KEC LT XLPE Cables Brochure

TECHNICAL CATALOGUE
Company Profile
Company
Profile
Silvassa Plant
Thane Plant
Mysore Plant
RPG Cables, a division of KEC International Limited has established itself as one of the leading manufacturers of Power, Control &
Telecommunication Cables in India. One of the oldest cable manufacturing company (1958), we have been serving the industries with
quality cables for over 5 decades. The state-of-the art manufacturing plants are located at Thane for HT Cables upto 33 kV and EHV Cables
upto 132 kV and Silvassa for LT Cables upto 1.1 kV (Power and Control). The manufacturing facility at Mysore manufactures LT Power and
Control Cables, apart from Telecom Cables (Fiber Optic & Jelly Filled), Instrumentation, Fire Survival and Signaling Cables. RPG Cables
also offers expertise in Turnkey contracts involving cable laying, jointing, testing and commissioning. To keep pace with the changing
needs of the customers and requirement of cables for voltage grades above 132 kV, the company is coming up with a new manufacturing
unit near Halol, Gujarat with capability to manufacture cables up to 400 kV. The brand name Asian is synonymous with stringent norms
in quality, environment and safety management. The plants have been ISO 9000 and ISO 14000 certifed.
RPG Cables has been making major export thrust in keeping with its global aspirations. We match international quality standards
and cables can be designed to comply with required international standards. The division has also been given recognition by the
Govt. of Maharashtra for achieving excellence in Exports.
Manufacture of LT Cables
Asian brand LT Cables are being manufactured for over 50 years
having presence in more than 10 countries. Since year 2000 LT
cables manufacturing was shifted to SILVASSA and MYSORE
plants from Thane.
SILVASSA Unit
LT cables are manufactured at Silvassa unit since year 2000.
PVC insulated and XLPE insulated cables are manufactured upto
1000 sqmm (single core) and 630 sqmm (Multicore) conforming
to IS, IEC & BS standards. Special cables, as per user
requirement, such as screened drive cables, XLPE insulated Fire
Survival Cables etc. are also manufactured.
MYSORE Unit
Incorporated in 1982, Mysore Plant started manufacturing
Telecom Cables. LT Cables, manufacturing range was added in
the year 2008.
PVC insulated and XLPE insulated LT Power and Control Cables,
Instrumentation Cables, Jelly Filled (Telecom) & Optic Fiber
cables are manufactured to National and International standards.
Unit is equipped to manufacture multi - tube, unitube, aerial
bunched, armoured and un-armoured cables.
SPECIFICATION & CONSTRUCTION

1.1Kv cables are designed and manufactured based on the national (IS) & international (IEC, BS) standards and project based customer
specifications. Following are the standard stages of cable design & manufacturing.
CONDUCTOR - The current carrying component :
KEC offer cables with Electrolytic Copper (Plain or Tinned) and Aluminium conductor in form of Solid, Stranded Circular, Compacted
Circular and Shaped as per IS 8130, IEC 60228 & BS EN 60228. The sector shaped conductor are manufactured with pre-spiral lay which
gives compact shape to the cable with reduced diameter at laid up stage.
INSULATION - The dielectric barrier to meet rated voltage level :
XLPE, the 90C thermoset dielectric, is applied as insulation over the conductor by extrusion process.
Cross Linked Polyethyelene (XLPE) as per IS 7098-1, IEC 60502-1, BS 7655.
Laying up of Cores The multi-cores are Laid-up with appropriate tooling to form a compact circular shape, PVC fillers can be applied (wherever necessary) to
provide circular shape.
INNERSHEATH - The bedding for armour :
PVC / LSZH innersheath is applied as a protection over the laid up cores, Innersheath can be offered in two forms Extruded or Taped.
Extruded PVC bedding of ST2/LSZH PVC as per IS 5831, IEC 60502-1, BS 7655.
Taped Bedding of Thermoplastic tape to be compatible with temperature rating of the cable as per IS 7098-1, IEC 60502-1.
ARMOUR - The mechanical protection (or Earthing element) of cable :
Galvanised Steel Round Wire as per IS 3975, IEC 60502-1, BS 10257.
Galvanised Steel Flat Strip as per IS 3975, IEC 60502-1.
For Single Core cables to be used in AC circuits Aluminium Round Wire or Flat Strip armour is provided to avoid magnetic hysteresis losses.
For cables to be used in mines, required armour conductance (may be 75% to 40%) can be achieved by Double wire armour or by
incorporating Tinned Copper Wires with Galvanised Steel Wires
OUTERSHEATH PVC / LSZH outersheath is applied by extrusion process generally Black in colour with sequential length marking and required details
Printed with non-contact ink jet printer.
Poly-Vinyl Chloride (PVC) as per IS 5831, IEC 60502-1, BS 7655.
Low Smoke Zero Halogen (LSZH) as per IEC 60502-1.
SPECIAL REQUIREMENTS
KEC Cables can be custom designed & manufactured for special requirements as follows :
FR innersheath & outersheath material can be offered to meet the requirement of reduced Flame propagation characteristics
as per ASTM-2863, IEC 60332 Part 3.
FRLS innersheath & outersheath material can be offered to meet the requirement of reduced Flame propagation
characteristics and Low Smoke & Low acid gas emission as per ASTM 2843, ASTM-2863, IEC 60332 Part 3, IEC 60754-1,
SS 424-14-75.
Copper tape, Copper wires or Aluminium tape can be provided as shielding / screening over laid up cores or innersheath.
Cables with LEAD sheath over bedding can be offered.
Fire Survival cables :

Heat barrier Glass backed mica tape can be applied over the conductor for Fire Survival cables to meet the test requirements of
750C for 3 hours as per IEC 60331. Fire Survival Cables are used where the applications require circuit integrity during a fire
mainly in Fire Alarm systems, sprinkler systems in schools, hospitals, shopping malls, cinemas etc.
TYPICAL CROSS SECTIONAL VIEW OF LT CABLES

1. Conductor
- Copper or Aluminium (A)
2. Insulation
- Type XLPE (2X)
3. Outersheath - ST2 PVC (Y)

1 Core Unarmoured Cable
Typical Cable Codes : 2XY, A2XY
1. Conductor
2. Insulation
- Type " XLPE" (2X)
3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

Typical Cable Codes : 2XY(P), 2XY(T), A2XY(P), A2XY(T)
1. Conductor
2. Insulation
- Type " XLPE" (2X)

1. Conductor
2. Insulation
- Type " XLPE" (2X)

3.5 Core Unarmoured Cable
1. Conductor
2. Insulation
- Type " XLPE" (2X)

TYPICAL CROSS SECTIONAL VIEW OF LT CABLES

1. Conductor
2. Insulation
- Type " XLPE" (2X)

4. Armoured
- Aluminium Round wire / Flat strip

1 Core Armoured Cable
Typical Cable Codes : 2XWaY(P), 2XWaY(T), 2XFaY(P), 2XFaY(T), A2XWaY(P), A2XWaY(T), A2XFaY(P), A2XFaY(T).
1. Conductor
2. Insulation
- Type " XLPE" (2X)

4. Armoured
- G.S.Round wire / Flat strip

Typical Cable Codes : 2XWY(P), 2XWY(T), 2XFY(P), 2XFY(T), A2XWY(P), A2XWY(T), A2XFY(P), A2XFY(T).
1. Conductor
2. Insulation
- Type " XLPE" (2X)

4. Armoured

1. Conductor
2. Insulation
- Type " XLPE" (2X)

4. Armoured

3.5 Core Armoured Cable
1. Conductor
2. Insulation
- Type " XLPE" (2X)

4. Armoured

1. Conductor
2. Insulation
- Type " XLPE" (2X)

4. Armoured

Multicore Control Cable
TABLE-1A
Technical Data for Class-2 conductor as per IS: 8130 - 1984
Conductor
cross
sectional Area
(Note 1)
Minimum No of wires
Non Compacted
Compacted
Circular
Maximum D.C. Resistance

