HT Xlpe Cables

POLYCAB WIRES PVT LTD
TECHNICAL DETAILS
HT XLPE CABLES
UPTO 45Kv
WIRES & CABLES
CONTENTS
INTRODUCTION ADVANTAGE OF POLYCAB XLPE CABLES SELECTION OF CABLES TECHNICAL DATA Conductor Resistance Current Rating Cable Short Circuit Rating Capacitance & Reactance Rating Factors Important Formulae WEIGHT, DIMENSION DATA & CURRENT CARRYING CAPACITY OF CABLES HANDLING STORAGE & LAYING OF CABLES
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WIRES & CABLES
POLYCAB PERFORMANCE
POLYCAB has earned trust and reputation in India and abroad by winning the customer confidence. Several thousands kilometers of XLPE Cables in the voltage range of 6.6 kV, 11 kV, 22 kV and 33 kV have been manufactured and are in operation in India and abroad. POLYCAB cables are the preferred choice in Power plants, Process plants, Distribution system, heavy industries and various utilities. MANUFACTURING PROCESS HIGHLIGHTS POLYCAB has most modern and state of art manufacturing facilities for XLPE Insulation. It has True Tripple Extrusion & Dust free environment for XLPE insulation, ON-LINE thickness Measurement and Control, fitted on with the best Dry Cure CCV (Continuous Catenary Vulcanization) Lines.
CCV Line
POLYCAB XLPE HIGH VOLTAGE CABLES (H.T.)

From the beginning of 20th Century, Paper Insulated Oil Impregnated lead sheathed Power Cables were the unanimous choice of Power Engineers for underground transmission and distribution, due to their excellent electrical and thermal properties. The cables which were laid in 1950 in our country are still in operation. These cables were heavy due to lead sheath and were not suitable for vertical runs as in that case the oil got accumulated in the lower portion of the cables. Any puncture in the lead sheath lead to cable failure as the electrical properties of Manila Paper weakens in the presence of moisture. The jointing of the cables also required a special skill. Cables up to 132 kV were made with paper insulation and they are still in the service. Polymer technology made in a rapid stride during and after second world war and we witnessed a Plastic revolution. Various plastics like PVC,
POLYETHYLENE, NYLON, POLYESTER etc, were invented and put to commercial use during this period. Plastics can be divided in to two categories: 1) Thermosetting 2) Thermoplastics.
Thermosetting plastics are those plastics which set when the heat and pressure are applied due to formation of intra molecular bonds and subsequently heating will not soften them. Bakelite, Mellamine, UF Resins are coming in this category.
Thermoplastics are the plastics which become soft on application of heat and become hard when the heat is removed. PVC, Polyethylene, Nylon, Polystyrene are thermoplastics and they can be recycled.
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PVC is a versatile plastic and it is a compound of various chemicals. Its properties can be varied to a great extend by changing the proportion of its ingredients. It has found a wide application in LT Power Cables, Building wires, Flexibles, Auto Cables, etc. It is a thermoplastic and it can be operated continuously at 70oC. Due to its higher Dielectric constant, the cables with PVC Insulation has a higher capacitance and hence it is not preferred as insulating material for HT Cable and Telecommunication cables. Polyethylene has got excellent electrical properties. Its dielectric constant is 2.3 and hence it is found wide application in Telecommunication filed as insulating material Polyethylene can be operated continuously at 65oC and hence it has found little application in Power Cables. In Sixties, Scientists found that the linear molecular chains of Polyethylene can be interlinked by adding some peroxide and thus its thermal rating can be upgraded. Due to cross linking, the Polyethylene turns from thermoplastic to thermosetting and it can be operated at 85oC continuously. It can withstand 230oC temperature under short circuit compared to 150oC for PVC. Due to thermosetting nature of the cross-linked polyethylene, its scrap cannot be recycled. Cross-linked Polyethylene which is commonly known as XLPE is invariably used as insulating material for HT Cables. Cables up to 230 kV with XLPE Insulation are in commercial use. XLPE Insulated cables are lighter in weight, easy to install and terminate and unaffected by moisture and most of the chemicals.
CONSTRUCTION OF HT CABLES: 1. Conductor: Stranded Class 2 - Annealed Plain / Tinned Copper / Aluminium IS:8130 / IEC 60228/ BS 6360. Conductor Screen: Extruded semiconducting compound IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. Insulation: XLPE IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. Insulation Non-metallic Screen: Extruded semi-conducting compound IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. Insulation Metallic Screen: Copper Wire / Tape or Aluminium Wire / Strip IS:7098 Part 2, IEC:60502 Part 2, BS:6622, BS:7835. Fillers: Non Hygroscopic PVC * / Polypropelene Fiber to maintain roundness of cable. Inner sheath/Bedding: PVC ST 2 as per IS:7098 Part 2, IEC:60502 Part 2, BS:6622, LSOH to BS:7835. Armour: IS:7098 Part 2, IS: 3975, IEC:60502 Part 2, BS:6622, BS:7835. Outer Sheath: PVC ST 2, FR, FRLS as per IS:7098 Part 2, IEC:60502 Part 2, BS:6622, LSOH to BS:7835.
2.
3. 4.
5.
6.
7.
8. 9.
* Weights given in the Tables are with PVC Fillers.
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Polycab manufactures following voltage grade cables as per IS-7098[Part-2], IEC-60502 Part-2 and BS-6622 & BS:7835
45 kV or 33 kV (UE) Screened XLPE Cables as per customer requirement. 19/33 kV Screened Cable (36 kV Max) 12.7/22 kV Screened Cables (22 kV Earth) 11/11 kV i.e. 11 kV ( UE) Screened Cables. 6.35/11 kV, Screened Cables[6.6 kV (UE) 3.8/6.6 kV Screened Cables. 3.3kV (E) and (UE) Unscreened & Screened Cables. SIZES: 50 Sq.mm up to 1000 Sq.mm in Single Core Cables. 35 Sq.mm to 400 Sq.mm in Multi Cores Cables.
Flame Retardant (FR), Flame Retardant Low Smoke (FRLS) and Low Smoke Zero Halogen & Flame Retardant (LSOH) Sheathed HT XLPE cables are also manufactured. The XLPE cables are manufactured in sophisticated triple extrusion line, in highly quality conscious environment with testing and inspection from raw material to finished cable. The assurance of quality is further ensured by ISI certification No. CM/L-7180366 on cables and ISO 9001 certification by UL,USA, A-7913.
ROUTINE TEST SET UP
Quality Assurance Testing: Polycab XLPE Cables are tested to ensure high reliability in performance. Continuous process monitoring and post manufacturing tests ensure the compliance to Indian and International Standards.
Polycab is self sufficient to carry out all Routine & Type Tests in its own laboratory. It has world class Testing facilities for Routine & Type Tests.
Routine Tests: IS:7098 Part 2, IEC:60502, BS:6622, BS:7835 Partial Discharge Test High Voltage Test Conductor Resistance Test.
Routine Tests are performed on each manufactured length of cable in Routine Test Laboratory.
POLYCAB WIRES PVT LTD Page 5 of 28
Type Tests: IS:7098 Part 2, IEC:60502, BS:6622, BS:7835
a) b) c)
Electrical Type Tests Non-Electrical Type Tests Special Tests
The cable samples are type tested in-house to ensure conformance as to various standards.
NON-ELECTRICAL TYPE TEST LABORATORY
IMPULSE TEST SET UP
Polycab cables of various voltage grades are type tested at CPRI Bangalore & ERDA Vadodara. Short circuit tests on cable conductor and armour are successfully carried at CPRI Bhopal & ERDA Vadodara.
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WIRES & CABLES
general applications of power for utilities, distribution and generation purposes. The cables are manufactured conforming to Indian & International cables specifications for XLPE Insulated cables. Customer specific requirements can also be met. Polycab is manufacturing wide range of cables, so it is important that while placing enquiries or orders, as much information as possible shall be given to Polycab, so that the enquiries and orders are dealt quickly and efficiently. POLYCAB GUIDELINES FOR SELECTION OF CABLE 1) Voltage Grade 1.9 / 3.3 kV (E), 3.3 / 3.3 kV (UE), 3.8 / 6.6 kV (E) , 6.6 / 6.6 kV (UE), 6.35 / 11 kV (E), 11 / 11 kV (UE), 12.7 / 22 kV (E) & 33 kV (E), 33 kV (UE) & 45 kV 2) Relevant Indian Standard IS-7098 (Part-2) 1985 or International standard IEC-60502 (Part-2), BS-6622 & BS:7835. 3) Number of cores. Single & Three. 4) Conductor Size - 50 Sq.mm to 1000 Sq.mm in Single Core Cables & 25 Sq.mm to 400 Sq.mm in 3Core cables. 5) Conductor Material- Copper/Aluminium 6) Type of Insulation XLPE 7) Type of Inner Sheathing Wrapped/PVC Extruded. PVC
ADVANTAGES OF POLYCAB XLPE CABLES

