Power Delivery System Electricity from the Generating Site (the Power Plant) is delivered to residential, commercial and

d industrial customers through a system of wires (overhead) or cables (underground), switches, protection & control devices and transformers

Presentation on Electrical Cables & Accessories

Manufacturing Process of Electrical Power Cables

Conductor (CU / AL) Drawing

Sheathing Taping Laid Up Cables Laying Up (For Multi Core)

Inner Sheathed cables

Armouring Armoured Cables

Sheathing Cores Wires Testing and Packing Bunching Stranding Insulation Finished Cables

Conductor

Manufacturing Process Wire Drawing

Finest Electrolytic Grade 99.9 % Pure Copper or Aluminium The process reduces the wire rods to Specified or desired wire diameter. Annealing & Tinning of fine copper wires.
Conductor (CU / AL) Drawing

Wires

Manufacturing Process Stranding

The individual strands are bunched together to form a conductor of specified size.
Conductor (CU / AL) Drawing

Wires

Bunching Stranding Conductor

Manufacturing Process Insulation

Extruders Triple Extrusion line for HT cables

Manufacturing Process : Copper Screening

Only for HT Cables above 6.6 KV Grade Copper tape with the number/color marking is applied over the cores. Where required Water blocking tape can also be provided. Copper tape Screening & Copper wire screening.

Manufacturing Process Laying Up

Lay up to 100 cores with Extruded/taped inner sheath
Conductor (CU / AL) Drawing Laid Up Cables Laying Up (For Multi Core)

Cores Wires

Bunching Stranding

Insulation

Conductor

Manufacturing Process Armouring

Armouring up to 72 Wires. Round and Flat armour.
Conductor (CU / AL) Drawing Sheathing Taping Laid Up Cables Laying Up (For Multi Core) Inner Sheathed cables Armouring Armoured Cables

Cores Wires

Bunching Stranding

Insulation

Conductor

Manufacturing Process Sheathing

Emboss/Print on line on outer sheath.
Sheathing Taping Laid Up Cables Laying Up (For Multi Core) Sheathing Cores Wires Finished Cables Insulation Inner Sheathed cables

Conductor (CU / AL) Drawing

Armouring Armoured Cables

Bunching Stranding

Conductor

Manufacturing Process
Quality treated wooden / steel Drums for winding the finished cables before final testing & delivery.
Conductor (CU / AL) Drawing Sheathing Taping Laid Up Cables Laying Up (For Multi Core) Sheathing Cores Wires Testing and Packing Bunching Stranding Insulation Finished Cables Inner Sheathed cables Armouring Armoured Cables

Conductor

Emphasis On Design
Four major parameters of cable design to illustrate the proper design Conductor Insulation Armouring Sheathing

Conductor
The heart of the cable is the Conductor.

Conductor
Example of selection of the no of strands in a conductor. WHY 19 STRANDS ARE REQUIRED FOR 70 SQ.MM. CONDUCTOR? NO OF STRAND:-19 SIZE:-2.24mm

d =2.24mm.

d=PITCH CIRCULAR DIAMETER FOR FIRST LAYER = 2X2.24mm = 4.48mm NO. OF WIRES IN FIRST LAYER = dX3.14/d = 4.48X3.14/2.24 6 WIRE

d =2Xd

Conductor
NO. OF WIRES ACCOMODATED IN FIRST LAYER = 6

1 1 0 1 1
d =PITCH CIRCULAR DIAMETER FOR SECOND LAYER = 4X2.24mm =8.96mm NO. OF WIRES IN FIRST LAYER = dX3.14/d = 8.96X3.14/2.24 2 12WIRE

1 1

2 2 2 1 1 2 2 1 0 1 2 2 1 1 2 2 2 2

THAT IS WHY 70 SQ.MM.=19 /2.24 [1+6+12]

Conductor
When conductors are not properly shaped, they have gaps , sharp edges in between the wires, which may lead to failures , after a period of time.

Gaps also increase Conductor Resistance

A properly designed conductor is smooth and compact.

Conductor
If the compaction is not proper, it can lead to air gaps, which increase conductor resistance.

A Bad Design of Conductor Can Cause 3% to 9% Transmission loss,Failure due to Sharp Edges.

Insulation

A good Insulation should have: High insulation resistance High dielectric strength Good mechanical properties Tenacity & elasticity should not be affected by chemicals. Should be non hygroscopic.

Insulation
Uniformity of Insulation Thickness & Eccentricity Avoids increase in charging current and lessens the voltage drop If dielectric is not uniform, it leads to increase in the capacitance of the conductor and resultant higher temperature.

