulation in case of single core cables & over inner sheath in
case of twin, three & multi core cables.

• Outer Sheath

Outer sheath /Jacket is usually an extruded plastic cover over the laid-up or armoured core.
PVC is a common sheathing material. Outer sheath provides mechanical, thermal, chemical
and environmental protection. No electrical function is assigned to Outer sheath. The colour
of outer sheath is normally black.

Back to Top

Cables can be divided into large number of types based on a combination of classifications as
follows:

• Based on the voltage ratings as low voltage, high voltage, extra high voltage cables, etc.
• Based on the conductor material, Copper conductor or Aluminium conductor.
• Based on the insulating material as Paper Insulated, PVC insulated, Rubber insulated, XLPE
insulated, etc.
• Armoured or Unarmoured cables.
• Based on the sheathing material, as PVC Sheathed, Rubber Sheathed, Lead Sheathed,
Aluminium Sheathed, etc.
• Based on the number of cores as single core, two core, three core, three-and-a-half core,
four core, multicore, etc.
• Based on the cross-section of the conductor.
CABLE TERMINOLOGY

• Based on the type of conductor, solid, stranded, sector shaped, etc.

From above it is evident that the types of cables will differ widely depending upon various factors
involved. To facilitate identification and description of the type of cable it is general practice to
adopt some form of type designations. With these designations it becomes easier to convey in a
few words the right type of cable.

The details of various cable types can be checked in catalogues.

Back to Top

Comparison of XLPE cables with PVC cables

The important difference is the extra toughness of insulation and, in particular, the ability to
withstand much high temperature without deformation due to mechanical pressure. The better
physical properties of XLPE enable the insulation thickness to be reduced and hence overall size of
the cable. The continuous temperature rating is increased from
70°C to 90°C and the temperature for short circuit ratings for the cable from 160°C to 250°C.

In general, XLPE insulated cables are competitive alternative to PVC cables for industrial use and
Paper insulated cables for public supply systems.

Back to Top

Screening in Cable

Electrical Screening is necessary only for cables with phase voltage > 1 kv and fulfills the following
functions.

• Potential grading and limiting of electrical fields

• Conduction of charge and discharge currents

To satisfy these functions, the screening normally comprises a combination of conducting layers
with metallic elements.

The magnitude of electric stress and the degree of sensitivity of the insulation material against
CABLE TERMINOLOGY

partial discharge govern the type of screening of the insulation with conducting layers.

Above certain voltages, as a means of containing the electrical field within the insulation,
semiconducting screens are applied over the conductor & insulation. Screens are provided to
achieve symmetrical dielectric fields within the cable structure & carry current during short circuit.
By this it is possible to eliminate any electrical discharges arising from air gaps adjacent to the
insulation.

The coefficient of expansion of polyethylene & EPR is approximately ten times greater than that of
either Copper or Aluminium, and when the conductor is at its maximum operating temperature of
90°C a sufficiently large gap is formed between the insulation and the surface of the conductor to
enable electrical discharge to occur. This discharge site & any others which are formed around a
conductor when conductor is bent can be eliminated by applying a semiconducting layer over the
conductor. Similarly, any discharges arising from air gaps between laid-up cores can be nullified by
the use of a screen over the insulation.

During the early 1960s semiconducting tapes were applied the conductor but these have since been
superseded by an extruded layer. This has the advantage of providing both a smoother finish and,
as it fills the interstices between the wires, a circular envelop around the conductor. By reducing
the concentration of the flux lines around the individual wires, the electrical stress around
conductor is reduced by between 10% to 15%. The semiconducting layer is compatible with, and
bonds to, the insulation and a nominal thickness of 0.7 mm is typical

Back to Top

FRLS H cable

Flame Retardant Low Smoke and Low Halogen cables have improved flame resistant characteristics
and emit lower smoke and toxic gases.

Special features

Reduced flame propagation

Low smoke emission
Low acid gas generation
CABLE TERMINOLOGY

Formulation for the FRLS compounds, which are mainly for the sheathing materials, require special
ingredients. These cables may have insulation of PVC or XLPE, but sheath is PVC based, suitably
compounded to meet FRLS H requirements.

Back to Top

General Packing Practices

Cables are generally received on wooden/steel drum. There is an arrow painted on the flanges of
the drum which indicate the direction in which the drum should be rolled. The cable will unwind
and become loose if the drum is rolled in the opposite direction. All drums should be stored in such
a manner as to leave sufficient space between them for air circulation. In no case should the drums
be stored ' on the flat' i.e. with flange horizontal.

Back to Main Faq's

CONDUCTORS

1. What are the different Conductor materials used as conductor?

2. What is the criterion for selecting particular type of conductor?
3. What are the different types of conductor?

Conductor is a current carrying element made up of Aluminium or Copper with a specific cross
section for the assigned rating, having resistance / km within certain specified limits.

