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Torrent Cables Ltd

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Continuous Current rating

Three Core Dimensional Details

Single Core Dimensional Details


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11 kv Cable
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Aluminium
Copper
Continuous Current Rating for
Single Core Cable
(Single End bonding)
When Laid in
When Laid in
Ground
Air

Continuous Current Rating for Single/Three Core Cables


with Aluminium / Copper Conductor
Nominal
Cross
Sectional
Area of
Conductor
Sq.mm.
35

50

70

95

120

150

Tips:
3.Key Manufacturing Process in HT Cable
Manufacturing.

185

240

XLPE Screenings and Insulation by Extrusion


300

Conductors made through stranding process are


subjected to this operation to form cores. The
process requires three extrusion operations, which
are done simultaneously using three extruders but
a common head.

400

Continuous Current Rating for


Three Core Cable
When Laid in
Ground

When Laid in
Air

amps

amps

amps

amps

115

125

115

140

145

165

150

180

130

150

140

170

170

195

175

215

160

190

170

210

210

240

215

270

190

230

200

255

250

295

260

325

220

260

230

295

280

335

295

375

245

295

255

335

310

380

320

425

275

335

290

385

350

430

370

495

315

395

330

455

400

500

425

580

355

450

375

520

450

570

475

670

400

520

425

610

500

650

540

760

600

485

720

740

600

900

--

550

830

--

670

1010

--

620

950

--

730

1140

--

670

1070

--

790

1250

455
500
The core consists of three concentric layers of
550
extruded material. The first is a layer of black semi
conducting compound formed over the stranded
-630
compacted conductor using the first extruder. Just
-on top of this a layer of white insulation compound
is extruded to form the second layer and finally
-800
through another extruder a layer of black semi
-conducting compound is extruded over insulation
layer. The semi conducting layer formed over
-conductor is called conductor screen and the one
1000
-over insulation is called insulation screen. The three
layers i.e .conductor screen, insulation and
0
C
Ambient
Air
Temperature:
40
insulation screen are formed through a common
0
Ground temperature : 30 C
head known as triple head.

Depth of Laying
3.3 kv to 11 kv Above 11 kv
900 mm
1050 mm

Thermal Resistivity of Soil : 1500 C cm/w

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Maximum Continuous Conductor temperature : 900 C


Single Core Cable laid in Trefoil
Three Core Cable laid Singly
Maximum Conductor Temperature
after Short Circuit : 2500 C
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22/10/2011 12:13 PM

Torrent Cables Ltd

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PVC power cables with aluminium conductors


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1.1kv Power Cables(Un Armoured)


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Constructional details aluminium


Pvc power cables with aluminum conductors (unarmourded cables)
Minimum
Nominal
conductor nos.of wires in
conductor
area sq.mm.
Sr.no
Main
coreE
1

4 $

6 $

Half
core
-

#
-

#
3

10 $

#
4

16 $

Main

Nominal
thickness of
insulation in
mm

Neutral Main

Minimum thickness
of innersheath in
mm

Nominal thickneness of
outer sheath in mm

Approximate overall
diameter in mm

Approximate weight of
cable in kg/kms.

