Welcome to Presentation on
CABLES
By
J.KARTHIK
Definition
Definition
Encased group of insulated wires for transmitting
electricity etc., (Source : Oxford Dictionary)
Cable is an insulating conductor, used for
Transporting electrical power from one point to
other
Contents
Types of Cables
Cable Construction
Comparison of various types of cables
Types of Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules
1)
Types of Cables
2)
Cable Construction
3)
Comparison of various types of cables
4)
Cable Installation
5)
Cable Tray and Support Systems
6)
Design Steps
7)
Cable Termination Schedules
Types of Cables
Cable are classified based on Voltage level & based on the application
1.
EHV power (66 kV and above)
2.
HV power (3.3 kV 33 kV)
3.
LV power (415 V and below)
4.
Control cable
5.
Data & signal cable
Types of Cables
Voltage Grade (Earthed & Un earthed)
6.6kV (UE) / 11kV (E)
This cable is suitable for
6.6kV Un-Earthed System as well as 11kV Earthed System
This cable is not suitable for
11kV Un-Earthed System
This cable will be a costly proposal for
6.6kV Earthed System
Types of Cables
Consider a 11 KV system
If the system is earthed, then the thickness of insulation of the cable is 3.4
mm
If the system is Unearthed, then the thickness of insulation of the cable is
4.5 mm
Hence in an unearthed system, the cost of cable is high.
In an Unearthed system, when a Phase to earth fault occurs, the Healthy
phase to ground voltages rises by 1.732 times. Hence in an unearthed
system, the insulation of all three phases should be designed to take care of
increased voltages.
Please note 6.6kV (E) cable is different from 6.6kV(UE) & 3.8(UE)/6.6(E)
is different from 6.6(UE)/11(E)
Earthed & Unearthed Cables
NORMAL CONDITION
Earthed & Unearthed Cables
B PHASE TO GROUND FAULT
Earthed & Unearthed Cables
B PHASE TO GROUND FAULT
(Un-Detected)
Earthed & Unearthed Cables
B-G FAULT and Y-G FAULT
(Detected as Phase to Phase Fault)
Earthed & Unearthed Cables
PHASE TO EARTH VOLTAGE SHOOTS UP
(BECOMES PHASE TO PHASE)
Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules
Cable Construction
Components
Components of
of Cable
Cable
1. Conductor
Copper / Aluminium
2. Insulation
PVC / XLPE / Paper
3. Armour
Armoured (Steel/Alum, Round/Flat)
4. Outer sheath
PVC / HR PVC / FRLS / FR etc.,
5. Screening
Screened or not
6. Shielding
Shielded or Un-shielded
Special
Special Cable
Cable
Marine Cables- high flexibility, reliability & suitable for corrosive atmosphere
Festooning Cables- for mobile equipment, crane application, cross bridge trolley
Halogen Free Cables-low toxicity, low smoke, high flexible
Oil Filled Cables - high insulation, temperature control,
Cable Construction
Conductor
Conductor
The conductor of a typical power cable is made up of Copper or Aluminium.
The shape of the conductor can be circular or sector shape. It can be single or
multi-stranded
Insulation
Insulation
Paper or natural Rubbers were used for many years as insulating material in
underground power cables. Presently synthetic materials are preferred for
insulation of cables. The chemical composition of such material can be altered
to produce polymers with special chemical, electrical and mechanical
properties. Though the list is extensive, XLPE & EPR are widely used.
Both EPR & XLPE has similar characteristics, XLPE is preferred for
transparent and phenomena like treeing.
Cable Construction
145kV Single Core
33kV Three Core
415V Three Core
Copper
Aluminium
Aluminium
Cable Construction
Semiconductor
Semiconductor shield
shield
In a typical high voltage cable, two layers of semiconductor material surround the
Metallic core.
First layer placed directly around the conductor has the following purposes
1.
To distribute the electric field uniformly around the conductor
2.
To prevent the formation of ionized voids in the conductor
3.
To dampen impulse currents traveling over the conductor surface
Second layer of semiconductor material is placed around the first insulating
layer and has the following purposes.
