Welcome to Presentation on

CABLES
By
J.KARTHIK

Definition
Definition

Encased group of insulated wires for transmitting

electricity etc., (Source : Oxford Dictionary)
Cable is an insulating conductor, used for
Transporting electrical power from one point to
other

Contents

Types of Cables
Cable Construction
Comparison of various types of cables

Types of Installation

Cable Tray and Support Systems

Design Steps
Cable Termination Schedules

1)

Types of Cables

2)

Cable Construction

3)

Comparison of various types of cables

4)

Cable Installation

5)

Cable Tray and Support Systems

6)

Design Steps

7)

Cable Termination Schedules

Types of Cables

Cable are classified based on Voltage level & based on the application

1.

EHV power (66 kV and above)

2.

HV power (3.3 kV 33 kV)

3.

LV power (415 V and below)

4.

Control cable

5.

Data & signal cable

Types of Cables

Voltage Grade (Earthed & Un earthed)

6.6kV (UE) / 11kV (E)

This cable is suitable for

6.6kV Un-Earthed System as well as 11kV Earthed System
This cable is not suitable for
11kV Un-Earthed System
This cable will be a costly proposal for
6.6kV Earthed System

Types of Cables

Consider a 11 KV system
If the system is earthed, then the thickness of insulation of the cable is 3.4
mm
If the system is Unearthed, then the thickness of insulation of the cable is
4.5 mm
Hence in an unearthed system, the cost of cable is high.
In an Unearthed system, when a Phase to earth fault occurs, the Healthy
phase to ground voltages rises by 1.732 times. Hence in an unearthed
system, the insulation of all three phases should be designed to take care of
increased voltages.
Please note 6.6kV (E) cable is different from 6.6kV(UE) & 3.8(UE)/6.6(E)
is different from 6.6(UE)/11(E)

Earthed & Unearthed Cables

NORMAL CONDITION

Earthed & Unearthed Cables

B PHASE TO GROUND FAULT

Earthed & Unearthed Cables

B PHASE TO GROUND FAULT

(Un-Detected)

Earthed & Unearthed Cables

B-G FAULT and Y-G FAULT

(Detected as Phase to Phase Fault)

Earthed & Unearthed Cables

PHASE TO EARTH VOLTAGE SHOOTS UP

(BECOMES PHASE TO PHASE)

Types of Cables

Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules

Cable Construction

Components
Components of
of Cable
Cable
1. Conductor

Copper / Aluminium

2. Insulation

PVC / XLPE / Paper

3. Armour

Armoured (Steel/Alum, Round/Flat)

4. Outer sheath

PVC / HR PVC / FRLS / FR etc.,

5. Screening

Screened or not

6. Shielding

Shielded or Un-shielded

Special
Special Cable
Cable
Marine Cables- high flexibility, reliability & suitable for corrosive atmosphere
Festooning Cables- for mobile equipment, crane application, cross bridge trolley
Halogen Free Cables-low toxicity, low smoke, high flexible
Oil Filled Cables - high insulation, temperature control,

Cable Construction

Conductor
Conductor
The conductor of a typical power cable is made up of Copper or Aluminium.
The shape of the conductor can be circular or sector shape. It can be single or
multi-stranded

Insulation
Insulation
Paper or natural Rubbers were used for many years as insulating material in
underground power cables. Presently synthetic materials are preferred for
insulation of cables. The chemical composition of such material can be altered
to produce polymers with special chemical, electrical and mechanical
properties. Though the list is extensive, XLPE & EPR are widely used.
Both EPR & XLPE has similar characteristics, XLPE is preferred for
transparent and phenomena like treeing.

Cable Construction

145kV Single Core

33kV Three Core

415V Three Core

Copper

Aluminium

Aluminium

Cable Construction

Semiconductor
Semiconductor shield
shield
In a typical high voltage cable, two layers of semiconductor material surround the
Metallic core.
First layer placed directly around the conductor has the following purposes
1.

To distribute the electric field uniformly around the conductor

2.

To prevent the formation of ionized voids in the conductor

3.

To dampen impulse currents traveling over the conductor surface

Second layer of semiconductor material is placed around the first insulating

layer and has the following purposes.
1.