Nos. of cores

Nos. of cores

Nos. of cores

Nos. of cores

Neutral
2

3.5

3.5

3.5

3.5

0.3

0.3

0.3

1.80

1.80

1.80

14.3

15.0

16.1

232

256

298

0.3

0.3

0.3

1.80

1.80

1.80

14.8

15.6

16.8

250

250

318

0.3

0.3

0.3

1.80

1.80

1.80

15.5

16.3

17.7

280

315

371

0.3

0.3

0.3

1.80

1.80

1.80

16.3

17.2

18.5

305

340

400

0.3

0.3

0.3

1.80

1.80

1.80

16.8

17.8

19.2

307

360

425

0.3

0.3

0.3

1.80

1.80

1.80

18.0

19.0

20.6

335

390

460

0.3

0.3

0.3

1.80

1.80

2.00

20.0

21.2

23.5

415

491

612

0.3

0.3

0.3

2.00

2.00

2.00

24.1

25.5

28.0

592

732

848

25 #

1.2

25 @

16 #

1.2

1.0

0.3

0.3

0.3

0.3

2.00

2.00

2.00

2.00

20.0

23.4

25.4

25.9

461

600

35 @

16 #

1.2

1.0

0.3

0.3

0.3

0.3

2.00

2.00

2.00

2.00

21.5

25.3

27.5

28.2

552

725

825

920

50 @

25 @

1.4

1.2

0.3

0.3

0.3

0.4

2.00

2.00

2.00

2.20

23.9

28.5

31.2

33.0

700

928

1070

1250

70 @

35 @

12

1.4

1.2

0.3

0.4

0.4

0.4

2.00

2.20

2.20

2.20

26.7

32.0

34.8

35.8

871

1230

1415

1570

10

95 @

50 @

15

1.6

1.4

0.4

0.4

0.4

0.4

2.20

2.20

2.20

2.40

30.4

35.7

38.9

40.5

1180

1577

1818

2065

11

120 @

70 @

15

12

1.6

1.4

0.4

0.4

0.5

0.5

2.20

2.20

2.40

2.40

32.4

38.2

42.2

43.2

1384

1860

2262

2485

12

150 @

70 @

15

12

1.8

1.4

0.4

0.5

0.5

0.5

2.40

2.40

2.40

2.60

35.6

42.5

46.2

47.8

1688

2322

2642

3030

13

185 @

95 @

30

15

2.0

1.6

0.5

0.5

0.5

0.6

2.40

2.60

2.60

2.80

39.0

46.7

50.8

53.0

2066

2840

3270

3760

14

240 @ 120 @

30

15

2.2

1.6

0.5

0.6

0.6

0.6

2.60

2.80

3.00

3.00

43.5

52.3

57.2

58.8

2605

3640

4225

4736

15

300 @ 150 @

30

15

2.4

1.8

0.6

0.6

0.6

0.7

2.80

3.00

3.20

3.40

48.0

57.5

62.9

65.0

3222

4430

5135

5902

16

400 @ 185 @

53

30

2.6

2.0

0.7

0.7

0.7

0.7

3.20

3.40

3.40

3.60

54.5

65.0

70.5

73.0

4165

5818

6515

7422

-Extruded Pvc Inner Sheath

-Standard drum length for all sizes : 500mtrs. 5%

# = Stranded Circular Alumimium Conductor

695

760

= Solid Circular Aluminium Conductor

@ =Standard Sector Shaped Aluminum Conductor

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22/10/2011 12:19 PM

Torrent Cables Ltd

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Control cables with stranded circular copper conductor

Control cables with solid circular copper conductor


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1.1kv Control Cables(Armoured)


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Control cables with stranded circular copper conductor (armoured)

No.of cores
and
conductor
area sq.mm.

C opper
conductor
minimum
no.of wires

Thickness of
insulation
(mm)

2 X 1.5

3 X 1.5

4 X 1.5

Sr.no.

Thickness of innersheath
in mm

Armour size in mm
& type

Minimum
Approximate
Approximate
thickness of
overall diameter weight of cables
outer sheath
(kg./km)
(mm)
(mm)

Extruded

Wrapped

Round
wire

Flat strip

0.8

0.3

1.4

1.24

14.2

420

0.8

0.3

1.4

1.24

14.5

460

0.8

0.3

1.4

1.24

15.5

510

5 X 1.5

0.8

0.3

1.4

1.24

16.5

562

7 X 1.5

0.8

0.3

1.4

1.24

17.1

605

10 X 1.5

0.8

0.3

1.4

1.40

20.9

820

12 X 1.5

0.8

0.3

4 X 0.8

1.24

20.0

700

14 X 1.5

0.8

0.3

4 X 0.8

1.40

21.1

785

16 X 1.5

0.8

0.3

4 X 0.8

1.40

22.0

865

10

19 X 1.5

0.8

0.3

4 X 0.8

1.40

23.1

955

11

24 X 1.5

0.8

0.3

4 X 0.8

1.40

26.3

1175

12

27 X 1.5

0.8

0.3

4 X 0.8

1.40

27.0

1240

13

30 X 1.5

0.8

0.3

4 X 0.8

1.40

27.9

1340

14

37 X 1.5

0.8

0.3

4 X 0.8

1.40

29.7

1545

15

44 X 1.5

0.8

0.3

4 X 0.8

1.56

33.0

1840

16

52 X 1.5

0.8

0.4

4 X 0.8

1.56

35.0

2070

17

61 X 1.5

0.8

0.4

4 X 0.8

1.56

37.0

2340

Thickness of innersheath Armour size in mm


in mm
& type

No.of cores
and conductor
area sq.mm.