1.
To reduce the surface voltage to zero
2.
To confine the electric field to the insulation, eliminating tangential
stresses.
3.
To offer direct path to ground for short circuit current if the shield is
grounded.
Cable Construction
Cable Construction
Cable Construction
Cable Construction
Cable Construction
2x
A
CONDUCTOR
A
- Aluminium
Nil - Copper
Wa
INSULATION ARMOUR
OUTER SHEATH
2x
- XLPE
W - Round wire
Y - PVC
- PVC
F - Strip or Flat
2Y-Polyethylene
a - Non magnetic
Cable Construction
Constituents
Code
Aluminum conductor
XLPE insulation
2x
Steel round wire armour
Steel strip armour
Steel double round wire armour
WW
Steel double strip armour
FF
Non-magnetic (A1) round wire armour
Wa
Non-magnetic (A1) strip armour
Fa
Lead Alloy Sheath
Ly
Polyethylene Outer Sheath
2Y
PVC Insulation / Outer sheath
Cable Construction
A2XY
- Aluminium Conductor XLPE Insulated PVC Sheathed Cables
Unarmoured
A2XWaY - Aluminium Conductor XLPE Insulated PVC Sheathed Cables
Round Wire Armoured (Non magnetic)
2XY
- Copper Conductor XLPE Insulated PVC Sheathed Cables
Unarmoured
YWY
- Copper Conductor PVC Insulated PVC Sheathed Cables
Round Wire Armoured
Types of Cables
Cable Construction
Comparison of various
types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules
Comparison of Conductors
Merits of Copper
Current Carrying capacity of Copper is almost 1.6 times of Aluminium.
Resistance of Copper is less compared to Aluminium.
No Steel Reinforcement is required like ACSR
Merits of Aluminium
Cost of Aluminium Cable is less compared to Copper
Weight of Aluminium Cable is less compared to Copper
Size of Cable for same
current requirement
Comparison of XLPE & PVC
The XLPE material has a stronger Electrical & Mechanical properties
compared to PVC material, and consequently it has a longer life time. Current
Carrying capacity of XLPE > PVC
On special environmental condition, XLPE material has more resistance
capabilities than PVC material.
In XLPE material the absorption of moisture is low, and due to polyethylene
abilities, it has a lower penetration property compared to PVC material. PVC
material absorbs moisture as it has more carbonate calcium.
XLPE doesnt loose its shape, in heat , and in other words it is THERMO SET.
Moreover, it is fire and smoke retardant.
XLPE has enough resistance to 90oC temperature, whereas, PVC material
looses its resistance in temperature higher than 70oC
Comparison of Outer Sheath
Flame Resistance
The ability of a burning material to extinguish its own flame, once its flameinitiating heat source is removed.
Flame Retardant
Ability of a material to prevent the spread of combustion by a low rate of travel so
the flame will not be conveyed.
Fire Retardant Low Smoke
Ability of a material to prevent the spread of combustion by a low rate of travel so
the flame will not be conveyed. Low smoke.
Low Smoke Halogen Free
Does not emit toxic gases and does not suffocate human beings hence safe to
human & electronic equipments.
Technical Comparison
Current
Current Carrying
Carrying Capacity
Capacity
Technical Comparison
Impedance
Impedance // KM
KM
10
1
0
0.1
0.01
100
200
300
400
500
PVC, Al
XLPE, Al
PVC, Cu
XLPE, Cu
Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules
Types of Installation
1.
Directly buried in ground
2.
Laid in cable trenches
3.
Laid in cable racks
4.