To reduce the surface voltage to zero

2.

To confine the electric field to the insulation, eliminating tangential

stresses.

3.

To offer direct path to ground for short circuit current if the shield is
grounded.

Cable Construction

Cable Construction

Cable Construction

Cable Construction

Cable Construction

2x

A
CONDUCTOR
A

- Aluminium

Nil - Copper

Wa

INSULATION ARMOUR

OUTER SHEATH

2x

- XLPE

W - Round wire

Y - PVC

- PVC

F - Strip or Flat

2Y-Polyethylene

a - Non magnetic

Cable Construction

Constituents

Code

Aluminum conductor

XLPE insulation

2x

Steel round wire armour

Steel strip armour

Steel double round wire armour

WW

Steel double strip armour

FF

Non-magnetic (A1) round wire armour

Wa

Non-magnetic (A1) strip armour

Fa

Lead Alloy Sheath

Ly

Polyethylene Outer Sheath

2Y

PVC Insulation / Outer sheath

Cable Construction

A2XY

- Aluminium Conductor XLPE Insulated PVC Sheathed Cables

Unarmoured

A2XWaY - Aluminium Conductor XLPE Insulated PVC Sheathed Cables

Round Wire Armoured (Non magnetic)
2XY

- Copper Conductor XLPE Insulated PVC Sheathed Cables

Unarmoured

YWY

- Copper Conductor PVC Insulated PVC Sheathed Cables

Round Wire Armoured

Types of Cables
Cable Construction

Comparison of various
types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules

Comparison of Conductors

Merits of Copper
Current Carrying capacity of Copper is almost 1.6 times of Aluminium.
Resistance of Copper is less compared to Aluminium.
No Steel Reinforcement is required like ACSR

Merits of Aluminium
Cost of Aluminium Cable is less compared to Copper
Weight of Aluminium Cable is less compared to Copper

Size of Cable for same

current requirement

Comparison of XLPE & PVC

The XLPE material has a stronger Electrical & Mechanical properties

compared to PVC material, and consequently it has a longer life time. Current
Carrying capacity of XLPE > PVC
On special environmental condition, XLPE material has more resistance
capabilities than PVC material.
In XLPE material the absorption of moisture is low, and due to polyethylene
abilities, it has a lower penetration property compared to PVC material. PVC
material absorbs moisture as it has more carbonate calcium.
XLPE doesnt loose its shape, in heat , and in other words it is THERMO SET.
Moreover, it is fire and smoke retardant.
XLPE has enough resistance to 90oC temperature, whereas, PVC material
looses its resistance in temperature higher than 70oC

Comparison of Outer Sheath

Flame Resistance
The ability of a burning material to extinguish its own flame, once its flameinitiating heat source is removed.
Flame Retardant
Ability of a material to prevent the spread of combustion by a low rate of travel so
the flame will not be conveyed.

Fire Retardant Low Smoke

Ability of a material to prevent the spread of combustion by a low rate of travel so
the flame will not be conveyed. Low smoke.

Low Smoke Halogen Free

Does not emit toxic gases and does not suffocate human beings hence safe to
human & electronic equipments.

Technical Comparison

Current
Current Carrying
Carrying Capacity
Capacity

Technical Comparison

Impedance
Impedance // KM
KM

10

1
0

0.1

0.01

100

200

300

400

500

PVC, Al
XLPE, Al
PVC, Cu
XLPE, Cu

Types of Cables
Cable Construction
Comparison of various types of cables

Cable Installation
Cable Tray and Support Systems
Design Steps
Cable Termination Schedules

Types of Installation

1.

Directly buried in ground

2.

Laid in cable trenches

3.

Laid in cable racks

4.

