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Power Delivery System Electricity from the Generating Site (the Power Plant) is delivered to residential,
commercial and industrial customers through a system of wires (overhead) orcables (underground), switches, protection & control devices and transformers
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PresentationonElectrical Cables&Accessories
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Conductor
(CU / AL)
Wires
Conductor
Armoured
Cables
Laid Up
Cables
Inner
Sheathed
cables
FinishedCables
Cores
Drawing
Bunching
Stranding
Laying Up
(For Multi Core)
Sheathing
Taping Armouring
Testing and
Packing
Insulation
Sheathing
Manufacturing Process of Electrical Power Cables
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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.
Wire DrawingManufacturing Process
Conductor
(CU / AL)
Wires
Drawing
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StrandingThe individual strands are bunched together
to form a conductor of specified size.
Manufacturing Process
Conductor
(CU / AL)
Wires
Conductor
Drawing
Bunching
Stranding
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Extruders
Triple Extrusion line for HT cables
Manufacturing ProcessInsulation
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Manufacturing Process : Copper ScreeningOnly 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.
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Lay up to 100 cores with Extruded/taped inner sheath
Manufacturing ProcessLaying Up
Conductor
(CU / AL)
Wires
Conductor
Laid UpCables
Cores
Drawing
Bunching
Stranding
Laying Up
(For Multi Core)
Insulation
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Emboss/Print on line on outer sheath.
Manufacturing ProcessSheathing
Conductor
(CU / AL)
Wires
Conductor
Armoured
Cables
Laid Up
Cables
Inner
Sheathedcables
Finished
Cables
Cores
Drawing
Bunching
Stranding
Laying Up
(For Multi Core)
Sheathing
Taping Armouring
Insulation
Sheathing
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Quality treated wooden / steel Drums for winding the finished cables
before final testing & delivery.
Manufacturing ProcessConductor
(CU / AL)
Wires
Conductor
Armoured
Cables
Laid Up
Cables
Inner
Sheathed
cables
Finished
Cables
Cores
Drawing
Bunching
Stranding
Laying Up
(For Multi Core)
Sheathing
Taping Armouring
Testing and
Packing
Insulation
Sheathing
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Four major parameters of cable design to
illustrate the proper design
Conductor
Insulation
Armouring
Sheathing
Emphasis On Design
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The heart of the cable is the Conductor.
Conductor
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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:-2.24mm1
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 WIRE3 1 2
d =2Xd
Conductor
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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
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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.
Conductor
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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
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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.
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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 insertedbetween the cores, to prevent displacement of
the cores in manufacturing as well as in laying of
cable at site.
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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.
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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.
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ArmouringApart 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/stripsplays a very important role
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ArmouringExample : 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
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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
Armouring
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This Protects the Overall Cable
Embossing / printing options on the outer sheath.
Outer Sheathing
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Stringent Quality checks at each and every level.
Raw materials.
In Process.
Finished goods.
Emphasis On Quality
EMPHASIS ON QUALITY : TESTING LABS
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Raw Material Testing
The major raw materials in a Cable are :-
Copper/Aluminium Rods
PVC/XLPE Compounds
Armour Wires/Strips
Emphasis On Quality
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Copper/Aluminium Rods
Tensile Strength
Resistivity
Purity
Surface Finish
Diameter
Aluminium Rods
Emphasis On Quality : R.M.Testing
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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 : R.M.Testing
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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.
Diameter
Surface finish
Tensile/Wrapping test for Aluminium
Annealing/Elongation test for Copper
Resistivity
Emphasis On Quality
Wire Drawing : R. M. Testing
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No. of strands
Stranding Sequence
Surface finish
Resistance
Conductor screening (HT)
Thickness
Tensile strength & Elongation
Hot Set test
Surface finish
Type of Compound
Dia. Over conductor
Dia. Over insulation & Insulation screening (HT)
Stranding : Quality Checks
Insulation : Quality Checks
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No. of wires / Diameter of wire (Wire Screening)
Gap between wires (Wire Screening)
Lay length (Taping / Wire screening)
Tape Overlap (Taping)
Sequence of Laying
Diameter over laid up cores
Lay length
Laying Up Quality Checks
Copper Screening : Qulaity Checks
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Thickness
Diameter over inner sheath
Surface finish
Inner Sheath : Quality Checks
Armouring : Quality Checks Dimension of wire/strip
Diameter over armouring
Gap between wires/strip
No. of wires/Strip
Direction of lay and lay length
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Thickness
Diameter over outer sheath
Tensile strength & Elongation
Surface finish & Marking/Embossing
Colour of sheath & Type of Compound
Outer Sheath : Quality Checks
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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 ofcustomers.
Testing Facilities should include :
Partial Discharge
FRLS Testing
Oxygen Index
Smoke Density
Halogen Gas
High Voltage / Impulse Voltage
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Packing & Marking
Testing of End sealing.
Testing of packing and wooden drums
Inspection for marking and scripts
Emphasis On Quality Packing Drums
Inspection of Marking on sheath
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CABLE LAYING&INSTALLATION
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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 tothe 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
Planning
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Inspection of cable route :The cable route is first inspected as per the main plan for visibleobstruction such as trees, manholes, road crossing etc.
Trial Holes:After inspection of the cable route, it is advisable to have theknowledge 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
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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
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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.
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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.
