shyam cable catalogue
TRANSCRIPT
All Types Of Cables Manufacturer CompanyEngineering Customized Power Solutions
SHYAM CABLE INDUSTRIES
1
WELCOME TO OUR COMPANY
Page No.Chapter
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
PROPERTIES OF RAW MATERIAL USED
28
TELEPHONE CABLES 40
33
LIST OF REGISTRATION CERTIFICATE & PERFORMANCE CERTIFICATES 42
LIST OF PURCHASE ORDERS 52
2
SALIENT FEATURES
CLIENTELE
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.
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.
3
PRODUCTSS.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 630Silicon 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 630Insulated & Sheathed) 61 x 2.5
3. Trailing Cables IS: 9968/88/Pt-1 & Pt-II 1 x 1000Upto 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 CablesScreened Cables IS: 5608Instrumentation CablesCompensating 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 2.5Flat Cables IS: 9968/88/Pt-1 4 x 400
9. XLPE Cables IS: 7098 1 x 1000(Armoured/ Unarmoured XLPE 3.5 x 630Insulated & Sheathed Cables) 61 x 2.5
10. Kynar / HMWPE All Sizes
4
LIST OF
GOVERNMENT CLIENTSS 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
B E M L
N T P C
O N G C
N A L C O
N H P C
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.
5
LIST OF OTHER
REPUTED CLIENTSRELIANCE INDUSTRIES LIMITED
RELIANCE PETROLEUM LIMITED
ELECON ENGINEERING CO. LTD.
FENNER INDIA LTD.
I S G E C
DC M SHRIRAM (DAURALA)
B A L C O
A.B.B. LTD.
ESSAR GROUP
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.
.
ENERCON
GUJARAT AMBUJA CEMENT
BHUSHAN STEEL LTD.
JINDAL STAINLESS LTD.
JINDAL PIPE LTD.
SIEMENS LIMITED
L&T LTD.
ADANI GROUP
JINDAL STEEL & POWER
.
6
LIST OF
MACHINERYPVC Extruders (150 mm)
PVC Extruders (100 mm)
PVC Extruders (75 mm)
PVC Extruders (40 mm)
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
Kneader
PVC Mixtures
Rubber Mixing Mills
M.S. Vulcanisers Complete with
7
LIST OF TESTING EQUIPMENTS
AC High Voltage Tester 10 KV
AC High Voltage Tester 30 KV
Double Kelvin Bridge
Million Meghohms Meter
Hot Deformation Test Apparatus
Volumetric Test Apparatus
Annealing Test Apparatus
Hot Water Bath
DC High Voltage
Hydraulic Press
Capacitance Meter
Flamability Test Apparatus
Standard Resistance Box
Micrometer
Digital Milliohm Meter
Air Hot Oven
Fault Locator
Physical Balance
Multimeter
Ageing Oven
Ageing Air Oven
Single Pan Electrical Balance
Mandral for Bending Test
Dombell Die with Stand
Tear Resistance Attachment
Air & Oxygen Bomb Apparatus
Oxygen Cylinder
Meggar
Spark Tester
Air Compressor
Tensile Testing Machine
Travelling Microscope
Flame Resistance Test Apparatus
Hot set Test Apparatus
Humidity Conditioning Chamber
Ozone Test Apparatus
Cold Band Test Apparatus
Smoke Density
Oxygen Index
Halogen Acid Gas Generation
Swedish Chimney
Ladder Test
8
QUALITY CONTROLQUALITY CONTROL
Shyam Cables
RAW MATERIAL CONTROL
PROCESS CONTROL
PRODUCT CONTROL
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.
1. Raw Material Control.2. Process Control & Continuous on-line testing.3. Product Control.
maintains very high standards of product quality through a very strict and efficient quality control system mainly.
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 is controlled and checked by a team of experts and any deviations from standard process in immediately checked and corrective action is taken.
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.
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.
9
CURRENT RATINGS The current ratings in table 1 & 2 based on the normal conditions of installation as described below : 1. Maximum condr. Temperature 70
0C 5. Thermal resistivity of soil 150
0C cm/watt
2. Ambient air temperature 400C 6. Thermal resistivity of cable 650
0C cm/watt
3. Ground temperature 300C 7. Max. short-circuit conductor temp. 160
0C
4. Depth of laying (for cable 8. Max. Ambient Air Temperature 550C
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
Ground temperature
0C 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
Air temperature
0C 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
Rating factor for axial spacing No. of cables
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
Rating factor for axial spacing No. of cables
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. mm.