Laid in duct banks
Guidelines
Cable Installation IS 1255
Minimum Permissible Bending Radii
Voltage Grade
Single Core
(XLPE/PVC)
Multi Core
(XLPE/PVC)
Up to 1.1kV
15D
12D
Above 1.1 To 11kV
15D
15D
Above 11kV To 33kV
20D
15D
D Diameter of Cable
Guidelines
Cable
Cable Laying
Laying
Use Different Trays with sufficient clearance for
Power, Control & Signal Cables
Power cables of Different Voltage levels
Top or Bottom
HT at top or bottom As per Client requirement
Single Core Cables
Use Trefoil formation using Trefoil clamps
Trefoil clamps shall be non-magnetic type
HT
INS-SIG
LT
INS-CON
CON
CON
INS-CON
LT
INS-SIG
HT
Directly Buried in Ground
Minimum
Minimum Depth
Depth of
of Laying
Laying
Voltage Grade
Depth From FGL To Top Of Cable
Up to 1.1kV
750 mm
Above 1.1 To 11kV
900 mm
Above 11kV To 33kV
1050 mm
Typical drawings
Laid in Cable Trays
LAID IN CABLE TRAYS
Cable Trays, Fittings & Accessories
Prefabricated/ Site Fabricated
Prefabricated Ladder/ Perforated
Material Ms/Galvanized Sheet steel
Std Widths 150, 300, 450 & 600mm
Std Lengths 2.5/3m
Std Height 100/ 75mm
Fittings Bends, Elbows,
Fittings Reducers, Tees
Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and
Support Systems
Design Steps
Cable Termination Schedules
Cable & Tray Supports
SITE FABRICATED
Horizontal Member ISA 50x50x6
@ 750/600mm interval for cable support without trays
@1500mm interval for cable tray support
Vertical Member
Size & interval to be decided based on design criteria
Vertical Member
Horizontal Member
Cable & Tray Supports
FLEXIBLE CABLE TRAY SUPPORT SYSTEM
Cable & Tray Supports
FLEXIBLE CABLE TRAY SUPPORT SYSTEM
Cables laid in Duct Bank
LAID IN DUCT BANKS
Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules
Design Steps
HV
HV &
& LV
LV Power
Power Cable
Cable Sizing
Sizing
Design Input
Load details
Motor Rating (kW)/ Trafo Rating (kVA)
Operating Voltage
Operating Frequency
Operating & Starting Power Factor (for Motor Loads)
Efficiency
Short circuit withstand capacity and its duration
Starting Method DOL/ Star - Delta/ Soft Starter (for Motor Loads)
Allowable Steady state voltage Drop
Allowable Transient Voltage Drop ( for Motor Loads)
Design Steps
Cable Data
Voltage Grade
Conductor Material
Cross Sectional area
Number of cores
Insulation Material (XLPE/PVC)
Current Carrying Capacity in air
Impedance of cable
Short circuit withstand capacity - current
Name of Likely Manufacturer
Based on Cable Installation & Environmental Conditions
Temperature Correction Factor
Correction Factor for Grouping
Correction Factor for Depth of laying
Design Steps
Control
Control Cable
Cable Sizing
Sizing
Material of Conductor Copper
Voltage Grade 1.1kV
Minimum cross sectional area
Generally 2.5 Sq.mm
CT/ PT circuits 2.5 / 4 / 2# 2.5 Sq.mm
Number of Cores
CT/ PT Circuits 4C
Others Schemes/ Application
Transformers Mech. Faults/ Cooler Control/ OLTC control
Motors Depending on Type/ Levels of Control & Indication
Requirements (LPB/ MCC/ PLC)
Design Steps
EHV CABLES
Single core & three core cable
Given in specification
Single core
Easy to handle & terminate
Higher ampacity
More drum length
Conductor copper/ aluminium
Size to be designed
Load requirements
Installation conditions
Manufacturers specific
Design Steps
MV
LV Motors
LV
(Non Motors)
Steady State Voltage Drop
Transient Voltage Drop
Type of Check
Thermal
Short Circuit Withstand
Capability
Thermal Ampacity
Laid in Ground
Laid in Air
Current Carrying Capacity of Cable
Current Carrying Capacity of Cable
De-rate for Ground Temperature
De-rate for Grouping of Cables
De-rate for Air Temperature
