Icc HV Cables

Quality Aspect:
International Cables Co. SAE Policy is to supply customers with products meeting fully their stated needs. The products perform their required functions safely, consistently and reliably for their intended use. They fully meet customer requirements. International Cables Co. SAE is affiliated to "Nexans Group" the world leader in cables and cabling systems which support with the latest developments in the field of materials and manufacturing methods. International Cables Co. SAE sources its raw material from reputed suppliers. Right from the beginning, all incoming material and cable constituents are analyzed and tested to ensure their quality and compliance with specifications before being processed. During manufacturing again complete tests are performed on physical, mechanical and electrical properties of insulation and sheath material. Products have already been type tested from Extra High Voltage Labs. Testing facilities are equipped with up-to-date most modern and advanced laboratories as per international standards. International Cables Co. SAE implemented in its system total quality management. Its commitment towards quality is reflected by achievement of ISO 9001:2000 (SGS certified). Chairman
M. Mamdouh Khalaf
General Information
Selecting a power cable
The following factors are important when selecting a cable: Maximum operating voltage Insulation level Load to be carried Magnitude & duration of possible short-circuit current Voltage drop Way of installation - Underground direct buried, ducts or in air Nature of soil Specifications & requirements to be met If the ambient conditions are different than that given in our technical tables, it is recommended to modify current rating by multiplying values in technical data tables by correction factors given in Section 4 . If flame propagation of fire is expected, it is recommended to have flame retarding materials or halogen free materials for cable sheathing. If chemicals (acids, alkaline) are expected in soil, we give special care for choice of PVC or PE or XLPE materials, to resist this severe condition, when insulating or sheathing the cable. If wet or muddy conditions in soil are expected, or cable will be submerged in water, water blocking tapes are used for cables to prevent water penetration inside. Voltage The standard rated voltage of a cable is denoted by Uo / U (Um) Where Uo : is the rated power-frequency voltage between conductor & earth or metallic screen. U : is the rated power-frequency voltage between conductors. Um: is the maximum continuously permissible operating voltage
Uo/U (kV) Um 0.6/1 1.2 1.8/3 3.6 3.6/6 7.2 6/10 12 8.7/15 17.5 12/20 24 18/30 36 38/66 72.5 76/132 145
127/220
245
Note: cable design for 6/10, 12/20, 18/30 kV is applicable for 6.35/11, 12.7/22 and 19/33 kV respectively.
Standards Cables described in this catalogue are all standard types, and their performance has been proved in operation. Construction and tests are in accordance with the recommendation of IEC publications. Power cables in accordance to other standards (e.g. BS, ASTM, VDE) can be produced upon request. Weight and Dimension Weight and dimension characteristics are approximate. Deviations are due to manufacturing tolerance. Jacket Marking Standard Marking printed on outer jacket consisting of: 1- Name of manufacturer. ICC Cables 2- Type designation, size of conductor 3- Rated Voltage 4- Year of manufacturing 5- Any special parts upon request
International Cables Co.
Power Cables
Technical Information
Cable Construction
1 / Conductors:
According to IEC 60228, the conductors are either circular, circular compacted or sector shaped and consist of: a) Plain annealed copper or aluminium class 1 or 2. b) Plain or metal coated copper class 5 or 6 for flexible. The IEC 60228 gives minimum number of wires with minimum and maximum wire diameters and maximum D.C. resistance for each conductor cross sectional area (C.S.A.) according to its formation; if solid (class 1), stranded (class 2), or flexible (class 5 or 6). Comparison between copper and aluminium can be stated as follows Properties
Density Resistivity Constant mass temperature coefficient Conductivity Temperature coefficient at C Specific heat per unit weight Coefficient of linear expansion Ultimate tensile stress (annealed), approx. (hard drawn), approx.
Unit
g / Cm3 Ohm. mm2 / km 1 / C Siemens m/mm2 C w / g / C 1 / C Kg /mm2
Copper
8.89 17.241 0.00393 58 234.5 0.389 17 x 10-6 25.0 42.0
Aluminium
2.703 28.264 0.00403 36 228 0.8870 23 x 10-6 11.5 15.5 -
2 / Insulating Materials:
a) Thermoplastics:
Polyvinyl chloride (PVC) is used for cables with rated voltage Uo / U1.8/3 kV.
b) Thermosetting: Cross linked polyethylene (XLPE) is used for all kV ratings.
Thickness of insulation for each kind according to cable kV rating is indicated in IEC 60502
Power Cables
Main properties of insulation compounds are shown in the following table:
Properties Max. operating temperature Max. short circuit temperature Mechanical properties
Without Ageing Tensile strength Elongation at break Ageing temperature Duration After Ageing in Tensile strength Air Oven Variation Elongation at break Variation, max. Ozone Resistance - Concentration - Duration Hot Set Test - Ageing temperature - Duration under load (20 N/mm )
2
UNIT
C C N/mm % C Hours N/mm2 % % % % hours C minutes % %
2
XLPE
90 250 min. 12.5 min. 200 135 168 max. 25 max. 25 200 15 max. 175 max. 15
PVC
70 160 Min. 12.5 min. 120 100 168 min. 12.5 max. 25 min. 12.5 max. 25 -
Physico-chemical properties
- Elongation under load - Permanent elongation after cooling Water Absorption: Gravimetric method for 14 days at 85 C. - Variation of mass Resistance to - Acids - Alkaline - Oil - Heat distortion Volume resistivity at 20 C
g/cm2
max. 1 E E E E
E E E F min. 1013 min. 1011 max. 1000 6-8
. cm . cm X 10-4 -
min. 1016 min. 1012 max. 40 2.5
Electrical properties
Volume resistivity at max. rated temperature Dielectric power factor at ambient temperature: * Tan at Uo Dielectric constant: * at rated temperature Insulation resistance Constant Ki: *at 20 C * at max. rated temperature
M. Km M. Km
3.67
367 0.037
E = excellent
G = good
F = fair
Power Cables
Comparison between XLPE and PVC insulation material
Properties
Max permissible operating temperature Max. permissible short circuit temperature Emergency operating temperature Dielectric loss factor, tan Dielectric constant, r Density Volume resistivity Thermal resistivity
UNIT
C
XLPE
90
PVC
70
Operating temp. (C)