@ 20C
(Circular / Shaped)
Plain Copper
Tinned
Copper
Aluminium
sq.mm
CU
AL
CU
AL
ohm/km
ohm/km
ohm/km
1.50
3
3
12.10
12.20
18.10
2.50
3
3
7.41
7.56
12.10
4
7
3
4.61
4.70
7.41
6
7
3
3.08
3.11
4.61
10
7
7
6
1.83
1.84
3.08
16
7
7
6
6
1.15
1.16
1.91
25
7
7
6
6
0.727
0.734
1.20
35
7
7
6
6
0.524
0.529
0.868
50
19
19
6
6
0.387
0.391
0.641
70
19
19
12
12
0.268
0.270
0.443
95
19
19
15
15
0.193
0.195
0.320
120
37
37
18
15
0.153
0.154
0.253
150
37
37
18
15
0.124
0.126
0.206
185
37
37
30
30
0.0991
0.100
0.164
240
61
37
34
30
0.0754
0.0762
0.1250
300
61
61
34
30
0.0601
0.0607
0.1000
400
61
61
53
53
0.0470
0.0475
0.0778
500
61
61
53
53
0.0366
0.0369
0.0605
630
91
91
53
53
0.0283
0.0286
0.0469
800
91
91
53
53
0.0221
0.0224
0.0367
1000
91
91
53
53
0.0176
0.0177
0.0291
Note 1 : Conductors of 1.5 sq.mm to 10 sq.mm can be manufactured as per class-1 solid conductor as per IS 8130.
Maximum A.C. Resistance

@ 90C
Plain Copper
Tinned
Copper
Aluminium
ohm/km
15.50
9.48
5.90
3.94
2.34
1.47
0.93
0.671
0.495
0.343
0.247
0.196
0.159
0.127
0.0965
0.0769
0.0602
0.0468
0.0362
0.0283
0.0225
ohm/km
15.63
9.67
6.01
3.98
2.35
1.48
0.94
0.68
0.500
0.323
0.250
0.197
0.162
0.128
0.0975
0.0777
0.0608
0.0472
0.0366
0.0287
0.0226
ohm/km
23.17
15.50
9.48
5.90
3.94
2.44
1.54
1.11
0.820
0.567
0.410
0.324
0.264
0.210
0.1600
0.1280
0.1000
0.0774
0.0600
0.0470
0.0372
TABLE-1B
Technical Data for Class-5 Flexible Copper conductor as per IS: 8130 - 1984
Maximum D.C. Resistance
Maximum A.C. Resistance
@ 20C
@ 90C
Conductor
cross
sectional Area
Maximum dia
of individual
strand in
conductor
Plain Copper
sq.mm
0.50
0.75
1.00
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
mm
0.21
0.21
0.21
0.26
0.26
0.31
0.31
0.41
0.41
0.41
0.41
0.41
0.51
0.51
0.51
0.51
0.51
0.51
0.51
0.51
0.61
0.61
ohm/km
39.00
26.00
19.50
13.30
7.98
4.95
3.30
1.91
1.21
0.780
0.554
0.386
0.272
0.206
0.161
0.129
0.106
0.0801
0.0641
0.0486
0.0384
0.0287
Tinned
Copper
ohm/km
40.10
26.70
20.00
13.70
8.21
5.09
3.39
1.95
1.24
0.795
0.565
0.393
0.277
0.210
0.164
0.132
0.108
0.0817
0.0654
0.0495
0.0391
0.0292
Plain Copper
ohm/km
49.76
33.18
24.89
17.03
10.21
6.33
4.22
2.44
1.55
0.9976
0.7093
0.4937
0.3252
0.2636
0.2062
0.1654
0.1358
0.1025
0.0820
0.0622
0.0491
0.0367
Tinned
Copper
ohm/km
51.16
34.07
25.53
17.54
10.50
6.51
4.34
2.49
1.58
1.0167
0.7233
0.5027
0.3315
0.2687
0.2100
0.1692
0.1383
0.1045
0.0837
0.0634
0.0500
0.0373
TABLE: 2 - CAPACITANCE
1.1kV XLPE INSULATED CABLES - APPROXIMATE CAPACITANCE (microfarads/km)
Conductor
cross
sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Single Core
Unarmoured
0.189
0.229
0.300
0.354
0.441
0.515
0.512
0.592
0.598
0.624
0.723
0.774
0.734
0.712
0.763
0.790
0.839
0.857
0.917
0.946
0.965
Two Core
Multicore
(More than Two
Cores)
0.064
0.071
0.081
0.087
0.096
0.100
0.105
0.111
0.115
0.117
0.122
0.127
0.126
0.127
0.130
0.130
0.132
0.133
0.137
-
0.161
0.191
0.244
0.283
0.347
0.401
0.406
0.464
0.479
0.490
0.564
0.605
0.569
0.563
0.594
0.616
0.649
0.666
0.714
-
Armoured
0.371
0.391
0.450
0.483
0.512
0.592
0.641
0.607
0.617
0.665
0.693
0.705
0.707
0.766
0.778
0.803
TABLE 3 - REACTANCE
1.1kV XLPE INSULATED CABLES - APPROXIMATE REACTANCE (ohms/km)
Conductor
cross
sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Single Core
Unarmoured
0.120
0.113
0.107
0.103
0.098
0.094
0.095
0.092
0.092
0.088
0.086
0.0857
0.0863
0.0858
0.0851
0.0843
0.0837
0.0835
0.0829
0.0826
0.0823
Armoured
0.101
0.100
0.097
0.096
0.091
0.089
0.0879
0.0886
0.0875
0.0866
0.0857
0.0855
0.0851
0.0843
0.0841
0.0836
Multicore
0.108
0.1007
0.0947
0.0902
0.0852
0.0815
0.0816
0.0794
0.0792
0.0752
0.0734
0.0726
0.0732
0.0727
0.0719
0.0711
0.0705
0.0703
0.0697
-
TABLE 4 A- IMPEDANCE (Plain Copper Conductor) @ 90C

1.1kV XLPE INSULATED CABLES - APPROXIMATE IMPEDANCE (ohms/km)
Conductor
cross sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Single Core @ 90C

Unarmoured
15.5005
9.4807
5.9010
3.9413
2.3421
1.4730
0.9348
0.6773
0.5035
0.3542
0.2617
0.2139
0.1809
0.1533
0.1286
0.1141
0.1031
0.0957
0.0904
0.0873
0.0853
Armoured
1.4735
0.9353
0.6780
0.5041
0.3549
0.2625
0.2148
0.1820
0.1542
0.1297
0.1151
0.1045
0.0971
0.0917
0.0888
0.0866
Multicore @
90C
15.5004
9.4805
5.9008
3.9410
2.3416
1.4723
0.9336
0.6757
0.5013
0.3511
0.2577
0.2090
0.1750
0.1463
0.1204
0.1048
0.0927
0.0845
0.0785
-
TABLE 4 B- IMPEDANCE (Aluminium Conductor) @ 90C

1.1kV XLPE INSULATED CABLES - APPROXIMATE IMPEDANCE (ohms/km)
Conductor
cross sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Single Core @ 90C

Unarmoured
23.1703
15.5004
9.4806
5.9009
3.9412
2.4418
1.5429
1.1138
0.8252
0.5738
0.4190
0.3351
0.2777
0.2269
0.1812
0.1532
0.1304
0.1138
0.1023
0.0950
0.0903
Armoured
2.4421
1.5432
1.1142
0.8255
0.5743
0.4195
0.3357
0.2785
0.2275
0.1819
0.1540
0.1315
0.1150
0.1034
0.0964
0.0915
Multicore @
90C
23.1702
15.5003
9.4805
5.9007
3.9409
2.4414
1.5422
1.1128
0.8238
0.5720
0.4165
0.3320
0.2740
0.2222
0.1754
0.1464
0.1224
0.1046
0.0920
-
TABLE 5 A- VOLTAGE DROP (Plain Copper Conductor) @ 90C

1.1kV XLPE INSULATED CABLES - APPROXIMATE VOLTAGE DROP (mV/A/m)
Conductor
cross sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Single Core @ 90C

