gci ehv catalogue book

Extra High Voltage Cable

Connecting the World

Extra High Voltage Servicing Electric Utility markets

This catalog features in-depth information on the most comprehensive line of Extra High Voltage Power Cable available today.

The spec-on-a-page format was developed to meet your needs. It features up-to-the-minute product Information, from applications and constructions todetailed technical and specification data.

And, of course, if you need any further data, General Cable's Customer Service staff provides the answer you need quickly and efficiently.

All information in this catalog is presented solely as a guide product selection and is believed to be reliable. All printing errors are subject to correction in subsequent releases of this catalog. Although General Cable has taken precautions to ensure the accuracy of the product specifications at the time of publication, the specifications of all products contained herein are subject to change without notice.

E-mail: [email protected]

General Cable Energy India Pvt LtdCorporate office: Centrum Plaza, Level 3, Tower A, 312 S, Golf Course Road, Sector- 53, Gurgaon-122 002, Haryana. Phone: (0124) 4326000 Fax: (0124) 4326019

Connecting the WorldConnecting the World

INTERNATIONALISO 9001:2000CERTIFICATION

General Cable Corporation, headquartered in Highland Heights Kentucky, a sales of USD 6.2 billion and over 13000 associates, is a world leader in cable manufacturing with 46 modern production facilities in North America, Europe and rest of the world and provides service to global network of clients.

General Cable is recognized as world leader in EHV systems, having pioneered and led development of solid dielectric extruded cable technique over more than 5 decades. General Cable provide its customer with unrivalled know-how and experience world-wide.

General Cable's complete line of Silec, Phelps dodge, XLPE insulated Extra High Voltage underground energy cable, from 63KV to 550KV and our stateof-the-art accessories-such as pre-moulded Joints and terminals- enable us to provide turnkey design and engineering services for the global, system-engineered electric utility market.

With best in class research and development, superior engineering and manufacturing, leading logistics capabilities, the broadest product range in all the industry segments, with a strong group of 13 000 associates seamlessly teaming up to satisfy customers worldwide & differentiates General Cable from all others and makes us the world leader in cable & wire Industry.

General Cable India, a 100% subsidiary of General Cable Corporation US, is Catering to Indian customer through its state of the art modern facility in 20 acre (Approx 80937 sq. mtrs) situated at the Industrial town of Baddi in the beautiful state of Himachal Pradesh. The range of products manufactured includes extra high voltage, high voltage, low voltage, and specialty cables. General Cable has extensive sales network across India. General Cable India, benefit not only from General Cable's depth and breadth of products and its innovative technology development and transfer for Indian operations, but can also source the EHV products from its Global production facilities to suit the Indian utility requirements .

General Cable bases its activities on a series of Corporate Values which guide all its operations: Customer Satisfaction as an absolute priority; Integrity in all of its actions; People as the main source of value; Teamwork as a path to excellence; Speed of delivery as a competitive advantage; and Continuous improvement as a constant objective.

This philosophy can only be assumed by a global company such as General Cable with extremely broad, diversified range, able to meet any requirement, however specific, anywhere on the planet.

World Leader in Extra-High-Voltage Cable Systems

Aerial view of General Cable factory at Baddi, H.P., India


General Cables Global Reach

General Cable serves customers through a global network of 46 manufacturing facilities in 23 countries

and sales representatives and distribution centers worldwide. The Company is solely dedicated to the

production of high-quality energy, industrial, specialty and communications wire and cable products. In

addition to its breadth of product line and strong brand recognition, the Company offers competitive

strengths in such areas as technology, manufacturing, distribution and logistics, and sales and customer

service. This combination enables General Cable to better serve its customers as they expand into new

geographic markets.

International CorpNSW

General Cable Footprint General Cable Footprint

Directing Traffic without Gridlock

Building Bridges in the Sky

Making Contact with the World


General Cable is a leader in the development,

design, manufacture, marketing and

distribution of copper, aluminum and fiber

optic wire and cable for the energy, industrial,

specialty and communications markets.

Our products inspire progress worldwide......Customers use our value-added products to

create global infrastructure that improves the

standard of living for people everywhere.

Each day were bui lding business

momentum-developing ideas into innovative

solutions and industry-leading products,

expanding geographic access and furthering

our investment in highly capable associates,

Lean Manufacturing, material science and

technology resources.

General Cable is influencing the world...with more than two-thirds of our sales generated outside North America and more than 13,000 associates in 46 manufacturing facilities throughout 23 countries. As the fifth largest wire and cable manufacturer, we are the One Company Connecting the World.

Energy CablesOur cables carry energy across the world-through the air, underground and under the sea. Increasing demand for energy is accelerating investment in exploration, extraction, power generation, transmission and distribution-whether based on coal, natural gas, oil, nuclear, wind or water.

Industrial & Specialty CablesWe have the competitive product mix and global reach to support the production of oil, gas and petrochemical; construction of new factories and maintenance of existing industrial facilities; factory automation; and special applications such as military, nuclear, marine, mining, transit and automotive.

Communications CablesOur cables keep information flowing-facilitating a non-stop stream of words and images around the world. We meet the high-speed bandwidth needs of global communications networks from fiber optic, submarine communications cables, copper and fiber aerial and underground cables to copper and fiber optic enterprise cables and system solutions.

India Headquarters General Cable Energy India Pvt LtdCorporate office: Centrum Plaza, Level 3, Tower A, 312 S, Golf Course Road, Sector- 53, Gurgaon-122 002, Haryana. Phone: (0124) 4326000 Fax: (0124) 4326019 E-mail: [email protected]

World HeadquartersGeneral Cable4 Tesseneer DriveHighland Heights, KY41076-9753 U.S.A

BRAND


Quality is Forethought

General Cable is committed to exceeding our customers expectations for quality and performance.