20
Tan XLPE
0.00034
PVC
0.070
250
160
30
0.00035
0.085
130
110
40
0.00037
0.078
0.004 2.3 g/cm3 . cm K.m/W 0.92 1016 3.5
0.09 4.5 - 8 1.45 1014 6
50 60 70 80 90
0.00039 0.000042 0.00048 0.00055 0.00062
0.063 0.057 0.034 -
3 / Screening:
Screening of cores in single and multi core cables, mainly for M.V cables: a) Conductor screen: It consists of a layer of extruded semi conducting compound. It is used at rated voltages from 3.6/6 (7.2) kV in XLPE insulated cables and above. b) Insulation Screen: 1 - Non metallic layer (applied upon the core insulation) of extruded semi conducting compound. Insulation screen is used at rated voltages from 3.6/6 (7.2) KV in XLPE insulated cables and above. 2 - Metallic layer of one or more copper tapes or of copper wires where the dimensional, physical and electrical requirements of the metallic screen are according to national regulations and standards. It is applied on each core or over cores assembly.
Power Cables
Practical formula for metallic screen:
> Effective screen area
eff:
A . dM . t.
eff =
100 2(100 - Overlap %) mm2
where: dM = Mean diameter over screen. t = Tape thickness.
4 / Assembly of cores, inner covering and fillers:

Cores are laid-up to form a cable, where for circular cores polypropylene fillers are used to fill the interstices between cores to get round shaped cable. Also, for sector shaped cores the fillers are used (if needed) to fill the interstices if any to get circular shaped cable, then cable is wrapped with polyester tape for tightness. For armored cables, a layer of extruded PVC is applied with a thickness according to IEC 60502.
5 / Armouring:
a) For single core cables: Aluminum tape armoring Aluminum wire armoring b) For multi core cables: Double steel tape armoring Steel wires armoring (DST). (SWA). (ATA) (AWA).
The nominal diameters of round armour wires and nominal thickness of armour tapes are according to IEC 60502.
6 / Outer Sheath:
It consists of PVC compound for cables working at rated temperatures up to 70 C or PVC type ST2 for cables of rated working temperature 90 C We can use polyethylene (PE) or low smoke and halogen free sheath material where required.
Power Cables
Main properties of different types of covering and sheathing materials are shown in the following table:
Properties
Without Ageing Tensile strength Elongation Temperature Duration Ageing in air oven Tensile strength Variation Elongation at break Variation properties Pressure test at high temp. Heat shock test Duration Temperature Variation Duration Temperature
UNIT
N/mm2 % C hours N/mm2 % % % hours C % hours C
PVC
min. 10 min. 300 100 240 min. 10 max. 20 min. 300 max. 20 No
PVC (ST2)
min. 12.5 min. 150 100 168 max. 10 max. 20 min. 250 max. 20 4 70 max 50 1 150 Yes
PE
min. 12.5 min, 150 100 168 min. 12.5 max. 25 min. 100 max. 20 6 80 max 50 1 150 No
Physico-chimical properties
Physical
Mechanical properties
- Flame propagation * Resistance to * Humidity * Chemicals * Hydrocarbons * Ozone * Weathering
Good Good Good V. G. Good
Excellent Good Variable V. G. V. G.
Good Good Good V. G. Good
Power Cables
Technical Data & Cable Parameters