1.00 0.99 0.98 0.97 0.96 0.95
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
10
PROCESS FLOW
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
QUALITY ASSURACE CHART FOR PVC CABLES
15
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”
POWER & CONTROL CABLE AS PER IS-1554 (PART-I) 1988
Material :
Insulation :
Inner Sheath : (Common Covering)
Armoured :
Outer Sheath :
Conductor :
THE CABLES AMPACITY
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.
It is of PVC compound conforming to the requirements of Type - A,B,C, of IS-5831-84
a) Vulcanised or unvulcanised rubberb) Thermoplastic materialc) Proofed or plastic tape
a) Galvanised round steel wireb) Galvanised steel strip
The outer sheath is of PVC compund conforming to the requirements of Type ST-1, ST-2 of IS-5831-1970
2(Nominal Cross Sectional/Area in mm )
Copper Aluminium Solid/Stranded
1.5 1.5 Solid2.5 to 6 2.5 to 10 Solid10 and above 6 and aboveStranded Stranded
Standard Conditions of installation for which the current carrying capacity is given in the ensuing tables are :
0 Conductor temperature : 70 C Maximum0 Thermal resistivity of soil : 150 C cm/w0 Thermal resistivity of PVC : 650 C cm/w
0 Ambient temperature : 40 C0 Ground temperature : 30 C
Depth of laying cable : 75 cm in the ground
16
C u rren t R atin g
N o. o f C rores
& C ross S ection al A rea N O
x m m 2 .
T h ick n ess o f P V C
in su ta ion (N o m .)
m m
T h ick n ess o f P V C
In n ersh eath (M in )
m m
T h ikn ess o f P V C
ou tersh eath (N o m .)
m m
A p p rox . O .D .
m m
A p p rox . N et.
W eigh t o f
C ab les K g/k m
S tan d ard D elivery L en gth in M trs. D irect in
G rou u n d A m p s.
In A ir/D u ct
A m p s.
2 x 1 .5 0 .8 0 .3 1 .8 11 .8 185 1000 23 20
3 x 1 .5 0 .8 0 .3 1 .8 12 .3 190 1000 21 17
4 x 1 .5 0 .8 0 .3 1 .8 13 .2 225 1000 21 17
5 x 1 .5 0 .8 0 .3 1 .8 14 .1 260 1000 16 14
6 x 1 .5 0 .8 0 .3 1 .8 15 .1 295 1000 15 13
7 x 1 .5 0 .8 0 .3 1 .8 15 .1 315 1000 14 13
10 x 1 .5 0 .8 0 .3 1 .8 18 .4 425 1000 13 11
12 x 1 .5 0 .8 0 .3 1 .8 18 .9 480 1000 12 10
14 x 1 .5 0 .8 0 .3 1 .8 19 .8 535 1000 11 10
16 x 1 .5 0 .8 0 .3 1 .8 20 .7 595 1000 11 9
19 x 1 .5 0 .8 0 .3 2 .0 22 .5 720 1000 10 9
24 x 1 .5 0 .8 0 .3 2 .0 25 .8 880 1000 9 8
27 x 1 .5 0 .8 0 .3 2 .0 26 .3 960 1000 9 8
30 x 1 .5 0 .8 0 .3 2 .0 27 .2 1040 1000 9 7
37 x 1 .5 0 .8 0 .3 2 .0 29 .1 1230 1000 8 7
2 x 2 . 5 0 .9 0 .3 1 .8 13 .0 230 1000 32 27
3 x 2 . 5 0 .9 0 .3 1 .8 13 .6 240 1000 27 24
4 x 2 . 5 0 .9 0 .3 1 .8 14 .6 290 1000 27 24
5 x 2 . 5 0 .9 0 .3 1 .8 15 .7 335 1000 23 19
6 x 2 . 5 0 .9 0 .3 1 .8 16 .9 385 1000 21 18
7 x 2 . 5 0 .9 0 .3 1 .8 16 .9 420 1000 20 17
10 x 2 . 5 0 .9 0 .3 1 .8 20 .8 570 1000 18 15
12 x 2 . 5 0 .9 0 .3 2 .0 22 .2 690 1000 17 14
14 x 2 . 5 0 .9 0 .3 2 .0 23 .2 775 1000 16 13
16 x 2 . 5 0 .9 0 .3 2 .0 24 .3 860 1000 15 13
19 x 2 . 5 0 .9 0 .3 2 .0 25 .5 985 1000 14 12
24 x 2 . 5 0 .9 0 .3 2 .0 29 .4 1215 1000 13 11
27 x 2 . 5 0 .9 0 .3 2 .0 30 .0 1330 1000 12 10
