SHYAM CABLE INDUSTRIES

All Types Of Cables Manufacturer Company

Engineering Customized Power Solutions
WELCOME TO
OUR COMPANY
Chapter Page No.
INTRODUCTION 1
PRODUCT RANGE 2
LIST OF GOVERNMENT CLIENTS 3
LIST OF OTHER REPUTED CLIENTS 4
LIST OF MACHINERY 5
LIST OF TESTING EQUIPMENTS 6
QUALITY CONTROL 7
CURRENT RATING 8
PROCESS FLOW CHART (PVC CABLES) 9
QUALITY ASSURANCE PLAN (PVC CABLES) 10
CONSTRUCTION OF POWER CABLES 14
PROCESS FLOW CHART (RUBBER CABLES) 23
QUALITY ASSURANCE PLAN (RUBBER CABLES) 24
TECHNICAL OF ELASTOMERIC CABLES 26
TECHNICAL OF WELDING CABLES 28
PROPERTIES OF RAW MATERIAL USED 33
TELEPHONE CABLES 40
LIST OF REGISTRATION CERTIFICATE & PERFORMANCE CERTIFICATES 42
LIST OF PURCHASE ORDERS 52

1
SALIENT FEATURES
1. Well equipped and most modern laboratory having ISO-9001 and ISI carrying out
extensive tests from raw materials to final products at various stages.

2. Cables manufacturing conforming to various National and International specifications

having four “BIS” License: 9968/Pt-I/1988, 1554/Pt-1/1988, 9857/90 & 694/90.

3. Approval accorded by a number of Organisations and Inspection agencies of International

repute like IFFCO, BHEL, NLC, RSP, BSP, SAIL, ONGC, NTPC, DGS&D, Air Hqs., DGQA
(Naval) LGT, MECON, PDIL etc.

4. Specialisation in Elastometric / Flexible Cables (Butyl/EPR, PCP /CSP and Silicon Rubber
Cables)

5. 40 successful years of regular supply to numerous Government Departments / Public /

Private Sector Industrial Enterprises.

6. 80% of Production ongoing to Government Department and reputed public Sector

Undertaking all over the country.

CLIENTELE
Our more than 40 years of journey towards service with excellence has given us numerous all over
India in all the sectors of the India Economy, 80% of them in government / Public Sector. Today
hundreds of industrial enterprises rely on Shyam Cable in the key sectors like Steel plants, Power
Projects, Aeronautics, Ordnance factories, Railways, Fertilizer Plants, Atomic Energy, Air Force,
Petroleum, Navy, Shipyards, Mines, Power Stations, Oil & Natural Gas, Port Trusts, Coalfields,
Heavy Engineering, Telecommunication. Electrical and Electronics, Wind Energy and so on.

2
PRODUCTS
S.No. Type of Cables Specification Size (Including &
upto)
No of cores x Area in Sq.mm

1. Elastomeric Cables IS: 9968/88/Pt-1 1 x 1000

(VIR/TRS, EPR, PCP/CSP & “ISI Marked” 3.5 x 630
Silicon Rubber Insulated Cables) 61 x 2.5

2. Power & Controls Cables IS: 1554/88/Pt-1 1 x 1000

(Armoured /Unarmoured PVC “ ISI Marked” 3.5 x 630
Insulated & Sheathed) 61 x 2.5

3. Trailing Cables IS: 9968/88/Pt-1 & Pt-II 1 x 1000

Upto 6.6/11 KV 3.5 x 630
61 x 2.5

4. Welding Cables IS: 9857/90 All Sizes

(Copper & Aluminium) “ ISI Marked”

5. PVC Wires/Cables IS: 694/90 All Sizes

“ISI Marked”
Lighting Cables
Screened Cables IS: 5608
Instrumentation Cables
Compensating Cables IS: 8784

6. FRLS Cables ASTM/D-2843 IS: 1554/88 All Sizes

7. Telephone Cables ITD-3003 100 Pairs

(Armoured /Unarmoured) G/WIR-06/02

8. Submersible IS: 694/90 61 x 2.5

Flat Cables IS: 9968/88/Pt-1 4 x 400

9. XLPE Cables IS: 7098 1 x 1000

(Armoured/ Unarmoured XLPE 3.5 x 630
Insulated & Sheathed Cables) 61 x 2.5

10. Kynar / HMWPE All Sizes

3
 LIST OF
GOVERNMENT CLIENTS
S A I L / BHILAI STEEL PLANT
S A I L / BOKARO STEEL PLANT
S A I L / ROURKELA STEEL PLANT
S A I L / DURGAPUR STEEL PLANT
NEYVELI LIGNITE CORP. LTD.
B H E L (HARIDWAR & TIRUCHIRAPALLI)
DAMODER VALLEY CORPORATION
R C F (KAPURTHALA)
MAZGOAN DOCK LTD.
NATIONAL FERTILIZER LIMITED
NUMALIGARH REFINERY LIMITED
THERI HYDRO DEVP. CORP. LTD.
CONTAINER CORP. OF IND. LTD.
N.E.E.P.C.O. LIMITED
ORDNANCE FACTORIES
HINDUSTAN STEEL WORKS CONS. LTD.
INDIA AIR FORCE
SATLUJ JAL VIDYUT NIGAM LTD.
NORTHERN RAILWAYS
P.D.I.L
BEML
NTPC
ONGC
NALC O
NHPC
GAIL (INDIA) LIMIITED
TRIVENI STRUCTURALS LTD.
NATIONAL MINERALS DEVELOPMENT CORP. LTD.
VISHAKHAPATNAM PORT TRUST
I F F C O Limited
URANIUM CORPORATION INDIA LIMITED
BONGAIGAON REFINERY & PETROCHEMICALS LTD.
PANIPAT THERMAL POWER STATION
COAST GUARD
NAVAL (MUMBAI, KOCHI, GOA)
BHARAT HEAVY PLATES & VESSELS LTD.
CHENNAI PORT TRUST
VISAKHAPATNAM STEEL PLANT
MEC0N LTD.
INDIAN OIL CORP. LTD.
4
LIST OF OTHER
REPUTED CLIENTS
RELIANCE INDUSTRIES LIMITED ENERCON
RELIANCE PETROLEUM LIMITED GUJARAT AMBUJA CEMENT
ELECON ENGINEERING CO. LTD. BHUSHAN STEEL LTD.
FENNER INDIA LTD. JINDAL STAINLESS LTD.
ISGEC JINDAL PIPE LTD.
DC M SHRIRAM (DAURALA) SIEMENS LIMITED
BALCO L&T LTD.
A.B.B. LTD. ADANI GROUP
ESSAR GROUP JINDAL STEEL & POWER
PRAKASH INDUSTRIES LIMITED
SUZLON ENERGY LTD.
MUKAND LIMITED
BEEKAY ENGG. CORPORATION .
RATHI SUPER STEEL LIMITED
BAJAJ HINDUSTAN LTD.
MONNET ISPAT & ENERGY LTD.
SIMPLEX ENGG. & FOUNDRY WORKS (P) LTD.

5
 LIST OF
MACHINERY
PVC Extruders (150 mm) Kneader

PVC Extruders (100 mm) PVC Mixtures

PVC Extruders (75 mm) Rubber Mixing Mills

PVC Extruders (40 mm) M.S. Vulcanisers Complete with

Rubber Extruders (100 mm)

Rubber Extruders (75 mm)

Rubber Extruders (40 mm)

Tray and stand.

