HT XLPE CABLES - cablecoindia.com

1 TECHNICAL DETAILS HT xlpe CABLES UPTO 45Kv POLYCAB WIRES PVT LTD C O N T E N T S INTRODUCTION ADVANTAGE OF POLYCAB xlpe CABLES SELECTION OF CABLES TECHNICAL DATA Conductor Resistance Current Rating cable Short Circuit Rating Capacitance & Reactance Rating Factors Important Formulae WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF CABLES HANDLING STORAGE & LAYING OF CABLES POLYCAB WIRES PVT LTDPage 2 of 28 POLYCAB PERFORMANCE POLYCAB has earned trust and reputation in india and abroad by winning the customer confidence. Several thousands kilometers of xlpe CABLES in the voltage range of kV, 11 kV, 22 kV and 33 kV have been manufactured and are in operation in india and abroad.

2 POLYCAB CABLES are the preferred choice in Power plants, Process plants, Distribution system, heavy industries and various utilities. MANUFACTURING PROCESS HIGHLIGHTS POLYCAB has most modern and state of art manufacturing facilities for xlpe Insulation. It has True Tripple Extrusion & Dust free environment for xlpe insulation, ON-LINE thickness Measurement and Control, fitted on with the best Dry Cure CCV (Continuous Catenary Vulcanization) Lines. CCV Line POLYCAB xlpe HIGH VOLTAGE CABLES ( ) From the beginning of 20th Century, Paper Insulated Oil Impregnated lead sheathed Power CABLES were the unanimous choice of Power Engineers for underground transmission and distribution, due to their excellent electrical and thermal properties.

3 The CABLES which were laid in 1950 in our country are still in operation. These CABLES were heavy due to lead sheath and were not suitable for vertical runs as in that case the oil got accumulated in the lower portion of the CABLES . Any puncture in the lead sheath lead to cable failure as the electrical properties of Manila Paper weakens in the presence of moisture. The jointing of the CABLES also required a special skill. CABLES up to 132 kV were made with paper insulation and they are still in the service. Polymer technology made in a rapid stride during and after second world war and we witnessed a Plastic revolution. Various plastics like PVC, POLYETHYLENE, NYLON, POLYESTER etc, were invented and put to commercial use during this period.

4 Plastics can be divided in to two categories: 1) Thermosetting 2) Thermoplastics. Thermosetting plastics are those plastics which set when the heat and pressure are applied due to formation of intra molecular bonds and subsequently heating will not soften them. Bakelite, Mellamine, UF Resins are coming in this category. Thermoplastics are the plastics which become soft on application of heat and become hard when the heat is removed. PVC, Polyethylene, Nylon, Polystyrene are thermoplastics and they can be recycled. POLYCAB WIRES PVT LTDPage 3 of 28 PVC is a versatile plastic and it is a compound of various chemicals. Its properties can be varied to a great extend by changing the proportion of its ingredients.

5 It has found a wide application in LT Power CABLES , Building wires, Flexibles, Auto CABLES , etc. It is a thermoplastic and it can be operated continuously at 70oC. Due to its higher Dielectric constant, the CABLES with PVC Insulation has a higher capacitance and hence it is not preferred as insulating material for HT cable and Telecommunication CABLES . Polyethylene has got excellent electrical properties. Its dielectric constant is and hence it is found wide application in Telecommunication filed as insulating material Polyethylene can be operated continuously at 65oC and hence it has found little application in Power CABLES . In Sixties, Scientists found that the linear molecular chains of Polyethylene can be inter-linked by adding some peroxide and thus its thermal rating can be upgraded.

6 Due to cross linking, the Polyethylene turns from thermoplastic to thermosetting and it can be operated at 85oC continuously. It can withstand 230oC temperature under short circuit compared to 150oC for PVC. Due to thermosetting nature of the cross-linked polyethylene, its scrap cannot be recycled. Cross-linked Polyethylene which is commonly known as xlpe is invariably used as insulating material for HT CABLES . CABLES up to 230 kV with xlpe Insulation are in commercial use. xlpe Insulated CABLES are lighter in weight, easy to install and terminate and unaffected by moisture and most of the chemicals. CONSTRUCTION OF HT CABLES : 1. Conductor: Stranded Class 2 - Annealed Plain / Tinned Copper / Aluminium - IS:8130 / IEC 60228/ BS 6360.

7 2. Conductor Screen: Extruded semi-conducting compound IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. 3. Insulation: xlpe IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. 4. Insulation Non-metallic Screen: Extruded semi-conducting compound IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. 5. Insulation Metallic Screen: Copper Wire / Tape or Aluminium Wire / Strip IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. 6. Fillers: Non Hygroscopic PVC * / Polypropelene Fiber to maintain roundness of cable . 7. Inner sheath/Bedding: PVC ST 2 as per IS:7098 Part 2, IEC:60502 Part 2, BS:6622, LSOH to BS:7835.

8 8. Armour: IS:7098 Part 2, IS: 3975, IEC:60502 Part 2, BS:6622, BS:7835. 9. Outer Sheath: PVC ST 2, FR, FRLS as per IS:7098 Part 2, IEC:60502 Part 2, BS:6622, LSOH to BS:7835. * Weights given in the Tables are with PVC Fillers. POLYCAB WIRES PVT LTDPage 4 of 28 Polycab manufactures following voltage grade CABLES as per IS-7098[Part-2], IEC-60502 Part-2 and BS-6622 & BS:7835 Flame Retardant (FR), Flame Retardant Low Smoke (FRLS) and Low Smoke Zero Halogen & Flame Retardant (LSOH) Sheathed HT xlpe CABLES are also manufactured. The xlpe CABLES are manufactured in sophisticated triple extrusion line, in highly quality conscious environment with testing and inspection from raw material to finished cable .

9 The assurance of quality is further ensured by ISI certification No. CM/L-7180366 on CABLES and ISO 9001 certification by UL,USA, A-7913. ROUTINE TEST SET UP Quality Assurance Testing: Polycab xlpe CABLES are tested to ensure high reliability in performance. Continuous process monitoring and post manufacturing tests ensure the compliance to Indian and International Standards. Polycab is self sufficient to carry out all Routine & Type Tests in its own laboratory. It has world class Testing facilities for Routine & Type Tests. Routine Tests: IS:7098 Part 2, IEC:60502, BS:6622, BS:7835 Partial Discharge Test High Voltage Test Conductor Resistance Test. Routine Tests are performed on each manufactured length of cable in Routine Test Laboratory.

10 45 kV or 33 kV (UE) Screened xlpe CABLES as per customer requirement. 19/33 kV Screened cable (36 kV Max) kV Screened CABLES (22 kV Earth) 11/11 kV 11 kV ( UE) Screened CABLES . kV, Screened CABLES [ kV (UE) kV Screened CABLES . (E) and (UE) Unscreened & Screened CABLES . SIZES: 50 up to 1000 in Single Core CABLES . 35 to 400 in Multi Cores CABLES . POLYCAB WIRES PVT LTDPage 5 of 28 Type Tests: IS:7098 Part 2, IEC:60502, BS:6622, BS:7835 a) Electrical Type Tests b) Non-Electrical Type Tests c) Special Tests The cable samples are type tested in-house to ensure conformance as to various standards. NON-ELECTRICAL TYPE TEST LABORATORY IMPULSE TEST SET UP Polycab CABLES of various voltage grades are type tested at CPRI Bangalore & ERDA Vadodara.]