1) Higher Electrical Strength Retention 2) Higher Short Circuit Rating 3) Better Electrical , Mechanical & Thermal Properties 4) Easy Jointing & Termination
Selection of Cables.
Power Cables are generally selected considering the application. However, following factors are important for selection of suitable cable construction required to transport electrical energy from one end to the other. 1) Maximum operating voltage, 2) Fault Level, 3) Load to be carried, 4) Possible overloading duration & magnitude, 5) Route length and voltage drop. 6) Mode of installation considering installlation environment such as ambient & ground temperature chemical & physical properties of soil. 7) Flame retardant properties. All sizes of POLYCAB XLPE cables are designed to standard operating conditions in India and abroad. The standards adopted are considering the geographical/climatical conditions and
8) Type of Armour Unarmoured / Strip Armoured/Wire Armoured. 9) Type of Outer Sheath PVC/Flame Retardant/Flame Retardant Low Smoke / Zero Halogen (LSOH). 10) Length of cable required and drum length.
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WIRES & CABLES
The details to the above Guidelines are given in tables.

Table 1 *Conductor Technical Information for Single Core and Multicore cables conforming to IS-8130 /1984 ( Stranded Class-2) Copper & Aluminium Conductors.
Nominal Size of Conductor Sq.mm 25 35 50 70 95 120 150 185 240 300 400 500 630 800 1000 Minimum No. of wires Compacted Round /Shaped CU. ALU. 6 6 6 6 6 6 12 12 15 15 18 15 18 15 30 34 34 53 53 53 53 53 30 30 30 53 53 53 53 53 Max. D.C. Resistance at 20oC Plain Copper Aluminium Ohm/Km 0.727 0.524 0.387 0.268 0.193 0.153 0.124 0.0991 0.0754 0.0601 0.0470 0.0366 0.0283 0.0221 0.0176 Ohm/Km 1.20 0.868 0.641 0.443 0.320 0.253 0.206 0.164 0.125 0.100 0.0778 0.0605 0.0469 0.0367 0.0291 A.C. Resistance at 90oC Plain Copper Ohm/Km 0.930 0.671 0.495 0.343 0.247 0.196 0.159 0.127 0.0965 0.0769 0.0602 0.0468 0.0362 0.0283 0.0225 Aluminium Ohm/Km 1.54 1.11 0.82 0.567 0.410 0.324 0.264 0.210 0.160 0.130 0.10 0.0774 0.060 0.0470 0.0372
* Conductor meeting requirements of IEC-60228 and BS 6360 can also be manufactured.
Table-2
SHORT CIRCUIT RATING FOR 1 SECOND DURATION FOR COPPER AND ALUMINIUM XLPE CABLES (CURRENT IN K. AMPS)
Nominal Size Sq.mm 25 35 50 70 95 120 150 185 240 300 400 500 630 800 1000 XLPE Insulated Copper Aluminium 3.6 2.4 5.0 3.3 7.1 4.7 10.0 6.6 13.6 17.1 21.4 26.4 34.3 42.9 57.1 71.4 90.0 114.3 142.9 9.0 11.3 14.2 17.5 22.6 28.3 37.7 47.2 59.4 75.5 94.3
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XLPE Cables as per IS-7098 (Part-2)-1985 1) Max. Conductor Temperature during operation: 90oC 2) Max. Conductor Temperature during short Circuit: 250oC Formula relating Short Circuit Rating with duration It =I sh Where t It = Short Circuit Rating for t Seconds. t = duration in seconds I sh = Short Circuit rating for 1 second.
WIRES & CABLES
Table 3
CAPACITANCE
Approximate Capacitance (Microfarads/km) for Single Core Cables Size 1.9/3.3& 3.3/3.3 0.30 0.34 0.39 0.43 0.49 0.52 0.59 0.67 0.76 0.77 0.81 0.86 0.88 3.8/6.6 0.27 0.31 0.34 0.37 0.42 0.44 0.50 0.53 0.55 0.57 0.64 0.73 0.80 Voltage Grade(kV) 6.6/6.6 & 11/11 6.35/11 0.23 0.16 0.27 0.18 0.31 0.20 0.33 0.22 0.36 0.24 0.39 0.25 0.43 0.28 0.48 0.32 0.53 0.36 0.50 0.39 0.69 0.43 0.79 0.49 0.88 0.53
12.7/22 0.15 0.17 0.19 0.20 0.22 0.24 0.26 0.30 0.33 0.36 0.40 0.45 0.49
19/33 0.12 0.14 0.15 0.16 0.17 0.18 0.20 0.23 0.25 0.27 0.29 0.33 0.35
50 70 95 120 150 185 240 300 400 500 630 800 1000
Table 4
CAPACITANCE
Approximate Capacitance ( Microfarads/km) For Three Core Cables Size 1.9/3.3& 3.3/3.3 0.21 0.24 0.27 0.31 0.35 0.39 0.42 0.46 0.51 0.57 0.63 3.8/6.6 0.22 0.25 0.27 0.31 0.35 0.38 0.43 0.45 0.51 0.54 0.57 Voltage Grade(kV) 6.6/6.6 & 11/11 6.35/11 0.18 0.14 0.21 0.16 0.22 0.17 0.25 0.19 0.29 0.21 0.31 0.23 0.34 0.25 0.36 0.27 0.41 0.30 0.46 0.33 0.52 0.37
12.7/22
19/33
25 35 50 70 95 120 150 185 240 300 400
0.15 0.16 0.18 0.20 0.22 0.23 0.25 0.28 0.31 0.34
0.12 0.14 0.15 0.16 0.18 0.18 0.20 0.23 0.25

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WIRES & CABLES
Table 5
REACTANCE
Approximate Reactance At 50 Hz( Ohms/km) For Single Core Cables Size 1.9/3.3& 3.3/3.3
Arm Un-Arm
3.8/6.6
Arm Un-Arm
Voltage Grade(kV) 6.6/6.6 & 11/11 6.35/11

