POWER, CONTROL AND INSTRUMENTATION CABLES
THEORY
POWER CABLES:
INSULATION
PAPER INSULATED LEAD COVERED (PILC) (OBSOLETE)
PVC INSULATED , PVC SHEATHED (PVC)
CROSS LINKED POLYETHYLENE CABLES (XLPE)
EARTHED GRADE (E) / UNEARTHED GRADE (UE)
INSULATION IS PH-N / PH-PH FOR CORE INSULATION FOR E / UE GRADES.
VOLTAGE RATINGS
• 1.1KV / 3.3KV / 6.6KV / 11KV / 22KV / 33KV / 66KV / 110KV / 220KV
SELECTION OF CABLE SIZE
CURRENT CARRYING CAPACITY.
SHORT CIRCUIT RATING.
PERMISSIBLE VOLTAGE DROP.
CURRENT CARRYING CAPACITY
SITE RATING = BASE RATING X RATING FACTOR
BASE RATING FOR ALUMINIUM CONDUCTOR CABLES ARE FURNISHED IN INDIAN
STANDARDS AND MANUFACTURERS CATALOGUES AS FOLLOWS.
1.1KV AL PVC / 1.1KV AL XLPE, E / UE
3.3KV AL PVC / 3.3KV AL XLPE, E / UE
6.6KV AL PVC / 6.6KV AL XLPE, E / UE
11KV AL PVC / 11KV AL XLPE, E / UE
STANDARD CONDITIONS OF LAYING
CURRENT RATINGS GIVEN ARE VALID FOR FOLLOWING LAYING CONDITIONS :
THERMAL RESISTIVITY OF SOIL – 150 DEG. C / CM/W
GROUND TEMPERATURE – 30 DEG C.
AMBIENT AIR TEMPERATURE – 40 DEG. C.
Page 1 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
DEPTH OF LAYING
1.1KV - 750 MM.
3.3KV – 11KV - 900 MM.
RATING FACTORS
AMBIENT GROUND / AIR TEMPERATURE (KA)
DEPTH OF LAYING (KD)
GROUP DERATING (KG)
TOTAL DERATING FACTOR (K) = KA X KD X KG
MAXIMUM DERATING CAN BE LIMITED TO 0.7 TO 0.75
SHORT CIRCUIT RATING
ACB CONTROLLED FEEDERS.
CONSIDER 0.2 OR 0.6 SEC FOR O/G & I/C FEEDERS.
FOR FUSE / MCB CONTROLLED FEEDERS SHORT CIRCUIT DUTY NEED NOT BE
CONSIDERED.
FOR MCCB MAX CURRENT & TIME SET VALUES CAN BE USED
AREA OF CS (MM2) = ( ISH X √T ) / K
WHERE ISH = FAULT CURRENT IN AMPS.
T = FAULT CLEARING TIME IN SEC.
K = CONSTANT ( AMPS / MM²)
THE VALUE OF K IS AS FOLLOWS :
AL. CU.
PVC CABLE 75 112
XLPE CABLE 94 140
PERMISSABLE VOLTAGE DROP
2% FOR 415V SYSTEM (TRANSFORMER TO SWITCHGEAR / PCC TO MCC)
3% FROM MCC TO MOTORS.
STARTING VOLTAGE DROP – 15% FOR LT AND 20% FOR HT MOTORS.
Page 2 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
ABOVE FIGURES ARE ALSO APPLICABLE FOR HT SYSTEM (I.E. FOR 3.3/6.6/11KV
SWITCHGEAR AND MOTORS.)
VOLTAGE DROP
DC 2 OR 3 WIRE
(2 X I X D X R) / 1000
AC 1 PHASE
(2 X I X D X Z) / 1000
AC 3 PHASE
(1.732 X I X D X Z) / 1000
WHERE :
I = CURRENT IN AMPS
D = DISTANCE IN MTRS.
R = DC RESISTANCE IN OHMS / KM
Z = IMPEDANCE IN OHMS / KM
CONSTRUCTIONAL FEATURES
LT CABLE :
CONDUCTOR.
CORE INSULATION.
INNER SHEATH.
ARMOR (WIRE OR STRIP)
OUTER SHEATH
HT CABLE :
CONDUCTOR.
CONDUCTOR SCREEN.
INSULATION.
INSULATION SCREEN.
FILLER.
Page 3 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
INNER SHEATH.
ARMOUR.
OUTER SHEATH.
DRUM DETAILS
SIZE - 300MM TO 2820MM.
LENGTH - 200MM TO 500MM.
WEIGHT - 50KG TO 4000KGS.
OUTER SHEATH OF FIRE RESISTANT LOW SMOKE (FRLS) CHARACTERISTICS IS USED IN
FIRE RISK AREAS.
CONTROL CABLES
APPLICATIONS
METERING.
ON / OFF CONTROL.
INTERLOCKS.
ANNUNCIATION.
VOLTAGE
1100V
CONDUCTOR
STRANDED, ANNEALED, HIGH CONDUCTIVITY COPPER 2.5 & 1.5SQMM.
CORES AND APPROX. CURRENT RATING :
(REFER MANUFACTURERS CATALOGUE FOR ACTUAL RATING)
2.5 SQ.MM 1.5 SQ.MM
1 2 TO 4 C 30A 22A
2 5 TO 7 C 25A 18A
3 8 TO 10C 21A 16A
4 12/14/16 18A 16A
5 19/21/24 16A 12A
6 27/30/33 14A 10A
7 37/44/52/61 11A 8A
Page 4 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
CORE INSULATION : PVC (EXTRUDED)
INNER SHEATH : TAPED OR EXTRUDED PVC.
ARMOR : GI WIRES (UPTO 13 MM Φ)
GI STRIPS (ABOVE 13MM Φ)
OUTER SHEATH : EXTRUDED PVC BLACK.
CODING : CORES COLOR CODED.
STANDARD LENGTH : 500M
INSTRUMENTATION CABLES
APPLICATION
ANALOGUE SIGNALS 4-20MA
DIGITAL SIGNALS.
TYPES
TWISTED PAIR WITH OVERALL SCREENING.
TWISTED PAIR WITH EACH PAIR SCREENED.
CORES
1 PAIR / 2 PAIR / 4 PAIR / 8 PAIR / 16 PAIR / 32 PAIR.
INSULATION
EXTRUDED PVC.
500ΜF / KM MAX.
SCREENING
TINNED COPPER OF 0.15 MM DIA COPPER OR AL. TAPE OF 0.008 MM THICK LAMINATED
TO A PLASTIC TAPE.
Page 5 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
DRAIN WIRE
TINNED COPPER 0.125SQMM. LAID LONGITUDINALLY IN CONTACT WITH TAPE.
INNER SHEATH / OUTER SHEATH / ARMOUR
SAME AS CONTROL CABLE
CODING
COLOR CODED AS PER IEC – 189-2.
LENGTH
500M
OTHER TYPES OF CABLES
MINERAL INSULATED CABLES
HR PVC CABLES
FLEXIBLE CABLES (FOR MOBILE APPLICATION SUCH AS CRANES, HOISTS, TIPPERS ETC.)
Page 6 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 7 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 8 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 9 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 10 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 11 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 12 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 13 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 14 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 15 of 16
POWER, CONTROL AND INSTRUMENTATION CABLES
Page 16 of 16