We strive to ensure this quality through extensive in-house and third-party testing, with strict adherence

to our product specification and industry standards. At General Cable, quality is not just a process, it

is forethought. It is the forethought of using the best materials and proactive prevention. This level of

quality is best represented in three core steps: Design, Technology and Control.

General Cable Corporation is committed to developing, producing and marketing product that meet

the performance, quality, value and safety requirements of our customers by continuously improving all

areas of our business. We apply Lean Sigma Company-wide, seeking innovative ways to differentiate our

products and services and to serve as our customers and suppliers most valued business partner.

DesignDesign

Quality

ControlControl

TechnologyTechnology

Quality



Rely on the World leader of EHV systems.Look at our Experiance & References

Through an ongoing quality assurance initiative, General Cable ensures the quality of product design,

manufacture, installation and expected service life, as well as environmentally sound products, processes

and policies, continuous research and development, combined with process control, quality audits and

prolonged stringent testing, provide an ever-growing range of specialty materials and designs that meet

Utility industry approvals and standards

Five decades of world wide First by General Cable Brands

63 KV 220 KV 400 KV500 KV

1962 : 1969 : 1985 : 1990 :

Quality Assurance Guaranteed

Voltage Level (KV) 63-161 220-230 330-500

*Cables supplied (km) ? 9312 ? 3598 ? 348

*Terminations (Nos.) ? 24000 ? 7255 ? 674

*Joints (Nos.) ? 12079 ? 5862 ? 450 *Supplied by General Cable plants in France & Spain (Ref. 2008)

BRAND


Our Green Initiative symbol recognizes our role

and responsibility in promoting sustainability.

The symbol also reflects our commitment to achieving

industry-leading standards and responding

proactively to environmental global issues.

IN T I N IE ATE IR VG E

Commitment To Environment - Green FactoryCompliant to Indian Green Building Council Rating

Commitment To Environment - Green FactoryCompliant to Indian Green Building Council Rating



Helping to power the world

Energy

BRAND

CONNECTING THE WORLD

Making Cables is about Creating Potential

General Cable products help to illuminate the world, inspire progress and open lines of communication. We connect people with energy, information, ideas and opportunities.

For more than a century, General Cable has been a leader in the development, manufacture, marketing and distribution ofwire and cable-our sole business. Today, we continue to direct our worldwide resources to deliver maximum value to customers through a powerful combination of product and service innovations.

At General Cable we aim to add value to our customers businesses by understanding and competitively servicing their needs through customer intimacy operational excellence.

General Cable provides a single source solutionThe cost effective advantage of a single resource, a single company that provides one of the broadest product ranges, highest levels of customer and technical support and responsive customer-first service.

THE POWER OF ONEAt General Cable, THE POWER OF ONE embodies our integrated approach to business: one company with the power of our products, expertise, systems and people all focused on one goal - fulfilling our customers needs. It means one source customers can count on for DATA, COMMUNICATION, INDUSTRIAL and ENERGY cables. Most of all, THE POWER OF ONE means one team, well trained and wholly committed to the highest level of customer satisfaction.

Manufacturing and logistics

With superior engineering and manu fac tu r i ng ope ra t i ons , i n d u s t r y - l e a d i n g l o g i s t i c s capabilities, one of the broadest product ranges in the industry, and a strong group of employees seamlessly teaming to satisfy customers, General Cable is strong, diversified and well positioned to meet the challenges of tomorrow.

Sales and Distribution Network

General Cable has a distribution network throughout India and a team of people committed to meeting the total needs of our customers- by providing enhanced distribution and warehousing services, and an unprecedented level of technical support.

Strength, Diversity and Teamwork

Every product reflects our POWER OF ONE business philosophy. We have become a leading cable supplier in Asla pacific through excellent customer relationships, the quality of our people and the highest standards of service.

GENERAL CABLE INDIA

Quality Products, People and Service


OUR VISIONStrive for leadership through growth and excellence.

General Cable India is a leading supplier of cable solutions for energy, industrial, data, communications and specialist applications. As part of the US based General Cable Corporation (one of the worlds largest wire and cable manufacturers) we serve customers through a global network of forty six manufacturing facilities in twenty three countries, with sales and distribution centers worldwide.

As part of a global business we are able to draw on innovative engineering developments, a comprehensive product range and the best research and technical support available, ensuring our customers are offered a competitive edge.


Centrum Plaza, Level 3, Tower A, 312-S, Golf Course Road, Sector-53, Gurgaon-122002, HarayanaPhone : +91 124 432 6000 Fax : +91 124 432 6019

General Cable Energy India Pvt. Ltd.


DESIGN & CONSTRUCTION OVERVIEWOF EHV CABLE

The EHV Cable has Copper or Aluminium conductor insulated with the cross-linked polyethylene, shielded with metallic screen (metal sheath or wire shield or both) and overall PVC or polyethylene sheathed.

Conductor

Conductor Screen

Insulation

Insulation Screen

Longitudinal Water Barrier

Outer Sheath

Metallic Sheath

The conductor consists of annealed copper or Aluminium stranded wires compacted circular and segmental compacted circular. The wires are wounded up concentrically. The segmental conductor consists of 4/5/6 segments are wounded up to form compacted circular conductor.

2 Segmental conductor design are recommended for the cross-section over 800 mm toprevent the increase of A. C. Resistance caused by skin effect.

The conductor screen consists of an extruded semi-conducting polyethylene is applied over conductor to minimize electrical stresses. The semi-conducting material used for conductor screen has no deleterious effect on the conductor. Semi-conducting tape is sometimes applied as a separator.

The insulation material is extruded cross-linked polyethylene. The conductor screen, the insulation and the insulation screen mentioned here are extruded simultaneously in one process (Triple extrusion and dry-nitrogen cured) to ensure clean interface and enhanced performance. The extrusion process is carried out under strictly controlled conditions.

The insulation screen is applied over the insulation by extruding the semi -conducting compound concentrically and circularly to minimize the possibility of ionization on the outer surface of the dielectric.