Conductor selection depends on various parameters like current carrying capacity , system voltage,
voltage drop, flexibility, shape, and economics.

The most commonly used metals are Copper and Aluminium.

Resistance (R) of a conductor is inversely proportional to the area of cross section and is given by :
CABLE TERMINOLOGY

R= þ x l / A

Where

þ= Resistivity of the conductor material.

l= Length of conductor.
A = cross sectional area of conductor.

Back to Top

Types of Conductor

Conductors are divided into different classes , the flexibility of the conductor increases with the
class number. These are as follows:

A) Cables for fixed installations classes 1 and 2

B) The flexibles classes 5 and 6

Solid Conductor (Class 1)

The conductor consists of single wire of plain or tinned annealed Copper and its cross-section is
circular.
Solid Aluminium conductor of sizes 1.5 mm2 , up to and including 16 mm2 is of circular cross-
section. Sizes 25 mm2 and above may be either circular or shaped cross-section.

Stranded Circular Non-Compacted Conductors ( Class 2 )

The conductor consists of plain or tinned annealed Copper or plain Aluminium. The number of wires
in the conductor are not less than the appropriate minimum number as specified in the standards.

Stranded Compacted Circular Conductors and Shaped Conductors (Class 2)

The conductor consists of plain or tinned annealed Copper or plain Aluminium. The number of wires
in the conductor are not less than the appropriate minimum number as specified in the standards.

Flexible Conductors(Classes 5 and 6 )

Conductor consists of plain or tinned annealed Copper. The diameter of the wires in any conductor
CABLE TERMINOLOGY

does not exceed the appropriate maximum value as given in the standards.
INSULATION OF CABLES

1. What are different types of insulating material?

2. List the important properties of cable insulation.
3. What are thermoplastic and thermoset materials?
4. What is the function of Conductor / Insulation Screen and material used?

Insulation is provided to electrically isolate the individual cores from one another. The applied
insulation must perform adequately in the specified temperature range, and its dielectric strength
should be sufficient to sustain the electrical stresses.

Cable insulation should have:

• High Dielectric Strength

• Low dielectric constant
• Good Mechanical properties
• Resistance to Ageing
• High temperature withstandability

Insulating materials are classified as thermoplastic or thermoset. Thermoplastic materials lose their
form upon heating. Thermoset materials maintain their form in spite of heating. Various types of
insulating materials used are : PVC, XLPE, Rubber, Impregnated Paper, etc.

Polyvinyl Chloride (PVC)

Polyvinyl chloride (PVC or vinyl) is a thermoplastic. PVC compound is the standard insulation for
cables rated at 11000 volts or less & sheathing of entire range of cables. PVC compound is a mixture
of PVC resin, plasticizer, fillers, stabilizers, lubricant, pigment. The quantity and type of each
ingredient determines the properties. A broad range of electrical, physical and chemical properties
is possible.

PVC has good electrical properties. It is tough and resistant to flame, moisture, and abrasion.
Resistance to ozone, acids, alkalis, alcohol, and most solvents is also adequate. PVC can be made
CABLE TERMINOLOGY

resistant to oils and gasoline.

PVC has the disadvantage of having a high dielectric constant and dissipation factor. Also plasticizer
loss can cause hardening and cracking.

Crosslinked Polyethylene

Crosslinked polyethylene (XLPE) is a thermoset. It is produced by compounding PE (polyethylene)

with a crosslinking agent, like organic peroxide. The molecules of polyethylene are "crosslinked",
forming an interconnected network. The terms "cured" and "vulcanised" are also used for
"crosslinked".

Elastomer

Elastomeric material are used for insulation and for sheaths. They are applied mainly where the
product has to be particular flexible. A wide range of elastomers is nowadays available to the cable
industry. This makes possible the manufacture of compounds with specific properties, such as
abrasion and oil resistance, weather and heat resistance and flame resistance, combined with good
overall electrical and mechanical charateristics.

The classical elastomeric material, natural rubber, has declined in significance in recent years. In its
place, the synthetic elastomers produced by the co-polymerisation of ethylene and propylene, are
constantly finding new areas of application in cable engineering. This co-polymers, are generally
known as EPR.

Rubber was the first insulant to be used in Electric cable manufacture but gave way to other
insulants like paper, PVC, XLPE etc. Rubber is still considered the preferred insulation for flexible
cables and cables where very small bending diameter is desired.

Paper

Paper tapes of specific thickness and suitable widths are lapped around the conductor. The
thickness of built up insulation depends on the rated voltage of the cable. Paper insulated cores are
dried and impregnated using mass impregnating non-draining compound.