Laid in duct banks

Guidelines

Cable Installation IS 1255

Minimum Permissible Bending Radii

Voltage Grade

Single Core
(XLPE/PVC)

Multi Core
(XLPE/PVC)

Up to 1.1kV

15D

12D

Above 1.1 To 11kV

15D

15D

Above 11kV To 33kV

20D

15D
D Diameter of Cable

Guidelines

Cable
Cable Laying
Laying
Use Different Trays with sufficient clearance for
Power, Control & Signal Cables
Power cables of Different Voltage levels
Top or Bottom
HT at top or bottom As per Client requirement
Single Core Cables
Use Trefoil formation using Trefoil clamps
Trefoil clamps shall be non-magnetic type

HT

INS-SIG

LT

INS-CON

CON

CON

INS-CON

LT

INS-SIG

HT

Directly Buried in Ground

Minimum
Minimum Depth
Depth of
of Laying
Laying

Voltage Grade

Depth From FGL To Top Of Cable

Up to 1.1kV

750 mm

Above 1.1 To 11kV

900 mm

Above 11kV To 33kV

1050 mm

Typical drawings

Laid in Cable Trays

LAID IN CABLE TRAYS

Cable Trays, Fittings & Accessories

Prefabricated/ Site Fabricated

Prefabricated Ladder/ Perforated

Material Ms/Galvanized Sheet steel
Std Widths 150, 300, 450 & 600mm
Std Lengths 2.5/3m
Std Height 100/ 75mm
Fittings Bends, Elbows,
Fittings Reducers, Tees

Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation

Cable Tray and

Support Systems
Design Steps
Cable Termination Schedules

Cable & Tray Supports

SITE FABRICATED
Horizontal Member ISA 50x50x6
@ 750/600mm interval for cable support without trays
@1500mm interval for cable tray support

Vertical Member
Size & interval to be decided based on design criteria

Vertical Member

Horizontal Member

Cable & Tray Supports

FLEXIBLE CABLE TRAY SUPPORT SYSTEM

Cable & Tray Supports

FLEXIBLE CABLE TRAY SUPPORT SYSTEM

Cables laid in Duct Bank

LAID IN DUCT BANKS

Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and Support Systems

Design Steps
Cable Termination Schedules

Design Steps

HV
HV &
& LV
LV Power
Power Cable
Cable Sizing
Sizing
Design Input
Load details

Motor Rating (kW)/ Trafo Rating (kVA)

Operating Voltage
Operating Frequency
Operating & Starting Power Factor (for Motor Loads)
Efficiency
Short circuit withstand capacity and its duration
Starting Method DOL/ Star - Delta/ Soft Starter (for Motor Loads)
Allowable Steady state voltage Drop
Allowable Transient Voltage Drop ( for Motor Loads)

Design Steps

Cable Data

Voltage Grade
Conductor Material
Cross Sectional area
Number of cores
Insulation Material (XLPE/PVC)
Current Carrying Capacity in air
Impedance of cable
Short circuit withstand capacity - current
Name of Likely Manufacturer

Based on Cable Installation & Environmental Conditions

Temperature Correction Factor
Correction Factor for Grouping
Correction Factor for Depth of laying

Design Steps

Control
Control Cable
Cable Sizing
Sizing
Material of Conductor Copper
Voltage Grade 1.1kV
Minimum cross sectional area
Generally 2.5 Sq.mm
CT/ PT circuits 2.5 / 4 / 2# 2.5 Sq.mm
Number of Cores
CT/ PT Circuits 4C
Others Schemes/ Application
Transformers Mech. Faults/ Cooler Control/ OLTC control
Motors Depending on Type/ Levels of Control & Indication
Requirements (LPB/ MCC/ PLC)

Design Steps

EHV CABLES
Single core & three core cable
Given in specification
Single core
Easy to handle & terminate
Higher ampacity
More drum length
Conductor copper/ aluminium
Size to be designed
Load requirements
Installation conditions
Manufacturers specific

Design Steps

MV

LV Motors

LV
(Non Motors)

Steady State Voltage Drop

Transient Voltage Drop

Type of Check
Thermal

Short Circuit Withstand

Capability

Thermal Ampacity

Laid in Ground

Laid in Air

Current Carrying Capacity of Cable

Current Carrying Capacity of Cable
De-rate for Ground Temperature

De-rate for Grouping of Cables

De-rate for Air Temperature

De-rate for Grouping of Cables

De-rate for Number of Layers

De-rate for Number of Layers

De-rate for Thermal Resistivity of

Soil

On Site Current Carrying Capacity

On Site Current Carrying Capacity

Voltage Drop

Formula for Steady State VD

E2 = (VCos+IR)2+(VSin + I (Xc+Xs))2
Formula for Transient VD
E = (V+IRCos+IXcSin ) (approx)