Bale Cutting Machine

Wire Stranding & Trapping Machines

Taping Heads

High Speed Bunching Machine

Armouring Machines

Braiding Machines of various sizes

Core Printing Machine

Sequential length marking machine

M. S. Trolley

Laying Machines

Spooling Machines

High Speed Bunching

Welding Machine

Oil Fired Boiler

6
LIST OF
TESTING EQUIPMENTS
AC High Voltage Tester 10 KV Single Pan Electrical Balance

AC High Voltage Tester 30 KV Mandral for Bending Test

Double Kelvin Bridge Dombell Die with Stand

Million Meghohms Meter Tear Resistance Attachment

Hot Deformation Test Apparatus Air & Oxygen Bomb Apparatus

Volumetric Test Apparatus Oxygen Cylinder

Annealing Test Apparatus Meggar

Hot Water Bath Spark Tester

DC High Voltage Air Compressor

Hydraulic Press Tensile Testing Machine

Capacitance Meter Travelling Microscope

Flamability Test Apparatus Flame Resistance Test Apparatus

Standard Resistance Box Hot set Test Apparatus

Micrometer Humidity Conditioning Chamber

Digital Milliohm Meter Ozone Test Apparatus
Air Hot Oven Cold Band Test Apparatus
Fault Locator Smoke Density
Physical Balance Oxygen Index
Multimeter Halogen Acid Gas Generation
Ageing Oven Swedish Chimney
Ageing Air Oven Ladder Test

7
 QUALITY CONTROL
QUALITY CONTROL

1. Raw Material Control.

2. Process Control & Continuous on-line testing.
3. Product Control.

Shyam Cables maintains very high standards of product quality through a very strict and efficient
quality control system mainly.

RAW MATERIAL CONTROL

All raw materials under go rigorous testing for the conformity and stability in the
manufacturing process. A highly qualified and experienced group of Chemists ensure that
no sub-standard material is used in processing of cables.

PROCESS CONTROL
Process is controlled and checked by a team of experts and any deviations from standard
process in immediately checked and corrective action is taken.

PRODUCT CONTROL
100% testing and checking is done for cables. So that they are capable of giving
satisfactory services in actual use. Our engineers ensure the cable conform to the
standards is specified and results are well within relevant values.

Elastometric Insulated Cables for working voltage upto and insulating 1100 Volts as per IS-
9968 - Part - I/1988 “ISI Marked” and upto as per IS:9968 Part - II/81.
The elastometric insulated cables for fixed wiring, flexible cables and flexible cords for
electric power and lighting for operation at voltage upto an including 6.6 K.V. is
manufactured as per the requirements specified in IS: 9968 (Part-II) 1981.
The type of cables covered under this standard are as follows:-
1) For Fixed Wiring.
a) Braided and Compounded/Varnished.
b) Elastomeric sheathed (general purpose)
c) Elastomeric with earth community conductor (ECC)
2) For Fixed Wiring.
a) Braided and Varnished.
b) Elastomeric sheathed (Heavy Duty)
3) For Flexible Cords.
a) Braided.
b) Elastomeric sheathed (general purpose)
c) Unlinkable flexible cords.

8
 CURRENT RATINGS
The current ratings in table 1 & 2 based on the normal conditions of installation as described below :
0 0
1. Maximum condr. Temperature 70 C 5. Thermal resistivity of soil 150 C cm/watt
0 0
2. Ambient air temperature 40 C 6. Thermal resistivity of cable 650 C cm/watt
0 0
3. Ground temperature 30 C 7. Max. short-circuit conductor temp. 160 C
0
4. Depth of laying (for cable 8. Max. Ambient Air Temperature 55 C
laid directly in ground ) 75 cm (1.1 KV)

Installation method and rating factors are given in tables 1 to 6.

Table -1
Rating for variations in ground temperature for cables laid directly in ground and in ducts

0
Ground temperature C 15 20 25 30 35 40 45 50 55
Rating factor 1.17 1.12 1.06 1.0 0.94 0.87 0.79 0.70 0.80

Table -2
Rating factors for variation in amblent air temperature

0
Air temperature C 25 30 35 40 45 50 55

Rating factor 1.25 1.16 1.09 1.00 0.90 0.80 0.69

Table- 3
Rating factors of groups of twin and multicore cables laid directly in ground in horizontal formation

No. of cables Rating factor for axial spacing

Touching 15 cm 30 cm 45 cm 60 cm

2 cables 0.78 0.81 0.85 0.88 0.90

3 cables 0.68 0.71 0.77 0.81 0.83

4 cables 0.61 0.65 0.72 0.76 0.79

6 cables 0.53 0.58 0.66 0.71 0.78

8 cables 0.48 0.54 0.62 0.67 0.72

Table -4
Rating factors of groups of twin and multicore cables laid directly in ground in tier formation

No. of cables Rating factor for axial spacing

Touching 15 cm 30 cm 45 cm 60 cm

4 cables 0.60 0.67 0.73 0.76 0.78

6 cables 0.51 0.57 0.63 0.67 0.69

8 cables 0.45 0.51 0.57 0.59 0.61

Table -5
Rating factors for variation in depth of laying in ground

Depth of laying 75 90 105 120 150 150& above

Rating factor upto 25 sq. 1.00 0.99 0.98 0.97 0.96 0.95
mm.

Table 6
Group-rating factors for cables installed in ground, separated by more than 7 cms.

No of cables 1 2 3 4 5 6

Single core D.C cables & multicore power cables 1.0 0.90 0.80 0.75 0.70 0.65

Single core A.C. cables 1.0` 0.80 0.75 0.70 0.65 0.60

9
PROCESS FLOW
CHART FOR PVC CABLES

10
 QUALITY ASSURACE
CHART FOR PVC CABLES

11
QUALITY ASSURACE
CHART FOR PVC CABLES

12
 QUALITY ASSURACE
CHART FOR PVC CABLES

13
QUALITY ASSURACE
CHART FOR PVC CABLES

14
 POWER & CONTROL CABLE AS PER IS-1554 (PART-I) 1988
1.1 K.V Grade, Copper/Aluiminum Conductor, PVC/HR PVC Insulated
core laid up and PVC Inner Sheath, G.I. Steel Wire/Strip armoured
and Overall PVC/HR PVC/FRLS PVC sheathed Cable “ISI MARKED”
Material :
Copper conductors are of annealed high conductivity copper wires complying to
IS:8130/1984.
Aluminium conductors are of aluminium wire complying to IS-8130-1984.

Insulation :
It is of PVC compound conforming to the requirements of Type - A,B,C, of IS-5831-84
Inner Sheath : (Common Covering)
a) Vulcanised or unvulcanised rubber
b) Thermoplastic material
c) Proofed or plastic tape
Armoured :
a) Galvanised round steel wire
b) Galvanised steel strip
Outer Sheath :
The outer sheath is of PVC compund conforming to the requirements of Type ST-1, ST-2
of IS-5831-1970
Conductor :
(Nominal Cross Sectional/Area in mm ) 2

Copper Aluminium Solid/Stranded

1.5 1.5 Solid

2.5 to 6 2.5 to 10 Solid
10 and above 6 and aboveStranded Stranded

THE CABLES AMPACITY

Standard Conditions of installation for which the current carrying capacity

is given in the ensuing tables are :

Conductor temperature : 70 C Maximum

0

Thermal resistivity of soil : 150 C cm/w

0

Thermal resistivity of PVC : 650 C cm/w

0

Ambient temperature : 40 C
0

Ground temperature : 30 C
0

Depth of laying cable : 75 cm in the ground

15
 UNARMOURED CONTROL CABLE IS : 1554 (Pt - I ) - 1988
N o. of T h ick n ess T h ick n ess T h ik n ess o f A p p ro x . A p p ro x . S ta n d a rd
C ro res of PV C of PV C PV C O .D . N et. D eliv ery
& C ro ss in su ta io n In n ersh ea th o u tersh ea th W eig h t L en g th C u rren t R a tin g
S ectio n a l (N o m .) (M in ) (N o m .) of in M trs. D irect in In
A rea N O mm C a b les G ro u u n d A ir/D u ct
x m m 2. mm mm mm K g /k m A m p s. A m p s.