Unarmoured
31.0009
18.9614
11.8020
7.8827
4.6841
2.9461
1.8696
1.3546
1.0070
0.7083
0.5234
0.4279
0.3618
0.3065
0.2573
0.2282
0.2061
0.1914
0.1808
0.1746
0.1706
Armoured
2.9469
1.8706
1.3559
1.0083
0.7097
0.5250
0.4296
0.3640
0.3085
0.2593
0.2302
0.2091
0.1942
0.1834
0.1775
0.1732
3 Phase
@ 90C
26.8156
16.4013
10.2083
6.8180
4.0509
2.5470
1.6151
1.1689
0.8673
0.6075
0.4458
0.3616
0.3028
0.2532
0.2082
0.1812
0.1604
0.1461
0.1359
-
TABLE 5 B- VOLTAGE DROP (Aluminium Conductor) @ 90C

1.1kV XLPE INSULATED CABLES - APPROXIMATE VOLTAGE DROP (mV/A/m)
Conductor
cross sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Single Core @ 90C

Unarmoured
46.3406
31.0008
18.9612
11.8018
7.8824
4.8837
3.0858
2.2277
1.6503
1.1476
0.8380
0.6703
0.5555
0.4537
0.3624
0.3065
0.2608
0.2277
0.2046
0.1901
0.1805
Armoured
4.8842
3.0864
2.2284
1.6511
1.1485
0.8391
0.6714
0.5569
0.4550
0.3639
0.3080
0.2631
0.2300
0.2069
0.1928
0.1831
3 Phase
@ 90C
40.0845
26.8156
16.4012
10.2082
6.8178
4.2236
2.6679
1.9252
1.4252
0.9895
0.7206
0.5744
0.4740
0.3845
0.3035
0.2533
0.2117
0.1809
0.1591
-
TABLE 6 - SHORT CIRCUIT CURRENT RATINGS

1.1kV XLPE INSULATED CABLES - Short Circuit Ratings for 1 second
Conductor
cross
sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
XLPE Insulated
(for 90C)
Copper
0.21
0.36
0.57
0.86
1.43
2.29
3.58
5.01
7.15
10.02
13.59
17.17
21.46
26.47
34.34
42.92
57.23
71.54
90.14
114.46
143.08
Aluminium
0.14
0.24
0.38
0.57
0.94
1.51
2.36
3.31
4.72
6.61
8.98
11.34
14.17
17.48
22.68
28.34
37.79
47.24
59.52
75.58
94.48
1) Maximum Initial Conductor temperature before short circuit :

for cross linked polyethelen (XLPE) - 90C
2) Maximum final Conductor temperature during short circuit : 250C
Short Circuit Rating for other duration can be calculated from :
IscT
Isc1
T
= Short Circuit rating for "T" seconds

= Short Circuit rating for one second
= Duration in seconds
BASIC ASSUMPTION FOR CURRENT RATINGS & RATING FACTORS

SCOPE
The current ratings of cables as indicated in various tables have been calculated on certain assumed conditions.
In actual practice these conditions may be different. Therefore to determine the actual current ratings as per installation conditions,
the tabulated ratings shall be multiplied with appropriate factors
BASIC ASSUMPTION FOR CURRENT RATINGS
l Maximum permissible temperature - 90C for Cross linked polyethylene
l Ground/Duct temperature - 30C
l Ambient temperature - 40C
l Thermal resistivity of soil - 150C cm/W
l Depth of laying for 1.1kV cables - 750 mm
Single core cables installed in one circuit in following arrangement
Multi core cables installed in single circuit
10
TABLE 7 - CURRENT RATINGS

Current Ratings for 2 Single Core Unarmoured / Armoured Cables according to IS 1554-1
Conductor
cross
sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Direct in Ground
(30C) Amp.
Copper
XLPE
31
41
54
68
89
116
148
181
213
259
310
352
393
444
518
583
657
731
823
907
981
Aluminium
XLPE
24
32
42
52
69
90
115
139
162
199
241
272
305
347
406
461
527
600
666
750
833
Direct in Duct
(30C) Amp.
Copper
XLPE
29
36
49
64
85
114
142
169
195
235
269
299
324
356
419
464
532
582
649
740
800
Aluminium
XLPE
22
29
39
50
65
85
110
127
145
181
212
237
253
278
327
368
431
490
542
619
687
Direct in Air
(40C) Amp.
Copper
XLPE
25
33
44
55
80
104
139
172
213
271
335
389
447
524
623
722
850
976
1130
1279
1430
Aluminium
XLPE
20
27
35
44
61
82
109
136
164
208
258
303
348
407
487
567
668
786
922
1065
1220
Note : Normal current ratings are given in standard conditions, if site conditions are different, current rating should be multiplied by rating factor as given in page no. 19 to 21

Current Ratings for 3 Single Core Unarmoured / Armoured Cables according to IS 7098-1
Conductor
cross
sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Direct in Ground
(30C) Amp.
Copper
XLPE
27
36
46
58
77
99
127
155
183
221
264
298
334
370
424
470
556
620
695
758
834
Aluminium
XLPE
20
28
36
44
59
76
97
116
139
168
204
231
259
290
340
382
437
500
565
629
704
Direct in Duct
(30C) Amp.
Copper
XLPE
26
35
45
57
76
97
127
149
177
204
240
262
292
315
350
389
466
518
555
637
702
Aluminium
XLPE
20
28
35
42
59
75
95
116
133
162
181
201
224
254
283
317
370
428
464
542
606
Direct in Air
(40C) Amp.
Copper
XLPE
22
29
41
52
71
96
126
157
196
248
299
357
411
479
569
659
769
877
1013
1148
1275
Aluminium
XLPE
17
23
31
39
53
73
99
122
149
190
235
275
320
370
445
514
605
704
822
940
1070
11

Current Ratings for 2 Cores Unarmoured / Armoured Cables according to IS 7098-1
Conductor
cross
sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Direct in Ground
(30C) Amp.
Copper
XLPE
33
43
54
66
90
114
147
177
210
260
309
351
392
448
509
579
638
-
Aluminium
XLPE
25
34
42
54
70
90
117
140
168
202
243
273
310
350
401
458
505
-
Direct in Duct
(30C) Amp.
Copper
XLPE
29
37
46
58
75
95
124
152
185
228
277
300
341
384
434
495
553
-
Aluminium
XLPE
22
29
35
46
57
75
99
117
143
177
217
247
271
305
345
393
453
-
Direct in Air
(40C) Amp.
Copper
XLPE
29
39
48
59
82
113
148
186
221
278
338
402
461
527
607
688
818
-
Aluminium
XLPE
23
31
36
47
62
79
108
143
173
212
257
295
342
395
465
532
622
-