The metallic screen consists of lead sheath and/or wire shield or corrugated aluminium sheath. Lead sheathed cable has following advantages :

? Electrostatic shielding ? Fault current carrying capability? Excellent water barrier ? Excellent oil and chemical resistance ? Excellent sulfides resistance

To protect the metallic sheath from electrical or chemical corrosion, it is covered by PE or PVC. Also there will be overall semi-conducting layer over this PE or PVC sheath.

Conductor

Insulation

Insulation Screen

Longitudinal Water Barrier

Outer Sheath

Copper Wire ScreenLaminated Radial Water Barrier

Conductor Screen

Metallic Screen

Insulation Screen

Outer Sheath

Insulation

Conductor Screen

Conductor





PRODUCT SELECTION LOCATOR

TECHNICAL INFORMATION 16 - 28

IEC : 60840

2XLyY/2XLy2Y

2XAY/2XA2Y

2XCY/2XC2Y

7 - 976/132 (145) KV CopperConductor XLPE Cable

IEC : 60840

2XLyY/2XLy2Y

2XAY/2XA2Y

2XCY/2XC2Y


IEC : 62067

2XLyY/2XLy2Y

2XAY/2XA2Y

2XCY/2XC2Y


IEC : 60840

2XLyY/2XLy2Y

2XAY/2XA2Y

2XCY/2XC2Y


2XLyY/2XLy2Y

2XAY/2XA2Y

2XCY/2XC2Y

38/66 (72.5) KV CopperConductor XLPE Cable 1 - 3IEC : 60840

EHV CABLES CABLE TYPE PAGE NO.CABLE

DESCRIPTIONREFERENCE STANDARD


Note: (1) C- Stranded Compacted Circular Conductor.(2) S- Stranded Compacted Segmental (Milliken) Conductor.(3) Additional Copper wires screen may be provided if Lead Sheath alone is not sufficient to meet the requirement of earth fault current.(4) Electrical Parameters are based on Standard Laying Conditions mentioned in Table-1. (5) Standard delivery Length specified above are for guidance only. Cables can be however supplied as per customer requirements.(6) Dimensions and weights are subject to industry tolerances.

Conductor : Compact Round/Segmental (Milliken) Copper Conductor shield : Semi-conducting tape (optional) with extruded

semi-conducting cross-linked polyethylene.Insulation : Cross-Linked polyethylene.Insulation Shield : Semi-conducting cross-linked polyethylene.Synthetic water blocking layer : Semi-Conductive water blocking tape.Shield & Radial water barrier : Lead Alloy E (Please also refer note (3) below)Sheath : Black polyethylene (ST-7) or PVC (ST-2)

Construction :

Preferably used for Power transmission network. Suitable for exposed in Air, direct burial, open tray & underground duct installation.

Application :

I Normal Operation..................................................90C I Emergency* Operation.........................................130CI Short Circuit Operation.......................................250C

Temperature Rating :

* Operation at the emergency overload temperature shall not exceed 100 hours in 12 consecutive months & not more than 500 hours during the lifetime of the cable.

? Triple-extruded for clean interfaces? Dry nitrogen cure for enhanced performance? Excellent moisture resistance? Super Clean XLPE insulation for Extra-high

dielectric strength? Low dielectric loss? Excellent resistance to treeing

Features & Benefits :

IEC : 60840Reference Standard :

90 KV (AC) for 30 minutes.H.V. Test Voltage :


Adventages of Lead Sheath

38/66 (72.5) KV COPPER CONDUCTOR LEAD SHEATHED CABLE

Shield & Radial water barrier

Conductor shield

Conductor

Insulation

Insulation shield

Synthetic water blocking layerSheath

1

NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil

StandardDeliveryLength

DuctDirect Buried

Air

DIMENSIONS ELECTRICAL PARAMETERS

Current RatingMax DCConductorResistance

at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter

(Sqmm) (mm) (Kg/km) (F/km) cfh (Amp)(Amp) (Mtr./Drum)(Amp) (Amp)

240 C 62.5 8,000 0.0754 0.20 540 530 625 710 500

300 C 65.0 8,500 0.0601 0.21 605 570 710 810 500

400 C 68.0 9,500 0.0470 0.23 695 645 820 945 500

500 C 72.0 11,000 0.0366 0.25 790 735 950 1100 500

630 C 75.0 13,000 0.0283 0.28 900 835 1100 1275 500

800 C 81.0 15,000 0.0221 0.30 1010 960 1245 1460 500

1000 S 87.0 18,000 0.0176 0.33 1180 1125 1500 1760 500

1200 S 92.0 20,000 0.0154 0.36 1280 1210 1650 1940 500

1600 S 100.0 24,500 0.0113 0.40 1470 1440 1910 2285 400

2000 S 106.0 30,000 0.0090 0.44 1630 1590 2130 2600 400



Note: (1) C- Stranded Compacted Circular Conductor.(2) S- Stranded Compacted Segmental (Milliken) Conductor.(3) Electrical Parameters are based on Standard Laying Conditions mentioned in Table-1. (4) Standard delivery Length specified above are for guidance only. Cables can be however supplied as per customer requirements.(5) Dimensions and weights are subject to industry tolerances.