2 x 1 .5 0 .8 0 .3 1 .8 1 1 .8 185 1000 23 20
3 x 1 .5 0 .8 0 .3 1 .8 1 2 .3 190 1000 21 17
4 x 1 .5 0 .8 0 .3 1 .8 1 3 .2 225 1000 21 17
5 x 1 .5 0 .8 0 .3 1 .8 1 4 .1 260 1000 16 14
6 x 1 .5 0 .8 0 .3 1 .8 1 5 .1 295 1000 15 13
7 x 1 .5 0 .8 0 .3 1 .8 1 5 .1 315 1000 14 13
1 0 x 1 .5 0 .8 0 .3 1 .8 1 8 .4 425 1000 13 11
1 2 x 1 .5 0 .8 0 .3 1 .8 1 8 .9 480 1000 12 10
1 4 x 1 .5 0 .8 0 .3 1 .8 1 9 .8 535 1000 11 10

1 6 x 1 .5 0 .8 0 .3 1 .8 2 0 .7 595 1000 11 9
1 9 x 1 .5 0 .8 0 .3 2 .0 2 2 .5 720 1000 10 9
2 4 x 1 .5 0 .8 0 .3 2 .0 2 5 .8 880 1000 9 8
2 7 x 1 .5 0 .8 0 .3 2 .0 2 6 .3 960 1000 9 8
3 0 x 1 .5 0 .8 0 .3 2 .0 2 7 .2 1040 1000 9 7
3 7 x 1 .5 0 .8 0 .3 2 .0 2 9 .1 1230 1000 8 7
2 x 2. 5 0 .9 0 .3 1 .8 1 3 .0 230 1000 32 27
3 x 2. 5 0 .9 0 .3 1 .8 1 3 .6 240 1000 27 24
4 x 2. 5 0 .9 0 .3 1 .8 1 4 .6 290 1000 27 24
5 x 2. 5 0 .9 0 .3 1 .8 1 5 .7 335 1000 23 19
6 x 2. 5 0 .9 0 .3 1 .8 1 6 .9 385 1000 21 18
7 x 2. 5 0 .9 0 .3 1 .8 1 6 .9 420 1000 20 17
10 x 2. 5 0 .9 0 .3 1 .8 2 0 .8 570 1000 18 15
12 x 2. 5 0 .9 0 .3 2 .0 2 2 .2 690 1000 17 14
14 x 2. 5 0 .9 0 .3 2 .0 2 3 .2 775 1000 16 13
16 x 2. 5 0 .9 0 .3 2 .0 2 4 .3 860 1000 15 13
19 x 2. 5 0 .9 0 .3 2 .0 2 5 .5 985 1000 14 12
24 x 2. 5 0 .9 0 .3 2 .0 2 9 .4 1215 1000 13 11
27 x 2. 5 0 .9 0 .3 2 .0 3 0 .0 1330 1000 12 10
30 x 2. 5 0 .9 0 .3 2 .0 3 1 .0 1450 1000 12 10
37 x 2. 5 0 .9 0 .3 2 .2 3 4 .1 1790 1000 11 9

Construction
1. Solid/ Stranded annealed copper conductor & Tinned / Bare
2. General Purpose /HR PVC insulation
3. Cores laid up (filled if needed )
4. FRLS / General Purpose PVC inner Sheath
5. FRLS / General Purpose PVC Outer sheath

Max Conductor D.C Resistance at 20 Deg C – Conductor Size:

1.5 sq mm -12.1 Ohm /km (Bare, 12.2 Q/km (Tinned)
2.5 sq mm -7.41 Ohm /km (Bare, 7.56 Q/km (Tinned)
*Dimensions specified are with stranded conductor

16
 1 CORE ALUMINIUM PVC ARMOURED POWER CABLES

Type No. of Min Thickness Nominal Min Overall Approx Max.D. Max AC Approx Approx.
cores no. of of PVC Dimension Thickness Deamte Net Wt C Resista Reactance Capacit
&Cross Wires insulation s of of PVC r of cable Resista nce at at 50Hz ance
Section (nom) Armour Outer (Approx nce at 70
al Area Wire (mm) Sheath ) 70

Mm (mm) (Kg/Km) Km
Ohms Ohms/k Km
(mm) /km m
Ayway 1Cx4 1 1.30 1.40 1.24 11 160 7.4100 8.8900 0.158 0.47

Ayway 1Cx6 1 1.30 1.40 1.24 12 180 4.6100 5.5300 0.148 0.56

Ayway 1Cx10 1 1.30 1.40 1.24 13 210 3.0800 3.7000 0.138 0.67

Ayway 1Cx16 6 1.30 1.40 1.24 14 240 1.9100 2.2900 0.128 0.81

Ayway 1Cx25 6 1.50 1.40 1.24 15 310 1.2000 1.4400 0.120 0.87

Ayway 1Cx35 6 1.50 1.40 1.24 16 360 0.8680 1.0400 0.114 1.00

Ayway 1Cx50 6 1.70 1.40 1.24 18 450 0.6410 0.7700 0.110 1.03

Ayway 1Cx70 12 1.70 1.40 1.40 20 560 0.4430 0.5300 0.103 1.21

Ayway 1Cx95 15 1.90 1.60 1.40 22 720 0.3200 0.3800 0.101 1.27

Ayway 1Cx120 15 1.90 1.60 1.40 24 830 0.2530 0.3000 0.096 1.42

Ayway 1Cx150 15 2.10 1.60 1.40 27 980 0.2060 0.2500 0.094 1.42

Ayway 1Cx185 30 2.30 1.60 1.40 28 1160 0.1640 0.2000 0.092 1.44

Ayway 1Cx240 30 2.50 1.60 1.56 31 1450 0.1250 0.1500 0.090 1.53

Ayway 1Cx300 30 2.70 2.00 1.56 35 1710 0.1000 0.1200 0.088 1.56

Ayway 1Cx400 53 3.00 2.00 1.56 39 2190 0.0778 0.0934 0.088 1.56

Ayway 1Cx500 53 3.40 2.00 1.72 40 2730 0.0605 0.0726 0.087 1.57

Ayway 1Cx630 53 3.90 2.00 1.88 48 3440 0.0469 0.0563 0.086 1.57

Ayway 1Cx800 53 3.90 2.00 1.88 52 4120 0.0367 0.0440 0.083 1.75

Ayway 1Cx1000 53 3.90 2.50 2.04 57 5090 0.0291 0.0349 0.082 1.94

17
 1 CORE ALUMINIUM PVC UNARMOURED POWER CABLES

Type No. of Min Thickness Nom. Overall Net Wt of Max.D.C Max AC Approx Approx.
cores no. of of insulation Thickness Diameter cable Resistan Resistance Reactanc Capacita
0
&Cross Wires (nom) of Outer (Appro) (approx) ce at at 90 C e at 50Hz nce
0
Sectional Sheath 20 C
Area
Mm (mm) (mm) (Kg/Km) Ohms Ohms/km Km Km
/km