Arm Un-Arm Arm
Un-Arm
12.7/22
Arm
Un-Arm
19/33
Arm
Un-Arm
50 70 95 120 150 185 240 300 400 500 630 800 1000
0.115 0.109 0.104 0.100 0.096 0.094 0.091 0.088 0.086 0.085 0.083 0.081 0.082
0.104 0.098 0.095 0.092 0.088 0.087 0.084 0.081 0.079 0.078 0.077 0.076 0.075
0.119 0.113 0.108 0.104 0.101 0.099 0.096 0.093 0.091 0.088 0.087 0.085 0.084
0.110 0.105 0.100 0.101 0.093 0.091 0.089 0.086 0.085 0.083 0.081 0.077 0.076
0.133 0.123 0.116 0.112 0.109 0.107 0.104 0.100 0.096 0.093 0.092 0.089 0.087
0.127 0.118 0.111 0.107 0.104 0.101 0.097 0.094 0.091 0.089 0.086 0.084 0.082
0.133 0.126 0.120 0.117 0.112 0.110 0.106 0.102 0.098 0.095 0.094 0.091 0.088
0.125 0.119 0.114 0.110 0.106 0.103 0.100 0.096 0.092 0.090 0.087 0.085 0.083
0.137 0.130 0.124 0.119 0.115 0.114 0.110 0.105 0.101 0.988 0.095 0.092 0.090
0.130 0.123 0.116 0.112 0.107 0.105 0.101 0.097 0.093 0.091 0.089 0.086 0.085
0.147 0.141 0.135 0.130 0.126 0.124 0.118 0.112 0.119 0.105 0.101 0.097 0.096
0.140 0.133 0.127 0.122 0.118 0.115 0.110 0.105 0.102 0.099 0.096 0.092 0.090
Table 6
REACTANCE
Approximate Reactance At 50 Hz( Ohms/km) For Three Core Cables Size 1.9/3.3& 3.3/3.3 0.098 0.094 0.087 0.084 0.081 0.078 0.076 0.075 0.073 0.072 0.071 3.8/6.6 0.109 0.104 0.098 0.094 0.090 0.087 0.085 0.083 0.081 0.079 0.078 Voltage Grade(kV) 6.6/6.6 & 11/11 6.35/11 0.116 0.152 0.111 0.144 0.104 0.137 0.100 0.129 0.095 0.123 0.092 0.117 0.089 0.114 0.087 0.110 0.085 0.106 0.082 0.103 0.079 0.099
12.7/22
19/33
25 35 50 70 95 120 150 185 240 300 400
0.147 0.140 0.132 0.125 0.120 0.116 0.113 0.108 0.105 0.101
0.133 0.125 0.121 0.116 0.112 0.110 0.105 0.100 0.097
Note: All figures given in various tables are indicative only.

POLYCAB WIRES PVT LTD Page 10 of 28
WIRES & CABLES
CURRENT RATINGS
POLYCAB RECOMMENDATIONS FOR CURRENT RATINGS: The current rating of power cable is defined by the maximum intensity of current (amperes) which can flow continuously through the cable, under permanent loading conditions, without any risk of damaging the cable or deterioration of its electrical properties. The value given in the tables are valid for one circuit in a three phase system under conditions specified. For grouping cables rating factors must be used. The current carrying capacities mentioned in POLYCAB technical data are intended as a guide, to assist operating engineers in selecting cables for safety and reliability. Basic assumptions and conditions of installation:1) Maximum Conductor Temperature : 90oC 2) Ambient Ground Temperature 3) Ambient Air Temperature 4) Thermal resistivity of soil : 30o C : 40o C : 150o C. Cm/W
*Max. Conductor temperature at the end of a short circuit
: 250oC
To obtain the maximum current carrying capacity of a cable operating at different conditions from the standard, various rating factors are to be multiplied, as follows :I a = K X Is in amperes Where ;
I a : Current rating at actual operating conditions (amperes)
Is : Current rating at standard operating

conditions (amperes) K : Rating factor as, applicable.
Depth of laying (to the highest point of the cables laid direct in the ground )
3.3, 6.6 & 11kV Cables : 90 cm
22 and 33kV
Cables
: 105 cm
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RATING FACTORS
WIRES & CABLES
A). FOR AIR AND GROUND TEMPERATURE. A. Rating factors for variation in ambient air temperature.
Ambient Temp (oC) Rating Factors 45 0.95 B. Rating factors for variation in ground temperature. Ground Temp (oC) 15 20 25 30 35 Rating Factors 1.12 1.08 1.03 1.00 0.96 3.3kV, 6.6kV & 11kV all sizes 1.00 0.99 0.98 0.96 0.95 120 150 200 25 1.14 30 1.10 35 1.04 40 1.00 50 0.90 40 0.91 45 0.87
B). FOR DEPTH OF LAYING (CABLES LAID DIRECT IN THE GROUND)

Depth of laying (cm) 90 105 120 150 180 or more Thermal Resistivity of Soil (occm/w) Factor 100 22kV & 33 kV all Size __ 1.00 0.99 0.97 0.96 250 300
C). FOR VARIATION IN THERMAL RESISTIVITY OF SOIL
1.20
1.11
1.0
0.89
0.80
0.73
GROUP RATING FACTORS

FOR SINGLE-CORE CABLES:A). Cables laid direct in the ground in horizontal formation.
Number of trefoils in group 2 3 4 5
Spacing between trefoils 3.3 to 22kV cables Touching 15cm 30cm 45cm 0.78 0.81 0.85 0.88 0.68 0.71 0.77 0.81 0.61 0.65 0.72 0.76 0.56 0.61 0.68 0.73
33 kV Cables. Touching 0.80 0.68 0.62 0.57 15cm 0.82 0.71 0.65 0.60 30cm 0.85 0.76 0.71 0.67 45cm 0.88 0.79 0.75 0.72
B). Cables laid on Racks / Trays in covered trench with removable covers where air circulation is restricted, Trefoils are separated by two cable diameter horizontally and the trays are in tiers having 300 mm distance.
1 1 0.95 2 0.90 3 0.88 6 0.86 C). As above B. but cables laid in open air. 1 1 2 1 3 1 6 1
No. racks/trays in tiers
No. of Trefoils in Horizontal formation 2 0.90 0.85 0.83 0.81 0.98 0.95 0.94 0.93 3 0.88 0.83 0.81 0.79 0.96 0.93 0.92 0.90
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WIRES & CABLES
GROUP RATING FACTORS
FOR MULTI-CORE CABLES:

A). Cables laid inside concrete trench with removable covers ,on cable trays where air circulation is restricted . The cables spaced by one cable diameter and trays are in tiers spaced by 300 mm. The clearance between the wall and the cable is 25 mm. No. of cables No. of cables trays in tier 1 2 3 6 9 1 0.95 0.90 0.88 0.85 0.84 2 0.90 0.85 0.83 0.81 0.80 3 0.88 0.83 0.79 0.78 0.81 6 0.86t 0.81 0.77 0.76 0.79 B) Cable laid on cable trays exposed to air , the cables spaced by one cable diameter and trays are in tiers spaced by 300 mm. The clearance of the cable from the wall is 25 mm. No. of cables No. of cables trays in tier 1 2 3 6 9 1 1 0.98 0.96 0.93 0.92 2 1 0.95 0.93 0.90 0.89 3 0.94 0.92 0.89 0.88 1 6 0.93 0.90 0.87 0.86 1 C).Cables laid on cable trays exposed to air, the cables touching and trays are in tiers spaced by 300 mm. The clearance between the wall and the cable is 25 mm. No. of cables per tray No. of cables trays. 1 2 3 6 1 1 0.84 0.80 0.75 2 1 0.80 0.76 0.71 3 1 0.78 0.74 0.70 6 1 0.76 0.72 0.68 D). Cables laid direct in ground in horizontal formation Distance of cables No. of cables in group Touching 15mm 30mm 2 0.79 0.82 0.87 3 0.69 0.75 0.79 4 0.62 0.69 0.74 5 0.58 0.65 0.72 6 0.54 0.61 0.69 9 0.73 0.69 0.68 0.66
45mm 0.90 0.83 0.79 0.76 0.75
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3.8 / 6.6 KV ( E ) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