Current Ratings for 3, 3.5, 4, 5 Cores Unarmoured / Armoured Cables according to IS 7098-1
Conductor
cross
sectional
Area
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Direct in Ground
(30C) Amp.
Direct in Duct
(30C) Amp.
Direct in Air
(40C) Amp.
Copper
Aluminium
Copper
Aluminium
Copper
Aluminium
XLPE
25
34
44
55
72
95
122
146
175
212
253
290
325
362
418
467
518
583
645
-
XLPE
20
27
34
43
57
73
96
115
134
165
198
225
252
285
330
371
423
474
532
-
XLPE
20
28
37
46
60
79
100
120
151
182
211
236
271
308
357
406
439
512
570
-
XLPE
18
23
28
37
48
61
80
96
116
141
168
189
210
243
282
316
366
412
463
-
XLPE
22
30
38
51
66
85
122
148
181
230
284
330
375
431
512
582
661
765
860
-
XLPE
18
23
31
45
60
70
95
117
141
177
221
257
293
338
401
459
536
620
715
-
Note : For 3.5 Core cables consider cable size above 16sqmm conductor area.
12
13
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
mm
1.00
1.20
1.20
1.30
1.40
1.40
1.50
1.70
1.90
2.00
2.10
2.40
2.60
2.80
3.10
3.30
mm
0.70
0.70
0.70
0.70
0.70
0.70
0.90
0.90
1.00
1.10
1.10
1.20
1.40
1.60
1.70
1.80
2.00
2.20
2.40
2.60
2.80
mm
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.40
0.40
0.40
0.50
0.50
0.60
0.60
0.70
0.70
-
mm
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.40
0.40
0.40
0.50
0.50
0.60
0.60
0.70
0.70
0.70
-
mm
0.30
0.30
0.30
0.40
0.40
0.40
0.50
0.50
0.60
0.60
0.70
0.70
0.70
-
mm
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.30
0.40
0.40
0.50
0.50
0.50
0.60
0.70
0.70
0.70
0.70
-
Minimum Innersheath
Minimum Innersheath Thickness
Conductor
Thickness
cross
Single
Multicore &
sectional
Core
Single Core 2 Core 3 Core 3.5 Core 4 Core
Area
Armoured Unarmoured
mm
1.40
1.40
1.40
1.40
1.40
1.56
1.56
1.56
1.72
1.72
1.88
1 Core
mm
1.40
1.40
1.40
1.56
1.56
1.56
1.72
1.72
1.88
2.04
2.36
2.52
2.68
-
2 Core
mm
1.24
1.40
1.40
1.40
1.56
1.56
1.56
1.72
1.88
2.04
2.20
2.52
2.68
2.84
-
mm
1.40
1.40
1.40
1.56
1.56
1.72
1.72
1.88
2.04
2.20
2.52
2.68
3.00
-
mm
1.40
1.40
1.40
1.56
1.56
1.56
1.72
1.88
2.04
2.20
2.36
2.68
2.84
3.00
-
3 Core 3.5 Core 4 Core
Minimum Outersheath Thickness

(Flat strip armoured cable)
mm
1.24
1.24
1.24
1.24
1.24
1.40
1.40
1.40
1.40
1.40
1.56
1.56
1.56
1.72
1.88
2.04
1 Core
mm
1.24
1.24
1.24
1.24
1.24
1.40
1.40
1.40
1.40
1.56
1.56
1.56
1.72
1.88
2.04
2.20
2.36
2.68
2.84
-
2 Core
mm
1.24
1.24
1.24
1.24
1.24
1.40
1.40
1.40
1.56
1.56
1.56
1.72
1.88
2.04
2.20
2.36
2.68
2.84
3.00
-
mm
1.40
1.40
1.56
1.56
1.56
1.72
1.88
2.04
2.20
2.36
2.68
2.84
3.00
-
mm
1.24
1.24
1.24
1.24
1.40
1.40
1.40
1.40
1.56
1.56
1.72
1.88
2.04
2.20
2.36
2.52
2.84
3.00
3.00
-
Minimum Outersheath Thickness

(Round wire armoured cable)
mm
1.80
1.80
1.80
1.80
1.80
1.80
1.80
1.80
1.80
1.80
1.80
1.80
2.00
2.00
2.00
2.00
2.20
2.20
2.20
2.40
2.60
mm
1.80
1.80
1.80
1.80
1.80
1.80
2.00
2.00
2.00
2.00
2.20
2.20
2.20
2.40
2.60
2.80
3.00
3.40
3.60
-
2 Core
mm
1.80
1.80
1.80
1.80
1.80
1.80
2.00
2.00
2.00
2.20
2.20
2.20
2.40
2.60
2.80
3.00
3.20
3.60
3.80
-
mm
2.00
2.00
2.00
2.20
2.20
2.20
2.40
2.60
2.80
3.00
3.40
3.60
4.00
-
mm
1.80
1.80
1.80
1.80
1.80
1.80
2.00
2.00
2.00
2.20
2.20
2.40
2.60
2.80
3.00
3.20
3.60
3.80
4.00
-
Nominal Outersheath Thickness

(Unarmoured cable)
1 Core
TABLE 11 - THICKNESSES
Insualtion, Innersheath, Outersheath Thicknesses of XLPE Insulated Cables according to IS 7098-1
14
sq.mm
1.50
2.50
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Conductor
cross
sectional
Area
mm
7.0
7.5
8.0
9.0
10
11
12
13
14
16
18
20
22
24
26
29
32
36
40
44
49
1 Core
mm
12
12
14
15
17
16
19
21
23
26
29
31
34
39
43
48
53
59
66
-
2 Core
mm
12
13
14
15
17
17
21
23
25
29
32
34
38
43
48
53
59
65
73
-
3 Core
mm
23
25
28
32
36
38
43
47
53
59
66
73
81
-
3.5 Core
Approximate O.D. ( +/-2 mm)

- Un-armoured
mm
13
14
15
17
19
19
23
25
28
33
36
39
44
49
55
60
67
75
83
-
4 Core
mm
20
22
23
25
28
30
34
38
42
46
51
1 Core
mm
17
20
22
24
28
30
32
36
39
44
48
54
60
66
-
2 Core
mm
18
22
24
26
30
33
35
39
43
49
53
60
66
73
-
3 Core
mm
24
26
29
33
37
39
43
48
54
59
66
73
82
-
3.5 Core

- Flat strip armoured
mm
21
24
26
30
34
37
40
45
49
55
61
68
75
84
-
4 Core
mm
13
14
16
17
19
21
23
25
27
29
32
36
40
44
49
55
1 Core
mm
13
14
15
16
18
18
21
23
25
29
32
34
38
42
47
52
57
64
71
-
2 Core
mm
14
15
16
17
19
20
23
25
28
32
35
37
42
47
52
57
64
71
80
-
3 Core
mm
25
27
31
35
39
41
46
52
57
63
71
78
89
-
3.5 Core

- Round wire armoured
TABLE 12 - OVERALL DIAMETER (OD)

Overall Diameter of XLPE Insulated Cables according to IS 7098-1
mm
15
16
17
18
21
22
25
27
31
36
39
43
48
53
59
65
73
82
90
-
4 Core
mm
1.40
1.40
1.40
1.40
1.40
1.60
1.60
1.60
1.60
1.60
1.60
2.00
2.00
2.00
2.00
2.50
1 Core
mm
1.40
1.40
1.40
1.40
1.40
1.40
1.60
1.60
1.60
1.60
2.00
2.00
2.00
2.00
2.50
2.50
2.50
3.15
3.15
-
2 Core
mm
1.40
1.40
1.40
1.40
1.40
1.60
1.60
1.60
1.60
2.00
2.00
2.00
2.00
2.50
2.50
2.50
3.15
3.15
4.00
-
3 Core
mm
1.60
1.60
1.60
2.00
2.00
2.00
2.00
2.50
2.50
2.50
3.15
3.15
4.00
-
3.5 Core
mm
1.40
1.40
1.40
1.40
1.40
1.60
1.60
1.60
1.60
2.00
2.00
2.00
2.50
2.50
2.50
3.15
3.15
4.00
4.00
-
4 Core
Nominal Diameter of Round wire armour
TABLE 13 - WEIGHTS
Approximate Nett Weight of Copper Conductor, XLPE Insulated Cables according to IS 7098-1
Conductor
cross
sectional 1 Core
Area
sq.mm
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
kg/km
64
77
96
120
168
231
313
410
540
737
995
1228
1502
1852
2392
2953
3779
4791
6118
7817
9691
Approximate Nett Weight

- Unarmoured
2 Core
3 Core
kg/km
163
198
249
312
436
448
669
868
1139
1542
2098
2561
3095
3884
5038
6285
7969
10159
12970
-
kg/km
183
227
292
374
534
607
919
1210
1604
2221
3002
3687
4542
5648
7388
9157
11632
14839
18984
-

3.5 Core 4 Core

kg/km
1095
1390
1871
2586
3495
4360
5230
6594
8575
10605
13501
17198
21999
-
kg/km
213
269
350
454
658
775
1180
1563
2083
2892
3926
4909
5996
7457
9752
12091
15435
19605
25099
-
1 Core
2 Core
3 Core
kg/km
1078
1318
1578
1943
2487
3087
3924
4949
6323
8018
9899
kg/km
860
1079
1393
1861
2433
2915
3520
4338
5550
6854
8635
10822
13725
-
kg/km
779
1130
1441
1878
2557
3379
4083
4997
6136
7956
9779
12353
15571
19803
-