38/66 (72.5) KV COPPER CONDUCTOR ALUMINIUM SHEATHED CABLE

Application :


semi-conducting cross-linked polyethylene. Insulation : Cross-Linked polyethylene.Insulation Shield : Semi-conducting cross-linked polyethyleneSynthetic water blocking layer : Semi-Conductive water blocking tape.Shield & Radial water barrier : Corrugated & Seamless Aluminium SheathSheath : Black polyethylene (ST-7) or PVC (ST-2)

Construction :


Application :









? Electrostatic shielding ? Fault current carrying capability? Excellent water barrier ? Excellent oil and chemical resistance

Adventages of Aluminium Sheath

2

Conductor

Conductor shield

Insulation

Insulation shield

Synthetic water blocking layer


Sheath

NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter

(Sqmm) (mm) (Kg/km) (F/km) $') (Amp)(Amp) (Mtr./Drum)(Amp) (Amp)

240 C 67.0 4,500 0.0754 0.20 525 490 600 675 500

300 C 70.0 5,000 0.0601 0.21 595 555 685 770 500

400 C 74.0 6,000 0.0470 0.23 670 630 780 890 500

500 C 79.0 7,000 0.0366 0.25 765 715 895 1025 500

630 C 81.0 9,000 0.0283 0.28 880 810 1025 1190 500

800 C 88.0 11,000 0.0221 0.30 965 930 1150 1350 500

1000 S 95.0 13,000 0.0176 0.33 1120 1080 1360 1620 500

1200 S 100.0 15,000 0.0151 0.36 1200 1150 1465 1750 500

1600 S 108.0 20,000 0.0113 0.40 1355 1315 1655 2035 400

2000 S 115.0 23,000 0.0090 0.44 1470 1435 1805 2275 400














Application :


semi-conducting cross-linked polyethylene.Insulation : Cross-Linked polyethylene.Insulation Shield : Semi-conducting cross-linked polyethyleneSynthetic water blocking layer : Semi-Conductive water blocking tape.Metallic Insulation Screen : Copper Wires applied Helically with open

Helix of copper tape Synthetic water blocking layer : Non-Conductive water blocking tape.Radial water barrier : Aluminium Laminated tapeSheath : Black polyethylene (ST-7) or PVC (ST-2)

Construction :

38/66 (72.5) KV COPPER CONDUCTOR COPPER WIRE SHIELDED CABLE


3

Conductor shield

ConductorInsulation

Insulation shield


Sheath

Metallic Insulation Screen

Radial water barrier


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


240 C 59.0 4,000 0.0754 0.20 530 485 610 695 500

300 C 61.0 5,000 0.0601 0.21 600 545 695 795 500

400 C 65.0 6,000 0.0470 0.23 685 615 800 925 500

500 C 68.0 7,000 0.0366 0.25 780 730 930 1075 500

630 C 72.0 8,000 0.0283 0.28 885 830 1065 1250 500

800 C 76.0 10,000 0.0221 0.30 980 930 1210 1430 500

1000 S 81.0 12,000 0.0176 0.33 1175 1090 1475 1730 500

1200 S 86.0 14,000 0.0151 0.36 1270 1175 1610 1895 500

1600 S 94.0 17,000 0.0113 0.40 1465 1375 1885 2245 500

2000 S 100.0 21,000 0.0090 0.44 1630 1530 2110 2555 400





64/110 (123) KV COPPER CONDUCTOR LEAD SHEATHED CABLE

Conductor : Compact Round/Segmental (Milliken) Copper Conductor shield : Semi-conducting tape (optional) with extruded.


Construction :


Application :












Conductor shield

Conductor

Insulation

Insulation shield


4


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter

(Sqmm) (mm) (Kg/km) (F/km) (Amp)(Amp) (Mtr./Drum)(Amp) (Amp)

240 C 74.0 9,500 0.0754 0.16 535 500 620 695 500

300 C 77.0 10,500 0.0601 0.17 605 560 705 995 500

400 C 80.0 12,000 0.0470 0.18 690 655 815 925 500

500 C 84.0 13,000 0.0366 0.19 785 745 940 1070 500

630 C 88.0 15,000 0.0283 0.21 890 845 1085 1245 500

800 C 93.0 17,000 0.0221 0.23 1000 950 1230 1425 500

1000 S 98.0 20,000 0.0176 0.25 1175 1110 1490 1720 500

1200 S 103.0 23,000 0.0151 0.27 1270 1235 1610 1870 500

1600 S 110.0 28,000 0.0113 0.30 1455 1415 1870 2205 400

2000 S 117.0 33,000 0.0090 0.33 1610 1565 2090 2505 4002500 S 125.0 39,000 0.0072 0.37 1700 1650 2200 2645 300



NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


240 C 80.0 6,000 0.0754 0.16 520 490 590 660 500

300 C 84.0 7,000 0.0601 0.17 590 550 675 755 500

400 C 87.5 8,000 0.0470 0.18 670 640 775 875 500

500 C 92.0 9,000 0.0366 0.19 760 725 890 1010 500

630 C 96.0 10,000 0.0283 0.21 860 820 1020 1170 500

800 C 102.0 12,000 0.0221 0.23 960 915 1145 1335 500

1000 S 107.0 14,000 0.0176 0.25 1110 1055 1345 1580 500

1200 S 113.0 17,000 0.0151 0.27 1190 1180 1450 1720 500

1600 S 119.0 21,000 0.0113 0.30 1340 1330 1635 1995 400

2000 S 127.0 26,000 0.0090 0.33 1460 1445 1790 2235 400

2500 S 135.0 32,000 0.0072 0.37 1540 1525 1885 2360 300



64/110 (123) KV COPPER CONDUCTOR ALUMINIUM SHEATHED CABLE


Application :













Construction :

Conductor

Conductor shield

Insulation

Insulation shield



Sheath

5






64/110 (123) KV COPPER CONDUCTOR COPPER WIRE SHIELDED CABLE










Application :




Construction :