Back to Top
CABLE TERMINOLOGY

Function of Conductor / Insulation Screen

The conductor shield is a layer of semi-conducting material. Semi-conducting materials do not

conduct electricity well enough to be a conductor but will not hold back voltage.

It "smoothes" out the surface irregularities of the conductor. The conductor shield makes the
voltage on the inside of the insulation the same. Industry specifications define the performance of
conductor shield.

Good insulation shields are extruded in tandem with the insulation.

The insulation shield consists of two components. These components are the extruded (auxiliary)
shield and the metallic (primary) shield.

The extruded shield consist of a semi-conducting layer similar to the conductor shield. It makes the
voltage on the outside of the insulation the same.

The primary shield can consist of metal tape, drain wires or concentric neutral (CN) wires.
Grounding the primary shield makes the voltage on the outside of the insulation ground. The
Copper of the shield is usually bare, but may be coated with lead or tin. Some primary shields
consists of drain wires and tape. Aluminium and lead can also be used as the shield.

Concentric neutral wires serve a two-fold purpose. They function as the metallic component of the
insulation shield and as a conductor for the neutral return current. Their cross sectional area must
be sized in order to function as the neutral conductor.

Cables with paper Insulation

The inner conducting layer consists of several layers of semi-conducting paper. The outer
conducting layer consists of metallised paper.

Cables with PVC Insulation

The inner conducting layer consists of PVC compound having high carbon black content. For the
outer conducting layer, a cover of conducting tapes is preferred.

Cables with PE or XLPE Insulation

Because of higher sensistivity to partial discharge the reliable well adhesive gap and cavity free
bonding to conducting layers is of greatest significance. The inner conducting layer consists of
polymer compound made conductive by adding carbon black. And the outer conducting layer is
CABLE TERMINOLOGY

formed by semi-conducting compound along with semi-conducting tapes.

PROTECTION OF CABLES

1. What is armour and why this is required in a cable?

2. What are different materials used for armouring?
3. In single core cable, why non-magnetic material is used?
4. What are different armour types and functions of the same?
5. Which armour type is generally used for different cable types?
6. What is an Outer sheath?
7. What are the different materials used for sheathing?
8. What are the functions of Metallic Sheaths used in cables?
9. Comparison between Lead sheath and Aluminium sheath used in cables

Armouring means metal in the form of wire, strip or tape applied helically to a cable to provide
either protection from mechanical damage from external sources or additional mechanical strength
during installation and service. Armour also serves the purpose of carrying earth fault currents.

The following are the general armouring materials that are used :

• Galvanised round steel wires

• Galvanised flat steel wires (strips)
• Galvanised or ungalvanised steel tapes
• Non-magnetic materials

Under normal circumstances, steel is used in much greater quantity than any other material for
armouring cables. However, magnetic materials like ordinary steel would add considerably to the
electrical losses in case of single core power cables. Hence, non-magnetic materials like Aluminium
and some of its alloys are used for single core cables.

Armouring is arranged over the core insulation (PVC) in case of single core cables and over the inner
sheath (common covering) in case of multi-core cables. In case of paper insulated cables it shall be
arranged over bedding.

Round steel wire armouring will tend to press deeper into the bending than Flat steel wire
armouring because for flat wire the force is more uniformly distributed as against the round wire
CABLE TERMINOLOGY

which has only a line contact with the bedding.

Armouring is provided for offering mechanical protection to cables after installation. When the
cable is directly buried the danger is mainly from crushing by sharp pike-axe used in excavating. The
double steel tape offers the best protection against this.

In case of round steel wire armouring the chances of a pick-axe piercing the inter-wire space are
more than flat steel wire armouring. This is because the tip of the pick-axe can easily slip and be
guided into the inter-wire space in case of round steel wire armouring. The flat wire armouring
apart from economic form of wiring also provides economy in transport and ease in handling and
erection. It is much lighter in weight and smaller in diameter which in turn allows a small bending
radius.

Back to Top

Generally used armour

It is a general practice to use galvanised round steel wire armouring for the cables having calculated
diameter below armour less than 13 mm. Where the calculated diameter below armour is greater
than 13 mm, the armour shall consist of either galvanised round steel wires or galvanised steel
strips.

The direction of lay of the armour is left hand. For double wire/ strip armoured cables, this
requirement is applied to the inner layer of wires/ strips. The outer layer shall, except in special
cases, is applied in the reverse the direction.

The joints in armour wires/ strips are made by brazing or welding & surface irregularities shall be
removed. A joint in any wire/ strip is at least 300 mm from the nearest joint in any other wire/ strip
in the completed cable.

The armouring by virtue of its being a metallic path parallel to the lead sheath/ metallic sheath,
shares the flow of line-to-line earth fault currents. From experience it is found that as far as earth
fault ratings are concerned, flat strip armouring practically as good as round wire armouring.