"POLYCAB" SINGLE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS: 7098 PART-2/1985:
N om i N nal om Si in ze o al N Th f Co om nd ic in In k n u al su ess cto Th la o r tio f X ic kn n A LP pp e E ro S ss o x. he f O a t PV ve h C ra O A ll ut pp C D er ro abl iam x. e. et er M We of i in im g h t um o f N of om In Th Cab le n i i . M nal er ckn in D She es im im a s um en th T sio A pp O hic n o ro ute kne f S tr x. r s O Sh s o ip ve ea f P ra th V A l C pp C l Di ro abl am N x. e. om et er in W e of al ig ht D im of M en C in ab si im o le um Wi n . re of Th Ro A p p O ic un ro ute kne d x. r ss O Sh o ve ea f P ra th V A l C pp C l Di ab a ro m le x. et W . er ei In of gh G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. at m al 40 o D C. el iv er y Le ng th .
mm Sq.mm. mm mm Kg/Km mm mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps.
WIRES & CABLES
TABLE - 7
UNARMOURED CABLE 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.2 2.2 2.2 2.4 2.4 2.6 2.8 20.0 21.0 23.0 24.5 26.0 27.0 29.0 32.0 34.5 38.5 42.0 45.5 50.0 55.0 450 500 600 730 840 950 1100 1330 1550 1960 2400 2850 3470 4230
ALUMINIUM STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.4 1.4 1.4 1.4 1.4 1.4 1.56 1.56 1.56 1.56 1.72 1.88 1.88 2.04 21.0 22.0 24.0 25.5 27.0 28.5 31.0 33.0 36.0 40.0 43.5 47.5 51.0 56.5 550 600 730 850 950 1100 1250 1500 1750 2180 2650 3200 3750 4600
ALUMINIUM ROUND WIRE ARMOURED CABLE 1.6 1.6 1.6 1.6 1.6 1.6 1.6 2.0 2.0 2.0 2.0 2.0 2.5 2.5 1.40 1.40 1.40 1.40 1.40 1.56 1.56 1.56 1.56 1.72 1.88 1.88 2.04 2.20 22.5 23.5 25.5 27.0 29.0 30.5 32.5 35.5 38.0 42.5 46.5 50.0 55.0 60.5 620 700 800 950 1050 1200 1400 1700 2000 2450 2950 3450 4300 5150
CURRENT CARRYING 120 140 170 205 230 260 295 340 385 440 500 570 640 710 105 125 150 180 205 230 260 300 335 385 435 495 550 610
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 3.0 3.3 3.5 3.5 3.5 3.6
0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.40 0.40 0.40 0.50 0.50 0.50 0.60
135 500 165 500 205 500 250 500 290 500 330 500 380 500 455 500 520 500 620 500 720 500 840 500 970 500
1100 500
3.8 / 6.6 KV ( E ) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

"POLYCAB" SINGLE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS: 7098 PART-2/1985:
N om i N nal om Si in ze o al N Th f Co om nd ic in In k n u al su ess cto Th la o r tio f X ic kn n A LP pp e E ro S ss o x. he f O a t PV ve h C ra O ll ut A C D pp er ro abl iam e. x. et er M We of in i im g h t um o f N of om In Th Ca b in n e i c k le al r S n D he ess M i in me ath of imu nsio PV m n C Th of A Ou ick Str p ip n t D pro er S ess ia x. h m O e A pp ete ve ath r o ra ro x. f ll W Ca N bl ei of om e. g A in h t of lu a m lD C M iniu im abl e. in m e n of imu Ro sio PV m un n C Th d A Ou ick Wi pp t n re D ro er S ess . ia x. h m O e A pp ete ve ath r o ra ro x. f ll W Ca b ei In g h le . G to ro fC un ab In d le at D 30 o . uc ta C. In t3 *N 0o A or ir C. m at al 40 o D el C. iv er y Le ng th .
WIRES & CABLES
TABLE - 8
UNARMOURED CABLE 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.2 2.2 2.2 2.4 2.4 2.6 2.8 20.0 21.0 23.0 24.5 26.0 27.0 29.0 32.0 34.5 38.5 42.0 45.5 50.0 55.0 670 810 1030 1320 1580 1880 2250 2820 3410 4440 5500 6750 8430
10430
ALUMINIUM STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.4 1.4 1.4 1.4 1.4 1.4 1.56 1.56 1.56 1.56 1.72 1.88 1.88 2.04 21.0 22.0 24.0 25.5 27.0 28.5 31.0 33.0 36.0 40.0 43.5 47.5 51.0 56.5 770 910 1160 1440 1690 2030 2400 2990 3610 4660 5750 7100 8710
10800
ALUMINIUM ROUND WIRE ARMOURED CABLE 1.6 1.6 1.6 1.6 1.6 1.6 1.6 2.0 2.0 2.0 2.0 2.0 2.5 2.5 1.40 1.40 1.40 1.40 1.40 1.56 1.56 1.56 1.56 1.72 1.88 1.88 2.04 2.20 22.5 23.5 25.5 27.0 29.0 30.5 32.5 35.5 38.0 42.5 46.5 50.0 55.0 60.5 840 1010 1230 1540 1790 2130 2550 3190 3860 4930 6050 7350 9260
11350
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 3.0 3.3 3.5 3.5 3.5 3.6
0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.40 0.40 0.40 0.50 0.50 0.50 0.60
175 500 215 500 265 500 325 500 375 500 425 500 490 500 580 500 670 500 780 500 900 500
1040 500 1180 500 1310 500
The above data is approximate and subject to manufacturing tolerance. * Delivery Length tolerance is + 5 %. Length more than normal as per customer request.
Page 14 of 28
6.35/11 KV (E), 6.6/6.6 KV (UE) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES
WIRES & CABLES
TABLE - 9
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6
0.30 0.30 0.30 0.30 0.30 0.30 0.40 0.40 0.40 0.40 0.50 0.50 0.50 0.60
135 500 165 500 205 500 250 500 290 500 330 500 380 500 455 500 520 500 620 500 720 500 840 500 970 500
1100 500
6.35/11 KV (E), 6.6/6.6 KV (UE) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES
WIRES & CABLES
TABLE - 10
10450
10800
11350
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6
0.30 0.30 0.30 0.30 0.30 0.30 0.40 0.40 0.40 0.40 0.50 0.50 0.50 0.60
175 500 215 500 265 500 325 500 375 500 425 500 490 500 580 500 670 500 780 500 900 250
1040 250 1180 250 1310 200
Page 15 of 28
11 / 11 KV ( UE ) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES
TABLE - 11
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
0.30 0.30 0.30 0.30 0.40 0.40 0.40 0.40 0.40 0.50 0.50 0.50 0.60 0.60
135 500 165 500 205 500 250 500 290 500 330 500 380 500 455 500 520 500 620 500 720 500 840 500 970 500
1100 500
11 / 11 KV ( UE ) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