1) Load Current: a) For single phase, A.C. system I = P / V cos A b) For three phases, A.C. system I = P / 3 V cos A Where P = Transmitted load in KW V = Phase to phase voltage in KV Cos = Power factor 2) Resistance: Value of conductor D.C resistance given is based on 20 C. In case of any other temperature the following formula is used: R = R20 [( 1 + 20 ( - 20 )] /km Where R : Conductor D.C resistance at C /km R20 : Conductor D.C. resistance at 20 C /km : Operating temperature. C : Resistance temperature coefficient 1/C = 0.00393 for Copper = 0.00403 for Aluminium To compute AC resistance of the conductor at its operating temperature the following formula is used: RAC = R ( 1 + ys + yp) Where ys = Skin effect factor (to be calculated as per IEC 287). yp = Proximity effect factor (to be calculated as per IEC 287). 3) Capacitance: C = r / (18 ln D/d) Where C : Operating Capacitance r : Insulation dielectric constant D : Diameter over insulation d : Conductor diameter f/ km f/ km mm mm 5) Charging current: The charging current is the capacitive current which flows when AC voltage is applied to the cables as a result of the capacitance between the conductor & earth. It can be derived form: Ic = Uo C 10-6 /km Where Ic : Charging current A/km Uo : Voltage between phase and earth Volt : 2f f : Frequency Hz C : Capacitance to neutral f/ km 6) Insulation Resistance: R = K ln (D/d) M.km Where R : Insulation resistance K : Constant depends on the insulation material d: Diameter of conductor (including semiconducting material) D : Diameter of insulated core 7) Dielectric Loss: The dielectric losses of a cable are proportional to the capacitance, frequency, phase voltage & power factor. D = 2 f C Uo tan 10-6 watt/km/phase Where D : Dielectric loss watt/km/phase f : Frequency Hz C : Capacitance to neutral f/ km tan : Dielectric power factor
4) Inductance: Self and mutual inductance are indicated as below: L = K + 0.2 ln(2S/d) mh/km Where L : Inductance mh/km K : Constant depends on conductors number of wires S : Axial spacing between cables in trefoil formation S : 1.26 x axial spacing between cables in flat formation
Power Cables
Technical Data & Cable Parameters

8) Cable Ampacity: Cable ampacity or current carrying capacity is defined as the continuous maximum current the cable can carry at its maximum operating temperature. The following installation conditions were assumed during current calculations: Ambient air temperature = 40 C for L.V & 45C for M.V Ground temperature = 30 C Ground thermal resistivity = 120 C.cm/watt Burial depth = 0.8 m - In case installation conditions are different than above, derating factors must be taken in advance - All calculations are based on IEC 60287 9) Cable short circuit capacity: Short circuit starts from the maximum operating conductor temperature Maximum temperature during short circuit XLPE = 250 C PVC = 160 C for C.S.A 300 mm2 PVC = 140 C for C.S.A > 300 mm2 Maximum short circuit duration is 5 seconds It can be derived from Is.c.t = Is.c.1 / t Where Is.c.t : Short circuit current for t second kA Is.c.1: Short circuit current for 1 second kA t : Duration Sec. 9) Voltage Drop: When current flows in a cable conductor there is a voltage drop between the ends of the conductor which is the product of the current and the impedance. It can be derived form: For Single phase circuit: Vd = 2 I (R cos + X sin ) Volt For Three phase circuit: Vd = 3 I (R cos + X sin ) Where Vd : Voltage drop I : Load current R : AC resistance X : Reactance Cos : Power factor : Length X = L 10-3 L = inductance Cos = 0.8 Sin = 0.6 Volt Volt Amp /km /km km /km /km
For L.V cables, voltage drop should be calculated so as not to exceed 3 to 5 % in normal operating conditions.
Power Cables
Permissible short circuit current