Ayy 1CX4 1 1.00 1.80 8 100 7.4100 8.8900 0.137 0.58

Ayy 1CX6 1 1.00 1.80 9 110 4.6100 5.5300 0.127 0.68

Ayy 1CX10 1 1.00 1.80 10 130 3.0800 3.7000 0.118 0.83

Ayy 1CX16 6 1.00 1.80 11 160 1.9100 2.2900 0.110 1.01

Ayy 1CX25 6 1.20 1.80 12 220 1.2000 1.4400 0.105 1.05

Ayy 1CX35 6 1.20 1.80 13 260 0.8680 1.0400 0.100 0.22

Ayy 1CX50 6 1.40 1.80 15 330 0.6410 0.7700 0.098 1.22

Ayy 1CX70 12 1.40 1.80 17 410 0.4430 0.5300 0.091 0.43

Ayy 1CX95 15 1.60 1.80 19 530 0.3200 0.3800 0.088 1.47

Ayy 1CX120 15 1.60 2.00 21 640 0.2530 0.3000 0.086 1.62

Ayy 1CX150 15 1.80 2.00 23 770 0.2060 0.2500 0.085 1.62

Ayy 1CX185 30 2.00 2.00 25 920 0.1640 0.2000 0.084 1.62

Ayy 1CX240 30 2.20 2.00 28 1160 0.1250 0.1500 0.082 1.72

Ayy 1CX300 30 2.40 2.00 30 1390 0.1000 0.1200 0.080 1.74

Ayy 1CX400 53 2.60 2.20 35 1760 0.0778 0.0934 0.080 1.81

Ayy 1CX500 53 3.00 2.20 39 2200 0.0605 0.0726 0.079 1.76

Ayy 1CX630 53 3.40 2.40 44 2620 0.0469 0.0563 0.077 1.77

Ayy 1CX800 53 3.40 2.40 48 3430 0.0367 0.0440 0.077 1.98

Ayy 1CX1000 53 3.40 2.60 53 4180 0.0291 0.0349 0.076 2.20

18
 2 CORE ALUMINIUM PVC ARMOURED POWER CABLES
Type No. of Min no. Thickne Min Nominal Min. Thickness OF Overall Diameter Appox Net Wt. of Max.D. Max Approx Approx.
cross & of Wires ss of Thic Dimension of pvc outer (approx) cable C AC Reacta Capacit
Cross PVC knes Armour strength Strip Wire Resista Resist nce at ance
Sectional insulati s of Strip Wire Strip Wire Armour Armour nce at ance 50Hz
Area on PVC Armour Armour Strip wire 20 at 70
(nom) Oute Armour
r (mm) (mm) (mm) Km
She Km
Mm ath( (Kg/Km) Ohms
mm) /km Ohms
/km

Aywy 2CX1.5 1 0.8 0.3 - 1.40 - 1.24 - 13.5 - 390 18.10 21.72 0.126 0.14

Aywy 2CX2.5 1 0.9 0.3 - 1.40 - 1.24 - 15.0 - 450 12.10 14.52 0.119 0.15

Aywy 2CX4 1 1.0 0.3 - 1.40 - 1.24 - 16.5 - 550 7.41 8.89 0.116 0.16

Aywy 2CX6 1 1.0 0.3 - 1.40 - 1.24 - 17.5 - 640 4.61 5.53 0.110 0.19

Aywy 2CX10 1 1.0 0.3 - 1.40 - 1.24 - 19.0 - 745 4.08 3.70 0.100 0.22

Aywy/
2CX16 6 1.0 0.3 4X0.8 1.60 1.40 1.40 20.5 22.5 565 830 1.91 2.29 0.097 0.29
Ayfy

Aywy/
2CX25 6 1.2 0.3 4X0.8 1.60 1.40 1.40 21.0 23.0 700 905 1.20 1.44 0.097 0.32
Ayfy

Aywy/
2CX35 6 1.2 0.3 4X0.8 1.60 1.40 1.40 22.5 24.0 810 1040 0.868 1.04 0.097 0.37
Ayfy

Aywy/
2CX50 6 1.4 0.3 4X0.8 1.60 1.40 1.56 25.0 27.0 1000 1290 0.641 0.77 0.094 0.37
Ayfy

Aywy/
2CX70 12 1.4 0.3 4X0.8 1.60 1.56 1.56 28.0 29.5 1230 1510 0.443 0.53 0.090 0.44
Ayfy

Aywy/
2CX95 15 1.6 0.4 4X0.8 2.00 1.56 1.56 31.5 34.0 1520 2060 0.320 0.38 0.090 0.44
Ayfy

Aywy/
2CX120 15 1.6 0.4 4X0.8 2.00 1.56 1.72 33.5 36.5 1765 2360 0.253 0.30 0.087 0.49
Ayfy

Aywy/
2CX150 15 1.8 0.4 4X0.8 2.00 1.72 1.72 37.0 39.5 2080 2700 0.206 0.25 0.087 0.49
Ayfy

Aywy/
2CX185 30 2.0 0.5 4X0.8 2.00 1.88 1.88 41.0 43.0 2500 3175 0.164 0.20 0.087 0.49
Ayfy

Aywy/
2CX240 30 2.2 0.5 4X0.8 2.50 2.04 2.04 45.5 49.0 3075 4230 0.125 0.15 0.087 0.50
Ayfy

Aywy/
2CX300 30 2.4 0.6 4X0.8 2.50 2.20 2.20 50.0 53.5 3760 4950 0.100 0.12 0.086 0.52
Ayfy

Aywy/
2CX400 53 2.6 0.7 4X0.8 3.15 2.36 2.52 55.5 60.5 4560 6560 0.0778 0.09 0.086 0.53
Ayfy

19
 3 CORE ALUMINIUM PVC ARMOURED POWER CABLES
Type No. of Min Thick Min Nominal Min. Thickness Overall Appox Net Wt. Max. Max Approx Approx
cores no. of ness Thi Dimension of OF pvc outer Diameter of cable D.C AC Reactan Capaci
&Cross Wires of ckn Strip/Wire strength (approx) Strip/wire Resist Resi ce at tance
Section PVC ess Armour Strip/ Wire Strip/Wire Armour ance stan 50Hz
al Area insula of Armour Armour at 20 ce at
tion PV 70
(nom) C
Out (mm) (mm) (mm) (Kg/Km) Ohms Ohm Km Km
er /km s/km
(mm) She
ath(
mm
)

Aywy 3Cx1.5 1 0.8 0.3 - 1.40 - 1.24 - 14.0 - 420 18.10 21.72 0.126 0.14

Aywy 3Cx2.5 1 0.9 0.3 - 1.40 - 1.24 - 15.0 - 500 12.10 14.52 0.119 0.15

Aywy 3Cx4 1 1.0 0.3 - 1.40 - 1.24 - 16.5 - 595 7.41 8.89 0.116 0.41

Aywy 3Cx6 1 1.0 0.3 - 1.40 - 1.24 - 17.5 - 685 4.61 5.53 0.110 0.47

Aywy 3Cx10 1 1.0 0.3 - 1.40 - 1.40 - 19.5 - 830 3.08 3.70 0.100 0.56

Aywy/
3Cx16 6 1.00 0.3 4x0.8 1.60 1.40 1.40 19.5 21.0 680 890 1.91 2.29 0.097 0.76
Ayfy

Aywy/
3Cx25 6 1.2 0.3 4x0.8 1.60 1.40 1.40 22.5 24.0 880 1120 1.20 1.44 0.097 0.86
Ayfy

Aywy/
3Cx35 6 1.2 0.3 4x0.8 1.60 1.40 1.40 24.0 25.5 1025 1305 0.868 1.04 0.097 0.98
Ayfy

Aywy/
3Cx50 6 1.40 0.3 4x0.8 1.60 1.56 1.56 27.5 29.0 1310 1605 0.641 0.77 0.094 1.02
Ayfy

Aywy 3Cx70 12 1.6 0.4 4x0.8 2.00 1.56 1.56 30.5 33.0 1630 2160 0.443 0.53 0.090 1.18

Aywy/
3Cx95 15 1.6 0.4 4x0.8 2.00 1.56 1.72 34.5 37.5 1990 2645 0.320 0.38 0.090 1.20
Ayfy

Aywy/
3Cx120 15 1.6 0.4 4x0.8 2.00 1.72 1.72 38.0 40.5 2375 3050 0.253 0.30 0.087 1.31
Ayfy

Aywy/
3Cx150 15 1.8 0.5 4x0.8 2.00 1.88 1.88 41.5 44.0 2825 3560 0.206 0.25 0.087 1.31
Ayfy

Aywy/
3Cx185 30 2.0 0.5 4x0.8 2.50 1.88 2.04 45.5 49.0 3365 4590 0.164 0.20 0.087 1.31
Ayfy

Aywy/
3Cx240 30 2.2 0.6 4x0.8 2.50 2.20 2.20 52.0 55.5 4250 5620 0.125 0.15 0.087 1.34
Ayfy

Aywy/
3Cx300 30 2.4 0.6 4x0.8 2.50 2.36 2.36 56.5 60.0 5140 6650 0.100 0.12 0.086 1.41
Ayfy

Aywy/
3Cx400 53 2.6 0.7 4x0.8 3.15 2.52 2.68 64.5 69.5 6270 8720 0.0778 0.09 0.086 1.45
Ayfy