In case of cables such as mining cables or submersible cables where the cable is subjected to lateral
pulls during installation and in service, single or double steel wire armouring is used.

Double steel tape armouring is commonly used for Paper Insulated Lead sheathed Cables (PILC)
CABLE TERMINOLOGY

while galvanised steel wires/ strips are used for armouring for thermoplastic cables. The armour
acts as a return path for such cables and has a dual purpose.

For Aluminium sheathed cables, often no armouring is required.

Unarmoured cables can be used more economically inside the factory, ducts and protected places
and due to this considerable amount of money can be saved.

Back to Top

Outer Sheath

Outer sheath /Jacket is usually an extruded plastic cover over the laid-up and/or armoured core.
PVC is a common sheathing material. Outer sheath provides mechanical, thermal, chemical and
environmental protection. No electrical function is assigned to Outer sheath. Outer sheath provides
protection to installed cores , and also designed to have characteristics like electrical resistance,
and suitability for environment in the vicinity. The colour of outer sheath is normally black.

Types of PVC as per IS : 5831 are as follows:

• Type ST1 General Purpose sheath intended for use in cables operating at a maximum rated
conductor temperature 70°C

• Type ST2 Heat resisting sheath intended for use in cables operating at a maximum rated
conductor temperature 90°C

Back to Top

Metallic Sheaths/Comparison between Lead sheath and Aluminium sheath

Metallic Sheath is provided in cables to prevent the ingress of moisture/water while maintaining
the flexibility of the cable. Water penetration is detrimental to insulation integrity. In the presence
of moisture and high electrical stresses, water tree growth is initiated leading to premature failure
of the cable.

Its other functions are:

• Act as an electrical shield

CABLE TERMINOLOGY

• Carry fault current

• Provide mechanical protection

Metallic sheaths of lead or Aluminium are used as a moisture barrier.

a) Lead Sheaths
Lead is one of the oldest (metallic) sheathing materials used on power cables. Lead is fed into a
cylinder. A hydraulic piston forces it around the cable. Lead is a very effective moisture barrier. This
contributes to the long-term reliability of cable.

A disadvantage of lead is weight. Lead is prone to deform under continuous load due to "creep".
Lead sheaths are also susceptible to fatigue failure from vibration and thermal cycling.

b) Aluminium Sheaths
Aluminium is also used as sheathing. It is lighter than lead and has good mechanical properties.
Aluminium sheaths may be extruded similar to lead. Aluminium sheaths can also be applied as a
thick metal tape around the core and welded. After forming, an Aluminium sheath can be
corrugated.

Superiority of Aluminium Sheath over Lead sheath

• Aluminium Sheath is economical..

• Superior mechanical properties. (Al is stronger than Lead).
• It can dispense steel armouring.
• Al sheath may work as neutral core.
• The smooth & soft Aluminium sheath allows sufficiently small bending radii.
• Good electrical conductivity ensures a good screening factor.
• Aluminium is not susceptible to vibration & does not tend to re-crystallize even at higher
ambient temperature.

Testing of Cables

1. Define Type tests, Acceptance tests, Routine tests and Optional tests.
2. What are the typical tests performed as
Type/ Routine/ Acceptance / Optional tests ?
CABLE TERMINOLOGY

3. What is the significance of following tests?

a. Annealing test
b. Armour resistance test
c. Bending test
d. Cold bend test
e. Conductor resistance test
f. Flammability test
g. High voltage test
h. Insulation resistance
i. Impulse Test
j. Loss of Mass Test
k. Partial Discharge Test
l. Tensile test
m. Wrapping Test (for Aluminium wires)

The tests performed on the cables are grouped as :

• Type Tests :
These are the tests required to be made before supply on a general commercial basis a type
of cable in order to demonstrate satisfactory performance characteristics to meet the
intended application.
• Acceptance Tests :
These are the tests carried out on samples taken from a lot for the purpose of acceptance of
the lot.
• Optional Tests :
These are the special tests which are to be carried out when required, by agreement
between the purchaser & the supplier.
• Routine Tests :
These are the tests made by the manufacturer on all finished cable lengths to demonstrate
the integrity of the cable.

Back to Top

Type tests :

a) Tests on conductor
CABLE TERMINOLOGY

• Annealing test (for conductor)

• Tensile test (for Aluminium)
• Wrapping test (for Aluminium)
• Conductor resistance test

b) Test for armouring wires/ strips

c) Test for thickness of insulation and sheath

d) Physical tests for insulation and outer :

• Tensile Strength and elongation at break

• Ageing in air oven
• Shrinkage test
• Hot deformation
• Loss of mass in air oven
• Heat Shock Test Thermal Stability

e) Insulation Resistance Test

f) High Voltage Test (water immersion test )

g) High voltage test at room temperature

h) Flammability Test

Acceptance tests

Various test performed under this group are:

a) Annealing test (for Copper)

b) Tensile test (for Aluminium)

c) Wrapping test (for Aluminium)

d) Conductor resistance test

CABLE TERMINOLOGY

e) Test for thickness of insulation and sheath.

f) Tensile strength and elongation at break of insulation and sheath.

g) Insulation resistance test .

h) High voltage test at room temperature.