Copper
conductor
minimum
no.of wires

Thickness of
insulation
(mm)

2 X 2.5

3 X 2.5

4 X 2.5

Sr.no.

Minimum
Approximate
Approximate
thickness of
overall diameter weight of cables
outer sheath
(kg./km)
(mm)
(mm)

Extruded

Wrapped

Round
wire

Flat strip

0.9

0.3

1.4

1.24

15.5

500

0.9

0.3

1.4

1.24

16.1

550

0.9

0.3

1.4

1.24

17.0

625

5 X 2.5

0.9

0.3

1.4

1.24

18.2

686

7 X 2.5

0.9

0.3

1.4

1.24

19.0

751

10 X 2.5

0.9

0.3

4 X 0.8

1.24

22.3

861

12 X 2.5

0.9

0.3

4 X 0.8

1.40

22.9

935

14 X 2.5

0.9

0.3

4 X 0.8

1.40

24.0

1030

16 X 2.5

0.9

0.3

4 X 0.8

1.40

25.0

1140

10

19 X 2.5

0.9

0.3

4 X 0.8

1.40

26.1

1270

11

24 X 2.5

0.9

0.3

4 X 0.8

1.40

30.1

1566

12

27 X 2.5

0.9

0.3

4 X 0.8

1.40

30.8

1675

13

30 X 2.5

0.9

0.3

4 X 0.8

1.40

32.3

1845

14

37 X 2.5

0.9

0.4

4 X 0.8

1.56

34.6

2170

15

44 X 2.5

0.9

0.4

4 X 0.8

1.56

38.5

2545

16

52 X 2.5

0.9

0.4

4 X 0.8

1.56

40.5

2860

17

61 X 2.5

0.9

0.4

4 X 0.8

1.56

42.5

3240

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22/10/2011 12:18 PM

Torrent Cables Ltd

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http://www.torrentcables.com/PVC_common_design_details.html

Standard Operating Parameters

Current Rating

Short Circuit Rating

Rating Factors
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PVC Common design details


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Standard Operating
Parameters
Maximum Conductor
Temperature

70 C (85 C for HR Cable)

Thermal resistivity of soil

150 C.cm./w

Thermal resistivity of PVC

650 C.cm./w

Ground temperature

30 C

Ambient air temperature

40 C

Depth of laying in Cms (Cables


75 cm
laid in ground)
Type of installation
Twin, Three & Multicore Cables Laid singly
3 Cores in close trefoil
formation

Single core Cable

Current Rating (ac) for Three Single Core 650/1100 VOLTS


Unarmoured / Non- Magnetic Armoured Cables according to is : 1554
(Part I) 1988

SR.NO.

Tips:
9.Following care should be taken while
laying the Cable Across Roads, Railway
Tracks or Water Pipe Lines :
Steel, Castlron, Plastics, Cement or earthenware
ducts or cable ducting blocks should be used
where cables cross roads and railways tracks.
Spare ducts for future extension should be
provided & sealed at both ends.
Ensure smooth entry of cable without undue
bending.

LAID DIRECT IN
LAID IN DUCT
LAID IN AIR
GROUND
NOMINAL
CROSS
SECTIONAL
AREA
(sq.mm.) C OPPER ALUMINIUM COPPER ALUMINIUM COPPER ALUMINIUM
(Amps)
(Amps)
(Amps)
(Amps)
(Amps)
(Amps)

1.5

22

17

21

17

20

2.5

30

24

29

24

27

15
21

39

31

38

30

35

27

49

39

48

37

44

35

10

65

51

64

51

60

47

16

85

66

83

65

82

64

25

110

86

110

84

110

84

35

130

100

125

100

130

105

50

155

120

150

115

165

130

10

70

190

140

175

135

205

155

11

95

220

175

200

155

245

190

12

120

250

195

220

170

280

220

13

150

280

220

245

190

320

250

14

185

305

240

260

210

370

290

15

240

345

270

285

225

425

335

16

300

375

295

310

245

475

380

The cable entry and exit should be through bell


mouth or padding.

