POWER (ARMOURED & UN-ARMOURED) CABLES

All cable conform to IS : 1554 (Part -1) : 1988 for working voltages upto 1100 volts. Wherever required, KCP can offer cables as per other
national or international standards or special requirements.

1. LOW TENSION COPPER / ALUMINIUM CONDUCTOR UN – ARMOURED PVC INSULATED & SHEATHED POWER CABLE

2. LOW TENSION COPPER / ALUMINIUM CONDUCTOR ARMOURED PVC INSULATED & SHEATHED POWER CABLE

Power cables are solid or stranded conductors surrounded by insulation, shielding, and a protective jacket. Generally the power cables are
rated Low Voltage (<1kV), Medium Voltage (6-36 kV), and High Voltage (>40 kV).

Cable jacket includes polyvinyl chloride (PVC) or cross-linked polyethylene (XLPE). Cable shielding is a metallic layer placed around an
insulated conductor or group of insulated conductors, to prevent electrostatic or electromagnetic interference between the enclosed wires and
external fields.

Cable insulation material used is of a high resistance to the flow of electric current to prevent leakage of current from a conductor. Common
materials include cross-linked polyethylene (XLP), polyethylene (PE), and polyvinyl chloride (PVC). A cable conductor is a wire or combination
of wires not insulated from one another, suitable for carrying electric current.
CONDUCTOR : Copper or Aluminium
APPLICABLE STANDARD : IS : 1554 (Part -1) : 1988
RANGE : 1C x 50 sq. mm to 1C x 400 sq. mm
2C x 1.5 sq. mm to 2C x 250 sq. mm
3C x 1.5 sq. mm to 3C x 250 sq. mm
4C x 1.5 sq. mm to 4C x 250 sq. mm
3.5 x 10 sq. mm to 3.5 x 250 sq. mm

CABLE CONSTRUCTION

Conductor: Copper or Aluminium used for the Conductors obtained in the form of rods (8.0 mm Copper or 9.5 mm aluminium rods). After
testing, rods are drawn into wires of required sizes. These wires are formed into final Conductor in the stranding machines under strict
“Quality Assurance Program”.

Insulation: PVC is insulated over Conductor by Extrusion process. Extruded layer of PVC 70°C/85°C/105°C (conforming to IS: 5831: 1984)
with colours as per specification or cores are identified by printing numbers under scheme as per IS: 1554(Part – 1): 1988.
Core Identification:
For Power cables the cores are identified by different colours as per IS 1554:
Single Core : Red, Black, Yellow or Blue
2 Core : Red and Black
3 Core : Red, Yellow and Blue
3½ Core : Red, Yellow, Blue, and reduced neutral core in Black
4 Core : Red, Yellow, Blue and Black

Laying: The insulated cores are laid up in right hand or alternating left & right hand direction of lay in the sequence of core numbers or
colours. Wherever necessary; non-hygroscopic PP/PVC fillers & binder tape are used to form a compact and reasonably circular cable.

Bedding/Inner Sheath: All armoured cables have extruded PVC bedding. The PVC used for bedding is compatible with the temperature of
Insulation material. An extruded layer of PVC is applied as bedding or PVC tape (conforming to IS: 5831: 1984)

Armouring (if requested): When armouring is required, the armour consists of single layer of Galvanized steel wire conforming to IS: 3975.
The armour is applied helically, with a left hand direction. We also provide other armours such as steel strip, tape or tinned copper. Single
core cables are armoured with Aluminium or copper wires.

Outersheath: The standard cables are manufactured with Extruded black PVC Type-9 of B.S. 7655 or ST-2 of IEC 60502. Outer sheath is
embossed or printed with the information required by the related standards. Special FR, FRLS compounds are used for outer sheathing of
cables, to suit customer’s specification requirements.

CURRENT RATINGS
The current rating in table of Unarmoured Single Core Power Cables( Table1), Unarmoured Twin & Multicore Power Cables (Table2) &
Armoured Twin & Multicore Power Cables (Table3 ) are as follows:
1. Maximum conductor temperature 70 °C
2. Ambient air temperature 40 °C
3. Ground temperature 30 °C
4. Depth of laying(for cable laid directly in ground 75 cm(1.1KV)
5. Thermal resistivity of soil 150 °C cm/watt
6. Thermal resistivity of cable 650 °C cm/watt
7. Max. short-circuit conductor temperature 160 °C
8. Max. Ambient Air Temperature 55 °C

CUSTOMIZATION

Other construction can be supplied on request:

FR [Flame Retardant PVC]
FRLS [Flame Retardant Low Smoke PVC]
Zero halogen/ Low Halogen Low smoke Cables: with polymeric insulation and sheath
High Temperature Cables: With ETFE/FEP/PTFE tape (wrap) insulation/sheath

APPLICATIONS

Power Cables are for use with heavy machines, feeders and branch circuits in industrial, commercial, and electric utility applications.