Routine tests

Various tests performed under this group are:

a) Conductor resistance test

b) High voltage test at room temp.

c) Armour resistance test (for mining cables )

Optional tests :

Various tests performed under this group are:

a) Cold bend test

b) Cold impact test

c) Armour resistance test (for other than mining cables)

Back to Top

Significance of Tests (Refer IS : 10810)

• Annealing test :
As the conductor of a cable is subjected to twisting & bending, 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 &
laying up the process.
CABLE TERMINOLOGY

• Armour resistance test :

In case of short circuit faults the armour has to carry the short circuit current. The resistivity
of the armour must be maintained within the designed value so that there is no excess
temperature rise above the designed value & also there is no excess voltage rise , to the
unsafe level.

• Bending test :
All electrical cables are subjected to bending operation during handling & installation. The
minimum radii are specified in the relevant specifications. In order to ensure that the cables
withstand, without damage or showing any cracking of the sheaths, the recommended
bending radii during installation & handling, it is necessary to conduct a bending test which
is more rigorous than what is likely to be subjected to in actual practice.

• Cold bend test :

Sometimes the cable have to be laid in the area of low temperature climatic conditions or
frost. Due to constant exposure of the cable to the low temperature or frost conditions, the
insulation or outer sheath of the cable will become hardened & stiff. However, this is a long
term effect. Such hardening or stiffness causes cracking of the insulation or outer sheath &
may lead to the failure of the cable. In order to ascertain the suitability or withstandability
of the insulating or sheathing materials at low temperature or frost conditions (when usage
of the cable so warrants), this cold bend test is carried out.

Back to Top

• Conductor resistance test :

Accurate control of resistance is necessary to meet system design parameters. Resistance is
influenced by conductor dimensions & construction, processing, conditions, temperature,
resistivity (composition/ impurity & temper of the material). It is expressed in terms of ohms
per kilometre corrected to 20 0C.

• Flammability test :
For certain location it may be important to use a cable which retards flame in case of a fire
& is self-extinguishing when the source of the fire is removed. This test is therefore carried
out on finished cables to verify this property.

• High voltage test :

The insulation material in a cable is used to isolate the conductors from one another and
from ground, as well as provide the necessary mechanical strength. The fundamental
CABLE TERMINOLOGY

requirement of the insulation in an electric cable is that it withstands the voltage imposed
on it in service. It is necessary that evaluation of the condition of the insulation be made by
imposing a higher voltage stress for a short duration.

• Insulation resistance :
The test is performed to determine insulation resistance, calculate volume resistivity and
insulation resistance constant of the dielectric material of electric cable by direct current
method. The dielectric material in a cable is used to insulate the conductors from one
another and from ground as well as to provide mechanical support for the components. For
this purpose it is desirable to have the insulation resistance as high as possible consistent
with acceptable mechanical, chemical and heat resisting properties. During the
manufacturing process non-uniformities may develop in the dielectric either in the form of
conductive impurities in the material or in the form of mechanical imperfections in the
dielectric affecting the quality of the cable. This test helps in detecting these imperfections.

Back to Top

• Impulse Test :
This test involves impulse testing ( simulated lightning impulse ) of electric cables. Insulating
material used in high voltage cable may be subjected to transient voltages resulting from
nearby lightning strokes. The ability of the insulating material to withstand these transient
voltages is important in establishing the reliability of the cable insulation

• Loss of Mass Test:

This test is performed to determine the thermal effect on the mass of thermoplastic
insulation and sheath. Themoplastic insulation and sheath exposed to heat are subjected to
many types of physical and chemical changes. The severity of exposure , in both time and
temperature, determines the extent and type of change that takes place. Extended periods
of exposure of insulation and sheath to elevated temperature cause degradation with
progressive changes. These changes are assessed by measuring the loss of mass on
subjecting the material to accelerating ageing.

• Partial Discharge Test:

This test involves detection and measurement of partial discharge occurring in screened
electric cables. Partial discharges remain unnoticed in the normal high voltage tests and
could be harmful to the life of the insulants. Extruded dielectric tends to deteriorate very
fast due to discharge in very small voids and cavities. It is therefore necessary that such
voids should be avoided in the extrusion process. Still certain minute voids are unavoidable
CABLE TERMINOLOGY

and these remain in the insulation. The magnitude of the discharge in such voids are
measured so as to determine whether these are within permissible limits

• Tensile test :
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 along
trenches are subjected to considerable force during pulling as well as manufacture, it is
necessary to ensure that the conductor material has adequate tensile strength.