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Transportation of cable drum: The cable drum must be handled properly to avoid any damageto 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 cabledrums 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.
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Transportation of cable drum:
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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.
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Pulling of cable drum:
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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, cablerollers 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
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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 15 D 12 D
3.3 kV to 11 kV 20 D 15 D 15 D 12 D
22 kV & 33 kV 25 D 20 D 20 D 15 D
Above 33 kV - - 20 D
- D = outer diameter of cable
Pulling of cable:
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Filling:After laying the cable, sand should be filled in the trench to completelysurround 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.
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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
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A very efficient protection against cable damage can be obtained by
using concrete troughs. The trough should be completely filled with
the sand.
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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
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BIRD CAGING
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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.
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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.
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Recommendation for Installation
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GROUP RATING FACTOR FOR SINGLE CORE
CABLES LAID IN TREFOIL FORMATION
B. Cables laid on Racks/Trays in covered trench withremovable covers where air circulation is restricted, trefoilsare separated by 2 cable dia. horizontally and the traysare in tiers with 300 mm. gap between them.
NO. OFRACKS/TRAYS IN
TIERS
NO. OF TREFOILS IN HORIZONTAL FORMATION
1236
1 2 3
0.950.900.880.86
0.900.850.830.81
0.880.830.810.79
NUMBER OFTREFOILS IN
GROUP
SPACING BETWEEN TREFOILS3.3 TO 22 KV CABLES
33 KV CABLES
TOUCH
ING
15
cm
30
cm
45
cm
TOUCH
ING
15
cm
30
cm
45
cm
2345
0.780.680.610.56
0.810.710.650.61
0.850.770.720.68
0.880.810.760.73
0.800.680.620.57
0.820.710.650.60
0.850.760.710.67
0.880.790.750.72
A. Cables laid in ground in horizontal formation
C. Cables laid as in 'B' but in open air
NO. OFRACKS/TRAYS IN
TIERS
NO. OF TREFOILS IN HORIZONTAL FORMATION
1
2
3
6
1 2 3
1.0
1.0
1.0
1.0
0.98
0.95
0.94
0.93
0.96
0.93
0.92
0.90
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GROUP RATING FACTOR MULTICORE CABLES
NO. OFRACKS/TRAYS IN
TIERS
NO. OF CABLES
12
36
1 2 3
0.950.90
0.880.86
6 9
0.900.85
0.830.81
0.880.83
0.810.79
0.850.81
0.790.77
0.840.80
0.780.76
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.
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 CABLETRAYS IN
TIERS
NO. OF CABLES
1236
1 2 3
1111
6 9
0.980.950.940.93
0.960.930.920.90
0.930.900.890.87
0.920.890.880.86
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 TRAYS
NO. OF CABLES
12
3
6
1 2 3
1.01.0
1.0
1.0
6 9
0.840.80
0.78
0.76
0.800.76
0.74
0.72
0.750.71
0.70
0.68
0.730.69
0.68
0.66
D. Cables laid direct in ground in horizontal formation.
NO. OFCABLES
IN GROUP
SPACING OF CALBLES
23
4
5
6
0.790.69
0.62
0.58
0.54
0.820.75
0.69
0.65
0.61
0.870.79
0.74
0.72
0.69
0.900.83
0.79
0.76
0.75
TOUCHING 15 cm 30 cm 45 cm
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RATING FACTOR
GROUNDTEMPERATURE(C)
FACTOR
15
1.12
20
1.08
25
1.03
30
1.00
35
0.96
40
0.91
45
0.87
A. Rating factors for ambient air temperature variation
AMBIENTTEMPERATURE (C)
25
1.14
30
1.10
35
1.04
40
1.00
45
0.95
50
0.90FACTOR
B. Rating factors for ground temperature variation
DEPTH OF LAYING (cm)
90
105
120
150
180or more
6 KV, 10 KV AND15 KV ALL SIZES
1.00
0.99
0.98
0.960.95
20KV AND 30 KVALL SIZES
---
1.00
0.99
0.970.96
C. Rating factors for depth of laying
( for cables laid direct in the ground)
THERMALRESISTIVITY
OF SOIL(ccm/w)
100
1.20
120
1.11
150
1.0
200
0.89
250
0.80
300
0.73FACTOR
D. Rating factors for variation in Thermal Resistivity of soil
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CABLE
ACCESSORIES
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SEPARABLE CONNECTORS
LOADBREAK
DEADBREAK
OTHER CONNECTORS
CABLE JOINTS CABLE TERMINATIONS
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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
Cable Joints Overview
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Terminations &
Cable Basics
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While Cable Basics uses the CableTermination as the base example, the
same principles apply anywhere a
shielded medium or high voltage cableis terminated.
Elbows, Joints, etc.
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Conductor
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+ Insulation
+ Conductor shield
Conductor
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+ Semi-Con Shield
+ Insulation
+ Conductor shield
Conductor
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In case of p remo ldedterminat ions
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The addi t ion o f a stress contro ltube tends to smooth the
st ress concentrat ions in case
of heat shr ink term inat ion s
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Only in case of
premolded terminations
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This same cone shape
is incorporated intomost Cable Accessories
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Right angle boot is
used in case ofHeat shrink
Terminations
http://www.shrinkpolymersystems.co.uk/3cPilcBeltedTermination.pdf -
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End of Session..