WIRES & CABLES
TABLE - 12
10800
11200
11850
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
0.30 0.30 0.30 0.30 0.40 0.40 0.40 0.40 0.40 0.50 0.50 0.50 0.60 0.60
175 500 215 500 265 500 325 500 375 500 425 500 490 500 580 500 670 500 780 500 900 500
1040 500 1180 500 1310 500
Page 16 of 28
12.7 / 22 KV ( E ) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES
TABLE - 13
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
0.30 0.30 0.30 0.40 0.40 0.40 0.40 0.40 0.40 0.50 0.50 0.50 0.60 0.60
145 500 175 500 220 500 270 500 310 500 350 500 400 500 470 500 540 500 630 500 730 500 840 500 950 500
1060 500
12.7 / 22 KV ( E ) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

WIRES & CABLES
TABLE - 14
11000
11350
12000
Mtrs.
35 50 70 95 120 150 185 240 300 400 500 630 800 1000
6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
0.30 0.30 0.30 0.40 0.40 0.40 0.40 0.40 0.40 0.50 0.50 0.50 0.60 0.60
190 500 230 500 285 500 345 500 400 500 450 500 510 500 600 500 690 500 790 500 910 250
1020 250 1140 250 1240 200
Page 17 of 28
19 / 33 KV ( E ) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

N om i N nal om Si in ze o al N Th f Co om nd ic in In k n u al su ess cto Th la o r ic tio f X kn n A LP pp es E ro S s o x. he f O a t PV ve h C ra O A l ut pp C l Di er ab a ro m le x. et . er M We of i in im g h t um o f N of om In Th Cab le n i i . M nal er ckn in D She es im im a s um en th T sio A pp O hic n o ut kn f S ro x. er ess tri O Sh o p ve ea f P ra th V A l C pp C l Di ab a ro N m le om x. et . er in W e of al ig ht D im of M en C in ab si im le W on um i . r of Th e Ro A p p O ic un ro ute kne d x. r Sh ss o O ve ea f P ra th V A l C pp C l Di ro abl am x. e et W . er ei In of gh G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. a m al t 40 o D C. el iv er y Le ng th .
WIRES & CABLES
TABLE - 15
UNARMOURED CABLE 2.2 2.2 2.2 2.4 2.4 2.6 2.6 2.8 2.8 3.0 3.2 37.5 39.0 40.0 43.0 45.0 48.0 51.0 54.0 57.5 62.0 67.0 1400 1550 1700 1900 2200 2500 2900 3400 3900 4600 5450
ALUMINIUM STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.56 1.72 1.72 1.72 1.88 1.88 2.04 2.04 2.2 2.36 2.36 39.0 41.0 42.0 44.5 47.0 49.0 52.5 56.0 60.0 64.0 69.0 1610 1800 1950 2200 2500 2750 3250 3700 4300 5050 5900
ALUMINIUM ROUND WIRE ARMOURED CABLE 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.5 2.5 2.5 2.5 1.72 1.72 1.72 1.88 1.88 2.04 2.04 2.2 2.36 2.36 2.52 41.5 43.0 44.5 47.0 49.5 52.0 55.0 60.0 63.0 67.0 72.5 1900 2050 2200 2500 2760 3100 3550 4250 4900 5600 6550
CURRENT CARRYING 205 230 260 290 335 380 430 485 550 610 660 180 300 225 255 290 325 370 420 470 520 560
Mtrs.
95 120 150 185 240 300 400 500 630 800 1000
8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8
0.40 0.40 0.40 0.50 0.50 0.50 0.50 0.60 0.60 0.60 0.70
270 500 310 500 350 500 400 500 470 500 540 500 630 500 730 500 840 500 950 500
1060 500
19 / 33 KV ( E ) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

