Company Profile

Polycab is one of the leading names in wires and cables, an ISO 9001:2000 certified company with Under Writers Laboratories USA, and with a proven track record of over three decades. Polycab has achieved a growth of over 40% per annum in the last 3 years & this growth is attributed to companys commitment towards The total customer satisfaction in terms of quality & services for the entire range of its products . Dedicated towards continuous improvements,

EHV Cables
Due to rapid industrial & economic growth it has become necessary to transmit bulk power to sustain the growth. It is also very important that while transmitting bulk power logistic & safety consideration are given due weightage. The most ideal solution, considering all the aspects is to transmit bulk power through underground cables & keeping in line with the basic philosophy of the organisation, POLYCAB has introduced extra high voltage cable.

upgradation of man, machinary & services, Polycab expanded its facilities from Halol to set up an ultra modern state of the art plant at Daman in 1996 spread over an area of 35 acres. The machineries and equipment are procured from world renowned manufacturer and these machines are manned by qualified, experienced and dedicated professionals. The company is now the largest manufacturer of HT XLPE, LT power / control, instrumentation, house wires & flexible, specialty cables, Catv, Lan, Data & Communication Cables. In addition to catering to various segment of Indian industry / power utilities, Polycab has made physical export of different types of cables to various countries.
Triple Extrusion Machine

SCHEMATIC DIAGRAM OF TYPICAL EHV CABLES

1. COPPER CONDUCTOR 2. SEMI-CONDUCTING TAPE (optional) 3. EXTRUDED SEMI-CONDUCTING LAYER 4. XLPE INSULATION (Super Clean Compund) 5. INSULATION SHIELD-SEMI CONDUCTING 6. WATER BLOCKING TAPE 7. LEAD SHEATH / POLYAL SHEATH 8. SEMI-CONDUCTING TAP 9. METALLIC SCREEN 10. COUNTER HELIX WITH COPPER TAPE 11. PVC/HDPE OUTER SHEATH WITH GRAPHITE COATING

EHV Testing Facility

CROSS BONDING METHOD

Metallic Sheath
Metallic Sheath is must for cables above 33 kV as the cable of voltage grade 66 kV & above are working with dielectric stress of above 6 kV / mm & at this level of dielectric stress presence of water triggers tree formation in the insulation resulting in cable failure. Water can enter the cable longitudinally as well as radially. Longitudinal water entry can be blocked by using water swellable tape on the core. Lead sheath
Two C. C. V. Line for XLPE Cables upto 132 kv

can block the entry in radial direction. Lead sheath is extruded by continuous lead extruder

Salient features of EHV / XLPE line

n

which is equipped with micro-processor based temperature controllers & drives to achieve uniform thickness, better concentricity. Lead sheath in addition to other electrical & manufacturing advantages has a life span of minimum 40 to 45 years.

The only manufacturer in the country to have 2 Dry cure / Dry cooled lines sourced from SCHOLZ Germany. Highly sophisticated extruders for conductor shield, insulation and insulation shield, employing a three layer single head triple extrusion method to eliminate contaminants in the insulating layers. These are sourced from ROYLE USA. Microprocessor based equipments control all the parameters required for the process within the specified limits. Separate pressurised rooms for semicon shield & XLPE insulation to avoid contamination & this material is handled by vacuum loaders. Air systems with air showers on doors to eliminate dust entry.

Cable selection / design parameters

Cable design mainly depends on
n n n n n

System voltage Impulse level Fault level & duration Ground & air temperature Thermal resistivity of soil

EHV Testing Lab

BOTH END BONDING METHOD BOTH END BONDING METHOD

Cable Termination Cable Termination

TYPICAL TRENCH CROSS SECTION TYPICAL TRENCH CROSS SECTION

Cables in Trefoil Formation Cables in Trefoil Formation
GL GL Excavated earth Excavated earth Backfill Backfill

Conductor Conductor

Pre-warning Tape Pre-warning Tape R.C.C. Protection Tile R.C.C. Protection Tile

BOTH END BONDING METHOD Screen Bonding Cable BOTH END BONDING METHOD Screen
Bonding Cable Cable Termination Cable Termination Link Box Link Box Conductor Conductor Link Box Link Box

Sieved Earth, Sieved Earth, Lightly compacted Lightly compacted

TYPICAL TRENCH CROSS SECTION TYPICALCables in Trefoil FormationSECTION TRENCH CROSS

Cables in Trefoil Formation
GL GL Sieved Earth, Sieved Earth, Firmly compacted Firmly compacted

Excavated earth Excavated Backfill earth Backfill

SINGLE POINT BONDING METHOD SINGLE POINT BONDING METHOD

Cable Termination Cable Termination Screen Screen Cable sheath Cable sheath insulated at insulated at termination termination Bonding Cable Bonding Cable Link Box Link Box

Pre-warning Tape TYPICAL TRENCH CROSS SECTION OF TYPICAL TRENCH CROSS SECTION OF R.C.C. Protection Tile ROAD R.C.C. Protection Tile CROSSING ROAD CROSSING

Pre-warning Tape

Cables in Sieved Earth, Cables in Sieved Earth, Lightly compacted Lightly compacted GL GL

Flat Formation Flat Formation

Link Box Conductor Link Box Conductor

Excavated earth Excavated earth Backfill Backfill

Sieved Earth, Sieved Earth, Firmly compacted Firmly compacted

SINGLE POINT BONDING METHOD Screen Bonding Cable SINGLE POINT BONDING METHOD Screen
Link Box Link Box Bonding Cable Cable Termination Cable Termination Link Box with Cable sheath insulated at Link Box SVL Unit with Cable sheath insulated at termination SVL Unit termination Conductor Conductor

Pre-warning Tape Pre-warning Tape R.C.C. Protection Tile R.C.C. Protection Tile TYPICAL

TYPICAL Sieved Earth, Sieved Earth, Lightly compacted Lightly compacted

GL GL Excavated earth Excavated earth Backfill Backfill

TRENCH CROSS SECTION OF TRENCH CROSS SECTION OF ROAD CROSSING PVC / PVC / ROAD CROSSING HDPE Pipe Cables in Flat Formation
HDPE Pipe Cables in Flat Formation Sieved Earth, Sieved Earth, Firmly compacted Firmly compacted

The complete solution

Screen Screen

Pre-warning Tape Pre-warning Tape R.C.C. Protection Tile R.C.C. Protection Tile Bonding Cable Bonding Cable Sieved Earth, Sieved compacted Lightly Earth, Lightly compacted PVC / PVC / Pipe HDPE HDPE Pipe Sieved Earth, Sieved Earth, Firmly compacted Firmly compacted

Polycab can provide complete solution to provide assistance in selecting the cables, manufacturing the cables Link Box with desired to the Link Box
SVL of specification & assist / provide turnkey execution Unit the cable Link Box LinkUnit with SVL Box

installation.

WIRES & CABLES

(an ISO 9001:2000 Company)

POLYCAB WIRES PVT. LTD.

Regd. & Head office : Hico House, 1st floor, Pandit Satawalekar Marg, Mahim (W), Mumbai 400 016. Tel. : 91-22-2432 7070 - 4, 2436 2199, 2432 9118 Fax : 91-22-2432 7075 E-mail : polycab@vsnl.com Website : www.polycab.com