20
 3.5 CORE ALUMINIUM PVC ARMOURED POWER CABLES

Type No. of Min Thickne Mi Nominal Min. Thickness Overall Appox Net Wt. Max.D Max Appro Approx
cores no. of ss of n Dimension of OF pvc outer Diameter of cable .C AC x .
&Cross Wires PVC Thi Armour strength (approx) Resist Resist React Capaci
Sectional insulatio ckn Strip Wire Strip Wire Strip Wire ance ance ance tance
Area n (nom) ess Armour Armour Armour Strip wire at 20 at 70 at
of Armour Armour 50Hz
PV (mm) (mm)
Mm C Km
Ou (mm) (Kg/Km) Ohms
ter /km Ohms/ Km
Sh km
eat
h(
m
m)

Aywy/ 3.5Cx 6/6 1.2/1.0 0.3 4x0.8 1.60 1.40 1.40 25.0 26.5 1000 1260 1.2000 1.44 0.097 0.86
Ayfy 25/16

Aywy/ 3.5Cx 6/6 1.2/1.0 0.3 4x0.8 1.60 1.40 1.40 26.0 27.5 1170 1450 0.8680 1.04 0.097 0.98
Ayfy 35/16

Aywy/ 3.5Cx 6/6 1.4/120 0.3 4x0.8 1.60 1.56 1.56 29.5 31.0 1470 1805 0.6410 0.77 0.094 1.02
Ayfy 50/25

Aywy/ 3.5Cx 12/6 1.4/1.2 0.4 4x0.8 2.00 1.56 1.56 33.5 36.0 1810 2405 0.4430 0.53 0.090 1.18
Ayfy 70/35

Aywy/ 3.5Cx 15/6 1.6/1.4 0.4 4x0.8 2.00 1.56 1.72 37.5 40.0 2305 3015 0.3200 0.38 0.090 1.20
Ayfy 95/50

Aywy/ 3.5Cx 15/12 1.6/1.4 0.5 4x0.8 2.00 1.72 1.88 41.0 43.0 2760 3545 0.2530 0.30 0.087 1.31
Ayfy 120/70

Aywy/ 3.5Cx 15/12 1.8/1.4 0.5 4x0.8 2.00 1.88 1.88 45.5 48.0 3215 4030 0.2060 0.25 0.087 1.31
Ayfy 150/70

Aywy/ 3.5Cx 30/15 2.0/1.6 0.5 4x0.8 2.50 2.04 2.04 50.0 53.5 3900 5300 0.1640 0.20 0.087 1.31
Ayfy 185/95

Aywy/ 3.5Cx 30/15 2.2/1.6 0.6 4x0.8 2.50 2.20 2.36 57.0 60.0 4840 6390 0.1250 0.15 0.087 1.34
Ayfy 240/120

Aywy/ 3.5Cx 30/15 2.4/1.8 0.6 4x0.8 3.15 2.36 2.52 61.5 66.0 5835 8210 0.1000 0.12 0.086 1.41
Ayfy 300/150

Aywy/ 3.5Cx 53/30 2.6/2.0 0.7 4x0.8 3.15 2.68 2.68 70.0 75.0 7250 9900 0.0778 0.09 0.086 1.45
Ayfy 400/185

21
 4 CORE ALUMINIUM PVC ARMOURED POWER CABLES
T ype No. o f Min T hick ne Min Nom ina l Min. Thic kness O vera ll Appo x Net M ax.D. M ax Ap pro A ppr
c ores no. s s of T hi Dim ension of O F pvc o uter Diam eter W t. of cable C AC x ox .
& Cros s of P VC c kn A rm our strength (approx) Res is t Resi R eact Capa
Sec tion W ir ins ulatio es s Strip /W ire Strip/W ire Strip/ W ire S trip /wir e ance at s tan anc e c itan
al A rea es n ( nom) of Ar mour A rm our Arm our 20 ce at at ce
PV 70 50Hz
C
Mm O ut (m m ) (m m) ( mm ) (K g/K m) Ohm s O hm
er /km s/km Km Km
S he
a th(
mm
)

A yw y 4CX 1 .5 1 0.8 0 .3 - 1.40 - 1.24 - 14 .5 - 470 18 .100 0 21 .72 0.126 0.14

A yw y 4CX 2 .5 1 0.9 0 .3 - 1.40 - 1.24 - 16 .0 - 560 12 .100 0 14 .52 0.119 0.15

A yw y 4C X 4 1 1.0 0 .3 - 1.40 - 1.24 - 17 .5 - 675 7.4100 8.89 0.116 0.41

4C X 6
A yw y 1 1.0 0 .3 - 1.40 - 1.24 - 19 .0 - 800 4.6100 5.53 0.110 0.47

A yw y 4CX 10
1 1.0 0 .3 4x0.8 1.60 1.40 14 0 21.5 23 .0 80 0 1 030 3.0800 3.70 0.100 0.56
/A yfy

A yw y 4CX 16
6 1.0 0 .3 4x0.8 1.60 1.40 1.40 23.0 25 .0 83 0 1 050 1.9100 2.29 0.097 0.76
/A yfy

A yw y 4CX 25
6 1.2 0 .3 4x0.8 1.60 1.40 1.40 25.0 27 .0 1075 1 350 1.2000 1.44 0.097 0.86
/A yfy

A yw y 4CX 35
6 1.2 0 .3 4x0.8 1.60 1.40 1.40 27.5 30 .0 1280 1 620 0.8680 1.04 0.097 0.98
/A yfy

A yw y 4CX 50
6 1.4 0 .4 4x0.8 2.00 1.56 1.56 32.0 34 .5 1620 2 175 0.6410 0.77 0.094 1.02
/A yfy

A yw y 4CX 70
12 1.4 0 .4 4x0.8 2.00 1.56 1.56 36.5 38 .0 2010 2 660 0.4430 0.53 0.090 1.18
/A yfy

A yw y
4CX 95 15 1.6 0 .4 4x0.8 2.00 1.72 17 2 40.0 42 .5 2550 3 280 0.3200 0.38 0.090 1.20
/A yfy

A yw y
4C X 120 15 1.6 0 .5 4x0.8 2.00 1.88 1.88 44.5 47 .0 3040 3 840 0.2530 0.30 0.087 1.31
/A yfy

A yw y
4C X 150 15 1.8 0 .5 4x0.8 2.50 1.88 2.04 48.0 51 .0 3580 4 880 0.2060 0.25 0.087 1.31
/A yfy

A yw y
4C X 185 30 2.0 0 .6 4x0.8 2.50 2.04 2.20 53.0 57 .0 4340 5 810 0.1640 0.20 0.087 1.31
/A yfy

A yw y
4C X 240 30 2.2 0 .6 4x0.8 2.50 2.36 2.36 60.0 64 .0 5460 7 050 0.1250 0.15 0.087 1.34
/A yfy

A yw y
4C X 300 30 2.4 0 .7 4x0.8 3.15 2.52 2.68 60.5 71 .0 6630 9 260 0.1000 0.12 0.086 1.41
/A yfy

A yw y
4C X 400 53 2.6 0 .7 4x0.8 3.15 2.84 2.84 73.0 78 .0 8185 11020 0.0778 0.09 0.086 1.45
/A yfy