of XLPE insulated power cables for 1-30 kV (Copper Conductor)
COPPER CONDUCTORS
Cond. max Construction temp. Normal Operation C XLPE Cable 90 Short Circuit Conductor Max. Temp C 250 143 149 90 80 Conductor Temp. at the beginning of short circuit 70 65 60 50 40 30 20
SHORT CIRCUIT CURRENT A./mm 154 157 159 165 170 176 181
Power Cables

of XLPE insulated power cables for 1-30 kV (Aluminium Conductor)
ALUMINIUM CONDUCTORS
Cond. max Construction temp. Normal Operation C XLPE Cable 90 Short Circuit Conductor Max. Temp C 250 94 98 90 80 Conductor Temp. at the beginning of short circuit 70 65 60 50 40 30 20
SHORT CIRCUIT CURRENT A./mm 102 104 105 109 113 116 120
Power Cables

for various cross section of round wire screens for M.V. Cables
Power Cables
38/66 (72.5) kV
Copper / XLPE / CUW / HDPE
C.S.A
Cond. screen
Insulation
Insulation screen
Overall Diam.
Weight
Max. Cond. Resistance DC at 20C /km

0.0754 0.0601 0.047 0.0366 0.0283 0.0221 0.0176 0.0151
Current Rating Capacitance Ground f / km

0.164 0.176 0.195 0.21 0.231 0.254 0.282 0.307
Air
mm2
240 R 300 R 400 R 500 R 630 R 800 R 1000 S 1200 S
mm
1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
mm
11 11 11 11 11 11 11 11
mm
1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
mm
59 61 64 68 71 74 82 89
kg/km
5300 6010 6900 8000 9335 10600 13850 15765
Amp.
487 547 611 685 761 842 967 1036
Amp.
459 482 551 598 618 668 712 744
Amp.
647 736 842 962 1097 1238 1454 1592
Amp.
640 724 813 919 1031 1152 1316 1420
Description Stranded circular compacted or segmental conductor with copper material ,Semi-Conducting layer as conductor screen , XLPE insulation , Semi-Conducting layer as insulation screen, Semi-Conductive water blocking tape , copper wire as metallic screen to achieve the required cross sectional area that carry the earth fault current , non conductive water blocking tape to protect the metallic screen area from longitudinal water penetration, double coated aluminum tape to protect the cable from radial water penetration and extruded HDPE Sheath with semi-conducting extruded material. Cables are designed and tested according to IEC 60228, 60840 and 60811.
high Voltage
> The Aluminium conductor can be manufactured upon request. > The Insulation thickness can be processed upon request. > The above dimensions can be processed upon request. > The above data is approximate and subjected to manufacturing tolerance. > The above data is calculated at 100% load factor. > The current rating for above table was based on double end bonded (long distance). R : Round S : Segmental
Power Cables
38/66 (72.5) kV
Copper / XLPE / LEAD / HDPE
C.S.A
Cond. screen
Insulation
Insulation screen
Overall Diam.
Weight

0.0754 0.0601 0.047 0.0366 0.0283 0.0221 0.0176 0.0151

0.164 0.176 0.195 0.21 0.231 0.254 0.282 0.307
Air
mm2
240 R 300 R 400 R 500 R 630 R 800 R 1000 S 1200 S
mm
1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
mm
11 11 11 11 11 11 11 11
mm
1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
mm
61 82 64 69 71 76 81 88
kg/km
9000 10080 11200 12315 13470 14120 18020 19000
Amp.
495 556 629 709 796 879 1012 1084
Amp.
503 533 591 671 716 767 843 884
Amp.
659 751 827 993 1138 1285 1513 1654
Amp.
660 749 859 977 1110 1241 1438 1557
Power Cables
high Voltage
Description Stranded circular compacted or segmental conductor with copper material, Semi-Conducting layer as conductor screen, XLPE insulation, Semi-Conducting layer as insulation screen, Semi-Conductive water blocking tape to protect the metallic screen area from longitudinal water penetration, Lead sheath with suitable thickness to achieve the required cross sectional area that carry the earth fault current and extruded HDPE Sheath with semi-conducting extruded material. Cables are designed and tested according to 1EC 60228, 60840 and 60811.
76/132 (145) kV
C.S.A
Cond. screen
Insulation
Insulation screen
Overall Diam.
Weight