TECHNICAL ADVISORY SERVICES

KCP’s staff includes specialist engineers with wide knowledge and decade long experience in the field of cables and their applications. This
time tested technical expertise and experience is available to all the clients in the selection of appropriate cable design.
TABLE I: 1 CORE, UNARMOURED (AYY) / ARMOURED (AYAWY) CABLES – 1100 VOLTS

Unarmoured Armoured AC Current Rating

Nominal Nominal Nominal Max. DC In Air at 40°C In Ground at 30°C
Nominal Approx. Approx.
Thickness Approx. Thickness Armour Approx Conductor
Area of Overall Overall PVC HRPVC PVC HRPVC
of PVC Wt. of PVC Size Wt. Resistance
Conductor Dia. Dia. Insulation Insulation Insulation Insulation
Insulation Insulation W F at 20°C
2C 3C 2C 3C 2C 3C 2C 3C
mm2 mm mm Kg/Km mm mm mm Kg/Km Ohm/Km Amps Amps Amps Amps
2.5 0.9 8 70 1.2 1.4 10.2 135 12.1 25 21 30 26 28 24 33 28
4 1 8.7 81 1.3 1.4 10.9 152 7.41 32 27 38 33 36 31 41 35
6 1 9.2 100 1.3 1.4 11.5 170 4.61 41 35 50 42 44 39 52 46
10 1.0 10 110 1.3 1.4 13 220 3.080 56 47 67 56 59 51 67 58
16 1.0 12 155 1.3 1.4 15 280 1.910 72 64 86 77 75 66 86 75
25 1.2 13 190 1.5 1.4 16 330 1.200 99 84 119 101 97 86 111 98
35 1.2 14 230 1.5 1.4 17 380 0.868 120 105 144 126 120 100 137 114
50 1.4 16 290 1.7 1.4 19 460 0.641 150 130 180 156 145 120 165 137
70 1.4 17 370 1.7 1.4 20 550 0.443 185 155 222 186 170 140 194 160
95 1.6 20 480 1.9 4X0.8 22 620 0.320 215 190 258 228 205 175 234 200
120 1.6 21 590 1.9 4X0.8 24 720 0.253 240 220 288 264 230 195 262 222
150 1.8 23 700 2.1 4X0.8 25 850 0.206 270 250 324 300 265 220 302 251
185 2.0 25 850 2.3 4X0.8 27 1010 0.164 305 290 366 348 300 240 342 274
240 2.2 28 1060 2.5 4X0.8 30 1245 0.125 350 335 420 402 335 270 382 308
300 2.4 30 1280 2.7 4X0.8 33 1495 0.100 395 380 474 456 370 295 422 336
400 2.6 34 1640 3.0 4X0.8 37 1860 0.0778 455 435 546 522 410 325 467 371
TABLE II: 2 CORE, UNARMOURED (AYY) / ARMOURED (AYWY & AYFY) CABLES – 1100 VOLTS

Unarmoured Armoured Max. DC AC Current Rating

Nominal Nominal Nominal Nominal In Air at 40°C In Ground at 30°C
Approx. Approx. Conductor
Area of Thickness Approx. Thickness Armour Approx
Overall Overall Resistance PVC HRPVC PVC HRPVC
Conductor of PVC Wt. of PVC Size Wt.
Dia. Dia. at 20°C Insulation Insulation Insulation Insulation
Insulation Insulation W F
mm2 mm mm Kg/Km mm mm mm Kg/Km Ohm/Km Amps Amps Amps Amps
4 1.0 14 200 1.0 1.4 18 580 7.410 27 32 32 36
6 1.0 15 240 1.0 1.4 19 660 4.610 35 42 40 46
10 1.0 17 280 1.0 1.4 21 740 3.080 47 56 55 63
16 1.0 20 400 1.0 4X0.8 23 770 1.910 59 71 70 80
25 1.2 20 430 1.2 4X0.8 21 680 1.200 78 94 90 103
35 1.2 22 50 1.2 4X0.8 23 780 0.868 99 119 110 125
50 1.4 25 650 1.4 4X0.8 26 960 0.641 125 150 135 154
70 1.4 28 820 1.4 4X0.8 29 1180 0.443 150 180 160 182
95 1.6 32 1100 1.6 4X0.8 33 1500 0.320 185 222 190 217
120 1.6 33 1260 1.6 4X0.8 34 1680 0.253 210 252 210 239
150 1.8 36 1530 1.8 4X0.8 38 1990 0.206 240 288 240 274
185 2.0 40 1860 2.0 4X0.8 41 2380 0.164 275 330 275 314
240 2.2 45 2370 2.2 4X0.8 46 2960 0.125 325 390 320 365
300 2.4 50 2920 2.4 4X0.8 51 3610 0.100 365 438 355 405
400 2.6 56 3700 2.6 4X0.8 57 4410 0.0778 420 504 385 439
TABLE IV: 3 ½ CORE, UNARMOURED (AYY) / ARMOURED (AYFY) CABLES – 1100 VOLTS
TABLE V: 4 CORE, UNARMOURED (AYY) / ARMOURED (AYWY & AYFY) CABLES – 1100 VOLTS