• Wrapping Test (for Aluminium wires) :

This test is performed to determine the ductility of aluminium wire used as conductor for
electric cables. This test brings out the property of the material, which makes it suitable for
winding and twisting. Cable conductors during the process of manufacture as well as during
installation are subjected to torsion due to axial twist and might break, if material is not
sufficiently ductile. The properties checked by wrapping test ensure the suitability of
material as cable conductor.

Back
Cable Accessories

1. What are the different types of cable accessories?

2. What are the objectives to be achieved by Termination Kits?
3. What are the objectives to be achieved by joints?
4. List down the various types of cable accessories.
5. Explain Heat Shrink technique
6. Explain Cast Resin technique

Types of cable accessories

i. Terminations :

Termination kits serve as a connection to electric apparatus or machines or switchgear and are
further categorized as Indoor and Outdoor Termination kits.

Indoor Termination kits (IDT) : IDTs are used for the indoor application i.e. for termination at Panels,
CABLE TERMINOLOGY

Transformers etc.

Outdoor Termination kits (ODT) : ODTs are used for terminating at switchyards, outdoor
substations, on poles etc. where these are directly exposed to atmospheric conditions.

ii. Joints :

Cable joints connect lengths of cables in long routes or at points of repair. These facilitate transfer
of power over long distances as many a times it is not possible to supply long cable lengths due to
various reasons such as manufacturing & transportation constraints, site conditions etc.

There are two types of joints :

1. Straight Through Joint : These joints are required when two cables having the same type of
insulation are to be joined ( eg :XLPE to XLPE insulated cable).

2. Transition Joint : When two cables having different types of insulation are required to be joined,
transition joints are required ( eg : XLPE insulated cable with PILC insulated cable etc ).

Back to Top

Objectives to be achieved by Termination Kits

The following objectives must be fulfilled :

• connection of the conductor

• stress grading at screen cut point of both radial & longitudinal stresses for medium and high
voltage cables
• Avoid ingress of water and to protect against ambient influences
• protection of core insulation (e.g. against U.V. radiation)
• insulation from earthed parts

Back to Top

Objectives to be achieved by joints

• The following objectives must be fulfilled :

• connection of the conductors v insulation of the conductors
CABLE TERMINOLOGY

• reinstatement of the elements of the cable for Medium & high Voltage Cables
• protection against all ambient conditions of the ground
• establishment of branch points for service cables in low voltage cables.

List of various types of cable accessories.

The various types of cable accessories are :

• Heat Shrink type

• Pre-moulded /Pre-fabricated type (Factory Moulded)
• Cold Shrink type v Push-on type
• Cast Resin ( poly-eurethene / Epoxy compound filling ) type
• Cast Iron ( bitumen compound filling ) type

Back to Top

Heat Shrink technique

The heat shrink technique is a versatile technology which can be used for a variety of applications
vis-a-vis cable applications.

Thermoplastic based materials are used for manufacture of heat shrink components. After cross-
linking process the material is moulded into shape, expanded in hot condition itself and suddenly
cooled.(eg: expanded insulating tube, break-out etc). The component remains in the expanded
form. This pre-stretched form when heated recovers to its original dimensions. This is termed as
the Shape Memory Phenomenon. In this process the tube "shrinks" on to the subjacent parts.

As a heat source, a hot air blower or soft flame may be used. Shrink on products are easy to install,
simple, quick and independent of ambient temperature. They can also be used, because of their
flexibility, as additional protection against mechanical stress. These accessories are best suited for
application in 1.1 kV to 33kV range.

Cast Resin technique

This is a time tested method of jointing & terminating of cables. In this technology, basic insulation
is provided by lapping of insulating tapes. Stress grading, in case of MV & HV cables, is provided by
means of stress-cone which is built-up by lapping of semi-conducting tapes. Cast-resin compound
when set, gives protection against mechanical damage & moisture ingress. These accessories are
CABLE TERMINOLOGY

successfully in service in 1.1 kV to 33kV range.

Cable Characteristic

1. What is current carrying capacity of the cable?

2. What factors affect cable current carrying capacity?
3. What is Short circuit rating of the cable?
4. Calculation of Short Circuit Rating
5. What are different losses in Power cables?
6. What are the factors affecting cable selection?

Current carrying capacity of the cable

The current carrying capacity of a cable is determined by the thermal resistance of insulation,
outersheath and surroundings. Heat losses in a current carrying conductor are given by I2R. The
heat generated causes increase in the conductor temperature. This heat is dissipated to the
atmosphere through the cable materials and soil. As shown in the following fig. cable materials and
soil represent a series circuit of thermal resistors. The thermal resistance controls heat dissipation
from the conductor. The more the dissipation of heat the more is the current carrying capacity.