30 x 2 . 5 0 .9 0 .3 2 .0 31 .0 1450 1000 12 10
37 x 2 . 5 0 .9 0 .3 2 .2 34 .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
UNARMOURED CONTROL CABLE IS : 1554 (Pt - I ) - 1988
17
1 CORE ALUMINIUM PVC ARMOURED POWER CABLES
Type No. of cores
&Cross Sectional Area
Min no. of Wires
Thickness of PVC
insulation (nom)
Mm
Nominal Dimension
s of Armour
Wire (mm)
Min Thickness of PVC Outer Sheath
(mm)
Overall Deamte
r (Approx
)
(mm)
Approx Net Wt of cable
(Kg/Km)
Max.D.C
Resistance at
70
Ohms /km
Max AC Resistance at
70
Ohms/km
Approx Reactance at 50Hz
Km
Approx. Capacitance
Km
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
18
1 CORE ALUMINIUM PVC UNARMOURED POWER CABLES
Type No. of cores &Cross Sectional Area
Min no. of Wires
Thickness of insulation (nom) Mm
Nom. Thickness of Outer Sheath (mm)
Overall Diameter (Appro) (mm)
Net Wt of cable (approx) (Kg/Km)
Max.D.C Resistance at 20
0C
Ohms /km
Max AC Resistance at 90
0C
Ohms/km
Approx Reactance at 50Hz Km
Approx. Capacitance 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
19
2 CORE ALUMINIUM PVC ARMOURED POWER CABLES
Type No. of cross & Cross
Sectional Area
Min no. of Wires
Thickness of PVC
insulation
(nom)
Mm
Min Thickness of
PVC Oute
r Sheath(mm)
Nominal Dimension of
Armour Strip Wire
(mm)
Min. Thickness OF pvc outer strength
Strip Wire Armour Armour
(mm)
Overall Diameter (approx)
Strip Wire Armour Armour
(mm)
Appox Net Wt. of cable
Strip wire Armour
(Kg/Km)
Max.D.C
Resistance at
20
Ohms /km
Max AC
Resistance at 70
Ohms /km
Approx Reactance at 50Hz
Km
Approx. Capacit
ance
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/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
20
3 CORE ALUMINIUM PVC ARMOURED POWER CABLES
Type No. of cores
&Cross Sectional Area
Min no. of Wires
Thickness
of PVC
insulation
(nom)
(mm)
Min Thickness of PVC
Outer
Sheath(mm
)
Nominal Dimension of
Strip/Wire Armour
(mm)
Min. Thickness OF pvc outer
strength Strip/ Wire
Armour
(mm)
Overall Diameter (approx)
Strip/Wire Armour
(mm)
Appox Net Wt. of cable
Strip/wire Armour
(Kg/Km)
Max.D.C
Resistance at 20
Ohms /km
Max AC
Resistance at 70
Ohms/km
Approx Reactan
ce at 50Hz
Km
ApproxCapacitance
Km
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/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
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/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
Aywy/ Ayfy
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
21
3.5 CORE ALUMINIUM PVC ARMOURED POWER CABLES
Type No. of cores
&Cross Sectional
Area
Min no. of Wires
Thickness of PVC
insulation (nom)
Mm
Min
Thickness of PVC Outer Sheath(mm)
Nominal Dimension of
Armour Strip Wire
(mm)
Min. Thickness OF pvc outer
strength Strip Wire
Armour Armour
(mm)
Overall Diameter (approx)
Strip Wire Armour Armour
(mm)
Appox Net Wt. of cable
Strip wire Armour
(Kg/Km)
Max.D.C
Resistance at 20
Ohms /km
Max AC
Resistance at 70
Ohms/km
Approx
Reactance
at 50Hz
Km
Approx.