Nominal Unarmoured Armoured Max. DC AC Current Rating

Area of Nominal Approx. Approx. Nominal Nominal Approx. Approx Conductor In Air at 40°C In Ground at 30°C
Conductor Thickness Overall Wt. Thickness Armour Overall Wt. Resistance PVC HRPVC PVC HRPVC
of PVC Dia. of PVC Size Dia. at 20°C Insulation Insulation
Insulation Unarmoured Insulation W Armoured
F Max. DC AC CurrentInsulation
Rating Insulation
Nominal Nominal Nominal In Air at 40°C In Ground at Amps
30°C
mm2 mm Approx.
mm Kg/Km mm Nominal
mm Approx.
mm Kg/Km Ohm/Km
Conductor Amps Amps Amps
Area of Thickness Approx. Thickness Approx
Overall Armour Overall Resistance PVC HRPVC PVC HRPVC
4
Conductor of1.0
PVC 16 Wt.
280 of1.0
PVC 1.4 20 Wt.
690 7.410 23 28 28 32
Dia. Size (F) Dia. at 20°C Insulation Insulation Insulation Insulation
6 Insulation
1.0 17 340 Insulation
1.0 1.4 21 780 4.610 30 36 35 40
2
mm10 mm
1.0 mm
19 Kg/Km
415 mm
1.0 mm
4X0.8 mm
22 Kg/Km
720 Ohm/Km
3.080 Amps
40 Amps
48 Amps
46 Amps
52
16
25 1.0
1.2 23
25 600
675 1.0
1.2 4X0.8
4X0.8 26
26 1010
970 1.910
1.200 51
70 61
84 60
76 68
87
25 1.2 25 700 1.2 4X0.8 26 1000 1.200 70 84 76 87
35 1.2 27 800 1.2 4X0.8 28 1140 0.868 86 103 92 105
35 1.2 27 850 1.2 4X0.8 28 1200 0.868 86 103 92 105
50 1.4 31 1050 1.4 4X0.8 33 1450 0.641 105 126 110 125
50 1.4 32 1150 1.4 4X0.8 33 1550 0.641 105 126 110 125
70 1.4 36 1360 1.4 4X0.8 37 1810 0.443 130 156 135 154
70 1.4 36 1475 1.4 4X0.8 37 1930 0.443 130 156 135 154
95 1.6 41 1760 1.6 4X0.8 42 2270 0.320 155 186 165 188
95 1.6 41 1960 1.6 4X0.8 42 2460 0.320 155 186 165 188
120
120 1.6
1.6 42
43 2110
2300 1.6
1.6 4X0.8
4X0.8 45
44 2580
2880 0.253
0.253 180
180 216
216 185
185 211
211
150
150 1.8
1.8 45
48 2460
2800 1.8
1.8 4X0.8
4X0.8 47
48 3030
3390 0.206
0.206 205
205 246
246 210
210 239
239
185
185 2.0
2.0 50
53 3080
3490 2.0
2.0 4X0.8
4X0.8 51
54 3710
4120 0.164
0.164 240
240 288
288 235
235 268
268
240 2.2 57
59 3960
4425 2.2 4X0.8
4X0.8 58
61 4615
5200 0.125 280 336 275 314
300 2.4 63
66 4840
5500 2.4 4X0.8
4X0.8 64
67 5640
6350 0.100 315 378 305 348
400 2.6 70
74 6050
6870 2.6 4X0.8
4X0.8 71
75 6980
7870 0.0778 375 450 335 382
 RECOMMENDATIONS FOR STORAGE & INSTALLATION OF CABLES
For easy and convenient installation conditions, and desired performance, following recommendations are made:

1. No drums should be stored one above the other.

2. Drums should be stored on a plain ground without having any projected hard stones above the ground surface. The drums should be
stored preferably in the shade.
3. Drums should be stored and kept in such a way that the bottom cable end does not get damaged.
4. Drums should be rotated only in the direction marked on the drum.
5. While laying the cable in a trench, the cable end should be pulled with a pulling eye only after mounting the drum on the jack.
6. 100% drums should be checked for continuity and cross continuity to ensure that there is no internal damage to the cable during
transportation.
7. Insulation resistance should be measured with 500 V megger between the cores and all the cores to earth (Armour).
8. After the cable is installed, before commissioning, it should be tested for high DC voltage. The recommended volts and duration of the
test between each core and metallic armour (earth) is 3 KVDC for 5 minutes. During High Voltage test, all the electrical equipment
related to the cable installation must be earthed and adequate clearance should be maintained from the other equipments and from
work, to prevent flash over.
9. Where the cable is to be joined with an existing cable, the sequence of cores at the two ends to be joined should be in the opposite
direction i.e., if at one end it is in the clockwise direction, at the other end it should be in the anticlockwise direction. This is necessary
to avoid the crossing of cores while jointing. This will also decide the direction in which the cable is to be pulled.
10. The minimum bending radius for cable should not be less than the values shown below. Wherever possible 25% higher value should
be adopted.
8 x overall diameter: Single core cables as per table I
12 x overall diameter: Multi-core cables as per tables II, III, IV, V, VI, VII & VIII
11. Avoid excessively high temperature when sealing joints of cable. Cool the sealant to about 1000C before pouring.