17

400

400

325

335

275

550

435

18

500

425

345

355

295

590

480

The bending radii of steel or plastic ducts should


not be less than 1.5 m.

19

625

470

390

375

320

660

550

20

800

540

440

405

345

765

640

Single core cables should not be laid individually


in ducts, butall3 cables of the same system
should be laid in one duct.

21

1000

600

490

435

370

860

720

The duct/pipe joints should be covered by collars


to prevent settlement in between pipes.
The diameter of the cable conduit or pipe or duct
should be atleast 1.5 times the outer diameter
of cable. The pipe/duct should be mechanically
strong enough to withstand forces due to heavy
traffic when laid across road/railway tracks.

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22/10/2011 12:18 PM

Torrent Cables Ltd

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Standard Operating Parameters


Continuous Current Rating
Maximum short circuit rating of conductor for a duration of one second Rating Factor
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LT-XLPE Common Design Details


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Standard Operating Parameters


Maximum conductor temperature for continuous operations ( C)

PVC
70

XLPE
90

Ambient air temperature ( C)

40

40

Ground temperature ( C)

30

30

Thermal resistivity of soil ( C cm/watt)

150

150

Thermal resistivity ( C cm/w)

650

350

Depth of laying

75 cm

75cm

Cables are installed singly


Minimum bending radious ( for Multi core cables) times cable diameter.
Maximum conductor temperature During short circuit ( C)

12

12

160

250

Continuous current rating of 3 or 4 core cables armoured and unarmoured laid direct in
the ground or in air 1100 volts grade with Aluminium conductor.
3, 3.5 or 4 core cables to
IS : 1554 (Pt.1)
(PVC)
When Laid in
Approx.
Size
Voltage
Ground
Air
drop
sq. mm.
amps
amps
v/km/A

Tips:
6.Type of Tests conducted on Finished
Cables
Routine Tests
Routine tests are tests conducted on each and
every finished length of a cable. Routine tests
mean tests conducted on a cable to assess its
suitability during routine service condition.

25
35
50
70
95
120
150
185
240
300
400

76
92
110
135
165
185
210
235
275
305
335

70
86
105
130
155
180
205
240
280
315
375

2.50
1.80
1.30
0.94
0.68
0.55
0.46
0.37
0.30
0.27
0.22

3, 3.5 or 4 core cables to


IS : 7098 (Pt. 1)
(XLPE)
When Laid in
Approx.
Size
Voltage
Ground
Air
sq. mm.
drop
amps
amps
v/km/A
25
35
50
70
95
120
150
185
240
300
400

94
114
133
164
196
223
249
282
327
368
418

96
117
142
179
221
257
292
337
400
455
511

2.68
1.95
1.44
0.99
0.78
0.58
0.47
0.40
0.31
0.26
0.22

Type Tests
Type tests consist of a number of tests
conducted on a piece of cable (not on the entire
drum length) cut from a finished cable drum
length. The purpose of these tests is to confirm
the suitability of a cable against the type, which
has been constructed for a particular application.
The sample taken for type tests represents the
entire lot of cable manufactured of a particular
type.
Acceptance Tests
Acceptance tests also consist of a number of
tests conducted on few pieces of cables drawn
from a manufactured lot. These tests are
conducted during client's witness of test
programme on a manufactured lot in order to
decide about the lotto be shipped for usage or
not.
Special Tests
Special tests are those tests which do not get
covered under routine or type or acceptance
tests. Generally special tests are conducted to
assess a particular property or a set of
properties, which have been built in the cable to
exhibit desired requirement during its operation.