0.047 0.0366 0.0283 0.0221 0.0176 0.0151

0.162 0.171 0.189 0.202 0.223 0.259
Air
mm2
400 R 500 R 630 R 800 R 1000 S 1200 S
mm
1.2 1.2 1.2 1.2 1.2 1.2
mm
16 16 16 16 16 16
mm
1.5 1.5 1.5 1.5 1.5 1.5
mm
62 67 69 74 79 86
kg/km
8350 9420 10895 11175 14800 16705
Amp.
602 673 752 830 956 1022
Amp.
528 572 612 659 708 742
Amp.
575 959 1096 1237 1459 1468
Amp.
816 922 1037 1158 1332 1438
Description Stranded circular compacted or segmental conductor with copper material, Semi-Conducting layer as conductor screen, XLPE insulation, Semi-Conducting layer as insulation screen, Semi-Conductive water blocking tape, copper wire as metallic screen to achieve the required cross sectional area that carry the earth fault current, non conductive water blocking tape to protect the metallic screen area from longitudinal water penetration, double coated aluminum tape to protect the cable from radial water penetration and extruded HDPE Sheath with semi-conducting extruded material. Cables are designed and tested according to IEC 60228, 60840 and 60811.
high Voltage
Power Cables
76/132 (145) kV
C.S.A
Cond. screen
Insulation
Insulation screen
Overall Diam.
Weight

0.047 0.0366 0.0283 0.0221 0.0176 0.0151

0.162 0.171 0.189 0.202 0.223 0.259
Air
mm2
400 R 500 R 630 R 800 R 1000 S 1200 S
mm
1.2 1.2 1.2 1.2 1.2 1.2
mm
16 16 16 16 16 16
mm
1.5 1.5 1.5 1.5 1.5 1.5
mm
78 81 85 89 93 97
kg/km
12350 13700 14885 15300 18980 20805
Amp.
617 695 780 865 994 1054
Amp.
581 636 697 754 827 849
Amp.
858 983 1127 1276 1502 1634
Amp.
851 967 1101 1235 1434 1536
Power Cables
high Voltage
Description Stranded circular compacted or segmental conductor with copper material, Semi Conducting layer as conductor screen, XLPE insulation, Semi-Conducting layer as insulation screen, Semi-Conductive water blocking tape to protect the metallic screen area from longitudinal water penetration, Lead sheath with suitable thickness to achieve the required cross sectional area that carry the earth fault current and extruded with HDPE Sheath with semi-conducting extruded material. Cables are designed and tested according to IEC 60228, 60840 and 60811.
127/220 (245) kV
C.S.A
Cond. screen
Insulation
Insulation screen
Overall Diam.
Weight
Max. Cond. Resistance DC at 20C /Km

0.0221 0.0176 0.0151

0.167 0.186 0.200
Air
mm2
800 R 1000 S 1200 S
mm
1.5 1.5 1.5
mm
22 22 22
mm
1.5 1.5 1.5
mm
100 105 110
kg/km
12600 16720 18800
Amp.
826 949 1014
Amp.
662 709 739
Amp.
1230 1448 1583
Amp.
1159 1334 1441
Description Stranded circular compacted or segmental conductor with copper material, Semi-Conducting layer as conductor screen, XLPE insulation, Semi-Conducting layer as insulation screen, Semi-Conductive water blocking tape, copper wire as metallic screen to achieve the required cross sectional area that carry the earth fault current, non conductive water blocking tape to protect the metallic screen area from longitudinal water penetration, double coated aluminum tape to protect the cable from radial water penetration and extruded HDPE Sheath with semi-conducting extruded material. Cables are designed and tested according to IEC 60228, 62067 and 60811.
high Voltage
Power Cables
127/220 (245) kV
C.S.A
Cond. screen
Insulation
Insulation screen
Overall Diam.
Weight