Some of the factors affecting the underground cable current carrying capacity and hence the
selection of cable are :

• Depth of installation: the deeper the installed cable, lower is the current carrying capacity.
• Thermal Resistivity of Soil : the higher the thermal resistivity, the lower is the ampacity
• Ambient temperature of soil: the higher the ambient temperature, the lower is the ampacity
• Method of Installation: if installed in a duct , the lower is the ampacity

Back to Top

Short circuit rating of the cable

The conductor size necessary for an installation is often governed by its ability to carry short-circuit
rather than sustained current. During a short circuit there is a sudden inrush of current for a few
cycles followed by a steadier flow for a short period until the protection operates, normally
between 0.2 to 3 seconds.
CABLE TERMINOLOGY

At the commencement of the short circuit the cable may be operating at its maximum permissible
continuous temperature and increase in temperature caused by short circuit is a main factor in
deriving acceptable ratings. However, the current may be 20 or more times greater than the
sustained current

As the time involved is short and cooling follows rapidly, the cable insulation can withstand much
higher temperature than are allowed for sustained operation. The difference between maximum
conductor temperatures for sustained rating , and the temperature during short circuit, provides a
maximum temperature which can be used in short-circuit rating calculations.

It may be assumed that the whole of the energy input appears as heat which is absorbed by the
conductors

Following equation is obtained on the basis of equating heat input (I2 RT) to the heat absorbed
(product of mass, specific heat and temperature rise ) :

I2 = K2 S2 loge { (θ1 +β )/ (θ0+β ) }

Where I = short circuit current (r.m.s over duration ) (A)

T= duration of short circuit (second)

K = constant for the material of the conductor

S= area of conductor (mm2 )

θ1 = final temperature (0C)

θ0 = initial temperature (0C)

β= reciprocal of the temperature coefficient of resistance of the conductor ( per degree

Celsius)

Here the conductor refers to the current carrying component. The constants are given in the
CABLE TERMINOLOGY

following table :

Material K β Qc ρ20
-3
Copper 226 234.5 3.45 X 10 17.241 X 10 -6
Aluminium 148 228 2.5 X 10 -3 28.264 X 10 -6
Lead 42 230 1.45 X 10 -3 214.000X 10 -6
Steel 78 202 3.8 X 10 -3 138.000 X 10 -6

in which
K2 = Qc (β +20 }

ρ20

where Qc = volumetric specific heat of the conductor at 20 0 C (J/ 0 C mm3)

ρ20 = Resistivity of conductor metal at 20 0 C (mm)

For XLPE cable,

Conductor Temperature Short-Circuit

rise (0°C) Current (kA)
Copper 90-250 0.143 ST -1/2
Aluminium 90-250 0.094 ST -1/2

Back to Top

Example illustrating the calculation of the Short Circuit Rating.

Refer Tropothen-X catalogue

CABLE TERMINOLOGY

Table No. 1

Tropothen-X Armoured Cable. Type- A2XCEFY-3.8/6.6 kV (E)

No. Of cores & Cross Short circuit Rating for 1 second

sectional area of
Conductor
No. x sq. mm kA
-1/2
3 x 25 rm/v 0.094 x 25 x (1) = 2.35
3 x 35 rm/v 0.094 x 35 x (1) -1/2 = 3.29
3 x 50 rm/v 0.094 x 50 x (1) -1/2 = 4.70
3 x 70 rm/v 0.094 x 70 x (1) -1/2 = 6.58

Similarly, we can calculate short circuit ratings for other cable sizes.

Back to Top

Different losses in Power cables

The losses in the Power Cables are :

Conductor losses : Atoms of the conductor offer specific resistance to the flow of the electrons
(current) which causes loss of power in the form of heat. Heat generated is directly proportional to
the square of current & conductor resistance.

Heat generated = I2 x R

where I = current carried by the conductor

R = Resistance of the conductor

This power loss is also called Voltage Drop across the conductor.
CABLE TERMINOLOGY

Dielectric Loss : Electric Insulation surrounding a conductor creates a capacitor when the
conductor is electrically energised. Thus all insulated conductors are capacitors in which insulation
material acts as a dielectric. There is a loss of power which is proportional to the dielectric power
factor (tan δ).

The dielectric loss in watts per kilometre per phase is given by

D = 2π f CU02 tanδ 10-6 (watt/km per phase)

where f = frequency

C = Capacitance

Uo = Voltage applied over conductor

tanδ = Dielectric power factor

The power factor of the dielectric of cables should be of low value.

Theory of Dielectric Losses :

When a voltage is applied to a cable with a perfect dielectric, a charging current IC flows which is in
leading quadrature with the voltage .In such a perfect dielectric there would be no component of
the current in phase with U. However in actual practice the dielectric is imperfect and there is a
small current IR which is in phase with U. This current causes losses IRU in the dielectric in the
dielectric which generates heat.

