POWER CABLES

VINAY HARDAS,
Retd. EE, MAHAGENCO
 • POWER CABLE-

• Is an assembly of one or more conductors held together within an

overall sheath. It is used for transmission of electrical power.
• Cables has three main components:
• 1. Conductor
• 2. Insulation
• 3. Protective Jacket.
• Power Cable construction depends on:
• 1. Working Voltage- determining the thickness of insulation.

• 2. Current Carrying Capacity- determining cross section size of conductor.

• 3. Environmental Conditions- Temperature, water, chemical or sunlight

exposure, mechanical impact.
 TYPES OF CABLES:
• 1. PIC CABLE- PAPER INSULATED CABLE.
• 2. PILC CABLE- PAPER INSULATED LEAD COVERED CABLE.
• 3. POLYVINYL CABLE- POLYVINYL CHLORIDE CABLE.
• 4. OFPI CABLE- OIL FILLED PAPER INSULATED CABLE.
• 5. HPOF CABLE- HIGH PRESSURE OIL FILLED CABLE.
• 6. SF6 , COMPRESSED GAS INSULATED CABLE.
• 7. VULCANISED RUBBER CABLE.
• 8. XLPE CABLE- CROSS LINKED POLYETHYLENE CABLE.
AREAS OF APPLICATION OF CABLES:
• 1. SUBMERCIBLE CABLES- UTILISED UNDER WATER.
• 2. L.T. COMMUNICATION CABLES.
• 3. SHIPPING CABLES.
• 4. ARIEL CABLES.
• 5. RAILWAY SIGNALLING CABLES.
• 6. CABLES LAID ON ROCKS AND CLEATS.
• 7. MINING CABLES.IS-1554 APPROVED BY DGMS DHANBAD.
 WHY XLPE CABLES USED IN POWER
STATIONS?
• 1. GOOD ELECTRICAL & PHYSICAL PROPERTIES.
• 2. MAXIMUM CURRENT CARRYING CAPACITY.
• 3. NO HEIGHT RESTRICTIONS
• 4. EASY FOR INSTALLATION.
• 5. NEGLIGIBLE MAINTNANCE.
• 6. NO NEED OF METALLIC SHEATH.
 HOW TO SELECT PROPER CABLE?
• 1. LOAD- LOAD CURRENT = KW x 1000/(V X P.F.
• E.g. = (75 X 1000)/(415X0.8)=225 Amps.
• 2. System Voltage- DC 2 wire, AC 3 ph.3 wire., AC 3 ph. 4 wire.
• 3. Voltage Drop- (2 X I X d X z)/1000.I= Current, d= Distance, Z= Imp.
• 4. Insulation- Class of Insulation.
• 5. Method of Utilisation.
• 6. Short Ckt. Rating- Short Ckt current= KA/t, K= constant of conducting material, A=
Cross section area of cable in sqmm.t= time duration of short ckt in seconds.
 Contd…
• 7. Environmental Condition., where tha cable is to be used.
• 8. Protective Covering.
• 9. Economics- cost of cable feasibility.
• 10. Safety- Even in case of breakdown of cable, safety should be there
 CORE IDENTIFICATION OF CABLE:
NO OF CORES COLOUR OF CORE
• CABLE
1
CORES CAN BE IDENTIFIED WITH COLOUR OF
RED/BLACK/YELLOW/BLUE
INSULATION.
2 RED/BLACK