Conductor shield

ConductorInsulation

Insulation shield


Sheath




6


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


240 C 70.0 5,000 0.0754 0.16 530 495 605 685 500

300 C 73.0 5,500 0.0601 0.17 600 560 695 785 500

400 C 76.0 6,500 0.0470 0.18 680 650 800 910 500

500 C 79.0 7,500 0.0366 0.19 775 740 925 1055 500

630 C 82.0 9,000 0.0283 0.21 885 840 1065 1225 500

800 C 88.0 11,000 0.0221 0.23 995 945 1210 1410 500

1000 S 93.0 13,000 0.0176 0.25 1170 1105 1465 1695 500

1200 S 98.0 15,000 0.0151 0.27 1265 1230 1595 1850 500

1600 S 105.0 18,000 0.0113 0.30 1455 1415 1860 2185 500

2000 S 112.0 22,000 0.0090 0.33 1620 1570 2090 2490 400

2500 S 119.0 26,000 0.0072 0.37 1700 1655 2200 2625 400



NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


240 C 81.0 11,000 0.0754 0.14 530 495 615 680 500

300 C 83.0 12,000 0.0601 0.15 600 560 705 780 500

400 C 86.0 13,000 0.0470 0.16 685 640 810 905 500

500 C 90.0 14,000 0.0366 0.17 780 730 935 1050 500

630 C 94.0 16,000 0.0283 0.19 890 840 1080 1225 500

800 C 100.0 19,000 0.0221 0.21 1000 940 1225 1400 500

1000 S 104.0 22,000 0.0176 0.23 1170 1100 1470 1680 500

1200 S 109.0 25,000 0.0151 0.25 1265 1225 1600 1845 400

1600 S 116.0 30,000 0.0113 0.28 1450 1405 1855 2170 400

2000 S 123.0 35,000 0.0090 0.30 1600 1550 2065 2460 400

2500 S 131.0 41,000 0.0072 0.33 1690 1630 2175 2595 300








Construction :


Application :












Conductor shield

Conductor

Insulation

Insulation shield


7


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


240 C 90.0 7,000 0.0754 0.14 520 490 590 650 500

300 C 93.0 7,700 0.0601 0.15 585 550 670 745 500

400 C 95.0 8,700 0.0470 0.16 665 635 770 860 500

500 C 98.0 10,000 0.0366 0.17 755 715 885 995 500

630 C 103.0 11,500 0.0283 0.19 860 815 1010 1150 500

800 C 108.0 13,500 0.0221 0.21 960 945 1135 1315 500

1000 S 110.0 15,000 0.0176 0.23 1105 1095 1335 1555 500

1200 S 120.0 18,000 0.0151 0.25 1185 1170 1440 1695 400

1600 S 127.0 22,500 0.0113 0.28 1335 1325 1630 1975 400

2000 S 133.0 26,000 0.0090 0.30 1455 1435 1780 2210 400

2500 S 140.0 33,000 0.0072 0.33 1530 1515 1875 2330 300







Application :













Construction :

Conductor

Conductor shield

Insulation

Insulation shield



Sheath

8


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


240 C 77.0 6,000 0.0754 0.14 525 495 600 675 500

300 C 79.0 7,000 0.0601 0.15 595 555 690 775 500

400 C 82.0 8,000 0.0470 0.16 675 635 795 895 500

500 C 85.0 9,000 0.0366 0.17 770 715 910 1035 500

630 C 88.0 11,000 0.0283 0.19 875 810 1045 1200 500

800 C 94.0 12,000 0.0221 0.21 980 935 1185 1375 500

1000 S 100.0 15,000 0.0176 0.23 1145 1090 1420 1650 500

1200 S 104.0 16,000 0.0151 0.25 1235 1215 1546 1800 500

1600 S 112.0 20,000 0.0113 0.28 1415 1390 1785 2125 500

2000 S 118.0 24,000 0.0090 0.30 1570 1535 2000 2420 400

2500 S 126.0 28,000 0.0072 0.33 1655 1615 2110 2550 400















Application :




Construction :

Conductor shield

ConductorInsulation

Insulation shield


Sheath




9


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


300 C 88.0 12,000 0.0601 0.14 600 560 760 775 500

400 C 91.0 13,500 0.0470 0.15 685 650 805 900 500

500 C 94.0 15,500 0.0366 0.16 780 735 930 1045 500

630 C 100.0 17,500 0.0283 0.18 885 835 1075 1215 500

800 C 104.0 20,000 0.0221 0.19 995 940 1220 1390 500

1000 S 109.0 23,000 0.0176 0.22 1170 1130 1465 1670 500

1200 S 114.0 26,000 0.0151 0.24 1260 1220 1590 1825 400

1600 S 121.0 31,000 0.0113 0.26 1445 1400 1845 2155 400

2000 S 128.0 36,000 0.0090 0.28 1600 1540 2060 2445 300

2500 S 135.0 43,000 0.0072 0.31 1680 1620 2170 2575 300








Construction :


Application :












Conductor shield

Conductor

Insulation

Insulation shield


10


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


300 C 97.0 8,000 0.0601 0.14 585 560 670 740 500

400 C 100.0 9,000 0.0470 0.15 665 635 770 855 500

500 C 103.0 10,000 0.0366 0.16 755 720 880 990 500

630 C 108.0 12,000 0.0283 0.18 855 810 1010 1150 500

800 C 113.0 14,000 0.0221 0.19 955 940 1135 1310 500

1000 S 117.0 17,000 0.0176 0.22 1100 1090 1330 1550 500

1200 S 125.0 19,000 0.0151 0.24 1180 1165 1430 1685 400

1600 S 132.0 23,000 0.0113 0.26 1330 1310 1630 1970 400

2000 S 139.0 28,000 0.0090 0.28 1450 1420 1775 2200 300

2500 S 145.0 34,000 0.0072 0.31 1525 1500 1870 2315 300







Application :













Construction :

Conductor

Conductor shield

Insulation

Insulation shield



Sheath

11


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


300 C 83.0 8,000 0.0601 0.14 590 555 685 765 500

400 C 86.0 9,000 0.0470 0.15 675 630 790 890 500

500 C 89.0 10,000 0.0366 0.16 765 715 910 1030 500

630 C 94.0 11,500 0.0283 0.18 870 830 1045 1195 500

800 C 98.0 13,000 0.0221 0.19 980 930 1180 1370 500

1000 S 103.0 15,500 0.0176 0.22 1145 1080 1415 1640 500

1200 S 108.0 17,000 0.0151 0.24 1235 1210 1535 1790 500

1600 S 116.0 20,500 0.0113 0.26 1405 1385 1765 2100 500

2000 S 123.0 24,500 0.0090 0.28 1555 1525 1975 2385 400

2500 S 130.0 29,000 0.0072 0.31 1635 1605 2080 2510 400















Application :