Short Circuit Withstand Capability

Fault Current at Motor Terminal is given by

LV Cables : If = V1/(1000 x (Rc+j(Xc+Xs))) kA
MV Cables : If = Bus Fault Level
For Safe operation,
Fault withstand capacity of Cable for t sec > If
Fault withstand Capacity for t sec
If (t) = If(1) / Sqrt(t)
Fault withstand time t sec is decided by the Protection given for cables
Fuse protected : 0.2 sec (Fuse operating time <10ms)
Breaker + Relay : 0.35 sec 3 sec (Relay operating time with grading +
breaker opening time)

Cable Critical Length Chart

Presentation to L&T Engineers on 30 July 2010

Comparison of Cable Size - Various Types

Input
Input Data
Data
Motor Rating

110 kW

Cable Length

500 m

SS Voltage Drop

5%

Output
Output Data
Data
Cable Type

Thermal

SS VD

Final

Deciding factor

Aluminium, PVC

2#150

2#185

2#185

SS VD

Aluminium, XLPE

1#240

2#185

2#185

SS VD

Copper, PVC

1#300

1#300

1#300

Both

Copper, XLPE

1#240

1#400

1#400

SS VD

Effect of input Data

Requirement of
Increase in these will result in

Thermal

SS VD

Power
Distance
Fault Current
Fault clearing Time
Starting Current
Less Stringent

More Stringent

TR VD

SC W/S

Effect of input Data

Hence,
In case, the length indicated in the cable schedule differs from the actual
length (considerable change), please refer to the Design Department.
The cable size may change.

Please follow the design recommendation for cable installation. Say cable
touching each other or with one Dia spacing. If the cable is designed for one
dia spacing and laid touching each other,
The cable will get heated up and life may reduce.

LV Cable Sizing

LV POWER CABLE SIZING

Initial & Running Cost

Description
Load Current

150
Sq.mm

185
Sq.mm

Unit

100.68

100.68

De-rated Cable
Current

125

146

Resistance / KM

0.249

0.199

Resistance for 250m

0.0747

0.0597

Power Loss (I2 x R)

0.76

0.61

Energy loss / day

18

15

kWH

Energy loss / year

5452

4357

kWH

Energy Cost Rs./kWH

5.00

5.00

Rs.

27260

21786

Rs.

-5474

Rs.

Cost of Power Loss

Difference

ohms/KM
ohms
kW

Cable Cost/mtr

188.5

236.5

Rs.

Initial Cost

47125

59125

Rs.

12000

Rs.

Difference
Payback period

2.19

Years

Types of Cables
Cable Construction
Comparison of various types of cables
Cable Installation
Cable Tray and Support Systems
Design Steps

Cable Termination
Schedules

Control Cabling

Points
Points to
to remember
remember

Separate Cable shall be laid for Trip-1 & Trip-2

Closing Coil can be combined with Trip-1 0r Trip-2

DC-1 and DC-2 Cables shall be separate
Always keep some spare cores
Try to reduce the number of cores by combining common signals
Care should be taken for Voltage drop restriction

Control Cabling

Typical
Typical Interconnection
Interconnection Chart
Chart

Control Cabling

Standard
Standard Practice
Practice for
for Ferrule
Ferrule Numbering
Numbering
Letter

Application

Letter

Application

CT Main

DC supply

CT Busbar

Control

CT - Back-up

Indication and
Announciation

CT Metering

Busbar Protection

PT Voltage

SCADA

Synchronising

Spare

Aux. Contact
multiplier relay

AC

Useful Tips

Extra
Extra Care
Care for
for Single
Single Core
Core Cables
Cables

1.

Use Un-armoured Cable. If armouring is must, use Aluminium armoured

cable (Non-magnetic, to reduce eddy current)

2.

Use Trifoil clamps for Cable Installations

3.

Armouring should be earthed only on one side

4.

Use Aluminium Gland Plate or MS Gland Plate cut into two pieces

FOR MORE INFO... CONTACT ME AT JKARTHIK@LNTECC.COM