Capacitance
Km
Aywy/ Ayfy
3.5Cx 25/16
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
Aywy/ Ayfy
3.5Cx 35/16
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
Aywy/ Ayfy
3.5Cx 50/25
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
Aywy/ Ayfy
3.5Cx 70/35
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
Aywy/ Ayfy
3.5Cx 95/50
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
Aywy/ Ayfy
3.5Cx 120/70
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
Aywy/ Ayfy
3.5Cx 150/70
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
Aywy/ Ayfy
3.5Cx 185/95
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
Aywy/ Ayfy
3.5Cx
240/120
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
Aywy/ Ayfy
3.5Cx
300/150
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
Aywy/ Ayfy
3.5Cx
400/185
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
22
4 CORE ALUMINIUM PVC ARMOURED POWER CABLES Type No. o f
cores &Cross Sec tional A rea
Min no. of
W ires
Thickness of PVC
insulation (nom)
Mm
Min Thickness of PVC
Outer
Shea th(mm
)
Nom ina l Dim ension of
A rm our Strip /W ire
(m m )
Min. Thickness OF pvc o uter
strength Strip/W ire
Armour
(m m)
Overa ll Diam eter (approx)
Strip/ W ire A rm our
(mm )
Appo x Net Wt. of cable
S trip /wire
Arm our
(Kg/Km)
M ax.D.C
Res is tance at
20
Ohm s /km
M ax AC Resis tance a t
70
Ohms/km
Ap prox
R eactance
at 50Hz
Km
Approx .
Capac itan
ce
Km
Aywy 4CX1 .5 1 0.8 0 .3 - 1.40 - 1.24 - 14 .5 - 470 18 .100 0 21 .72 0.126 0.14
Aywy
4CX2 .5
1 0.9 0 .3 - 1.40 - 1.24 - 16 .0 - 560 12 .100 0 14 .52 0.119 0.15
Aywy 4C X4 1 1.0 0 .3 - 1.40 - 1.24 - 17 .5 - 675 7.4100 8.89 0.116 0.41
Aywy 4C X6
1 1.0 0 .3 - 1.40 - 1.24 - 19 .0 - 800 4.6100 5.53 0.110 0.47
Aywy /Ayfy
4CX10
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
Aywy /Ayfy
4CX16
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
Aywy /Ayfy
4CX25
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
Aywy /Ayfy
4CX35
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
Aywy /Ayfy
4CX50
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
Aywy /Ayfy
4CX70
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
Aywy /Ayfy
4CX95 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
Aywy /Ayfy
4C X120 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
Aywy /Ayfy
4C X150 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
Aywy /Ayfy
4C X185 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
Aywy /Ayfy
4C X240 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
Aywy /Ayfy
4C X300 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
Aywy /Ayfy
4C X400 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
23
ARMOURED CONTROL CABLE IS: 1554 (Pt-I) -1988
No. of Crores &Cross
Sectional Area NO x mm2.
Thickness of
PVC Insulatio
n (Nom) mm
Thickness
of Innersheath (min) Extruded mm
STRIP ARMOURED CABLE
WIRE ARMOURED CABLE
Standard
Delivery
Length in
Mtrs.
Current Rating
Strip Size Mm
Thickness PVC Outer
Sheath (Min) Mm
Approx. OD
Mm
Approx. Net
weight of cable Kg/km
Round
WireDia
mm
Thickness PVC Outer
Sheath (Min) Mm
Approx. OD
Mm
Approx. New
Weight of cable Kg/km
Direct in
Ground
Amps
In Air/ Duct.