0.0221 0.0176 0.0151

0.167 0.186 0.200
Air
mm2
800 R 1000 S 1200 S
mm
1.5 1.5 1.5
mm
22 22 22
mm
1.5 1.5 1.5
mm
103 108 114
kg/km
16900 20790 22830
Amp.
855 983 1066
Amp.
752 825 868
Amp.
1269 1484 1630
Amp.
1236 1424 1548
Description Stranded circular compacted or segmental conductor with copper material, Semi Conducting layer as conductor screen, XLPE insulation, Semi-Conducting layer as insulation screen, Semi-Conductive water blocking tape to protect the metallic screen area from longitudinal water penetration, Lead sheath with suitable thickness to achieve the required cross sectional area that carry the earth fault current and extruded with HDPE Sheath with semi-conducting extruded material. Cables are designed and tested according to IEC 60228, 62067 and 60811.
Power Cables
high Voltage
Explanation notes
Current Carrying Capacities are based on the following conditions:
A) In Air: Ambient temperature 45C (load factor = 0.8) where cables are protected from direct solar radiation. B) In Ground: Soil temperature 30C, soil thermal resistivity 1.2 Km/W, and depth of laying 80 cm (load factor = 0.8). C) Arrangement of the cables: 1Trefoil 3 cores laid in triangular shape. 2Flat 3 cores laid side by side. Clearance: in soil 7 cm. in air 1 x cable diameter. Note: Earthing of screens is on both ends __________________
Rating Factor for Current Carrying Capacity & Cable Installation

When laying or operating conditions differ than the normal one stated before, the following rating factors should be used for calculating the current carrying capacity: In Air Ambient Temp. C Factor
25 1.2 30 1.16 35 1.1 40 1.05 45 1.00 50 0.94 55 0.81
In Ground a) Variation in soil temperature: Soil Temp.C Factor

25 1.05 30 1.00 35 0.96 40 0.91 45 0.87 50 0.82
b) Variation in soil thermal resistivity: Soil Thermal Resistivity Km /KW Factor c) Variation in depth of laying:
0.70 1.19 1.00 1.085 1.20 1.00 1.50 0.91 2.00 0.82
explation notes
Soil, Depth of Laying (m) Factor
0.50 1.04
0.80 1.00
1.00 0.98
1.25 0.96
1.50 0.94
2.00 0.90
d) Factor for laying in ducts and pipes: Cables in Ducts Cables in Pipes
Bedding and filling with tamped sand and cover with bricks Cable trough with cover, hollow space, air filled pipe Factor = 1 Factor = 0.85
Power Cables
e) Factors for grounding in soil: 1 - Single core cables in 3-phase system: Cable in Flat Formation (Clearance between System 7 cm) Load Factor Thermal Resistivity of Soil Km / KW
1 2 3 0.7 0.99 0.86 0.77 0.73 0.69 0.67 0.64 0.62 1.0 1.00 0.87 0.77 0.73 0.70 0.68 0.65 0.63 0.8 1.2 1.005 0.874 0.775 0.734 0.700 0.680 0.650 0.630 1.5 1.01 0.88 0.78 0.74 0.70 0.68 0.65 0.63 2.0 1.020 0.880 0.785 0.740 0.705 0.685 0.650 0.630 1.0 0.7 2.0 0.85 0.71 0.62 0.58 0.55 0.53 0.52 0.49
N of Systems in the trench
4 5 6 8 10
Cable in Trefoil Formation, Touching (Clearance between System 7 cm 25 cm) Load Factor Thermal Resistivity of Soil Km / KW Clearance between Systems cm
1 2 3 4 5 6 8 10 7 0.99 0.84 0.74 0.69 0.65 0.62 0.58 0.56 0.7 1.0 0.8 1.2 1.5 2.0 1.0 0.7 2.0
25 0.99 0.89 0.81 0.78 0.74 0.72 0.70 0.68
7 1.00 0.85 0.77 0.70 0.66 0.63 0.59 0.56
25 1.00 0.89 0.81 0.78 0.74 0.72 0.70 0.68
7 1.01 0.86 0.76 0.70 0.66 0.63 0.59 0.56
25 1.01 0.90 0.82 0.79 0.75 0.73 0.70 0.68
7 1.01 0.86 0.77 0.71 0.67 0.64 0.59 0.57
25 1.01 0.90 0.82 0.79 0.75 0.73 0.70 0.68
7 1.02 0.87 0.77 0.71 0.67 0.64 0.59 0.57
25 1.02 0.91 0.83 0.79 0.76 0.74 0.71 0.69
7 0.87 0.71 0.61 0.56 0.52 0.50 0.46 0.44
25 0.87 0,75 0.67 0.64 0.60 0.59 0.56 0.54
2 - Three core cables, all KV ratings: Load Factor Thermal Resistivity of Soil Km / KW
1 2 3 0.7 0.99 0.84 0.74 0.69 0.65 0.63 0.59 0.56 1.0 1.00 0.85 0.75 0.70 0.66 0.63 0.59 0.56 0.8 1.2 1.006 0.86 0.76 0.71 0.67 0.64 0.60 0.57 1.5 1.01 0.86 0.77 0.71 0.67 0.64 0.60 0.57 2.0 1.015 0.865 0.770 0.715 0.670 0.650 0.600 0.570 1.0 0.7 2.0
0.72 0.62 0.57 0.54 0.51 0.47 0.44
4 5 6 8 10
Power Cables
explation notes
0.89
Factors for laying and grouping in air