3.5 Core 4 Core

kg/km
1350
1664
2187
2963
3910
4852
5746
7167
9200
11306
14263
18051
23040
-
kg/km
983
1434
1837
2423
3267
4365
5361
6505
8023
10392
12806
16233
20467
26185
-
1 Core
2 Core
3 Core
kg/km
310
403
509
651
858
1174
1424
1695
2067
2628
3242
4181
5237
6654
8416
10517
kg/km
357
403
478
578
750
766
1100
1347
1681
2186
3005
3517
4208
5123
6784
8229
10148
13249
16374
-
kg/km
389
445
546
651
859
1008
1381
1735
2232
3102
4009
4775
5781
7394
9371
11297
14780
18243
23991
-
3.5 Core 4 Core

kg/km
1621
1979
2580
3593
4626
5601
6621
8541
10798
13024
16973
21047
27558
-
kg/km
431
510
628
768
1039
1224
1721
2167
2792
3898
5090
6173
7783
9441
12012
15249
18966
24720
30763
-
TABLE 14 - WEIGHTS
Approximate Nett Weight of Aluminium Conductor, XLPE Insulated Cables according to IS 7098-1
Conductor
cross
sectional 1 Core
Area
sq.mm
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
kg/km
77
91
106
132
168
204
254
333
422
510
631
765
945
1143
1461
1817
2269
2878
3592

- Unarmoured
2 Core
3 Core
kg/km
219
265
311
264
377
453
561
726
940
1111
1335
1688
2116
2630
3287
4152
5196
-
kg/km
239
292
347
332
481
587
737
997
1265
1512
1903
2355
3005
3674
4609
5827
7324
-

3.5 Core 4 Core

kg/km
566
675
858
1155
1468
1777
2183
2722
3467
4242
5380
6726
8511
-
kg/km
277
341
409
408
595
733
927
1260
1609
2009
2478
3066
3908
4780
6071
7590
9552
-
1 Core
2 Core
3 Core
kg/km
505
601
707
856
1040
1277
1606
1975
2475
3079
3800
kg/km
568
664
815
1045
1274
1465
1761
2143
2628
3199
3953
4814
5951
-
kg/km
503
692
818
1011
1333
1641
1908
2358
2843
3574
4296
5330
6560
8143
-
15

3.5 Core 4 Core

kg/km
821
950
1173
1531
1883
2269
2699
3294
4093
4944
6142
7579
9552
-
kg/km
617
850
1006
1266
1635
2048
2461
2986
3631
4548
5495
6869
8452
10638
-
1 Core
2 Core
3 Core
kg/km
211
259
303
365
454
600
707
824
980
1181
1432
1863
2263
2806
3477
4418
kg/km
472
555
625
583
808
932
1103
1370
1846
2067
2449
2927
3862
4573
5466
7241
8601
-
kg/km
505
594
672
732
943
1113
1365
1879
2271
2600
3142
4100
4989
5814
7756
9232
12331
-
3.5 Core 4 Core

kg/km
-
1091
1264
1567
2162
2599
3018
3574
4668
5690
6662
8852
10575
14071
-
kg/km
578
678
789
858
1137
1337
1636
2267
2773
3273
4264
5050
6168
7938
9602
12705
15216
-
16
Minimum
Inner sheath
Thickness Round wire
armoured
UnFlat strip
armoured
armoured
dia
Nominal
Outer sheath
Round wire
armoured
UnFlat strip
armoured
armoured
Approximate Overall Diameter

Round wire
armoured
UnFlat strip
armoured
armoured
Nett Weight of Cable

In Ground
(30C)
Amps
29
20
20
20
19
20
17
16
15
14
13
13
12
11
11
10
9
9
8
8
8
8
8
In Duct
(30C)
Amps
29
22
22
22
19
18
18
17
16
15
14
14
13
12
11
11
10
10
9
9
9
9
8
In Air (40C)
Current Ratings
(TYPE A 70C PVC)
mm
mm
mm
mm
mm
mm
mm
mm
kg/km
kg/km
kg/km
Amps
2
0.30
1.24
1.80
1.40
13
12
357
163
33
3
0.30
1.24
1.80
1.40
14
12
389
183
25
4
0.30
1.24
1.80
1.40
15
13
431
213
25
5
0.30
1.24
1.80
1.40
16
14
499
230
25
6
0.30
1.24
1.80
1.40
16
15
564
266
22
7
0.30
1.24
1.80
1.40
16
15
577
274
21
8
0.30
1.24
1.80
1.40
17
16
636
309
20
9
0.30
1.24
1.80
1.40
18
17
702
345
19
10
0.30
1.24
1.80
1.40
20
18
759
368
18
12
0.30
1.24
1.80
1.40
20
18
826
412
17
14
0.30
1.40
1.80
1.40
21
19
931
462
16
16
0.30
1.40
1.40
1.80
1.60
23
21
20
1083
833
515
16
19
0.30
1.40
1.40
1.80
1.60
23
22
21
1179
911
577
15
24
0.30
1.40
1.40
2.00
1.60
27
25
24
1436
1139
733
13
27
0.30
1.40
1.40
2.00
1.60
27
26
25
1532
1218
797
13
30
0.30
1.40
1.40
2.00
1.60
28
27
26
1634
1327
867
12
33
0.30
1.40
1.40
2.00
1.60
29
27
27
1755
1413
940
12
37
0.30
1.40
1.40
2.00
1.60
30
28
27
1891
1540
1023
11
44
0.30
1.56
1.40
2.00
1.60
33
31
31
2209
1794
1197
11
48
0.30
1.56
1.40
2.00
1.60
34
32
31
2330
1897
1280
11
52
0.30
1.56
1.56
2.00
1.60
34
33
32
2457
2058
1367
10
56
0.30
1.56
1.56
2.00
1.60
35
34
33
2603
2170
1461
10
61
0.40
1.56
1.56
2.20
2.00
37
35
34
2983
2322
1596
9
Number
of
Cores
Minimum Outer
sheath Thickness
TABLE 15 - CONTROL CABLES

1.5sq.mm Multi core Control XLPE Insulated Cables according to IS 7098-1
mtrs
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
Standard
Drum Length
17
Minimum
Inner sheath
armoured
Nominal
Outer sheath
Approximate Overall Diameter
Nett Weight of Cable
In Air (40C)
Amps
39
30
30
30
26
25
24
22
21
20
19
18
17
16
16
14
14
13
12
12
12
11
11
In Duct
(30C)
Amps
37
28
28
28
24
23
22
21
20
19
18
17
16
15
15
13
13
12
11
11
11
11
10
Current Ratings
(TYPE A 70C PVC)
dia
UnUnUnFlat strip
Round wire Flat strip
Round wire Flat strip
In Ground
armoured
armoured
armoured
armoured
armoured armoured
armoured armoured
(30C)