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22/10/2011 12:16 PM

Torrent Cables Ltd

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Single core

Two core

Three Core

Three & Half Core

Four Core
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LT-XLPE UnArmoured Cables


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SINGLE CORE UNARMOURED CABLES - 1100 VOLTS ALUMINIUM CONDUCTOR WITH XLPE INSULATION
Single Core unarmoured Cables
Nominal
Area of
Conductor

Delivery
length with
+/- 5%
tolerance

Standard
Max DC
resistance
at 20C

AC
resistance
at
Operating
Temp
90C

Nominal
Thickness
of
Insulation

Nominal
diameter
of round
Alu. Wire

Approx.
Overall
diameter
of cable

Approx
weight of
finished
cables

sq.mm.

mm.

mm.

mm.

kg/km

meters

ohms/km

ohms/km

25

0.9

1.8

13.0

177

1000

1.2000

1.536

35

0.9

1.8

14.0

209

1000

0.8680

1.111

50

1.0

1.8

15.0

258

1000

0.6410

0.820

70

1.1

1.8

17.0

337

1000

0.4430

0.567

95

1.1

1.8

17.0

401

1000

0.3200

0.410

120

1.2

1.8

21.0

535

1000

0.2530

0.324

150

1.4

2.0

23.0

642

1000

0.2060

0.264

185

1.6

2.0

25.0

774

500

0.1640

0.210

240

1.7

2.0

27.0

968

500

0.1250

0.160

300

1.8

2.0

30.0

1162

500

0.1000

0.128

400

2.0

2.2

33.0

1491

500

0.0778

0.100

Conductor : Stranded Compacted Circular. ( Except 25 sq.mm. Stranded circular)


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TWO / THREE CORE UNARMOURED CABLES - 1100 VOLTS ALUMINIUM CONDUCTOR WITH XLPE INSULATION

Nominal
Area of
Conductor

Two core unarmoured Cable


3 core unarmoured C able
AC
Standard
(Shaped C ond.)
(Shaped Cond.)
resistance
Delivery
Nominal
Max DC
Approx.
Approx
at
length
Thickness Minimum Nominal Approx.
Minimum Nominal Approx.
resistance
Weight
weight
Operating
with
of
Thickness Thickness Overall
Thickness Thickness Overall
at 20C
of
of
Temp
+/- 5 %
Insulation of inner of outer diameter
of inner of outer diameter
finished
finished
90C
tolerance
sheath of cable
sheath
sheath of cable
sheath
cable
cables

sq.mm.

mm.

mm.

mm.

mm.

kg/km

mm.

mm.

mm.

kg/km

25

0.90

0.3

2.0

20.0

295

0.3

2.0

23.0

411

meters ohms/km ohms/km


500

1.2000

1.536

35

0.90

0.3

2.0

22.0

377

0.3

2.0

25.0

525

500

0.8680

1.111

50

1.00

0.3

2.0

24.0

496

0.3

2.0

28.0

686

500

0.6410

0.820

70

1.10

0.3

2.0

27.0

669

0.4

2.2

32.0

983

500

0.4430

0.567

95

1.10

0.4

2.2

30.0

912

0.4

2.2

35.0

1253

500

0.3200

0.410

120

1.20

0.4

2.2

32.0

1167

0.4

2.2

37.0

1587

500

0.2530

0.324

150

1.40

0.4

2.2

36.0

1413

0.5

2.4

42.0

2001

500

0.2060

0.264

185

1.60

0.5

2.4

40.0

1786

0.5

2.6

46.0

2467

500

0.1640

0.210

240

1.70

0.5

2.6

44.0

2252

0.6

2.8

51.0

3163

500

0.1250

0.160

300

1.80

0.6

2.8

48.0

2784

0.6

3.0

56.0

3841

500

0.1000

0.128

400

2.00

0.6

3.0

54.0

3539

0.7

3.2

63.0

4948

500

0.0778

0.100

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22/10/2011 12:16 PM

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Single core

Two core

Three Core

Three & Half Core

Four Core
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LT-XLPE Armoured Cables


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SINGLE CORE ARMOURED CABLES - 1100 VOLTS ALUMINUM CONDUCTOR WITH XLPE INSULATION
Hard drawn Aluminium round wire Armoured
Nominal
Area of
Conductor