a) Grouping in air, single core cables in three phase system:
explation notes
International Cables Co. Power Cables
b) Grouping in air, Multi-core cables in three phase system:
Power Cables
explation notes
CABLE PULLING, LAYING AND HANDLING INSTRUCTIONS

TABLE I - Installation Bending Radius for Low Voltage Cables Multiplying Factor Type of Cable Single core (Un-armoured / Armoured) Multi-core (Un-armoured / Steel Wire Armoured) Multi-core (Steel Tape Armoured) Installation bending radius During Installation
9 / 12 12 / 15 15
Fixed Installation
9 9
TABLE II - Installation Bending Radius for Medium Voltage Cables Cable outermost sheath or covering PVC HDPE Lead Sheathed (Un-Armoured) Lead Sheathed Armoured Factor to be multiplied by Overall diameter of cable During Installation
15 20 18 15
Fixed Installation
10 15 12 10
TABLE III - Installation Bending Radius for High Voltage Cables Factor to be multiplied by Overall diameter of cable
During Installation 25 Fixed Installation 25
TABLE IV - Permissible pulling force in the laying of LV, MV and HV cables Means of pulling
With pulling head attached to the conductors
Type of Cable
All types of cables
Formula
P = . A
Factor
= 50 N/mm Copper = 30 N/mm Alum. = 50 N/mm Copper = 30 N/mm Alum. k = 9 N/mm k = 3 N/mm
Un-armoured Cables* With pulling stocking Armoured Cables** Lead Sheath Cables
P=.A P = k. d P = k. d
* When pulling 3 single core cables simultaneously with a common pulling stocking. the same maximum pulling force applies, whereas the pulling force 3 laid-up single core cables is 3 times that of a single core and for 3 non-laid-up single core cables is 2 times that of a single core. ** Not applicable for high voltage cables P = Pull in Newton A = Total cross sectional area in mm of all conductors (but not screen or concentric conductor) d = Outside diameter of the cable in mm = Permissible tensile stress of conductor in N/mm k = Empirically derived factor in N/mm
explation notes
Power Cables
Earthing of Single Core H.V. and E.H.V. Cables

Distribution voltage cables are normally installed with solidly bonded sheaths and, in order to minimize the sheath circulating currents on single-core cables produced by the magnetic flux linking the conductors and sheaths, they are nearly always laid in close touching trefoil formation. However, trefoil formation is poor for heat dissipation, as the three cables have a considerable heating effect upon one another. This is generally not a limitation for cable system at 33 kV but with larger conductor sizes and higher voltages alternative specially bonded systems are more economic. Special bonding involves earthing the single-core cable sheaths at one point only and insulating all other points of the sheath from earth, so that the circulating sheath losses are eliminated and the phase cables can design be spaced apart to reduce their mutual heating effect without increasing sheath losses. If one termination only is grounded, the sheaths are subjected to a standing voltage of zero at the ground connection and maximum at the point furthest from this connection. This voltage is proportional to the conductor current and cable spacing. To protect the sheath insulation against transient voltages arising from lightning or switching transients it is therefore necessary to fit sheath voltage limiters (SVLs) at all joint and sealing end positions where the sheath is insulated from earth. Three basic variations of specially bonded systems are commonly used: single end bonding, midpoint bonding and cross-bonding.
Specially Bonded Cable Systems Single End Bonding System
In this system the sheaths at one termination are earthed and at the other termination are insulated from ground and fitted with SVLs. It is necessary to provide a separate earth continuity conductor for fault currents which would normally return via the cable sheaths. The standing voltage is proportional to the cabie length and therefore the voltage limitation imposes a limitation on the length of the cable that may be bonded in this manner.
Mid-point Bonding System
Bonding of the mid-point is used where the route length is too long to employ a single end bonding system. In this system the cable is earthed at the mid-point (at joint) of the route and is insulated from ground and provided with SVLs at each termination or vice versa. It can be seen that this doubles the possible route length as the maximum allowable standing voltage can be tolerated at each sealing end or joint.
Cross-bonding System
Power Cables
explation notes
In long routes, the route is split up into i:major sections, each comprised of three lengths and special joints are fitted. At each third joint position the sheaths are connected together and at all other positions they are connected so that all sheaths occupying the same position in the cable trench are connected in series The sheaths at the intermediate positions are also connected to SVLs. The three sheaths connected in series are associated with conductors of different phases and when the cables are installed in trefoil formation their currents, and hence the sheath voltages, have equal magnitude but phase displacements of 120. The overall effect if that the resultant voltage and current in the three sheaths are zero. When cables are laid in flat formation the voltages induced in the sheaths of the outer cable are greater than induced on the sheath of the middle cable and the phasor sum is not zero. The cables are therefore transposed at every joint position and the crossconnections are made with a phase rotation opposite to that of transposition so that the sheaths are effectively straight connected.
Drum Handling Instructions