mm
mm
mm
mm
mm
mm
mm
mm
kg/km
kg/km
kg/km
Amps
2
0.30
1.24
1.80
1.40
14
12
403
198
43
3
0.30
1.24
1.80
1.40
15
13
445
227
34
4
0.30
1.24
1.80
1.40
16
14
510
269
34
5
0.30
1.24
1.80
1.40
17
15
558
292
34
6
0.30
1.24
1.80
1.40
18
16
645
342
29
7
0.30
1.24
1.80
1.40
18
16
656
355
27
8
0.30
1.24
1.80
1.40
19
17
728
402
26
9
0.30
1.40
1.80
1.40
20
18
820
452
25
10
0.30
1.40
1.24
1.80
1.60
22
20
19
948
696
482
24
12
0.30
1.40
1.40
1.80
1.60
23
21
20
1028
778
546
22
14
0.30
1.40
1.40
1.80
1.60
24
22
21
1131
872
617
21
16
0.30
1.40
1.40
2.00
1.60
24
23
22
1222
944
712
20
19
0.30
1.40
1.40
2.00
1.60
26
24
23
1345
1058
804
19
24
0.30
1.40
1.40
2.00
1.60
29
28
27
1644
1286
992
17
27
0.30
1.40
1.40
2.00
1.60
30
28
27
1753
1403
1085
16
30
0.30
1.40
1.40
2.00
1.60
31
29
28
1869
1500
1185
16
33
0.30
1.56
1.40
2.00
1.60
32
30
29
2031
1626
1289
15
37
0.30
1.56
1.40
2.00
1.60
33
31
30
2184
1768
1409
15
44
0.40
1.56
1.56
2.20
2.00
37
35
34
2770
2084
1688
14
48
0.40
1.56
1.56
2.20
2.00
38
36
35
2892
2229
1811
14
52
0.40
1.56
1.56
2.20
2.00
39
37
36
3072
2356
1940
13
56
0.40
1.56
1.56
2.20
2.00
40
38
37
3230
2511
2073
13
61
0.40
1.56
1.56
2.20
2.00
41
39
38
3430
2683
2223
12
Number
of
Cores
Minimum Outer
sheath Thickness
TABLE 16 - CONTROL CABLES

2.5 sq.mm Multi core Control XLPE Insulated Cables according to IS 7098-1
mtrs
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
Standard
Drum Length
TABLE 17 - STANDARD DRUM LENGTH FOR 1.1kV XLPE COPPER POWER CABLES
Conductor
cross
sectional
Area
Unarmoured Cables
1 Core
2 Core
3 Core
Armoured Cables
3.5 Core
4 Core
sq.mm
STANDARD LENGTH (MTS) WITH +/-5% TOLERANCE
1.5
1000
1000
1000
1000
2.5
1000
1000
1000
1000
4
1000
1000
1000
1000
6
1000
1000
1000
1000
10
1000
1000
1000
1000
16
1000
1000
1000
1000
25
1000
1000
1000
1000
35
1000
1000
1000
1000
50
1000
1000
1000
1000
70
1000
1000
1000
1000
95
1000
1000
1000
1000
120
1000
1000
1000
500
150
1000
1000
500
500
185
1000
500
500
500
240
1000
500
500
500
300
1000
500
500
250
400
1000
500
250
250
500
500
400
250
250
630
500
250
250
250
800
500
1000
400
Note : For multicore copper cables above 400 sq.mm steel drum required.
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
500
500
500
500
250
250
250
250
250
-
1 Core
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
500
500
500
500
400
2 Core
3 Core
3.5 Core
4 Core

1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
500
1000
1000
500
500
1000
500
500
500
500
500
500
500
500
500
500
400
500
500
400
250
500
250
250
250
400
250
250
250
250
250
250
250
250
250
250
250
-
TABLE 18 - STANDARD DRUM LENGTH FOR 1.1kV XLPE ALUMINIUM POWER CABLES
Conductor
cross
sectional
Area
Unarmoured Cables
1 Core
2 Core
3 Core
Armoured Cables
3.5 Core
4 Core
sq.mm
1.5
1000
1000
1000
1000
2.5
1000
1000
1000
1000
4
1000
1000
1000
1000
6
1000
1000
1000
1000
10
1000
1000
1000
1000
16
1000
1000
1000
1000
25
1000
1000
1000
1000
35
1000
1000
1000
1000
50
1000
1000
1000
1000
70
1000
1000
1000
1000
95
1000
1000
1000
1000
120
1000
1000
1000
1000
150
1000
1000
1000
1000
185
1000
1000
1000
1000
240
1000
1000
1000
500
300
1000
500
500
500
400
1000
500
500
500
500
1000
500
500
500
630
500
500
500
500
800
500
1000
500
Note : For multicore copper cables above 400 sq.mm steel drum required.
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
500
500
500
500
500
500
-
18
1 Core
2 Core
3 Core
3.5 Core
4 Core

1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
500
500
1000
1000
500
500
500
1000
500
500
500
500
1000
500
500
500
500
1000
500
500
500
500
1000
500
500
250
250
500
500
250
250
250
500
500
-
Method of Installation
The current ratings are also based on the following methods of installation:
A) Single core cables:
Type of Installation
Method of Installation
a) Laid direct in the ground :
i) Three cables in close trefoil formation or

ii) Two cables touching in horizontal formation.
b) In air :
i) Two single-core cables are installed one above the other & fixed to a
vertical wall as follows: the distance between the wall & the surface of
the cable being 25 mm in each case.
l Cables of sizes upto & including 185 mm2 are installed at a distance
between centres of twice the overall diameter of cable.
l Cables if sizes 240 mm2 & above are installed at a distance between
centres of 90mm.
The ratings for two cables may be applied with safety in case where
such cables are installed in horizontal formation, on brackets fixed to
a wall, either spaced as indicated above or touching throughout.
ii) Three single-core cables are installed in trefail formation touching.
B) Twin & Multi-core cables :
Installed singly in ground & in air.
A) RATING FACTORS
i) Rating factors related to variation in ambient air temperature
Air temperature in Deg. C
25
30
XLPE
1.14
1.10
Rating factor
35
1.04
ii) Rating factors related to variation in ambient ground temperature

Ground temperature in Deg. C
15
20
25
XLPE
1.12
1.08
1.04
Rating factors
40
1.00
30
1.00
35
0.96
B) RATING FACTORS
i) for depth of laying
(Cables laid direct in the ground)
Depth of laying
cm
75
90
105
120
150
180 & above
Size
up to
25mm2
1.00
0.99
0.98
0.97
0.96
0.95
19
45
0.95
above
25mm2
up to
300mm2
above
300 mm2
1.00
0.98
0.97
0.96
0.94
0.93
1.00
0.97
0.96
0.95
0.92
0.91
50
0.89
40
0.91
45
0.87
ii) for variation in thermal resistivity of soil

(twin & multi-core Cables laid direct in the ground)
Nominal area of
conductor mm2
for value of thermal Resistivity of soil in C cm/W

120
150
200
250
1.05
1.00
0.92
0.86
1.05
1.00
0.92
0.86
1.05
1.00
0.92
0.86
1.05
1.00
0.92
0.86
1.06
1.00
0.92
0.85
1.06
1.00
0.91
0.84
1.08
1.00
0.91
0.84
1.08
1.00
0.91
0.84
1.08
1.00
0.91
0.84
1.08
1.00
0.90
0.83
1.08
1.00
0.90
0.83
1.08
1.00
0.90
0.82
1.09
1.00
0.90
0.82
1.09
1.00
0.89
0.81
1.09
1.00
0.89
0.81
1.09
1.00
0.89
0.81
1.10
1.00
0.89
0.81
-
100
1.10
1.10
1.10
1.10
1.10
1.12
1.14
1.15
1.15
1.15
1.15
1.17
1.17
1.18
1.18
1.18
1.19
-
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
300
0.81
0.81
0.81
0.81
0.80
0.79
0.78
0.77
0.77
0.76
0.76
0.76
0.76
0.75
0.75
0.75
0.75
-
iii) for variation in thermal resistivity of soil (2 & 3 single-core Cables laid direct in the ground)
Nominal area of
conductor mm2
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
2 cables touching, for value of thermal

Resistivity of soil in C cm/W
100
1.15
1.15
1.15
1.15
1.15
1.17
1.18
1.18
1.18
1.19
1.19
1.21
1.21
1.21
1.21
1.21
1.21
1.21
1.21
120
1.08
1.08
1.08
1.08
1.08
1.09
1.09
1.09
1.09
1.09
1.09
1.10
1.10
1.10
1.10
1.10
1.10
1.10
1.10
150
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
200
0.91
0.91
0.91
0.91
0.90
0.90
0.90
0.90
0.90
0.89
0.89
0.89
0.89
0.89
0.89
0.89
0.89
0.89
0.89
3 cables in Trefoil touching, for value of thermal