22
 ARMOURED CONTROL CABLE IS: 1554 (Pt-I) -1988

No. of Thic Thick Standa Current

kne ness
Crores ss of
rd Rating
&Cross of Inners Deliver
Sectional PVC heath y
Area NO Insu (min) Length
latio Extru
x mm 2. in
n ded
(No mm Mtrs.
m) STRIP ARMOURED CABLE WIRE ARMOURED CABLE
mm
Strip Thicknes Approx. Approx. Roun Thickness Approx. Approx. Direct In Air/
Size s PVC OD Net d PVC Outer OD New in Duct.
Mm Outer weight WireD Sheath Weight Groun
Sheath Mm of cable ia (Min) Mm of cable d Amps
(Min) Kg/km Mm Kg/km
Mm mm Amps
2 x 1.5 0.8 0.3 - - - - 1.4 1.24 13.6 415 1000 23 20
3 x 1.5 0.8 0.3 - - - - 1.4 1.24 14.1 430 1000 21 17
4 x 1.5 0.8 0.3 - - - - 1.4 1.24 15.0 490 1000 21 17
5 x 1.5 0.8 0.3 - - - - 1.4 1.24 15.9 545 1000 16 14
6 x 1.5 0.8 0.3 - - - - 1.4 1.24 16.9 604 1000 15 13
7 x 1.5 0.8 0.3 - - - - 1.4 1.24 16.9 630 1000 14 13
10 x 1.5 0.8 0.3 - - - - 1.4 1.40 20.6 835 1000 13 11
12 x 1.5 0.8 0.3 4x0.8 1.24 19.5 760 1.8 1.40 21.5 950 1000 12 10
14 x 1.5 0.8 0.3 4x0.8 1.40 20.8 830 2.0 1.40 22.4 1040 1000 11 10
16 x 1.5 0.8 0.3 4x0.8 1.40 21.7 920 2.0 1.40 23.3 1130 1000 11 9
19 x 1.5 0.8 0.3 4x0.8 1.40 23.1 1040 2.0 1.40 24.7 1265 1000 10 9
24 x 1.5 0.8 0.3 4x0.8 1.40 26.4 1250 2.0 1.40 28.0 1510 1000 9 8
27 x 1.5 0.8 0.3 4x0.8 1.40 26.9 1355 2.0 1.40 28.5 1610 1000 9 8
30 x 1.5 0.8 0.3 4x0.8 1.40 27.8 1430 2.0 1.40 29.4 1700 1000 9 7
37 x 1.5 0.8 0.3 4x0.8 1.40 29.7 1670 2.0 1.40 31.3 1960 1000 8 7
2 x 2.5 0.9 0.3 - - 1.24 14.8 500 1000 32 27
3 x 2.5 0.9 0.3 - - 1.24 15.4 520 1000 27 24
4 x 2.5 0.9 0.3 - - 1.24 16.4 590 1000 27 24
5 x 2.5 0.9 0.3 - - 1.24 17.5 660 1000 23 19
6 x 2.5 0.9 0.3 - - 1.24 18.7 745 1000 21 18
7 x 2.5 0.9 0.3 - - 1.24 18.7 780 1000 20 17
10 x 2.5 0.9 0.3 4x0.8 1.40 21.8 900 2.0 1.40 23.4 1110 1000 18 15
12 x 2.5 0.9 0.3 4x0.8 1.40 22.8 1020 2.0 1.40 24.4 1240 1000 17 14
14 x 2.5 0.9 0.3 4x0.8 1.40 23.8 1130 2.0 1.40 25.4 1340 1000 16 13
16 x 2.5 0.9 0.3 4x0.8 1.40 24.9 1210 2.0 1.40 26.5 1455 1000 15 13
19 x 2.5 0.9 0.3 4x0.8 1.40 26.1 1355 2.0 1.40 27.7 1605 1000 14 12
24 x 2.5 0.9 0.3 4x0.8 1.40 30.0 1655 2.0 1.56 32.0 1970 1000 13 11
27 x 2.5 0.9 0.3 4x0.8 1.40 30.6 1770 2.0 1.56 32.6 2100 1000 12 10
30 x 2.5 0.9 0.3 4x0.8 1.56 32.0 1940 2.2 1.56 33.6 2250 1000 12 10
37 x 2.5 0.9 0.4 4x0.8 1.56 34.7 2300 2.2 1.56 37.1 2900 1000 11 9

23
PROCESS FLOW CHART
FOR RUBBER CABLES

24
QUALITY ASSURACE CHART
FOR RUBBER CABLES

25
QUALITY ASSURACE CHART
FOR RUBBER CABLES

26
 TABLE- 3
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR) INSULATED OVERALL
PCP, CSP/TRS SHEATHED FLAT THREE CORE (WITHOUT ECC) CABLE
“ISI MARKED” AS PER IS : 9968/Pt-1/1988

Nominal Cross Nominal of Thickness of Sheath Nominal cross

Sectional Area Insulation Flat Flat Sectional Area of
Earth
of Conductor
Twin Three Continuity Conductor
mm2 mm mm mm 2
mm 2

1.0 1.0 1.0 1.0 1.0

1.5 1.0 1.0 1.1 1.5
2.5 1.0 1.10 1.1 1.5
4 1.0 1.20 1.2 1.5
6 1.0 1.20 1.2 2.5
10 1.2 1.3 1.4 4.0
16 1.2 1.4 1.4 6.0
TABLE- 2
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR) INSULATED OVERALL
PCP, CSP/TRS SHEATHED SINGLE-CORE CIRCULAR TWIN CORE THREE CORE THREE & FOUR
CORE CABLE “ISI MARKED” AS PER IS: 9968/Pt-1/1988

Nominal Cross Thickness Single Twin Three Four

Sectional Area of Insulation Core Core Core Core
of Conductor
mm 2
mm mm mm mm mm
1 1.0 1.0 1.0 1.0 1.1
1.5 1.0 1.0 1.0 1.1 1.1
2.5 1.0 1.0 1.1 1.1 1.1
4 1.0 1.0 1.20 1.2 1.2
6 1.0 1.0 1.2 1.2 1.3
10 1.20 1.1 1.3 1.4 1.4
16 1.20 1.1 1.4 1.4 1.5
25 1.40 1.2 1.5 1.6 1.7
35 1.40 1.2 1.6 1.7 1.7
50 1.6 1.3 1.8 1.8 2.0
70 1.6 1.4 1.9 2.0 2.1
95 1.8 1.4 2.1 2.2 2.4
120 1.8 1.5 2.2 2.3 2.5
150 2.0 1.6 2.4 2.5 2.7
185 2.2 1.7 2.6 2.7 2.9
240 2.4 1.8 2.8 3.0 3.2
300 2.6 1.90 3.0 3.2 3.5
400 2.8 2.0 3.2 3.4 3.8
500 3.0 2.2 - - -
630 3.0 2.3 - - -

27
 TABLE-4
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR)/SILICON INSULATED
OVERALL PCP, CSP/TRS SHEATHED CABLE SINGLE TWIN, THREE AND FOUR-CORE GLASS
FIBRE BRAIDED AND VARNISHED CABLES AND CORDS “ISI MAREKED” AS PER IS: 9968/Pt-
1/1988

Thickness of Insulation
Nominal Cross-Sectional Cables for Fixed Flexible cables or
Area of Conductor Wiring Cords
mm2 mm mm

0.50 - 1.0
0.75 - 1.0
1 1.0 1.0
1.5 1.0 1.0
2.5 1.0 1.0
4 1.0 1.0
6 1.0 1.0
10 1.2 1.2
16 1.2 1.2
25 1.2 1.2
35 1.4 1.4
50 1.6 1.6

TABLE-5
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR)/SILICON INSULATED
OVERALL PCP, CSP/TRS SHEATHED CABLE SINGLE-CORE, CIRCULAR TWIN, THREE-CORE,
FOUR-CORE AND FIVE CORE
“ISI MARKED” AS PER IS: 9968/Pt-1/1988

Nominal Cross Thickness Thickness of Sheath (ts)

Sectional Area of Insulation Single Twin Three Four Five
of Conductor (ft) Core Core Core Core Core

6 1.0 1.6 2.0 2.1 2.50 2.50

16 1.2 1.9 2.5 2.7 2.9 3.2
10 1.2 1.8 2.4 2.5 2.7 2.9
25 1.20 2.0 3.2 3.3 3.4 -
35 1.4 2.2 3.3 3.4 3.5 -
50 1.60 2.4 3.5 3.6 3.7 -
70 1.6 2.6 3.6 3.7 3.9 -
95 1.80 2.8 3.8 4.0 4.1 -
120 1.8 3.0 4.0 4.1 4.3 -
150 2.0 3.2 4.2 4.3 4.5 -
185 2.2 3.4 4.3 4.5 4.8 -
240 2.4 3.5 4.6 4.8 5.1 -
300 2.6 3.6 4.9 5.1 5.4 -

28
 WELDING CABLES
COPPER/ALUMINIUM WELDING CABLES WITH HOFR
COVERING/GENERAL PURPOSE ELECTROMETRIC SHEATHED AS
PER IS-9857/1990 “ISI MARKED”

The welding cable is suitable for use where combination of ambient temperature and
temperature rise due to load results a conductor temperature not exceeding 60 °C for
general purpose rubber copound cables and 85°C for general purpose HOFR compound
cables. (Heat resisting, oil resisting and flame retardant).