Construction :

Conductor shield

ConductorInsulation

Insulation shield


Sheath




12


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


400 C 103.0 18,000 0.0470 0.14 680 640 795 870 500

500 C 107.0 19,000 0.0366 0.15 770 745 915 1010 500

630 C 111.0 22,000 0.0283 0.16 880 850 1095 1175 500

800 C 116.0 24,000 0.0221 0.17 985 950 1200 1345 400

1000 S 122.0 28,000 0.0176 0.19 1155 1110 1430 1610 400

1200 S 126.0 30,000 0.0151 0.20 1245 1195 1555 1760 400

1600 S 134.0 36,000 0.0113 0.23 1425 1400 1800 2070 300

2000 S 140.0 42,000 0.0090 0.24 1525 1545 2000 2345 300

2500 S 148.0 47,000 0.0072 0.27 1655 1625 2110 2465 300








Construction :


Application :












Conductor shield

Conductor

Insulation

Insulation shield


13


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


400 C 110.0 10,000 0.0470 0.14 660 640 760 835 500

500 C 114.0 12,000 0.0366 0.15 745 725 865 965 500

630 C 118.0 14,000 0.0283 0.16 845 825 990 1110 500

800 C 125.0 15,000 0.0221 0.17 945 915 1115 1270 500

1000 S 130.0 16,000 0.0176 0.19 1090 1060 1310 1505 500

1200 S 135.0 21,000 0.0151 0.20 1165 1130 1405 1630 400

1600 S 142.0 26,000 0.0113 0.23 1315 1325 1600 1900 400

2000 S 150.0 30,000 0.0090 0.24 1440 1425 1760 2145 300

2500 S 160.0 35,000 0.0072 0.27 1515 1500 1850 2255 300







Application :













Construction :

Conductor

Conductor shield

Insulation

Insulation shield



Sheath

14


NominalArea of

Conductor

Approx.Capacitance

Flat Trefoil


DuctDirect Buried

Air



at 20C

Approx.Cable

Wt.

Approx.OverallCable

Diameter


400 C 98.0 10,000 0.0470 0.14 670 635 780 865 500

500 C 102.0 11,000 0.0366 0.15 760 720 895 1000 500

630 C 106.0 12,500 0.0283 0.16 865 845 1030 1160 500

800 C 111.0 14,500 0.0221 0.17 970 945 1170 1325 500

1000 S 115.0 17,000 0.0176 0.19 1130 1100 1390 1585 500

1200 S 120.0 19,000 0.0151 0.20 1220 1185 1515 1735 500

1600 S 128.0 23,000 0.0113 0.23 1400 1355 1750 2040 400

2000 S 134.0 27,000 0.0090 0.24 1545 1490 1950 2310 400

2500 S 142.0 31,000 0.0072 0.27 1625 1570 2050 2430 300















Application :




Construction :

Conductor shield

ConductorInsulation

Insulation shield


Sheath




15






TECHNICAL INFORMATION

S.NO. INFORMATION PAGE NO.

16

1 Short Circuit Current Rating 17

2 Standard Laying Conditions & Rating Factors 18

3 Sheath Bonding Methods 19-20

4 Method of Installation 21

5 Checklist for Specifications 22

6 Metric Conversion Factors 23

7 Recommended Reel Handling Practices 24

8 Recommended Cable Handling Practices 25

9 Recommended Cable Storage Practices 26

10 Installation Feed-In Setups 27-28





SHORT CIRCUIT CURRENTRATINGS

The short circuit capacity of the conductor and metallic sheath or shield of a cable are related principally to their heat capacities and are limited by the maximum temperature permitted under short circuit. The calculation is based on following :-

17

I = 0 x 226S 0 St In + 234.5f + 234.5i

Where,I = Permissible Short Circuit Current (A)S? = Factor to allow for heat loss into the Adjacent ComponentsS = Cross-Sectional Area of Conductor (sqmm)t = Duration of Short circuit (s) = Final Temperature (250C) = Initial Temperature (90C)

0

I = 0 x 41S 0 St In + 230f + 230i

Where,I = Permissible Short Circuit Current (A)S? = Factor to allow for heat loss into the Adjacent ComponentsS = Cross-Sectional Area of sheath (sqmm)t = Duration of Short circuit (s) = Final Temperature (200C) = Initial Temperature (80C)

0

I = 0 x 226S 0 St In + 234.5f + 234.5i

Where,I = Permissible Short Circuit Current (A)S? = Factor to allow for heat loss into the Adjacent ComponentsS = Cross-Sectional Area of Screen (sqmm)t = Duration of Short circuit (s) = Final Temperature (200C) = Initial Temperature (80C)

0

Copper Conductor

Lead Sheath

Copper Screen

Aluminium Sheath

I = 0 x 148S 0 St In + 228f + 228i

Where,I = Permissible Short Circuit Current (A)S? = Factor to allow for heat loss into the Adjacent ComponentsS = Cross-Sectional Area of sheath (sqmm)t = Duration of Short circuit (s) = Final Temperature (200C) = Initial Temperature (80C)

0





STANDARD LAYING CONDITION& RATING FACTORS

RATING FACTORS FOR VARIATION IN AMBIENT AIR TEMPERATURE WHEN CABLE LAID IN AIR

Air Temperature (C)

Rating Factor

20c 25c 30c 35c 40c 45c 50c

1.2 1.16 1.10 1.05 1.0 0.94 0.88

RATING FACTORS FOR VARIATION IN GROUND TEMPERATURE WHEN CABLE LAID DIRECT IN GROUND

Air Temperature (C)