N om i N nal om Si in ze o al N Th f Co om nd ic in In k n u al su ess cto Th la o r ic tio f X kn n A LP pp es E ro S s o x. he f O a t PV ve h C ra O l ut A C l Di pp er ab a ro m le x. et . er M We of in i im g h t um o f N of om In Th Ca b in n e i c k le al r S n es M Dim hea s in th e of imu nsio PV m n C Th of A Ou ick Str pp t ip n D ro er S ess ia x. h m O e A pp ete ve ath r o ra ro x. f ll W Ca N of om eigh ble. A in lu a t of m lD C M iniu im abl e. in m e n of imu Ro sio n PV m un C Th d A Ou ick Wi pp t n re D ro er S ess . ia x. h m O e A pp ete ve ath r o ra ro x. f ll W Ca b ei In g h le . G to ro fC un ab In d le at D 30 o . uc ta C. In t3 *N 0o A or i C. m r at al 40 o D el C. iv er y Le ng th .
WIRES & CABLES
TABLE - 16
UNARMOURED CABLE 2.2 2.2 2.2 2.4 2.4 2.6 2.6 2.8 2.8 3.0 3.2 37.5 39.0 40.0 43.0 45.0 48.0 51.0 54.0 57.5 62.0 67.0 1610 1860 2130 2490 2940 3430 4050 4890 5760 7080
8550
ALUMINIUM STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.56 1.72 1.72 1.72 1.88 1.88 2.04 2.04 2.2 2.36 2.36 39.0 41.0 42.0 44.5 47.0 49.0 52.5 56.0 60.0 64.0 69.0 1820 2110 2380 2790 3240 3680 4400 5190 6160 7530
9000
ALUMINIUM ROUND WIRE ARMOURED CABLE 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.5 2.5 2.5 2.5 1.72 1.72 1.72 1.88 1.88 2.04 2.04 2.2 2.36 2.36 2.52 41.5 43.0 44.5 47.0 49.5 52.0 55.0 60.0 63.0 67.0 72.5 2110 2360 2630 3090 3500 4030 4700 5740 6760 8080
9650
CURRENT CARRYING 265 300 330 375 430 480 540 600 660 720 760 230 260 290 325 370 415 465 520 570 620 660
Mtrs.
95 120 150 185 240 300 400 500 630 800 1000
8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8
0.40 0.40 0.40 0.50 0.50 0.50 0.50 0.60 0.60 0.60 0.70
345 500 400 500 450 500 510 500 600 500 690 500 790 250 910 250
1020 250 1140 250 1240 200
Page 18 of 28
1.9/3.3 KV (E) & 3.3/3.3 KV (UE) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES
"POLYCAB" THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED SCREENED CABLES CONFORMING TO IS: 7098 PART-2/1985:
N om i N nal om Si in ze o al Th f Co nd ic k u M Ins n e ss cto in u l r im a t o f N o om f P um ion XL PE V in T al C I hic Th nn kn ic er es kn S s A pp e he ro S ss o ath x. he f O a t PV ve h C ra O A l ut pp C l Di er ab a ro N le me om x. . te ro in W e ig al f ht D im o M en f C in ab si im o l um Str n o e. i Th p f G A IF p p O ic la ro ute kne t x. r Sh ss o O ve ea f P ra th V A l C pp C l Di ro abl am x e N et om . W . er ei of in gh al D t of M in R ime Ca im o u n b um nd sio le. W no T A pp O hic ire f G I ro ute kne x. r Sh ss o O ve ea f P ra th V l A C pp C l Di ab a ro le me x. te W . ro ei In gh f G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. at m al 40 o D C. el iv er y Le ng th .
mm Sq.mm. mm mm mm Kg/Km mm mm mm Kg/Km mm mm mm Kg/Km Amps. Amps. Amps.
WIRES & CABLES
TABLE - 17
UNARMOURED CABLE 2.2 2.2 2.4 2.6 2.6 2.8 3.0 3.0 3.2 3.6 38.0 40.0 44.5 48.5 52.0 55.5 60.0 65.0 70.0 78.0 1500 1700 2150 2600 3000 3500 4150 4900 5850 7300
FORMED WIRE / STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.56 1.72 1.72 1.88 2.04 2.04 2.2 2.36 2.52 2.68 37.0 39.5 44.0 47.5 51.5 54.5 59.0 64.5 70.0 76.5 1950 2200 2650 3150 3650 4100 4800 5750 6650 8100
ROUND WIRE ARMOURED CABLE 2.0 2.0 2.0 2.5 2.5 2.5 2.5 2.5 3.15 3.15 1.72 1.72 1.88 2.04 2.04 2.2 2.36 2.36 2.68 2.84 40.5 42.5 47.0 51.5 55.5 58.5 63.0 68.0 75.0 82.0 2600 2900 3450 4400 5000 5550 6350 7350 9250
CURRENT CARRYING 115 135 165 195 220 245 280 320 360 94 10 140 165 185 210 235 270 305 350
Mtrs.
35 50 70 95 120 150 185 240 300 400
2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2
0.4 0.4 0.5 0.5 0.5 0.6 0.6 0.7 0.7 0.7
120 500 145 500 185 500 225 500 355 500 295 500 340 500 400 500 460 500 535 500
11000 410
1.9/3.3 KV (E) & 3.3/3.3 (UE) KV HT XLPE THREE CORE COPPER CONDUCTOR CABLES
"POLYCAB" THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED SCREENED CABLES CONFORMING TO IS: 7098 PART-2/1985:
N om i N nal om Si in ze o al Th f Co nd ic k u M Ins n e ss cto in u l r im a t o f N o om f P um ion XL PE V in T al C I hic Th nn kn ic er es kn S s A pp e he ro S ss o ath x. he f O a t PV ve h C ra O A l ut pp C l Di er ab a ro N le me om x. . te ro in W e ig al f ht D im o M en f C in ab si im o l um Str n o e. i Th p f G A IF p p O ic la ro ute kne t x. r Sh ss o O ve ea f P ra th V A l C pp C l Di ro abl am x e N et om . W . er ei of in gh al D t of M in R ime Ca im o u n b um nd sio le. W no T A pp O hic ire f G I ro ute kne x. r Sh ss o O ve ea f P ra th V A l C pp C l Di ab a ro le me x. te W . ro ei In gh f G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. at m al 40 o D C. el iv er y Le ng th .
WIRES & CABLES
TABLE - 18
ROUND WIRE ARMOURED CABLE 2.0 2.0 2.0 2.5 2.5 2.5 2.5 2.5 3.15 3.15 1.72 1.72 1.88 2.04 2.04 2.2 2.36 2.36 2.68 2.84 40.5 42.5 47.0 51.5 55.5 58.5 63.0 68.0 75.0 82.0 3230 3830 4740 6170 7220 8340 9800
CURRENT CARRYING 145 170 210 250 285 315 355 120 145 175 210 240 270 300 350 390 440
Mtrs.
35 50 70 95 120 150 185 240 300 400
2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2
0.4 0.4 0.5 0.5 0.5 0.6 0.6 0.7 0.7 0.7
155 500 190 500 235 500 290 500 330 500 375 500 435 500 510 500 590 500 670 250
11820 410 14830 460 18440 520
Page 19 of 28
3.8 / 6.6 KV ( E ) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

"POLYCAB" THREE CORE ALUMINIUM CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS: 7098 PART-2/1985:
N om i N nal om Si in ze o al Th f Co nd ic k u M Ins n e in ul ss ctor N o imu atio of X om f P m n LP in VC Th E al In ick Th n ic er nes kn S s A pp e he ro S ss o ath x. he f O a t PV ve h C ra O A ll ut pp C Di er ro abl am N x. e. om et er in W e of ig al ht D im of M en C in ab si im o l um Str n o e. ip f G Th A IF p p O ic la ro ute kne t x. r ss O Sh o ve ea f P ra th V A l C pp C l Di ab a ro m le x N et om . W . er of in eig ht al D of M in R ime Ca im o u n b um nd sio le. n Th Wi of A p p O ic r e G I ro ute kne x. r s O Sh s o ve ea f P ra th V l A C pp C l Di ab a ro le me x. te W . ro ei In gh f G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. at m al 40 o D C. el iv er y Le ng th .
WIRES & CABLES
TABLE - 19
ROUND WIRE ARMOURED CABLE 2.0 2.0 2.0 2.5 2.5 2.5 2.5 3.15 3.15 4.0 1.72 1.88 1.88 2.04 2.20 2.2 2.36 2.52 2.68 3.0 43.0 45.5 49.5 54.0 58.5 61.0 66.0 73.0 78.5 89.0 2800 3200 3700 4700 5400 5900 6700 8600 9900
CURRENT CARRYING 115 130 160 190 220 245 275 315 355 97 115 140 165 190 210 240 275 310 350
Mtrs.
35 50 70 95 120 150 185 240 300 400
2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 3.0 3.3
0.4 0.5 0.5 0.5 0.6 0.6 0.6 0.7 0.7 0.7
125 500 150 500 190 500 230 500 260 500 295 500 335 500 395 500 450 250 520 250
13200 400
3.8/6.6 KV ( E ) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

"POLYCAB" THREE CORE COPPER CONDUCTOR, XLPE INSULATED, UNARMOURED & ARMOURED CABLES CONFORMING TO IS: 7098 PART-2/1985:
N om i N nal om Si in ze o al Th f Co nd ic k u M Ins n e in ul ss ctor N o imu atio of X om f P m n LP in VC Th E al In ick Th n ic er nes kn S s A pp e he ro S ss o ath x. he f O a t PV ve h C ra O A ll ut pp C Di er ro abl am N x. e. om et er in W e of ig al ht D im of M en C in ab si im o l um Str n o e. ip f Th G A IF p p O ic la ro ute kne t x. r ss O Sh o ve ea f P ra th V A l C pp C l Di ab a ro m le x N et om . W . er of in eig ht al D of M in R ime Ca im o u n b um nd sio le. n Th Wi of A p p O ic r e G I ro ute kne x. r s O Sh s o ve ea f P ra th V A l C pp C l Di ab a ro le me x. te W . ro ei In gh f G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. at m al 40 o D C. el iv er y Le ng th .
WIRES & CABLES
TABLE - 20
ROUND WIRE ARMOURED CABLE 2.0 2.0 2.0 2.5 2.5 2.5 2.5 3.15 3.15 4.0 1.72 1.88 1.88 2.04 2.20 2.2 2.36 2.52 2.68 3.0 43.0 45.5 49.5 54.0 58.5 61.0 66.0 73.0 78.5 89.0 3430 4130 4990 6470 7620 8690
CURRENT CARRYING 145 170 210 250 280 310 125 150 180 215 240 270 305 350 390 440
Mtrs.
35 50 70 95 120 150 185 240 300 400
2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 3.0 3.3
0.4 0.5 0.5 0.5 0.6 0.6 0.6 0.7 0.7 0.7
165 500 195 500 240 500 295 500 335 500 380 500 430 500 500 500 570 250 650 200
10150 350 13070 400 15480 445 20640 500
Page 20 of 28
6.35 / 11 KV ( E ) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES
TABLE - 21
ROUND WIRE ARMOURED CABLE 2.0 2.5 2.5 2.5 2.5 2.5 3.15 3.15 3.15 4.0 1.88 2.04 2.04 2.20 2.20 2.36 2.52 2.68 2.84 3.0 45.5 49.5 52.5 56.5 59.5 63.0 68.0 73.0 78.0 86.5 3250 4000 4600 5250 5850 6450 8100 9250
CURRENT CARRYING 115 130 160 190 220 245 275 315 97 115 140 165 190 210 240 275 310 350
Mtrs.
35 50 70 95 120 150 185 240 300 400
3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6
0.5 0.5 0.5 0.6 0.6 0.6 0.7 0.7 0.7 0.7
125 500 150 500 190 500 230 500 260 500 295 500 335 500 395 500 450 250 520 250
10400 355 13450 400
6.35 / 11 KV ( E ) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