Standard
Delivery
Max DC
length with
resistance
+/- 5 %
at 20C
tolerance

AC
resistance
at
Operating
Temp 90C

Nominal
Thickness
of
Insulation

Nominal
diameter
of round
Alu. Wire

Minimum
Thickness
of outer
sheat

Approx.
Overall
diameter
of cable

Approx.
Weight of
finished
cable

sq.mm.

mm.

mm

mm.

mm.

kg/km

meters

ohms/km

ohms/km

25

1.2

1.4

1.24

14.5

259

1000

1.2000

1.536

35

1.2

1.4

1.24

15.0

295

1000

0.8680

1.111

50

1.3

1.4

1.24

17.0

354

1000

0.6410

0.820

70

1.4

1.4

1.24

18.0

445

1000

0.4430

0.567

95

1.4

1.6

1.40

19.0

544

1000

0.3200

0.410

120

1.5

1.6

1.40

23.0

694

1000

0.2530

0.324

150

1.7

1.6

1.40

25.0

817

1000

0.2060

0.264

185

1.9

1.6

1.40

26.0

965

500

0.1640

0.210

240

2.0

1.6

1.40

29.0

1188

500

0.1250

0.160

300

2.2

1.6

1.56

32.0

1428

500

0.1000

0.128

400

2.4

2.0

1.56

36.0

1844

500

0.0778

0.100

Conductor : Stranded Compacted Circular. (Except 25 sq. mm. Stranded circular)

TWO CORE ARMOURED CABLES - 1100 VOLTS ALUMINIUM CONDUCTOR WITH XLPE INSULATION
Flat galvenised steel strip Armoured
( shaped cond)

Galvenised round steel wire


Armoured ( shaped cond)

AC
Standard
resistance
Delivery
Nominal Minimum
Max DC
Nominal
at
length
Thickness Thickness
resistance
Area of
Operating
with
of inner Nominal Minimum Approx. Approx Nominal Minimum Approx. Approx.
of
at 20C
Conductor
Weight
diameter
weight
Temp
+/- 5 %
Insulation sheath dimension Thickness Overall
Thickness Overall
of
of round
of
90C
tolerance
of outer diameter
of outer diameter
of flat
finished
g.s.
finished
sheath of cable
of cable
sheat
strip
cable
Wire
cables
sq.mm.

mm.

mm

mm.

mm.

mm.

kg/km

mm.

mm.

mm.

kg/km

25

0.90

0.3

4 x 0.8

1.40

21.0

527

1.6

1.40

22.0

741

meters ohms/km ohms/km


500

1.2000

1.536

35

0.90

0.3

4 x 0.8

1.40

22.0

633

1.6

1.40

24.0

866

500

0.8680

1.111

50

1.00

0.3

4 x 0.8

1.40

25.0

788

1.6

1.40

26.0

1050

500

0.6410

0.820

70

1.10

0.3

4 x 0.8

1.56

28.0

1024

1.6

1.56

29.0

1318

500

0.4430

0.567

95

1.10

0.4

4 x 0.8

1.56

31.0

1285

2.0

1.56

33.0

1822

500

0.3200

0.410

120

1.20

0.4

4 x 0.8

1.56

33.0

1574

2.0

1.56

35.0

2156

500

0.2530

0.324

150

1.40

0.4

4 x 0.8

1.72

37.0

1899

2.0

1.72

39.0

2546

500

0.2060

0.264

185

1.60

0.5

4 x 0.8

1.72

40.0

2295

2.0

1.88

43.0

3047

500

0.1640

0.210

240

1.70

0.5

4 x 0.8

1.88

44.0

2813

2.5

2.04

48.0

4031

500

0.1250

0.160

300

1.80

0.6

4 x 0.8

2.04

49.0

3402

2.5

2.20

52.0

4741

500

0.1000

0.128

400

2.00

0.6

4 x 0.8

2.36

55.0

4281

2.5

2.36

58.0

5738

500

0.0778

0.100

Extruded PVC inner sheath

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22/10/2011 12:15 PM

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Conductor resistance and Short Circuit Carrying Capacity Group Rating Factor for Single and Multi Core Cables
Group Rating Factors for Single/Multicore Cables
Rating Factor for Ambient Air/Ground Temperature variation
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HT Common design details