This losses in the dielectric are proportional to the cosine of the angle between the resultant
current It and applied voltage U.

Now It = (IR2 + IC2)1/2

CABLE TERMINOLOGY

IRU = ItU cosφ

and

cosφ = IR / (IR2 + IC2)1/2

As φ is close to 900, cosφ equates approximately to tan (90 - φ), i.e. equates (approximately) to tanδ,
and the dielectric power factor of a cable is frequently referred to as tanδ, where δ is known as the
dielectric loss angle (DLA).

The dielectric loss in watts per kilometre per phase is given by

D = 2π fCU02 tanδ 10-6 (watt/km per phase)

The power factor of the cable insulation is dependent on frequency, temperature and applied
voltage. It is of a very low order and consequently for cables of up to 50 kV operating voltage the
dielectric losses are small in comparison with conductor losses. However, for cables for operation
above this level the losses rise rapidly with voltage and this must be taken into consideration when
calculating the current carrying capacity of the cables.

Back to Top

The Factors affecting cable selection

Selection of a Cable for a given system depends upon :

 System voltage
 Rated current (future needs/ factor of safety)
 Ambient temperature
 Cable installation (laying method, no of cables in parallel, air/ under ground)
 Permissible voltage drop
 Initial size/ Type selection
 Economics with higher size (2 step) cables
 Comparison of initial cost + Running cost
CABLE TERMINOLOGY

 Final selection & specification freezing

To illustrate the selection procedure a following typical LT distribution circuit is considered.

Incoming cable

Rating factor for 45 0 C=0.9

Rating factor for 1m depth = 0.97

i.e. Rated current for cable selection of 300A ckt = 300/(0.9 X 0.97)

= 343 A

The minimum cross-section area for 343 A = 500 mm2

The initial selected cable is 3.5 X 500 / 240

Feeder cable

I) Rating factor for 450C =0.9

(Tropodur cables catalogue Table 12 : Rating factor for variation in Ambient Air Temperature)

Rating factor for cable laid in open rack = 0.96

(Tropodur cables catalogue Table 14 : Rating factor for multicore cables laid on open racks in air)

Therefore,
CABLE TERMINOLOGY

Current for cable selection of 200A ckt under specified service conditions

=200/(0.9 X 0.96) = 231A

Corresponding minimum cable size for 231 A (Tropodur cables catalogue: Table 2) 3.5 x 185 /
95.

Similarly,

Current for cable selection of 100A ckt under specified service conditions

=100/(0.9 X 0.96) = 116A

Selected minimum cable size 3.5 X 70 / 35

Now having selected the minimum cable cross-sections for given service conditions, the same may
be verified for voltage drop not exceeding the limits

Maximum permissible voltage drop limit is 9 % of voltage applied.

Therefore, permissible voltage drop for 240 V=21.6 volts

Voltage drop is = R x I x l

Where R = Approx. A.C. resistance at operating temperature 700C in Ω/ km.

I = circuit current in Amperes.

CABLE TERMINOLOGY

l = cable length in km.

500 mm2 (400 m) = 0.0767 x 300 A x 0.4

=9.2 volts

185 mm2 (300 m)= 0.198 x 200 A x 0.3

= 11.94 volts

70 mm2 (500 m) =0.532 x 100A x 0.5

=26.6 volts (not permissible)

70 mm2 (200 m) =0.532 x 100 x 0.2

=10.64 volts

Voltage drop for the selected cables is within permissible limits except for 70 mm2 , 500 m cable
length.

Therefore selecting next higher size (i. e. 3.5 x 95/50 sm ) for this cable length we get voltage drop
for

95 mm2 (500 m ) = 0.385 x 100 A x 0.5

= 19.25 volts which is within permissible limits.

So, the selected cable size for this cable length is 3.5 x 95/50 sm.

Modified Cable Selection is

CABLE TERMINOLOGY

CableLength CircuitCurrent(Amp) Selected Cable

(m)
400 300 3.5 X 500 / 240
sm
300 200 3.5 x 185 / 95 sm
500 100 3.5 x 95 / 50 sm
200 100 3.5 X 70 / 35 sm

Economics

The above calculations enable to select the minimum conductor cross section area. However
economics will govern the final optimum size which will offer the minimum capital + running cost.
For this purpose, the minimum size along with two or three higher sizes are considered, and annual
costs are worked out by calculating the cost of power loss across the cable and
interest/depreciation of the cable cost. The cross-section is one with minimum Total cost. Besides
this, for large distribution system other factors such as standardisation of cable sizes, future
expansion, standardisation of accessories etc., should also be considered for final selection of cable
size.