WIRES & CABLES
TABLE - 22
ROUND WIRE ARMOURED CABLE 2.0 2.5 2.5 2.5 2.5 2.5 3.15 3.15 3.15 4.0 1.88 2.04 2.04 2.20 2.20 2.36 2.52 2.68 2.84 3.0 45.5 49.5 52.5 56.5 59.5 63.0 68.0 73.0 78.0 86.5 3880 4930 5890 7020 8070 9240
CURRENT CARRYING 145 170 210 250 280 310 125 150 180 215 240 270 305 350 390 440
Mtrs.
35 50 70 95 120 150 185 240 300 400
3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6
0.5 0.5 0.5 0.6 0.6 0.6 0.7 0.7 0.7 0.7
165 500 195 500 240 500 295 500 335 500 380 500 430 500 500 250 570 250 650 250
11550 350 13720 400 15980 445 20890 500
Page 21 of 28
11 / 11 KV ( UE ) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES
TABLE - 23
ROUND WIRE ARMOURED CABLE 2.5 2.5 2.5 3.15 3.15 3.15 3.15 3.15 4.0 4.0 2.20 2.20 2.36 2.52 2.52 2.68 2.84 3.0 3.0 3.0 55.0 58.0 61.5 66.5 70.0 73.0 77.0 82.0 88.0 94.5 4750 5200 5900 7250 8000 8650 9650
CURRENT CARRYING 115 130 160 190 220 245 275 97 115 140 165 190 210 240 275 310 350
Mtrs.
35 50 70 95 120 150 185 240 300 400
5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
0.5 0.6 0.6 0.6 0.7 0.7 0.7 0.7 0.7 0.7
125 500 150 500 190 500 230 500 260 500 295 500 335 500 395 250 450 250 520 250
10850 315 13250 355 15200 400
11 / 11 KV ( UE ) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

WIRES & CABLES
TABLE - 24
ROUND WIRE ARMOURED CABLE 2.5 2.5 2.5 3.15 3.15 3.15 3.15 3.15 4.0 4.0 2.20 2.20 2.36 2.52 2.52 2.68 2.84 3.0 3.0 3.0 55.0 58.0 61.5 66.5 70.0 73.0 77.0 82.0 88.0 94.5 5380 6130 7190 9020
CURRENT CARRYING 145 170 210 250 125 150 180 215 240 270 305 350 390 440
Mtrs.
35 50 70 95 120 150 185 240 300 400
5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5
0.5 0.6 0.6 0.6 0.7 0.7 0.7 0.7 0.7 0.7
165 500 195 500 240 500 295 500 335 500 380 500 430 250 500 250 570 250 650 250
10220 280 11440 310 13100 350 15320 400 18830 445 22640 500
Page 22 of 28
12.7 / 22 KV ( E ) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

N om i N nal om Si in ze o al Th f Co nd ic k u M Ins n e in ul ss ctor N o imu atio of X om f P m n LP in VC Th E al In ick Th n ic er nes kn S s A pp e he ro S ss o ath x. he f O a t PV ve h C ra O A ll ut pp C Di er ro abl am N x. e. om et er in W e of ig al ht D im of M en C in ab si im o l um Str n o e. ip f Th G A IF p p O ic la ro ute kne t x. r ss O Sh o ve ea f P ra th V A l C pp C l Di ab a ro m le x N et om . W . er of in eig ht al D of M in R ime Ca im o u n b um nd sio le. n Th Wi of A p p O ic r e G I ro ute kne x. r s O Sh s o ve ea f P ra th V l A C pp C l Di ab a ro le me x. te W . ro ei In gh f G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. at m al 40 o D C. el iv er y Le ng th .
WIRES & CABLES
TABLE - 25
UNARMOURED CABLE 3.0 3.2 3.4 3.4 3.6 3.8 4.0 4.0 60.0 64.0 67.5 70.5 74.0 79.5 84.0 90.5 3850 4450 5050 5550 6300 7300 8300 9850
FORMED WIRE / STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.36 2.36 2.52 2.68 2.68 2.84 3.0 3.0 60.0 64.0 67.5 70.5 74.0 79.0 83.5 90.5 4700 5300 5900 6500 7250 8300 9350 10950
ROUND WIRE ARMOURED CABLE 2.5 3.15 3.15 3.15 3.15 4.0 4.0 4.0 2.36 2.52 2.68 2.68 2.84 3.0 3.0 3.0 63.5 69.0 72.0 75.5 79.0 85.5 90.0 96.5 6250 7750 8500 9200
CURRENT CARRYING 160 190 215 240 140 170 190 215 240 275 310 355
Mtrs.
70 95 120 150 185 240 300 400
6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
0.6 0.7 0.7 0.7 0.7 0.7 0.7 0.7
190 500 230 500 265 500 300 250 340 250 400 250 455 250 530 250
10150 270 12600 310 13850 350 15800 395
12.7 / 22 KV ( E ) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