Laying up & Inner Sheath

The cores are laid up, along with fillers & suitable binding tape, ensuring circularity. It is an international practice to have filler inserted between the cores, to prevent displacement of the cores in manufacturing as well as in laying of cable at site.

Laying up & Inner Sheath

Many times cores are laid up with nylon/cotton twine, which results in cores getting damaged, which effects not just the insulation thickness but also, the overall performance of the cable.

Laying up & Inner Sheath

CABLE WITH NON HYGROSCOPIC POLYPROPYLENE TAPE & FILLERS PP tape & Filler has very high melting point i.e. 160 C. Has very high insulation resistance property i.e. 150 Mohm/km Works as water barrier, prevents water penetration inside the cable. Less flexibility than other types of polyethylene, which prevents the cores from displacement in the cable.

Armouring
Apart from mechanical protection, an important feature of Armour design is to provide effective conductance of earth fault current. When designing an armoured cable, the selection of minimum number of armour wire/strips plays a very important role

Armouring
Example : 3.5 C X 240 SQ.MM A2XFY cable. Min. 34 strips require for 100% coverage. And with this the armour resistance at 20 C will be 1.62 ohm/km & short circuit current carrying capacity will be 4.2 kA/Sec, where as the Max requirement as per IS 7098 part I is 1.64 ohm/km If we use 30 strips in place of 34, there will be a gap and the armour resistance will be increased to 1.79 ohm/km & short circuit current carrying capacity will come down to 3.7 kA/sec

Armouring
Armouring protects the cable from mechanical damage. Maintain minimum 95% coverage to protect the cable from any mechanical damage because of sharp edges. Badly Armoured Cables

Outer Sheathing
This Protects the Overall Cable Embossing / printing options on the outer sheath.

Emphasis On Quality
Stringent Quality checks at each and every level. Raw materials. In Process. Finished goods.

EMPHASIS ON QUALITY : TESTING LABS

Emphasis On Quality
Raw Material Testing The major raw materials in a Cable are : Copper/Aluminium Rods PVC/XLPE Compounds Armour Wires/Strips

Emphasis On Quality : R.M.Testing

Copper/Aluminium Rods Tensile Strength Resistivity Purity Surface Finish Diameter

Aluminium Rods

Emphasis On Quality : R.M.Testing

XLPE & PVC Compounds Tensile Strength & Elongation Hot set Volume Resistivity Ageing Thermal Stability Density Galvanized Steel Wires / Strips Tensile Strength & Elongation Dimensions Zinc Coating (Dip Test) Torsion/Winding Resistivity

Emphasis On Quality
In process quality checks are performed at each and every stage of manufacturing Stage wise details of Quality checks performed are shown in the next set of folios.

Wire Drawing : R. M. Testing

Diameter Surface finish Tensile/Wrapping test for Aluminium Annealing/Elongation test for Copper Resistivity

Stranding : Quality Checks

No. of strands Stranding Sequence Surface finish Resistance

Insulation : Quality Checks

Conductor screening (HT) Thickness Tensile strength & Elongation Hot Set test Surface finish Type of Compound Dia. Over conductor Dia. Over insulation & Insulation screening (HT)

Copper Screening : Qulaity Checks

No. of wires / Diameter of wire (Wire Screening) Gap between wires (Wire Screening) Lay length (Taping / Wire screening) Tape Overlap (Taping)

Laying Up Quality Checks

Sequence of Laying Diameter over laid up cores Lay length

Inner Sheath : Quality Checks

Thickness Diameter over inner sheath Surface finish

Armouring : Quality Checks

Dimension of wire/strip Diameter over armouring Gap between wires/strip No. of wires/Strip Direction of lay and lay length

Outer Sheath : Quality Checks

Thickness Diameter over outer sheath Tensile strength & Elongation Surface finish & Marking/Embossing Colour of sheath & Type of Compound

Emphasis On Quality Checks

Finished Goods testing Routine tests are carried out as per relevant standards on each cable length. Type tests are carried out for each LOT (One manufacturing length) Acceptance tests and Inspections can be arranged as per requirements of customers. Testing Facilities should include : Partial Discharge FRLS Testing Oxygen Index Smoke Density Halogen Gas High Voltage / Impulse Voltage

Emphasis On Quality
Packing & Marking Testing of End sealing. Testing of packing and wooden drums Inspection for marking and scripts Packing Drums

Inspection of Marking on sheath

CABLE LAYING & INSTALLATION

Planning
Cable installation involves selection of cable route, mode of installation i.e. underground, in duct or cable ladder/ trays, associated accessories and man power For cable laying it is very essential to get acquainted with the visible as well as hidden obstacles and following activities are recommended prior to the actual laying work Inspection of cable route Trial holes to check thermal resistivity & underground obstacles. Excavation (Trenching) & preparation of cable bed Laying of necessary pipes Drum handling & cable pulling equipment including pay off jacks Arrangement of filling. Back filling

Inspection of cable route :

The cable route is first inspected as per the main plan for visible obstruction such as trees, manholes, road crossing etc.