Rating Factor

15c 20c 25c 30c 35c 40c 45c

1.08 1.04 1.0 0.96 0.91 0.87 0.83

RATING FACTORS FOR VARIATION IN THERMAL RESISTIVITY OF SOIL

Thermal Resistivity of Soil(cm/W)

Rating Factor

0.7 1.0 1.2 1.5 2.0 2.5 3.0

1.14 1.0 0.93 0.84 0.74 0.67 0.61

0.50 ~ 0.70

0.71 ~ 0.90

0.91 ~ 1.10

1.11 ~ 1.30

1.31 ~ 1.50

1.09

1.05

1.03

1.01

1.00

Rating FactorDepth of Laying (m)

RATING FACTORS FOR VARIATION IN DEPTH OF LAYING

TABLE-1STANDARD LAYING CONDITION

GROUND TEMPERATURE : 25C DEPTH OF LAYING : 1.5 m

SOIL THERMAL RESISTIVITY : 1.0C-m/W AMBIENT TEMPERATURE : 40C MAX. CONDUCTOR TEMPERATURE : 90C METHOD OF INSTALLATION : FLAT (S = 2 X OD) S = DISTANCE BETWEEN CABLES

OD = CABLE DIAMETER FREQUENCY : 50HZ

18

TABLE-2RATING FACTORS





EE

The simplest, known as solid bonding, involves bonding both ends of the cable screen/sheath circuit to earth, as shown here. Whilst this arrangement keeps the voltages on the sheath low it unfortunately provides a very good path for induced currents to flow in the sheath. Depending on the geometry of the installation these currents can be high and therefore lead to large sheath losses and lower current ratings. For cables where all three phases are within the sheath then this will often be the best arrangement.

SS

E

Mid Point Bonding :

The circuit length can be doubled if the bonding point is moved to the mid-point of the circuit as shown here. This arrangement is known as mid-point bonding has the same benefits and limitations as end-point bonding except that the circuit length can be greater. The mid-point bonding may be at a joint, as shown here, or by using a special sheath bond attachment.

SE

For shorter circuit lengths, it may be acceptable to bond only at one end to earth. The arrangement shown here, known as end-point bonding, involves bonding at one end of the cable circuit to earth and the other end is bonded to sheath voltage limiters. This arrangement allows the voltage to rise but the sheath voltage limiters form a conducting path to earth prevent the voltage rise too much (under fault conditions). By limiting the circuit length the induced voltage on the sheath at the end farthest from the earth bond can be kept below an acceptable value during normal operation. And no induced currents can flow during normal operation.

Single Point Bonding (End Point Bonding) :

SHEATH BONDING METHODS

19

This Engineering Recommendation deals with the earthing of cable screens which constitute an insulated three phase line, installed either in a service gallery, in an indoor installation or directly buried. To reduce the losses on the line and optimize the transport capacity, connection systems tend to be adopted which reduce the intensity of the currents induced on the screens. These systems involve specific connections of the screens to each other and to earth and give rise to permanent current and current surges on the screen circuits which must be considered.

ScopeThis Recommendation describes the systems and components used in the connections of the screen/sheath circuits of three phase power lines for voltages equal to or greater than 66 kV, made up of single-core cables with metallic screen and insulating sheath. Specific means may be required to withstand the permanent current and current surges which can occur between different parts of the screen/sheath circuit, and between the same and the earth. Various Sheath Bonding methods are given below :

Introduction

Both Ends Bonding (Solid Bonding) :





JOINT WITH SECTIONALISINGINSULATION

CONCENTRICLEADS LOCKABLE LINK BOX

WITH SHEATHVOLTAGE LIMITERS

JOINT BAY EARTHSYSTEM

Cross-Bonding :

EE E X X X X

Minor Section

Major Section

For longer circuit lengths, this arrangement, known as cross bonding, is commonly used for EHV Systems. The circuit is divided into major and minor sections such that there are three minor sections of approximately equal length in each major section. Both ends of a major section are bonded to earth and the other two positions within the major section are bonded to sheath voltage limiters. Because this would allow induced currents to flow in the sheath the cables are rearranged as shown and the sheaths are "crossed over" so that they remain at the same geometry, see below. This means that the induced currents are effectively cancelled due to the phase shift.

In this diagram, the colours represent the sheath connections and not phases. So, for example, as phase 1 enters from the left in the top position the sheath is represented in magenta, phase 1 is then transposed to the middle position to exit on the right and the sheath is now represented in yellow. The sheath of phase 1 on the left is shown bonded via the link box to the sheath of phase 3 on the right such that, in effect, the sheath both enters and exits in the top position whilst the phases are transposed.

20

SHEATH BONDING METHODS

Note : E stands for directly earthed S stands for Sheath Voltage Limiter (SVL)X stands for Link Box (LB) with SVL





METHOD OF INSTALLATION

21

Installation :

Laying conditions play a major role for reliable and optimized performance of EHV cable system. Extreme care to be taken while dealing with an EHV cable installation so that it can serve to its useful life. Specialized installation method for EHV cables are furnished here. Respect Bending radius as improper bending will result in insulation being unduly stressed. Also attention need to be paid for soil conditions under direct burial for improvement of heat dissipation properties.

Direct Burial Installation(Trefoil Formation)

Protection Tile

Backfill

1500

300

50

600

Sand Filling

G.L.

Warning Tape

To ensure safety during cable installation and reliability once the cable is installed, you should confirm the following prior to installation:

The cable selected is proper for your application

The cable has not been damaged in transit or storage

Review all applicable state and national codes to verify that the cable chosen is appropriate for the job. Also, consult your local authority.

Next, you must identify any existingcable damage and prevent any further damage from occurring. This is done through proper cable inspection, handling and storage.