Resistivity of soil in C cm/W
250
0.84
0.84
0.84
0.84
0.83
0.83
0.82
0.82
0.82
0.81
0.81
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
300
0.78
0.78
0.78
0.78
0.77
0.77
0.76
0.75
0.75
0.74
0.74
0.74
0.74
0.74
0.74
0.74
0.74
0.74
0.74
100
1.18
1.18
1.18
1.18
1.18
1.19
1.19
1.20
1.20
1.21
1.22
1.22
1.22
1.22
1.22
1.22
1.24
1.24
1.24
120
1.09
1.09
1.09
1.09
1.09
1.09
1.09
1.09
1.09
1.10
1.10
1.10
1.10
1.10
1.10
1.10
1.11
1.11
1.11
150
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
200
0.90
0.90
0.90
0.90
0.89
0.89
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
250
0.82
0.82
0.82
0.82
0.81
0.81
0.80
0.80
0.80
0.80
0.80
0.79
0.79
0.79
0.79
0.79
0.79
0.79
0.79
300
0.76
0.76
0.76
0.76
0.75
0.74
0.74
0.74
0.74
0.74
0.74
0.74
0.73
0.73
0.73
0.72
0.72
0.72
0.72
A) GROUP RATING FACTORS

For single core cables laid in Trefoil formation
A) Cable laid in ground in horizontal formation
No of Trefoils in
group
2
3
4
5
Distance/Spacing between trefoils

Touching
15 cm
30 cm
0.78
0.68
0.61
0.56
0.81
0.71
0.65
0.61
0.85
0.77
0.72
0.68
B) Cable laid in Trefoil Ducts in horizontal formation

45 cm
No of Trefoils
in group
0.88
0.81
0.76
0.73
2
3
4
5
20

Touching
15 cm
45 cm
0.87
0.79
0.74
0.71
0.90
0.83
0.79
0.76
0.91
0.86
0.82
0.80
C) Cable laid on Racks / Trays in covered trench with removable

covers where air circulation in restricted, Trefoils are
seperated by two cable diameter horizontally and the trays
are in tiers with 30 cm. gap between them.
D) Cable laid in open air trench, Trefoils are

seperated by two cable diameter horizontally
and the trays are in tiers with 30 cm. gap
between them.
No. of trefoils in Horizontal

formation
No of
racks / Trays
in tiers
1
2
3
6
0.95
0.90
0.88
0.86
0.90
0.85
0.83
0.81
No. of trefoils in Horizontal

formation
No of
racks / Trays
in tiers
0.88
0.83
0.81
0.79
1
2
3
6
1.00
1.00
1.00
1.00
0.98
0.95
0.94
0.93
0.96
0.93
0.92
0.90
B) GROUP RATING FACTORS

For Multi-core cables
A) Cable laid inside concrete trench with removable covers, on cables trays where air
circulation is restricted, the cables are spaced by one cable diameter & trays are
in tiers by 300 mm. The clearance from the wall is 25 mm.
No of Cable
trays in tier
1
2
3
6
0.95
0.90
0.88
0.86
0.90
0.85
0.83
0.81
No. of cables
3
0.88
0.83
0.81
0.79
0.85
0.81
0.79
0.77
0.84
0.80
0.78
0.76
B) Cable laid on trays exposed to air, the cables are spaced by one cable diameter &
trays are in tiers by 300 mm. The clearance between the wall & the cable is 25 mm.
No of Cable
trays in tier
No. of cables
3
1
2
3
6
1.00
1.00
1.00
1.00
0.98
0.95
0.94
0.93
0.96
0.93
0.92
0.90
0.93
0.90
0.89
0.87
0.92
0.89
0.88
0.86
B) Cable laid on trays exposed to air, the cables touching & trays in tiers by 300 mm.
The clearance between the wall & the cable is 25 mm.
No of Cable
trays in tier
No. of cables
3
1
2
3
6
1.00
1.00
1.00
1.00
0.84
0.87
0.78
0.76
0.80
0.76
0.74
0.72
0.75
0.71
0.70
0.68
0.73
0.69
0.68
0.66
D) Cable laid direct in ground in horizontal formation

No of Trefoils in
group
Touching
2
3
4
5
6
0.79
0.69
0.62
0.58
0.54

15 cm
30 cm
0.82
0.75
0.69
0.65
0.61
0.87
0.79
0.74
0.72
0.69
E) Cable laid in single way duct/pipes in horizontal

formation
45 cm
No of Trefoils
in group
Touching
0.90
0.83
0.79
0.76
0.75
2
3
4
5
6
0.88
0.82
0.77
0.74
0.71
21

15 cm
30 cm
0.90
0.84
0.80
0.78
0.76
0.92
0.87
0.84
0.82
0.81
45 cm
0.94
0.89
0.87
0.85
0.84
GUIDANCE ON HANDLING, STORING & LAYING OF POWER CABLES

Handling (Unloading at site) :
Damage to cables can occur due to the incorrect handling to which the drums & cables may be subjected, causing breakdown of the drum
flanges & in exceptional cases,movement of the drum barrel takes place.
The cable drums should not be dropped or thrown from railway wagons or trucks during unloading operations as the shock may cause
serious damage to cable layers. A crane should be used for unloading cable drums. When lifting drums with the crane, it is recommended
that the lagging should be kept in place to prevent the flanges from crushing on to the cable. If the crane is not available, a ramp should be
prepared with approximate inclination. The cable drum should be rolled over the ramp by means of ropes and winches. Additionally a sand
bed at the foot of the ramp may be prepared to brake the rolling of the cable drum.
Cable should not be dragged along the earth surface.
Cable ends should always be sealed by means of suitable end sealing materials to prevant moisturisation of cores and armour.
Drums should be rolled in direction of arrow marked on the drum.
Storage :
Cables should be stored in a dry covered place to prevent exposure to climatic conditions and wear and tear of wooden drums and it should
preferably be on a concrete firm surface which will not cause the drums to sink and thus lead to flange rot and extreme difficulty in moving
the drums.
All drums should be stored in a manner to leave sufficient space between them for air circulation. It is desirable for drums to stand on
battens placed directly under the flanges.
In no case should the drums be stored, On the Flat, i.e., with flange (see fig.)
Cables should be protected from direct rays of the sunrays by leaving the battens on or by covering the cables with thick black polythene sheet.
Note:- Cable ends must be sealed with end caps during storage & transportation.
Laying :
For laying of cables special care is to be taken to prevent sharp bending, kinking, twisting. Cable should be unwound from drum by proper
mounting of the cable drum on a cable wheel and ensuring the spindle strong enough to carry the weight without bending and that it is lying
horizontally in the bearings so as to prevent the drum creeping to one side or the other while it is rotating. It is important that the rolling of
the drum to this position should be in accordance with the arrow on the flange-to prevent loose turns during unwinding.
Provision should be made to break the drum to avoid further rolling & buckling of cable during sudden stop. A simple wooden plank can
serve this purpose.
Cable must be pulled

from the top
This is incorrect way of pulling the cable & will cause

kinks & twist in cable. Shall be avoided at all
22
However, following salient points are to be considered during laying procedure of cables laid in racks and in built-in trenches.
l Before laying cables shall be checked with megger as a primary check.
l During laying try to place power cables at the bottom most layer and control cables at the top most layer.
l Single core power cable for use on A.C. system shall not pass through steel conduit or shall not be surrounded by steel which may lead
to heat generation due to magnetic hysteresis.
l In case of multicore power cables, cables shall be laid side by side, with spacings not less than one cable diameter. However derating
factors for cables laid on trenches are to be referred.
l The clamps shall not be placed at intervals more than 1200 mm. for horizontal and 1000 mm. for vertical runs.
l Where the cables are necessarily laid & jointed in very cold regions, both the cables & the ambient temperatures should be above 0C
& the cable should not be bent to very small radius.
l This is due to the reason that at very low temperatures PVC compound become stiff & brittle & are likely to crack & shatter when struck
hard or bent to small radius.
l A joint being the weakest point of the electric power transmission system,the jointing work should be made skillfully. In this connection,
it is always advisable that the method & the working instruction of the supplier should be strictly followed.
l For armoured cables all bonding clamps at the joints and terminations and the armour wires should be thoroughly cleaned. The clamps
should be adequately tightened. This is necessary to ensure proper electrical contact, because armour is the only return path for earth
fault current.
l For Unarmoured cables the external earth bonding connector of adequate size should be used.
l All joints, terminations, armour wires and external metallic bonding should be connected to earth. Wherever possible armour at one
end of cable should be connected to main earth system of the supplying end with metallic connectors.
l The design of the junction box and the composition of the filling compound should provide effective sealing against ingress of moisture
to conductor ferrules/lugs and armour connectors.
l After installation 4kV dc voltage, increased gradually, shall be applied to the cable for 15minutes to each core against the balance cores
and armour. No breakdown should occur during the test.
Minimum Bending Radius for L.V. Cables:Type of cables :
Minimum internal radius of bend
l Single core Cables
:
15 D
l Multi core Cables
:
12 D
Where D is the overall diameter of cable.
Maximum permissible tensile strength for cables