Copper Conductor
Copper Conductor is of annealed high conductivity copper wire complying to
IS-8130-1984.

Aluminium Conductor
Aluminium Conductor is of Aluminium wire complying to IS-8130-1976.

TABLE-1
THICKNESS OF COVERING
Nominal Area Redial Thickness
of Conductor of Covering (tc)
mm 2
mm
16* 2.00
25 2.00
35 2.00
50 2.20
70 2.40
95 2.60
120** 2.80

* For copper conductor only

** For aluminium conductor only

29
 TABLE-2

CURRENT RATINGS OF GENERAL PURPOSE RUBBER

COMPOUND COVERED CABLE WITH COPPER CONDUCTIOR

Nominal Area Current Rating as a maximum duly cycle of

of Conductor 100% 85% 60% 30% 20%

mm 2
A A A A A

16 94 102 121 172 210

25 125 136 161 228 279
35 156 169 201 285 349
50 197 214 254 360 440
70 248 269 320 453 555
95 299 342 386 546 669

Ambient Air Temperature = 30oc Maximum Conductor temperature = 60oc

TABLE - 3

CURRENT RATINGS OF GENERAL PURPOSE HOFR COMPOUND

COVERED CABLES WITH COPPER CONDUCTOR

Nominal Area Current Rating at a Maximum duly cycle of

of Conductor 100% 85% 60% 30%

mm 2
A A A A

16 135 146 174 246

25 177 192 228 343
35 221 240 285 403
50 279 303 360 509
70 352 382 454 643
95 424 460 547 774

Ambient Air Temperature = 30oc Maximum Conductor temperature = 90oc

30
 TABLE -4

CURRENT RATING OF GENERAL PURPOSE RUBBER COMPOUND

COVERED CABLE WITH ALUMINIUM CONDUCTOR

Nominal Area Current Rating as a maximum duly cycle of

of Conductor 100% 85% 60% 30% 20%

2
mm A A A A A

25 100 108 129 183 224

35 123 133 159 225 275
50 155 168 200 283 347
70 196 213 253 358 438
95 237 257 306 433 530
120 283 307 365 517 633

Ambient Air Temperature = 30oc Maximum Conductor temperature = 60oc

TABLE- 5

CURRENT RATINGS OF GENERAL PURPOSE HOFR COMPOUND

COVERED CABLE WITH ALUMINIUM CONDUCTOR

Nominal Area Current Rating as a maximum duly cycle of

of Conductor 100% 85% 60% 30%

2
mm A A A A
25 144 156 186 263
35 176 191 227 321
50 222 241 287 405
70 280 304 361 511
95 339 368 438 619
120 404 438 522 738

Ambient Air Temperature = 30oc Maximum Conductor temperature = 60oc

31
 TABLE - 6

VOLTAGE DROP IN COPPER CONDUCTORS AT NORMAL

AND ELEVATED TEMPERATURES

Nominal Area DV Voltage Drop/100/A1/210 m of Cable at

of Conductor 20 C
0
60 C
0
90 C
0

2
mm V V V
16 1.19 1.438 1.587
25 0.780 0.922 1.018
35 0.552 0.655 0.773
50 0.390 0.456 0.503
70 0.276 0.321 0.355
95 0.244 0.244 0.269

TABLE - 7
VOLTAGE DROP IN ALUMINIUM CONDUCTORS AT NORMAL
AND ELEVATED TEMPERATURES

Nominal Area DC Voltage Drop/100A/10 m of Cable at

Sectional Area
of Conductor 20 C
0
60 C
0
90 C
0

2
mm V V V
25 1.23 1.427 1.574
35 0.901 1.045 1.153
50 0.634 0.735 0.811
70 0.445 0.516 0.570
95 0.334 0.387 0.428
120 0.256 0.297 0.328

32
 Table 3
STRANDED COPPER AND ALUMINIUM CONDUCTORS
(WEIGHT & DC RESISTANCE AT 200C )

Aluminium
Annealed plain Copper
Nominal Area of Approx. Max.d.c.resist-
Appox. Weight Max.d.c.resist- 0
Conductor 0 (kg\km) ance at 20 C
(kg\km) ance at 20 C
(sq. mm) (ohms/km)
(ohms/km)
1.0 9.0 18.1 2.70 29.9
1.5 13.3 12.1 4.1 18.1
2.5 22.4 7.41 6.8 12.1
4 36.1 4.61 10.4 7.41
6 54.0 3.08 16.4 4.61
10 90.8 1.83 27.7 3.08
16 145 1.15 43.9 1.91
25 229 0.727 69.5 1.20
35 317 0.524 96.4 0.868
50 429 0.387 131 0.641
70 620 0.268 189 0.443
95 860 0.193 262 0.320
120 1086 0.153 331 0.253
150 1334 0.124 406 0.206
185 1673 0.0991 409 0.164
240 2199 0.0754 669 0.125
300 2759 0.0601 839 0.100
400 3528 0.0470 1073 0.0778
500 4445 0.0366 1353 0.0605
630 5744 0.0283 1746 0.0469

33
 TABLE -4
FLEXIBLE COPPER CONDUCTORS

Nominal Area of Approx. Max. D.C.resistance at 200C (ohms/km)

Conductor Weight Annealed plain Copper Annealed tinned
(sq. mm) (kg\km Cooper
1.0 9.5 19.5 20.0
1.5 14.0 13.3 13.7
2.5 23.5 7.98 8.21
4 37.9 4.95 5.09
6 56.7 3.30 3.39
10 95.3 1.91 1.95
16 152 1.21 1.24
25 240 0.780 0.795
35 333 0.554 0.565
50 450 0.386 0.393
70 651 0.272 0.277
95 903 0.206 0.210
120 1140 0.161 0.164
150 1401 0.129 0.132
185 1757 0.106 0.108
240 2309 0.0801 0.0817
300 2897 0.0641 0.0654
400 3704 0.0486 0.0495
500 4670 0.0384 0.0391
630 6031 0.0287 0.0292

34
 TABLE -5
TEMPERATURE CORRECTION FACTORE FOR
CONDUCTOR RESISTANCE AT DIFFERENT TEMPERATURES

Temperature correction factor for

0
Temperature( C) Copper and Aluminium conductor
5 0.94
10 0.96
15 0.98
20 1.00
25 1.02
30 1.04
35 1.06
40 1.08
45 1.10
50 1.12
55 1.14
60 1.16
65 1.18
70 1.20
75 1.22
80 1.24
85 1.26
90 1.28

35
 VOLTAGE DROP CALCULATIONS

An approximate check can be made on voltage drop by means of the following formulae:

For d.c. and single phase a.c. two wire system:

= 2xIxLxRxt
1000

For three phase a.c. system :

= 1.732 x I x L x R x t
1000

Where I = Current in Amperes.

L = Length of cable run in metres (one conductor only).
R = Resistance in ohms of one conductor only from table 3-4.
T = temperature correction factor from table 5.

Notes:
1) Resistance values for copper and aluminium conductors are shown in table 3 and 4.
2). for conductor cross section above 70sqmm an allowance must be considered for skin and proximity
effect.

USEFUL 3 PHASE FORMULA

KW = KVA x power factor

KW = HP x 746
1000 x efficiency
= Line Amps x Line Volts x 1.732 x power factor
1000

HP = Line Amps x Line Volts x 1.732 x efficiency x p.f.