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
24
PROCESS FLOW CHART FOR RUBBER CABLES
25
QUALITY ASSURACE CHART
FOR RUBBER CABLES
26
QUALITY ASSURACE CHART
FOR RUBBER CABLES
27
TABLE- 3
2 mm2 mm mm mm
1.0 1.0 1.0 1.0 1.01.5 1.0 1.0 1.1 1.52.5 1.0 1.10 1.1 1.54 1.0 1.20 1.2 1.56 1.0 1.20 1.2 2.5
10 1.2 1.3 1.4 4.016 1.2 1.4 1.4 6.0
TABLE- 2
1 1.0 1.0 1.0 1.0 1.11.5 1.0 1.0 1.0 1.1 1.12.5 1.0 1.0 1.1 1.1 1.14 1.0 1.0 1.20 1.2 1.26 1.0 1.0 1.2 1.2 1.310 1.20 1.1 1.3 1.4 1.416 1.20 1.1 1.4 1.4 1.525 1.40 1.2 1.5 1.6 1.735 1.40 1.2 1.6 1.7 1.750 1.6 1.3 1.8 1.8 2.070 1.6 1.4 1.9 2.0 2.195 1.8 1.4 2.1 2.2 2.4120 1.8 1.5 2.2 2.3 2.5150 2.0 1.6 2.4 2.5 2.7185 2.2 1.7 2.6 2.7 2.9240 2.4 1.8 2.8 3.0 3.2300 2.6 1.90 3.0 3.2 3.5400 2.8 2.0 3.2 3.4 3.8500 3.0 2.2 - - -630 3.0 2.3 - - -
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
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 Nominal of Thickness of Sheath Nominal cross Sectional Area Insulation Flat Flat Sectional Area of
Earthof Conductor
Twin Three Continuity Conductor
Nominal Cross Thickness Single Twin Three FourSectional Area of Insulation Core Core Core Coreof Conductor
2mm mm mm mm mm mm
2mm
28
TABLE-4
Thickness of Insulation Nominal Cross-Sectional Cables for Fixed Flexible cables orArea of Conductor Wiring Cords
2mm mm mm
0.50 - 1.00.75 - 1.0 1 1.0 1.01.5 1.0 1.02.5 1.0 1.0 4 1.0 1.0 6 1.0 1.010 1.2 1.216 1.2 1.225 1.2 1.235 1.4 1.450 1.6 1.6
TABLE-5
Nominal Cross Thickness Thickness of Sheath (ts)Sectional Area of Insulation Single Twin Three Four Fiveof 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 -
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
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR) 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
/SILICON
29
WELDING CABLESCOPPER/ALUMINIUM WELDING CABLES WITH HOFR COVERING/GENERAL PURPOSE ELECTROMETRIC SHEATHED AS PER IS-9857/1990 “ISI MARKED”
Copper Conductor
Aluminium Conductor
THICKNESS OF COVERING
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 is of annealed high conductivity copper wire complying to
IS-8130-1984.
Aluminium Conductor is of Aluminium wire complying to IS-8130-1976.
TABLE-1
Nominal Area Redial Thickness
of Conductor of Covering (tc)2mm 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
30
TABLE-2
Nominal Area Current Rating as a maximum duly cycle of of Conductor 100% 85% 60% 30% 20%
2mm A A A A A
16 94 102 121 172 21025 125 136 161 228 27935 156 169 201 285 34950 197 214 254 360 44070 248 269 320 453 55595 299 342 386 546 669
o Ambient Air Temperature = 30 c Maximum Conductor temperature =
TABLE - 3
Nominal Area Current Rating at a Maximum duly cycle of of Conductor 100% 85% 60% 30%
2mm 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
o o Ambient Air Temperature = 30 c Maximum Conductor temperature = 90 c
CURRENT RATINGS OF GENERAL PURPOSE RUBBERCOMPOUND COVERED CABLE WITH COPPER CONDUCTIOR
CURRENT RATINGS OF GENERAL PURPOSE HOFR COMPOUND COVERED CABLES WITH COPPER CONDUCTOR
o60 c
31
TABLE -4
Nominal Area Current Rating as a maximum duly cycle of
of Conductor 100% 85% 60% 30% 20%
2mm 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
o o Ambient Air Temperature = 30 c Maximum Conductor temperature = 60 c
TABLE- 5
Nominal Area Current Rating as a maximum duly cycle of
of Conductor 100% 85% 60% 30%
2mm 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
o o Ambient Air Temperature = 30 c Maximum Conductor temperature = 60 c
CURRENT RATING OF GENERAL PURPOSE RUBBER COMPOUND
COVERED CABLE WITH ALUMINIUM CONDUCTOR
CURRENT RATINGS OF GENERAL PURPOSE HOFR COMPOUND
COVERED CABLE WITH ALUMINIUM CONDUCTOR
32
TABLE - 6
Nominal Area DV Voltage Drop/100/A1/210 m of Cable at
0 0 0 of Conductor 20 C 60 C 90 C
2mm 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