Overview

Inspect every cable reel for damagebefore accepting the shipment. Beparticularly alert for cable damage if:

A reel is laying flat on its side Several reels are stacked Other freight is stacked on a reel Nails have been driven into reel

flanges to secure shipping blocks

A reel flange is damaged A cable covering is removed,

stained or damaged A cable end seal is removed or

damaged A reel has been dropped

(Hidden damage likely)

Cable Inspection

Remove all nails and staples fromthe reel flanges before moving a reel, and avoid all objects that could crush, gouge or impact the cable when moving. NEVER use the cable as a means to move a reel.

When unreeling, observe recommended bending radii, use swivels to prevent twisting and avoid overruns.

Cabling Handling

Pre-installation Instructions :

Road Crossing(Trefoil Formation)

G.L.

Backfill

Sand Filling

RCC Tile

HDPE Pipe

1500

400

50

Concrete

War ng Tapeni

The following minimum bending radius should be observed, so that the cable and especially the insulation are not unduly stressed.

25 x OD for cables with PVC outer sheath,30 x OD for cables with HDPE outer sheath,

where, OD is the Overall Diameter of the cable

Bending Radius :





Size (sqmm)

Conductor Type (metal)

Insulation EPR XLPE Other

Insulation LevelEarthed Unearthed

Metallic Sheath Lead Alloy Corrugated Aluminum Smooth Aluminum Other

Metallic ShieldingBare/CoatedHelical copper tapesHelical wiresLongitudinal drain wiresOther

JacketHDPEPVCOther

Color

Voltage rating

Temperature rating

Approvals

Standards ISS BSS JIS AEIC CANENA CSA ICEA IEC Other

_________

______

____________

_______________

___ ___ ___

___________________________

CHECKLIST FOR SPECIFICATIONS

22

Testing Procedures ISS BSS JIS AEIC CAN ENA CSA ICEA IEC Other

Special Requirements (if any) Flame-retardant Sunlight-resistant Other

Documentation Certificates of Compliance Certified Test Reports Drawings Warranties Other

System Characteristics

Shipping Details Cut lengths Installation Recommendation Lagging Returnable reels Other

Identification Cable Circuit Reel

Fault Current Requirement ConductorMetallic SheathMetallic Wire Shield

Note: This checklist must beaccompanied by exact systemdetails about the environment andelectrical characteristics.Checklist for Specifications

___________________________

_________

_______________

_______________

_________

_________





METRIC CONVERSION FACTORS

Inches Millimeters 25.4Millimeters Inches 0.03937

Inches Centimeters 2.54Centimeters Inches 0.3937

Feet Meters 0.3048Meters Feet 3.2808

Kilofeet (1000 ft) kilometers 0.3048kilometers kilofeet (1000 ft) 3.2808

Square Inches Square Millimeters 645.16Square Millimeters Square Inches 0.00155

Square Inches Square Centimeters 6.4516Square Centimeters Square Inches 0.155

Square Inches Circular Mils 1,273,240-7Circular Mils Square Inches 7.854 x 10

4Circular Mils Square Millimeters 5.066 x 10Square Millimeters Circular Mils 1973.51

Square Feet Square Meters 0.0929Square Meters Square Feet 10.764

Pounds Kilograms 0.4536Kilograms Pounds 2.2046

Pound/Kilofeet Kilograms/Kilometer 1.4882Kilograms/Kilometer Pounds/Kilofeet 0.6720

Ohms/Kilofeet Ohms/Kilometer 3.2808Ohms/Kilometer Ohms/Kilofeet 0.3048

Microfarads/Kilofeet Microfarads/Kilometer 3.2808Microfarads/Kilometer Microfarads/Kilofeet 0.3048

Insulation Resistance:MegohmsKilofeet MegohmsKilometer 0.3048MegohmsKilometer MegohmsKilofeet 3.2808

Pounds/Square Inch Kilo Pascal* 6.895Kilo Pascal* Pounds/Square Inch 0.1432Pounds (force) Newtons 4.448

* 1 Pascal = 1 newton/m2

To Convert From To Multiply By

Length

Area

Weight

Electrical

Mechanical

23





RECOMMENDED REELHANDLING PRACTICES

How to Handle Cable Reels

24

Upended heavy reels will often arrivedamaged. Refuse or receive subject toinspection for hidden damage.

Reels can be hoisted with a shaftextending through both flanges.

Do not lift by top flange. Cable or reelwill be damaged.

Lower reels from truck usinghydraulic gate, hoist or fork lift.LOWER CAREFULLY.

Never allow forks to touch cable surfaceor reel wrap.

Always load with flanges on edge andchock and block securely.

Never drop reels.

Cradle both reel flanges between forks.





RECOMMENDED CABLE HANDLING PRACTICES

25

Unloading and Moving of Reels:

Cable reels are never shipped upended (flat side down). Cable reels that arrive in this manner should be rejected or received only after a thorough inspection for damage.

See Recommended Reel Handling Practices on the following pages.

Upon receipt, a cables protective covering and/or lagging should be inspected for evidence of damage during shipment. If evidence of damage is found, a report should immediately be made to the carrier.

Under no circumstances should reels be dropped from the delivering vehicle to the ground.

Unloading and reel handling should be accomplished so that the equipment used does not contact the cable surface, and in the case of protective wrap, that the equipment does not contact the protective wrap.

If unloading and reel handling is accomplished by crane, either a cradle supporting the reel flanges or a shaft through the bore hole should be used. If a fork lift is utilized, the forks must lift the reel at 90 to the flanges and the forks must be long enough to make complete lifting contact with both flanges. Under no circumstances should the forks come into contact with the cable surface or the protective wraps.

When a reel of cable is rolled from one point to another, care must be taken to see that there are no objects on the surface area which could contact or damage the cable surface or protective wrap.

If an inclined ramp is used for unloading, the ramp must be wide enough to contact both flanges completely. The stopping of the reels at the bottom shall be accomplished by using the reel flanges and not the surface of the cable.





RECOMMENDED CABLE STORAGE PRACTICES

26

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