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Conductor Resistance and Short Circuit Current Carrying Capacity


Nominal
Cross
Sectional
Area

Maximum
DC
Resistance

Approx.AC
Resistance
0

at 90 C
at 200 C
Aluminium Conductor
ohms/km
ohms/km
0.8680
1.137
0.6410
0.840
0.4430
0.580
0.3200
0.419
0.2530
0.331
0.2060
0.270
0.1640
0.215
0.1250
0.164
0.1000
0.131
0.0778
0.102
0.0605
0.079
0.0467
0.061
0.0367
0.048
0.0292
0.038

sq.mm
35
50
70
95
120
150
185
240
300
400
500
630
800
1000

Maximum
DC
Resistance

Approx.AC
Resistance

Short Circuit Current


for Conductor

at 90 C
at 200 C
Copper Conductor
ohms/km
ohms/km
0.5240
0.6864
0.3870
0.5070
0.2680
0.3511
0.1930
0.2528
0.1530
0.2004
0.1240
0.1624
0.0991
0.1298
0.0754
0.0988
0.0601
0.0787
0.0470
0.0616
0.0366
0.0479
0.0283
0.0371
0.0210
0.0280
0.0176
0.0231

Aluminium
ka/sec
3.29
4.70
6.58
8.93
11.28
14.10
17.39
22.56
28.20
37.60
47.00
59.22
75.20
94.00

Copper
ka/sec
5.01
7.15
10.01
13.58
17.16
21.45
26.46
34.32
42.90
57.20
71.50
90.09
114.40
143.00

Group Rating Factor for Single and Multi Core Cables


Single Core
Multi Core
Number of Cables
in Group
2
3
4
5
6

Spacing between Cables in mm


Touching
0.76
0.79
0.64
0.67
0.58
0.61
0.53
0.56
0.50
0.53

SINGLE CORE:

150
0.81
0.82
0.72
0.73
0.65
0.68
0.61
0.63
0.56
0.60

200
0.83
0.86
0.72
0.77
0.67
0.72
0.63
0.68
0.60
0.65

300
0.85
0.87
0.77
0.78
0.72
0.74
0.68
0.70
0.66
0.68

400
0.87
0.88
0.79
0.80
0.75
0.79
0.71
0.76
0.69
0.74

450
0.88
0.89
0.81
0.82
0.76
0.80
0.73
0.77
0.72
0.76

600
0.90
0.92
0.83
0.86
0.80
0.83
0.77
0.81
0.76
0.80

800
0.92
0.94
0.86
0.89
0.84
0.87
0.81
0.85
0.80
0.84

MULTI CORE:

A. Group Rating factors for Circuit of three Single core cables in Trefoils laid B. Group Rating factors for cables laid in Horizontal formation.
direct in Ground in Horizontal formation.

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22/10/2011 12:14 PM

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Continuous Current rating

Three Core Dimensional Details

Single Core Dimensional Details


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33 kv Cable
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Aluminium
Copper
Continuous Current Rating for
Single Core Cable
(Single End bonding)
When Laid in
When Laid in
Ground
Air

Continuous Current Rating for Single/Three Core Cables


with Aluminium / Copper Conductor
Nominal
Cross
Sectional
Area of
Conductor
Sq.mm.
35

50

70

95

120

150

Tips:
5.Key Manufacturing Process in HT Cable
Manufacturing.

185

240

Wet (Steam/Hot Water) Cure Process


The chemistry of
C-Si-O-Si-C linkage.

cross

linking

leads

300

to

400

The cores are cooled in water, post extrusion.


The cross linking
environment.

takes

place

in

wet
500

Curing is done by batch process.


630

Because of batch process, there is a limitation to


drum length of cable.

800

The plant and machinery are not very expensive.


Losses are less in case of equipment
/process malfunctioning.
This does not require very large factory space.