A) Maximum safe pulling force for cables (when pulled by pulling eye) :l For Copper Conductor Cables

l For Aluminium Conductor Cables

= 5.0 Kgf x number of cores x conductor cross-section

= 50 N x number of cores x conductor cross-section
= 3.0 Kgf x number of cores x conductor cross-section
= 30 N x number of cores x conductor cross-section
(Subjected to maximum of 2000kgf or 20,000 N)
B) Side wall Pressure :

= (Maximum Pulling force(Kgf x 100 ) /Minimum Bending Radius(mm)

(Subject to a maximum of 500kgf or 5,000 N/m)
C) For cables pulled with stocking :l Armoured cables

P = 9 D2
l Unrmoured cables
P = 9 D2
Where,
P = Pulling force in Newtons
D = Outer diameter of cables in mm
23
Manufacturing
Process forfor
LT PVC
Cables Cables
Manufacturing
Process
LT PVC
CONDUCTOR
WIRE DRAWING / ANNEALING / STRANDING
INSULATION
CURING
LAYING UP
SCREENING (OPTIONAL)
INNERSHEATH
EXTRUDED / TAPED
ARMOUR
G. I. ARMOUR / AL ARMOUR
OUTERSHEATH
TESTING
PACKING
24
KEC is one of the oldest players in the industry and global leader in the Infrastructure Engineering, Procurement and
Construction space. Established in 1945, KEC has a signifcant presence in the segments of Power Transmission &
Distribution, Cabling, Railway, Telecom and Water Resource management. KECs strengths lie in Engineering, Design,
Manufacture and Testing, supply of transmission towers, telecom towers, cables and Construction of turnkey infrastructure
projects. KECs focused approach towards project management enables the creation of world class products, innovative
solutions, customized to overcome extreme terrain and climate. With proven technical process in handling mega projects
and superior project management expertise, KEC has made an indelible mark on the world map by constantly and consistently
reengineering itselfto retain its position of leadership in the areas of quality, technology, capacity and capability.
RPG Enterprises is one of Indias largest business conglomerates. Since its inception in 1979, RPG Enterprises has been one of
the fastest growing business houses in India. RPG Enterprises has diverse businesses under its fold ranging from Power, Tyres,
Infrastructure, IT to Pharma. The Groups management comprises individuals extensively qualifed and experienced in their domain
areas. RPGs wide ranging business invite growing returns and high esteem in the eyes of all its stakeholders. The Group lives by
values of keen entrepreneurial skills, performance and excellence.
Corporate Office
6th Floor, RPG House, 463. Dr. Annie Besant Road, Worli, Mumbai - 400 030, India.
Tel.: +91-22-66670300, 24937244 I Fax : +91-22-24930206
email : powercables@kecrpg.com I telecomcables@kecrpg.com I exportcables@kecrpg.com
Works
Thane : II Pokharan Road, PB No. 11, Thane, Pin - 400 601, Maharashtra, India.
Silvassa : Plot No. 273/4, Demni Road, Dadra, Silvassa, Pin - 396 193, UT of D & NH, India.
Mysore : 349/350, Hebbal Industrial Area, Hootgalli, Belavadi Post, Mysore, Pin - 570 018, Karnataka, India.
Delhi
Zensar Business Centre | N-83,
1st Floor (Above PNB), Connaught Place,
New Delhi - 110 001, India.
Tel. : +91-11-66098599
Fax : +91-11-66098597
Mumbai
6th Floor, RPG House, 463.
Dr. Annie Besant Road, Worli,
Mumbai - 400 030, India.
Tel. : +91-22-66670300, 24937244
Fax : +91-22-24930206
Pune
Flat No.9, KSHITIJ,1 st Floor, 769/6,
Lane No.7, Prabhat Road, Deccan
Gymkhana, Pune - 411 004, India.
Tel. : +91-20-64706061, 6065
Fax : +91-20-25650414
Chennai
Bhavani Mansion No.3, 4th Lane,
Nungambakkam High Road,
Chennai - 600 034, India.
Tel. : +91-44-28332920, 28332918
Fax : +91-44-28332917
Kolkata
Halwasiya Mansion, Ground Floor,
6/2, Moira Street,
Kolkata - 700 017, India.
Tel. : +91-33-64590654
Fax : +91-33-22906720
Vadodara
A-304, Siddhi Vinayak Complex,
Faramji Compound, Bh. Rly. Station,
Alkapuri, Vadodara - 390 007, India.
Tel. : +91-265-3015454
Fax : +91-265-3015454
Hyderabad
406 & 407, Maheshwari Chambers,
Erramanzil, Somajiguda,
Hyderabad - 500 082, India.
Tel. : +91-40-30901642
Fax : +91-40-30901642
Bangalore
C/o. CEAT Limited, Jasmine
Mansion, 4th Floor, 19, J. C. Road,
Bangalore - 560 002, India.
Tel. : +91-80-22124444
Fax : +91-80-22124444
July 2011
MANGALAM M : +91 98203 48854
Sales Offices

KEC LT XLPE Cables Brochure

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KEC LT XLPE Cables Brochure

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TECHNICAL CATALOGUE

SPECIFICATION & CONSTRUCTION

Fire Survival cables :

TYPICAL CROSS SECTIONAL VIEW OF LT CABLES

- Copper or Aluminium (A)

- Type XLPE (2X)

3. Outersheath - ST2 PVC (Y)

Typical Cable Codes : 2XY, A2XY

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

Typical Cable Codes : 2XY(P), 2XY(T), A2XY(P), A2XY(T)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

Typical Cable Codes : 2XY(P), 2XY(T), A2XY(P), A2XY(T)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

Typical Cable Codes : 2XY(P), 2XY(T), A2XY(P), A2XY(T)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

Typical Cable Codes : 2XY(P), 2XY(T), A2XY(P), A2XY(T)

TYPICAL CROSS SECTIONAL VIEW OF LT CABLES

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

- Aluminium Round wire / Flat strip

5. Outersheath - ST2 PVC (Y)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

- G.S.Round wire / Flat strip

5. Outersheath - ST2 PVC (Y)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

- G.S.Round wire / Flat strip

5. Outersheath - ST2 PVC (Y)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

- G.S.Round wire / Flat strip

5. Outersheath - ST2 PVC (Y)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

- G.S.Round wire / Flat strip

5. Outersheath - ST2 PVC (Y)

- Copper or Aluminium (A)

- Type " XLPE" (2X)

3. Innersheath - ST2 Extruded PVC {(P)} or Thermoplastic tapes {(T)}

- G.S.Round wire / Flat strip

5. Outersheath - ST2 PVC (Y)

Maximum D.C. Resistance

Maximum A.C. Resistance

Maximum A.C. Resistance

TABLE 4 A- IMPEDANCE (Plain Copper Conductor) @ 90C

Single Core @ 90C

TABLE 4 B- IMPEDANCE (Aluminium Conductor) @ 90C

Single Core @ 90C

TABLE 5 A- VOLTAGE DROP (Plain Copper Conductor) @ 90C