746

36
 TABLE-8
PROPERTIES OF METALS USED IN CABLE

Annealed
Properties Unit Aluminium Steel Lead
Copper
Specific gravity - 8.89 2.703 7.86 11.37
Tensile strength
(Approx.)
Kg/mm2 25 12 to 15 30 to 50 1.8
1400
Melting point Deg. C 1083 659 327
Elongation % 23 to 40 2 to 6 15 30
Young’s Modules
of Elasticity Kg/mm2 9 to 15.5 103 7000 19000 1600
Co-efficient of
29
linear expansion Deg. C 17 10-6 23 10-6 11.5 10-6
10-6
Specific heat K cal/kg0C 0.093 0.217 0.114 0.031

Thermal resistivity 0
C cm/watt 0.25 0.48 2.20 2.96

Specific electrical
resistance at 200C Microhm/cm 1.7241 2.8264 1405 21.0

Temp. co-efficiect
of resistance at Per deg.C 0.00393 0.00403 0.0042 0.0042
20oC

37
 TABLE 9
PERFORMANCE AND SELECTION OF COMMONLY USED THERMOPLASTIC CABLES
INSULATING AND SHEATHING MATERIALS

General General Heat General Fluori-

purpose purpose resisting purpose nated
Heat resisting Special Poly tertre
PVC PVC PVC PVC Low ethy len
PVC sheath Heat Poly ethy - f luro
Material insulation insulation insulation sheath Temp. e
ty pe ST 2 to resistin lene ethy lene
ty pe A to ty pe B to ty pe C to ty pe ST 1 PVC propy le
IS-5831/84 g PVC (PTFE)
IS- IS- IS- to IS- ne
5831/84 5831/84 5831/84 5831/84 (FEP)

Max. cond. Tem. For

0
continous operation ( C)
70 105
70 70 85 90 70 70 260 200
Max. cond. Temp . at
the termination of
0
shorty circuit ( C) 160 160 160 160 160 160 160 130 500 250
0
Min. working temp. ( C) -20 -15 -15 -20 -15 -40 -30 -60 -75 -75

Resistance to Ozone E E E E E E E E G G

Coronaz E E E E E E E P P P

Weather G G G G G G G P E E

Oil G G G G G G G F E E

Water G E G G G G G G E E

Chemical G G G G G G G G E E

Solv ents F F F F F F F G E E

Abrasions G E E G E G E E E E
Flame resistance
E E E E E E E P E E
Electricals
Insulation resistance G E E NA NA G E E E E

Voltage breakdown G G G NA NA G G E E E

A.C.Losses F F F NA NA F F E E E

E- EXCELLENT : G- GOOD: F –FAIR: P- POOR: NA- NOT APPLICABLE

38
 TABLE 10
PERFOMANCE AND SELECTION OF COMMONLY USED ELASTOMERIC CABLES
INSULATING AND SHEATHING MATERIALS

Natureal Nitrile
Rubber Heat Butadiene Chlorosulp Cross
Ethylene Polychlo
(VIR Resist-ing rubber h-onated linked
propylen roprene Silicon
M aterial &TRS)in Natural blend with polyethylen Polyethy
e rubber rubber rubber
cluding rubber PVC e rubber lene
EPR PCP
blends with HRVIR (NBR- CSP (XLPE)
SBR PVC)

Max. cond. Tem. For

continous operation
(0 C) 90 90
60 75 90 90 90 150/180

Max. cond. Temp . at

the termination of
250
shortly circuit (0 C) 200 200 200 200 200 250 350
Min. working temp.
-55 -55 -50 -40 -30 -35 -40 -55
(0 C)
Resistance to Ozone P P E G G E G E
Corona P P E NA NA G P G
Weather P F G E G E G E
Oil P P P G E G G P/F
Water G G G F G G G G
Chemical F F G F F G G F
Solvents P P P G G G G G
Abrasions F F P G G G G P/F
Flame resistance
P P P E G E P E
Electrical
Insulation resistance G G G NA NA F E F
Vo ltage breakdown G G G NA NA G E G
A.C.Losses G G G NA NA F E G

E- EXCELLENT : G- GOOD: F –FAIR: P- POOR: NA- NOT APPLICABLE

39
 TELEPHONE CABLES
1. Telephone Switch Bard Multicore Cables are being extensively used by
Telephone Depart ment, Govt.Departments, railway and other industries in
their telecommunication network.
2. Conductor : Annealed tinned-electrolytic copper conductors, PVC colour coded
as per ITO Specification D-3003 ITD-S/WS-1138 or S/WS-1148 each wire twisted
with its mate wire in a right hand lay and each such pair twisted with its make wire
in a right hand lay and each such pair twisted with respect to all other airs in
concentric layers so as to supress cress talk. The conductors shall be 0.5, 0.6, 0.7
or 0. 9 mm Dia. and Cables are manufactured in one pair size to 100 pairs as per
costomers requirements.
3. Insulation : Hard Grade PVC with nominal radial thickness.
4. Colour Scheme : As per I.T.I.D. 3003,ITD S/WS-113B OF S/WB-114B.
5. Armouring : The armouring shall consist of galvanised steel wires having nominal
diameter of 1.4 mm for Cables having inner sheathed diameter uto 13mm in
Cables where the diameter of inner sheathing exceeds 13 mm, steel striof size 4 x
0.8 mm is to be used.
6. Sheathing : The outer sheath shall be extruded PVC Compound specially
designed to afford high degree of mechanical chemical and Thermal Properties.

RECOMMENDATIONS FOR INSTALLATION

The following are some of the salient factors which should be kept in view during
installation of PVC Insulated Heavy Duty Cables :
1. Before laying, the insulation of the cable should be checked with megger as a
preliminary check against any probably damage.

2. The drum should be always rolled in the "direction of arrow for rolling" marked on
the drum. In the absence of any such mark, the drum should be rolled in the
direction same as that of inside and of the cable and opposite to that of the outside
end.

3. Where the cable is to be jointed with existing cable, the sequence of cores at the
two ends to be jointed should be in the opposite direction i.e. If at one end it is in
clockwise direction, at the other end it should be in anticlockwise direction. This is
necessary to avoid the crossing of cores while jointing. This will also decide the
direction in which the cable is to be pulled.

4. Wherever possible bending radius of 12 times the overall diameter of the cable
should be maintained, but in any case it should not be less than 8 times.

40
 5. Where the cables are necessarily laid and jointed in very cold regions both the
cable and the ambient temperature should be above OC and have remained so
for the previous 24 hours. During such conditions, the cable should also not be
bent to ver small radius.
6. A joint being the weakest point of the electric power transmission system, all
necesaary precautions shuld be taken. Jointing materials and accessories like
conductiors ferules, solder, insulating and protective tapes, protective filling
compound, joint boxes etc. of right quality and sized should be procured. The
application of these materials should be made skilfully for joining work. In this
connection, it is always advisable that the method and the working instructions of
the supplier should be strictly followed.

7. 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.

Unarmoured Cables : In case of unarmoured cables, the external metallic earth

bodding connector of adequate sizes should be used.

8. Earth : All joints, terminations, armour wires and external metallic bonding should
be connected to earth. Wherever possible, armour at one end of the cable should
be connected to main earth system at the supplying end by employing metallic
connectors.

Precautions should be taken to eliminate the chemical and bimetallic corrosion of

the earth connectors or bonds.

9. Filling Compunds :

a) The design of the box and the cimposition of the filling compound should
provide an effective saving against entry of moisture to conductor ferrules and
a hour connector.

b) If not pouring protective compounds, are used, the temperatures of the

compound whicl pouring should not exceed 100 C. 0

10. Test after installion : After the cable is installed, a voltage test may be carried out.
Each core should be tested at 4KV against others and the armour, the latters
connected to the earth.

The voltage should be injcreased gradually to full value and maintained

continuously for 15 minutes. No breakdown of insulation occur during the test.

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