1000

Continuous Current Rating for


Three Core Cable
When Laid in
Ground

When Laid in
Air

amps

amps

amps

amps

110

130

115

140

145

165

150

185

130

155

135

170

170

200

175

225

160

190

165

215

205

245

215

275

190

230

195

255

245

300

250

340

215

265

225

295

275

340

290

390

240

300

250

330

305

385

325

440

270

340

280

380

345

435

365

500

310

400

325

450

395

510

420

590

350

455

370

520

440

580

470

680

395

530

420

610

495

660

530

780

445

610

480

710

550

750

590

900

--

--

550

820

--

--

660

1020

--

--

610

950

--

--

730

1140

--

--

680

1080

--

--

790

1240

Ambient Air Temperature: 400 C

Ground temperature : 300 C


The process requires an associated curing
Thermal
Resistivity of Soil : 1500 C cm/w
arrangement in the form of steam y chamber or
water tank etc.
Maximum Continuous Conductor temperature : 900 C
Single Core Cable laid in Trefoil
Curing is restricted to insulation only, semi Three Core Cable laid Singly
conducting layers are of y thermoplastic Maximum Conductor Temperature
compound based.
after Short Circuit : 2500 C

Depth of Laying
3.3 kv to 11 kv Above 11 kv
900 mm
1050 mm

Because of batch curing, extremely difficult to


crossing cores.beyond 33 kV. Chances of
non-uniform cross linking cannot be ruled out.
Maintenance expenses are comparatively lower.

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22/10/2011 12:14 PM

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PVC power cables with aluminium sector shaped conductors

PVC power cables with aluminium conductors


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1.1kv Power Cables(Armoured)


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Constructional details aluminium


Pvc power cables with aluminum sector shaped conductors (armourded cables)

Sr.no.

Nominal
conductor
area
sq.mm.

Minimum
nos. of
wires in
conductor

Minimum
Nominal
Nominal
Minimum thicknass of
thickness of thickness of
diameter/dimension of
outer sheath in mm
insulation in innersheath
G.I.armouring in mm
in mm
mm

Nos.of cores
Main Half
Main NeutralL Main Neutral
core core
2 3 3.5 4
1

25

16

1.2

Number.of cores
2

3.5

Number.of cores
2

4.0 x 4.0 x 4.0 x 4.0 x


1.40
0.8
0.8
0.8
0.8

1.0

0.3 0.3 0.3 0.3

1.0

4.0 x 4.0 x 4.0 x 4.0 x


1.40
0.3 0.3 0.3 0.3
0.8
0.8
0.8
0.8

1.2

4.0 x 4.0 x 4.0 x 4.0 x


1.40
0.3 0.3 0.3 0.4
0.8
0.8
0.8
0.8

1.2

4.0 x 4.0 x 4.0 x 4.0 x


1.56
0.3 0.4 0.4 0.4
0.8
0.8
0.8
0.8

Approximate overall
diameter in mm

Approximate weight
cable in kg/kms.

Number.of cores

Number.of cores

3.5

3.5

3.5

1.40

1.40

1.40

20.4

23.8

25.8

27.0

675

855

975

10

(1.6) (1.6) (1.6) (1.6) (1.40) (1.40) (1.40) (1.40) (21.8) (25.3) (27.2) (28.0) (901) (1125) (1265) (13
2

35

16

1.2

1.40

1.40

1.40

22.0

25.6

27.9

29.1

785

1005

1130

12

(1.6) (1.6) (1.6) (1.6) (1.40) (1.40) (1.40) (1.56) (23.2) (27.3) (29.2) (30.7) (1030) (1295) (1445) (16
3

50

25

1.4

1.56

1.56

1.56

24.5

29.3

31.8

33.5

970

1275

1450

16

(1.6) (1.6) (1.6) (2.0) (1.56) (1.56) (1.56) (1.56) (26.0) (30.9) (33.2) (35.2) (1275) (1605) (1805) (22
4

70

35

12

1.4

1.56

1.56

1.56

27.0

32.3

35.0

36.5

1195

1570

1780

19

(1.6) (2.0) (2.0) (2.0) (1.56) (1.56) (1.56) (1.56) (28.3) (34.6) (37.4) (38.0) (1500) (2165) (2430) (26
4 0 x 4 0 x 4 0 x 4 0 x
-Wrapped thermoplastic tape inner sheath
-Standard drum length for all sizes : 500 mtrs. 5 %
-Values written in bracket are for g.i. wire armoured cables

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22/10/2011 12:19 PM