Cables and Conductors should be installed by trained personnel in accordance with good engineering practices, recognized codes of practice, statutory local requirements, IEE wiring regulations and where relevant, in accordance with any specific instructions issued by the company Cables are often supplied in heavy cable reels and handling these reels can constitute a safety hazard. In particular, dangers may arise during the removal of steel binding straps and during the removal of retaining battens and timbers which may expose projecting nails.
explation notes
International Cables Co. Power Cables

Icc HV Cables

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Quality Aspect:

International Cables Co.

b) Thermosetting: Cross linked polyethylene (XLPE) is used for all kV ratings.

International Cables Co.

Main properties of insulation compounds are shown in the following table:

E E E F min. 1013 min. 1011 max. 1000 6-8

min. 1016 min. 1012 max. 40 2.5

International Cables Co.

Comparison between XLPE and PVC insulation material

Operating temp. (C)

0.004 2.3 g/cm3 . cm K.m/W 0.92 1016 3.5

0.09 4.5 - 8 1.45 1014 6

0.00039 0.000042 0.00048 0.00055 0.00062

0.063 0.057 0.034 -

International Cables Co.

Practical formula for metallic screen:

> Effective screen area

100 2(100 - Overlap %) mm2

where: dM = Mean diameter over screen. t = Tape thickness.

4 / Assembly of cores, inner covering and fillers:

International Cables Co.

- Flame propagation * Resistance to * Humidity * Chemicals * Hydrocarbons * Ozone * Weathering

Good Good Good V. G. Good

Excellent Good Variable V. G. V. G.

Good Good Good V. G. Good

International Cables Co.

Technical Data & Cable Parameters

International Cables Co.

Technical Data & Cable Parameters

International Cables Co.

Permissible short circuit current

International Cables Co.

Permissible short circuit current

International Cables Co.

Permissible short circuit current

International Cables Co.

Max. Cond. Resistance DC at 20C /km

Current Rating Capacitance Ground f / km

International Cables Co.

Max. Cond. Resistance DC at 20C /km

Current Rating Capacitance Ground f / km

International Cables Co.

Max. Cond. Resistance DC at 20C /km

Current Rating Capacitance Ground f / km

International Cables Co.

Max. Cond. Resistance DC at 20C /km

Current Rating Capacitance Ground f / km

International Cables Co.

Max. Cond. Resistance DC at 20C /Km

Current Rating Capacitance Ground f / km

International Cables Co.

Max. Cond. Resistance DC at 20C /km

Current Rating Capacitance Ground f / km

International Cables Co.

Rating Factor for Current Carrying Capacity & Cable Installation

In Ground a) Variation in soil temperature: Soil Temp.C Factor

Soil, Depth of Laying (m) Factor

International Cables Co.

N of Systems in the trench

25 0.99 0.89 0.81 0.78 0.74 0.72 0.70 0.68

7 1.00 0.85 0.77 0.70 0.66 0.63 0.59 0.56

25 1.00 0.89 0.81 0.78 0.74 0.72 0.70 0.68