Trial Holes:
After inspection of the cable route, it is advisable to have the knowledge of the underground obstruction. Trial holes are generally taken at every 50 meters interval along the planned cable route up to 10 cm below the planned depth of laying. The route is then inspected for underground obstruction e.g. water lines, drainage lines, telephone cables, power cables or other utilities etc. After this the cable route is finalized keeping in view that it should be straight as far as possible and proper depth is permissible. It is then marked suitably for trenching

Excavation work
After proper marking of the route, the excavation is started. Generally excavation is done manually, however, depending on the terrain other methods such as mechanical force, thrust bore or trench ploughing can be employed. Compressed air tools are used for breaking rocks & excavation across road.

Depth of laying
As a general rule, the desired depth of cable for underground laying is as under LV Power & Control cables : 0.75 m HV Power cables up to 11 kV : 0.9 m HV Power cable 22 & 33 kV : 1.05 m EHV Power cable : 1.2 m The actual depth of laying is, however, decided depending on the under ground obstacles. The deeper laying cause reduction on current carrying capacity.

Clearances :
The desired minimum clearances are as under Power to Control cables : 0.2 m Power to communication cables : 0.3 m Power cables to gas/water main : 0.3 m Inductive influence on sensitive control cable on account of near by power cable should also be checked.

Width of trench :
The width of trench depends on no & diameter of cables to be laid. For HV & EHV cables the width of excavation is generally as under No. of Cables HV Cables EHV Cables 3 0.65 m 0.8 m 4 0.85 m 1.05 m

Sand bedding:
Sand bedding of minimum 10 cm is provided for the cables laid directly in ground for protection. The grain size of sand should preferably be less than 8 mm. The material with high volume weight ratio has a good distribution among grain sizes and it has normally low thermal resistivity, even when it has lower moisture.

Laying of Ducts/ pipes:

Steel, cast iron, plastics, cements or earthenware ducts or cable ducting blocks are used for cables crossing roads/railway tracks. Spare ducts for future expansions should also be provided and should be properly sealed off. Buried ducts or ducting blocks should project into footpath or up to the edge of road, where there is no footpath, to permit smooth entry of cable without un-due bending. The duct/pipe should be mechanically strong to withstand the impact due to traffic when laid across road/railway tracks.

Laying of Ducts/ pipes (Continued):

The pipe/duct are generally laid at depth 1.0 & 1.2 metres across road and railway racks respectively. The diameter of duct or pipe should be at least 1.5 times the outer diameter of cable. Single core cable should never be laid individually in steel ducts. However, it is permissible to lay all three cables of same system in one duct.

Transportation of cable drum:

The cable drum must be handled properly to avoid any damage to cable during transportation. It is important that cable drum stands on the flanges during transportation, well fixed to the transport vehicle. Loading of drum should be done by crane or forklift. A ramp or crane should be used for unloading cable drums from vehicle. Where it is not possible, a temporary ramp with approx. inclination 1:3 to1:4 should be constructed and cable drums should then be rolled over the ramp by means of ropes and winches. An additional sand bed at foot of the ramp is also helpful to brake the rolling of cable drum. Where it is necessary to roll the cable on ground, it should be done slowly and carefully. The drum should always be rolled in the direction of arrow marked on the drum to avoid unwinding & loosening of cable in the drum as shown in the figure.

Transportation of cable drum:

Pulling of cable:
The cable drum shall be placed such that there is minimum inconvenience. Cable drum is normally placed on jacks at starting point, in such a way that direction arrow points to the opposite direction of the pulling, and a wire winch at the other end of the pulling distance of the trench. The pulling wire can be connected to the cable either by a cable stocking or directly to the conductor in such a manner that water or soil cannot enter the cable. Except for wire armoured cables, the cable is normally pulled by the conductor with pulling force limiting to the following Aluminum conductor : 30 N/mm2 Copper conductor : 50 N/mm2 The cable should be pulled from the top of the drum. To prevent crossing of turns on the drum due to sudden stop in pulling, a brake should be arranged at the cable drum as shown in figure and a man should be placed there to operate this brake rapidly.