Nominal Area DC Voltage Drop/100A/10 m of Cable at
Sectional Area
0 0 0 of Conductor 20 C 60 C 90 C
2mm 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
VOLTAGE DROP IN COPPER CONDUCTORS AT NORMAL
AND ELEVATED TEMPERATURES
VOLTAGE DROP IN ALUMINIUM CONDUCTORS AT NORMAL
AND ELEVATED TEMPERATURES
33
Table 3 STRANDED COPPER AND ALUMINIUM CONDUCTORS
(WEIGHT & DC RESISTANCE AT 200C )
Nominal Area of Conductor (sq. mm)
Annealed plain Copper Appox. Weight Max.d.c.resist-
(kg\km) ance at 200C
(ohms/km)
Aluminium Approx. Max.d.c.resist- (kg\km) ance at 20
0C
(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
34
TABLE -4 FLEXIBLE COPPER CONDUCTORS
Nominal Area of Conductor (sq. mm)
Approx. Weight (kg\km
Max. D.C.resistance at 200C (ohms/km) Annealed plain Copper Annealed tinned
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
35
TABLE -5 TEMPERATURE CORRECTION FACTORE FOR
CONDUCTOR RESISTANCE AT DIFFERENT TEMPERATURES
Temperature(0C) Temperature correction factor for 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
36
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:
= 2 x I x L x R x t 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
37
TABLE-8 PROPERTIES OF METALS USED IN CABLE
Properties Unit Annealed Copper
Aluminium Steel Lead
Specific gravity - 8.89 2.703 7.86 11.37 Tensile strength (Approx.)
Kg/mm2 25 12 to 15 30 to 50 1.8
Melting point Deg. C 1083 659 1400
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 linear expansion
Deg. C
17 10-6
23 10-6
11.5 10-6
29
10-6 Specific heat K cal/kg0C 0.093 0.217 0.114 0.031 Thermal resistivity
0C 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 20oC
Per deg.C
0.00393
0.00403
0.0042
0.0042
38
TABLE 9 PERFORMANCE AND SELECTION OF COMMONLY USED THERMOPLASTIC CABLES
INSULATING AND SHEATHING MATERIALS
Material
General purpose PVC insulation ty pe A to IS-5831/84
General purpose PVC insulation ty pe B to IS-5831/84
Heat resisting PVC insulation ty pe C to IS-5831/84
General purpose PVC sheath ty pe ST 1 to IS-5831/84
Heat resisting PVC sheath ty pe ST 2 to IS-5831/84
Low Temp. PVC
Special Heat resisting PVC
Poly ethy - lene
Poly tertre f luro ethy lene (PTFE)
Fluori- nated ethy lene propy lene (FEP)
Max. cond. Tem. For continous operation (
0C)
70
70
85
70
90
70
105
70
260
200
Max. cond. Temp . at the termination of shorty circuit (
0C)
160
160
160
160
160
160
160
130
500
250
Min. working temp. (0C) -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 Electricals
E E E E E E E P E E
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
39
TABLE 10 PERFOMANCE AND SELECTION OF COMMONLY USED ELASTOMERIC CABLES
INSULATING AND SHEATHING MATERIALS
Material
Natureal Rubber (VIR &TRS)in cluding blends with SBR
Heat Resist-ing Natural rubber HRVIR
Ethylene propylene rubber EPR
Polychloroprene rubber PCP
Nitrile Butadiene rubber blend with PVC (NBR-PVC)
Chlorosulph-onated polyethylene rubber CSP
Cross linked Polyethy lene (XLPE)
Silicon rubber
Max. cond. Tem. For continous operation (0C)
60
75
90
90
90
90
90
150/180
Max. cond. Temp . at the termination of shortly circuit (0C)
200
200
250
200
200
200
250
350
Min. working temp. (0C)
-55 -55 -50 -40 -30 -35 -40 -55
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 Electrical
P P P E G E P E
Insulation resistance G G G NA NA F E F
Voltage 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
40
TELEPHONE CABLES
RECOMMENDATIONS FOR INSTALLATION
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.
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.
41
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.
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 0compound whicl pouring should not exceed 100 C.
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.
9. Filling Compunds :
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60