De-rate for Grouping of Cables
De-rate for Number of Layers
De-rate for Number of Layers
De-rate for Thermal Resistivity of
Soil
On Site Current Carrying Capacity
On Site Current Carrying Capacity
Voltage Drop
Formula for Steady State VD
E2 = (VCos+IR)2+(VSin + I (Xc+Xs))2
Formula for Transient VD
E = (V+IRCos+IXcSin ) (approx)
Short Circuit Withstand Capability
Fault Current at Motor Terminal is given by
LV Cables : If = V1/(1000 x (Rc+j(Xc+Xs))) kA
MV Cables : If = Bus Fault Level
For Safe operation,
Fault withstand capacity of Cable for t sec > If
Fault withstand Capacity for t sec
If (t) = If(1) / Sqrt(t)
Fault withstand time t sec is decided by the Protection given for cables
Fuse protected : 0.2 sec (Fuse operating time <10ms)
Breaker + Relay : 0.35 sec 3 sec (Relay operating time with grading +
breaker opening time)
Cable Critical Length Chart
Presentation to L&T Engineers on 30 July 2010
Comparison of Cable Size - Various Types
Input
Input Data
Data
Motor Rating
110 kW
Cable Length
500 m
SS Voltage Drop
5%
Output
Output Data
Data
Cable Type
Thermal
SS VD
Final
Deciding factor
Aluminium, PVC
2#150
2#185
2#185
SS VD
Aluminium, XLPE
1#240
2#185
2#185
SS VD
Copper, PVC
1#300
1#300
1#300
Both
Copper, XLPE
1#240
1#400
1#400
SS VD
Effect of input Data
Requirement of
Increase in these will result in
Thermal
SS VD
Power
Distance
Fault Current
Fault clearing Time
Starting Current
Less Stringent
More Stringent
TR VD
SC W/S
Effect of input Data
Hence,
In case, the length indicated in the cable schedule differs from the actual
length (considerable change), please refer to the Design Department.
The cable size may change.
Please follow the design recommendation for cable installation. Say cable
touching each other or with one Dia spacing. If the cable is designed for one
dia spacing and laid touching each other,
The cable will get heated up and life may reduce.
LV Cable Sizing
LV POWER CABLE SIZING
Initial & Running Cost
Description
Load Current
150
Sq.mm
185
Sq.mm
Unit
100.68
100.68
De-rated Cable
Current
125
146
Resistance / KM
0.249
0.199
Resistance for 250m
0.0747
0.0597
Power Loss (I2 x R)
0.76
0.61
Energy loss / day
18
15
kWH
Energy loss / year
5452
4357
kWH
Energy Cost Rs./kWH
5.00
5.00
Rs.
27260
21786
Rs.
-5474
Rs.
Cost of Power Loss
Difference
ohms/KM
ohms
kW
Cable Cost/mtr
188.5
236.5
Rs.
Initial Cost
47125
59125
Rs.
12000
Rs.
Difference
Payback period
2.19
Years
Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination
Schedules
Control Cabling
Points
Points to
to remember
remember
Separate Cable shall be laid for Trip-1 & Trip-2
Closing Coil can be combined with Trip-1 0r Trip-2
DC-1 and DC-2 Cables shall be separate
Always keep some spare cores
Try to reduce the number of cores by combining common signals
Care should be taken for Voltage drop restriction
Control Cabling
Typical
Typical Interconnection
Interconnection Chart
Chart
Control Cabling
Standard
Standard Practice
Practice for
for Ferrule
Ferrule Numbering
Numbering
Letter
Application
Letter
Application
CT Main
DC supply
CT Busbar
Control
CT - Back-up
Indication and
Announciation
CT Metering
Busbar Protection
PT Voltage
SCADA
Synchronising
Spare
Aux. Contact
multiplier relay
AC
Useful Tips
Extra
Extra Care
Care for
for Single
Single Core
Core Cables
Cables
1.
Use Un-armoured Cable. If armouring is must, use Aluminium armoured
cable (Non-magnetic, to reduce eddy current)
2.
Use Trifoil clamps for Cable Installations
3.
Armouring should be earthed only on one side
4.
Use Aluminium Gland Plate or MS Gland Plate cut into two pieces