Pulling of cable drum:

Pulling of cable:
With temperature below 30C, the cables should be warmed before the laying out, otherwise the bending can damage the insulation/protective covering of cables. The cable laying should be carried out swiftly so that the cable does not cool down too much. Warming of cable may be achieved by storing the cable drum for adequately longer period, not less than 24 hours, in a heated building or in a tent with hot air heaters To protect the cable from damage during pulling out, cable rollers should be used, placed at suitable intervals. Bends must be arranged very carefully and cable is not allowed to bend beyond the limit specified as mention here under. Closely spaced and well fixed angle rollers are skid plates should be used at all corners

Pulling of cable:
MINIMUM PERMISSIBLE BENDING RADIUS PILC Cables PVC/XLPE Cables Cable Voltage single Multi single Multi rating core core core core Up to 1.1 kV 20 D 15 D 3.3 kV to 11 kV 20 D 15 D 22 kV & 33 kV 25 D 20 D Above 33 kV - - 20 D - D = outer diameter of cable 15 D 15 D 20 D 12 D 12 D 15 D

Filling:
After laying the cable, sand should be filled in the trench to completely surround the cable. The grain size of sand shall be less than 8 mm. The thickness of sand in all direction of the cable surface should normally not be less than 10 cm.

Backfilling:

Normally the backfill consists of material excavated earlier from the trench. However, bigger stones or pieces of rock should be removed.

Extra protection:
Important feeders and cables at places where high digging activity is expected can be further protected by means of tubes, slabs or troughs The tubes of non-magnetic material are mainly used at road crossing etc. The tube diameter should not be less than 2 times the cable diameter. The current rating of cables laid in tube is reduced up to 80% of the cable rating in ground. The tubes can be filled with material e.g. Bentonite, having thermal resistivity equal to the ground, to avoid reduction in ground rating.

In trenches, normally extra protection is achieved by providing flat concrete slabs of size selected according to the expected damage. Generally slab is 50 mm thick and of sufficient width to cover the cables. The slabs are placed directly on the sand as shown here below

A very efficient protection against cable damage can be obtained by using concrete troughs. The trough should be completely filled with the sand.

Warning tape (Specially for EHV cables):

A pre warning tape, e.g. of yellow PVC, should be laid in the ground around o.2 to 0.4 metre under the surface and at least o.4 mm above the cable. In a trench with several cables, the warning tape should not be spaced more than 0.15 metres apart and the outermost cable should always be covered by warning tapes.

Special precautions for single core cables:

Except for EHV cables, the spacing between three cables laid in one plane should generally be not less than the cable diameter. When the cables are arranged in a duct or on rack, the cables should be secured by non-magnetic, non-corrosive clamps. When the cable run is several kilometer long, the cable should be transposed at 1/3rd and 2/3rd of the total route length. For cables in trefoil formation, non-magnetic clamps are not essential and steel, copper, Aluminum or plastic tape may be used to bind the cable trefoil

The cables do not have to be bound/clamped when laid in ground. Single core cables should not be installed individually in protective steel ducts; instead all the three cores should be laid together in one single duct. Following scheme should be followed when number of single core cables are in use to ensure balanced current distribution.

BIRD CAGING

If the drum is kept on the flange or lifted from one side & cable unwound, there is all likelihood of twists in the armour, which would cause deformation of cores & outer-sheath. This process of deformation is called BIRD CAGING & is normally perceived as a manufacturing defect which is normally a HANDLING defect.

 This can be prevented by unwinding the cable by loading the drum on jacks & pulling in the proper direction with stocking or pulling eye. Proper Handling of cables is very important, both from safety as well as long life of the installation.

The most common causes of cable failure are due to mishandling of the product at installation stage.

In the following slides we show you some of the effects of mishandling of the cables.

Recommendation for Installation

GROUP RATING FACTOR FOR SINGLE CORE CABLES LAID IN TREFOIL FORMATION
B. Cables laid on Racks/Trays in covered trench with removable covers where air circulation is restricted, trefoils are separated by 2 cable dia. horizontally and the trays are in tiers with 300 mm. gap between them.
NO. OF RACKS/TRAYS IN TIERS 1 2 3 6 NO. OF TREFOILS IN HORIZONTAL FORMATION 1 0.95 0.90 0.88 0.86 2 0.90 0.85 0.83 0.81 3 0.88 0.83 0.81 0.79

A. Cables laid in ground in horizontal formation SPACING BETWEEN TREFOILS 33 KV CABLES NUMBER OF 3.3 TO 22 KV CABLES TREFOILS IN GROUP 45 TOUCH 15 45 TOUCH 15 30 30 cm cm cm cm ING cm ING cm 2 3 4 5 0.78 0.68 0.61 0.56 0.81 0.71 0.65 0.61 0.85 0.77 0.72 0.68 0.88 0.81 0.76 0.73 0.80 0.68 0.62 0.57 0.82 0.71 0.65 0.60 0.85 0.76 0.71 0.67 0.88 0.79 0.75 0.72