3 RED/YELLOW/BLUE
3.5 OR 4 RED/BLACK/YELLOW/BLUE(N-
BLACK)
5 RED/BLACK/YELLOW/BLUE/
GREEN
6 OR MORE THAN 6 BLUE & YELLOW TO EACH
ADJECENT CORE AND GREEN IN
OTHER CORES.
 CABLE CODES:
A ALUMINIUM CONDUCTOR, COPPER
CONDUCTOR WHERE A IS NOT
WRITTEN.
Y PVC INSULATION
YY PVC OUTER SHEATH
W ARMOUR OF STEEL ROUND WIRE
WW ARMOUR OF DOUBLE STEEL ROUND
F ARMOUR STEEL STRIP
FF ARMOUR DOUBLE STEEL STRIP
E.G. 400 SQMM, 3 CORE, 1100 V TYPE AYFY ALUMINIUM CONDUCTOR, PVC
INSULATED, STEEL STRIP, PVC OUTER
SHEATH.
 DIFFERENCE BETWEEN POWER & CONTROL CABLES:
SR. NO. POWER CABLE
1 OUT DOOR APPLICATION
2 MORE ELECTRIC CURRENT,
VOLTAGE- HIGH/MEDIUM/LOW
3 HIGH NORMAL CURRENT RATING
4 MORE CROSS SECTION AREA OF
CONDUCTOR
5 CURRENT RATING RELATED WITH
TEMP RISE
6 CONVENTIONAL COLOURS OF
CABLE INSULATION R/Y/B
7 --
CONTROL CABLE
INDOOR APPLICATION
LOW ELECTRIC CURRENT
FOR LOW VOLTAGE APPLIANCES (AC/DC CKT)
USED FOR PROTECTION PURPOSE,
USED FOR TELECOMMUNICATION &
SIGNALLING ETC.
LOW CURRENT RATING
LOW CROSS SECTION AREA OF CONDUCTOR
NOT APPLICABLE
DIFFERENT COLOURS FOR CABLE
INSULATION
HIGH SENSITIVITY CABLES
 SPECIAL CARE FOR CONTROL
/PROTECTION CABLES:
• MOST OF THE TIME THERE IS HUMMING SOUND IN
CONTROL/PROTECTION CABLES FOR MINIMISING THIS SOUND:
• 1. PROPER ROUTING OF CONTROL CABLES
• 2. DISTANCE BETWEEN POWER & CONTROL CABLE TO 0.3 MTR
MINIMUM.
• 3. SHIELDING SHOULD BE PROPER.
• 4. EARTHING TO BE PROVIDED.
 CABLE FAULTS & THEIR REASONS:
• 1.OPEN CIRCUIT OR CONDUCTOR SNAPPING IN BETWEEN.
• 2. SHORT CIRCUIT OR CONDUCTOR TO CONDUCTOR FAULT.
• 3. GROUNDED CIRCUIT OR CONDUCTOR TO GROUND FAULT.
• REASONS:
• 1.PUNCTURE OF LEAD SHEATH OF CABLE OR CRACK- MECHANICAL
DAMAGE.
• 2. BENDING THE CABLE MORE , DAMAGES WHILE DIGGING.
• 3. DUE TO SIPPAGE OF RAIN WATER INSIDE THE CABLE.
 CONTD…
• 2. CORROSION- DUE CORROSION OF ARMOUR, CABLE MAY
PUNCTURE OXIDATION WILL BE THERE, THIS IS PHENOMENA
OF ELECTROLYTIC EFFECT OF STRAY CURRENT , THIS STRAY
CURRENT GOES TO GROUND THROUGH SHEATH. THIS MAY
HAPPEN DUE TO CHEMICAL REACTION OR DUE TO CLAY NEAR
TO CABLE.
• 3. VIBRATIONS- CABLE SHEATH MAY CRACK DUE TO
VIBRATIONS. MAY HAPPEN IN RAILWAYS OR INDUSTRIES.
 CABLE JOINTING:
• AFTER PUNCTURE OF CABLE, CABLE IS TO BE CUT AND AFTER
REMOVING UNUSED PARTS, REMAINING CABLE PIECES ARE TO BE
JOINED. THIS WORK IS PRECIOUS AND TECHNICALLY IMPORTANT.
• IF IT IS NOT DONE PROPERLY, FAULT MAY GET REPEATED.
• VARIOUS TYPES OF READY MADE CABLE JOINTING KITS ARE
AVAILABLE IN MARKET.
• SELECTION OF JOINTING KIT DEPENDS ON- APPLICATION,USE,
TYPE OF CABLE, SYSTEM VOLTAGE, DRIVEN EQUIPMENT/LOAD.
 TYPES OF JOINTING KITS:
• 1. M-SEAL PRECAST KIT- THIS KIT USED FOR OUTDOOR TERMINATION OF PILC
CABLE FOR THE VOLTAGE LEVELS 11/33 KV.
• 2. M-SEAL TAPEX CABLE JOINTING KITS- USED JOINTING XLPE CABLE UPTO 33
KV.
• 3. M-SEAL CABLE TERMINATION WITH STRESS GRADE MATERIAL- FOR XLPE
CABLE.
• 4. M-SEAL CABLE JOINTING KITS- USED FOR XLPE & PILC OUTDOOR
TERMINATION UPTO 11 KV. USED FOR TRANSITION JOINTS/STRAIGHT THROUGH
JOINTS. FOR DIFFERENT CABLES LIKE XLPE & PILC OR XLPE & PVC CABLE.
 CONTD..
• 5. M-SEAL EPOXY COMPOUND KIT- 1. M-SEAL GENERAL PURPOSE EPOXY
COMPOUND KIT ,2. M-SEAL METAL FILLED EPOXY COMPOUND.
• IN THIS RESIN OF GREEN COLOUR AND HARDNER OF BLACK
COLOUR.RESIN IS OF LIQUID RESIN AND POWDER MIX AND HARDNER IS
IN LIQUID FORM. IT IS SET WITHIN 30 TO 40 MINUTES AFTER MIXING
GPFC ( GENERAL PURPOSE BUT FAST CURING TYPE).
• BEFORE STARTING WORK OF JOINTING CONDUCTOR SHOULD BE
THOROUGHLY CLEANED .
• ALSO RAYCHEM MAKE JOINTING KITS ARE USED .
 ADVANTAGES OF JOINTING:
• 1. EASY TO INSTALLATION
• 2. PERFECT INSTALLATION
• 3. LESS DOWN TIME
• 4. HUMAN ERRORS ARE ELIMINATED.
•THANKS