C. Cables laid as in 'B' but in open air

NO. OF RACKS/TRAYS IN TIERS 1 2 3 6 NO. OF TREFOILS IN HORIZONTAL FORMATION 1 1.0 1.0 1.0 1.0 2 0.98 0.95 0.94 0.93 3 0.96 0.93 0.92 0.90

GROUP RATING FACTOR MULTICORE CABLES

A. Cables laid inside concrete trench with removeable covers, on cable trays where air circulation is restricted. The cables spaced by one cable diameter and the trays in tiers by 300 mm. The clearance of the cable from the wall is 25 mm.
NO. OF RACKS/TRAYS IN TIERS 1 2 NO. OF CABLES
NO. OF TRAYS C. Cables laid on cable trays exposed to air, the cables touching and trays in tiers by 300 mm. The clearance between the wall and the cable is 25 rnm.

NO. OF CABLES

1 0.95 0.90

2 0.90 0.85

3 0.88 0.83

6 0.85 0.81

9 0.84 0.80
1 2 3 6

1 1.0 1.0 1.0 1.0

2 0.84 0.80 0.78 0.76

3 0.80 0.76 0.74 0.72

6 0.75 0.71 0.70 0.68

9 0.73 0.69 0.68 0.66

3 6

0.88 0.86

0.83 0.81

0.81 0.79

0.79 0.77

0.78 0.76

B. Cables laid on cable trays exposed to air, the cables spaced by one cable diameter and trays in tiers by 300 mm. The clearance between the wall and the cables is 25 mm.

D. Cables laid direct in ground in horizontal formation.

NO. OF CABLE TRAYS IN TIERS 1 2 3 6

NO. OF CABLES 1 1 1 1 1 2 0.98 0.95 0.94 0.93 3 0.96 0.93 0.92 0.90 6 0.93 0.90 0.89 0.87 9 0.92 0.89 0.88 0.86

NO. OF CABLES IN GROUP 2 3 4 5 6

SPACING OF CALBLES TOUCHING 0.79 0.69 0.62 0.58 0.54 15 cm 0.82 0.75 0.69 0.65 0.61 30 cm 0.87 0.79 0.74 0.72 0.69 45 cm 0.90 0.83 0.79 0.76 0.75

RATING FACTOR

C. Rating factors for depth of laying A. Rating factors for ambient air temperature variation ( for cables laid direct in the ground)

AMBIENT TEMPERATURE (C) FACTOR

25

30

35

40

45

50

DEPTH OF LAYING (cm)

6 KV, 10 KV AND 15 KV ALL SIZES

20KV AND 30 KV ALL SIZES

1.14

1.10

1.04

1.00

0.95

0.90

90 105 120 150 180 or more

1.00 0.99 0.98 0.96 0.95

--1.00 0.99 0.97 0.96

B. Rating factors for ground temperature variation

D. Rating factors for variation in Thermal Resistivity of soil THERMAL RESISTIVITY OF SOIL (ccm/w) FACTOR

GROUND TEMPERATURE(C) FACTOR

15

20

25

30

35

40

45

100

120

150

200

250

300

1.12

1.08

1.03

1.00

0.96

0.91

0.87 1.20 1.11 1.0 0.89 0.80 0.73

CABLE ACCESSORIES

SEPARABLE CONNECTORS LOADBREAK DEADBREAK OTHER CONNECTORS CABLE JOINTS CABLE TERMINATIONS

Cable Joints Overview

Utilize permanently crimped connectors Housings/Tubings are fully insulated, shielded and sealed Direct buried, vault, submersible and other severe service applications Units designed and tested per IS/VDE/IEEE Standards to assure system matched performance and ratings equal to cable

Terminations & Cable Basics

While Cable Basics uses the Cable Termination as the base example, the same principles apply anywhere a shielded medium or high voltage cable is terminated. Elbows, Joints, etc.

Conductor

+ Conductor shield

Conductor

+ Insulation

+ Conductor shield

Conductor

+ Semi-Con Shield

+ Insulation

+ Conductor shield

Conductor

In case of premolded terminations

The addition of a stress control tube tends to smooth the stress concentrations in case of heat shrink terminations

Only in case of premolded terminations

This same cone shape is incorporated into most Cable Accessories

This same cone shape is incorporated into most Cable Accessories

Right angle boot is used in case of Heat shrink Terminations

Thank You

For more details contact:anitagupta@ieema.org