N om i N nal om Si in ze o al Th f Co nd ic k u M Ins n e in ul ss ctor N o imu atio of X om f P m n LP in VC Th E al In ick Th n ic er nes kn S s A pp e he ro S ss o ath x. he f O a t PV ve h C ra O A ll ut pp C Di er ro abl am N x. e. om et er in W e of ig al ht D im of M en C in ab si im o l um Str n o e. ip f Th G A IF p p O ic la ro ute kne t x. r ss O Sh o ve ea f P ra th V A l C pp C l Di ab a ro m le x N et om . W . er of in eig ht al D of M in R ime Ca im o u n b um nd sio le. n Th Wi of A p p O ic r e G I ro ute kne x. r s O Sh s o ve ea f P ra th V A l C pp C l Di ab a ro le me x. te W . ro ei In gh f G to ro fC un ab In d le at D 30 o . uc ta In t 3 C. *N 0o A ir or C. at m al 40 o D C. el iv er y Le ng th .
WIRES & CABLES
TABLE - 26
UNARMOURED CABLE 3.0 3.2 3.4 3.4 3.6 3.8 4.0 4.0 60.0 64.0 67.5 70.5 74.0 79.5 84.0 90.5 5140 6220 7270 8340 9750 11770 13880 17290
FORMED WIRE / STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.36 2.36 2.52 2.68 2.68 2.84 3.0 3.0 60.0 64.0 67.5 70.5 74.0 79.0 83.5 90.5 5990 7070 8120 9290 10700 12770 14930 18390
ROUND WIRE ARMOURED CABLE 2.5 3.15 3.15 3.15 3.15 4.0 4.0 4.0 2.36 2.52 2.68 2.68 2.84 3.0 3.0 3.0 63.5 69.0 72.0 75.5 79.0 85.5 90.0 96.5 7540 9520
CURRENT CARRYING 205 245 180 215 245 275 305 350 390 440
Mtrs.
70 95 120 150 185 240 300 400
6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
0.6 0.7 0.7 0.7 0.7 0.7 0.7 0.7
245 500 300 500 340 500 385 250 435 250 510 250 580 250 660 200
10720 275 11990 305 13600 345 17070 395 19430 440 23240 495
Page 23 of 28
19 / 33 KV ( E ) HT XLPE THREE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES
TABLE - 27
UNARMOURED CABLE 3.6 3.8 4.0 4.0 4.0 4.0 4.0 77.0 80.0 83.0 87.0 91.5 96.0 6050 6750 7400 8150 9150 10200
FORMED WIRE / STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.84 2.84 3.0 3.0 3.0 3.0 3.0 77.0 80.0 83.5 87.0 91.5 93.0 7100 7750 8400 9250 10300 11350
ROUND WIRE ARMOURED CABLE 3.15 4.0 4.0 4.0 4.0 4.0 4.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 82.0 86.5 90.0 93.0 98.0
CURRENT CARRYING 170 190 215 240 275 310 355
Mtrs.
95 120 150 185 240 300 400
8.8 8.8 8.8 8.8 8.8 8.8 8.8
0.7 0.7 0.7 0.7 0.7 0.7 0.7
10050 190 12100 215 12800 240 13900 270 15150 310
230 500 265 500 300 250 340 250 400 250 455 250 530 250
102.0 16450 350 109.0 18550 395
102.5 11800
102.5 13100
19 / 33 KV ( E ) HT XLPE THREE CORE COPPER CONDUCTOR CABLES

WIRES & CABLES
TABLE - 28
UNARMOURED CABLE 3.6 3.8 4.0 4.0 4.0 4.0 4.0 77.0 80.0 83.0 87.0 91.5 96.0 7820 8970 10190 11600 13620 15780
FORMED WIRE / STRIP ARMOURED CABLE 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.84 2.84 3.0 3.0 3.0 3.0 3.0 77.0 80.0 83.5 87.0 91.5 93.0 8870 9970 11190 12700 14770 16930
ROUND WIRE ARMOURED CABLE 3.15 4.0 4.0 4.0 4.0 4.0 4.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 82.0 86.5 90.0 93.0 98.0
CURRENT CARRYING 215 245 275 305 350 390 440
Mtrs.
95 120 150 185 240 300 400
8.8 8.8 8.8 8.8 8.8 8.8 8.8
0.7 0.7 0.7 0.7 0.7 0.7 0.7
11820 245 14320 275 15590 305 17350 345 19620 395
300 250 340 250 385 250 435 250 510 250 580 200 660 200
102.0 22030 440 109.0 25990 495
102.5 19240
102.5 20540
Page 24 of 28
WIRES & CABLES
HANDLING STORAGE AND LAYING OF POLYCAB XLPE CABLES

A) HANDLING: C) PRE-INSTALLATION: 1. The cable with or without drum shall not be thrown or dropped on the ground from the carriers such as trucks or railway wagons , during unloading. 2. The cable drum shall be unloaded with the help of cranes or fork lifts or using a proper ramp having inclination 1:3 to 1:4 in order to avoid mechanical damage to the outer layers of cables. 3. The cable drums shall be lifted or stored with its flanges always vertical. 4. The cable drum shall be rolled in the direction of arrow only in order to avoid loosening of cable winding . The drum shall not be rolled on rocky, uneven surface and for longer distances , it may damage the drum and cable. B) STORAGE: 1. The cables shall be stored in dry covered places having concrete /firm surface capable of bearing the load of drum. 2. The cable ends shall be sealed properly in order to prevent moisture ingress. 3. Antirodent / termite repulsion treatment shall be applied to the site where the drum are stored for very long period of time. 1) Overview: To ensure safety during cable installation, following shall be checked prior to installation. The cable selected is proper for designed application. The cable has not been damaged in transit or storage. Review all applicable state and national codes to verify that the cable chosen is appropriate for the job. Also consult your local electricity authority. Next, you must identify any existing cable damage and prevent any further damaged from occurring. This is done through proper cable inspection, handling and storage. 2) Cable Inspection: Inspect every cable reel for damage before accepting the shipment. Be particularly alert for cable damage if: 1. A reel is lying flat on its side 2. Several reels are stacked 3. Other freight is stacked on a reel 4. Nails have been driven into reel flanges to secure shipping blocks 5. A reel flange is damaged 6. A cable covering is removed, stained or damaged 7. A cable end seal is removed or damaged. A reel has been dropped (hidden damage likely)
Page 25 of 28
WIRES & CABLES
D) CABLE HANDLING: Remove all nails and staples from the reel flanges before moving a reel, and avoid all objects that could crush, damage or impact the cables when moving. NEVER used the cable as a means to move a reel. When unreeling, observe recommended bending radii, use swivels to prevent twisting and avoid overruns. E). LAYING: 1. Polycab recommend the laying and installation of cables as per IS:1255/84. 2. Care shall be taken during laying to avoid sharp bending , and twisting. 3. Cable shall be un wound from the drum by lifting the drum on the center 4. shaft supported both ends with suitable jacks / stands. 5. Under no circumstances the cable winding shall be lifted off a coil or drum lying flat at the flanges. This would cause serious twist and damages. 6. Suitable protection shall be provided to the cables against mechanical damages, it includes covers, pipes etc. F) Recommended minimum bending radius for Heavy Duty cables. Single Core : 20 x D Multicore : 15 x D Where D= Diameter of cable in mm G) Recommended safe Pulling force with stockings:a). For Unarmoured Cable: P = 5 D2 Where P= Pulling Force b). For Armoured Cable : P = 9 D2 Where D= Diameter of cable in mm H) Recommended safe pulling force when pulled with pulling eye :a) For Aluminium Conductors : 30 N/mm2 b) For Copper Conductor : 50 N/mm2 IMPORTANT FORMULAE * TO CALCULATE VARIOUS ELECTRICAL PARAMETERS OF CABLES 1) Inductance: L = K+ 0.2 loge 2S(mH/km) d where K = Constant for different stranded conductors S = Axial Spacing between Cables & Conductors in mm. d = Conductor Diameter No. of wires in Conductor 7 19 37 61 Above 61 K 0.0642 0.0554 0.0528 0.0514 0.0500
2) Reactance: X = 2 f x L x 10-3 / km where f = frequency L = Inductance
Page 26 of 28
Xm = 2 fM x 103 ( / km)
WIRES & CABLES
M = 0.2 loge 3) Impedance: Z = (R2 + X2) / km Where R = A.C Resistance at operating temperature / km X = Reactance 4) Charging Current = A = Uo x 2 x f x C x 10-6 / km 1) Voltage Drop: For 3 Core Cables : 3 x Z V/A/Mtr For 1 Core Cables : 2 x Z Where Z = Impedance 6) Capacitance: C= Er 18 loge (D/d) where Er = Relative Permitivity for XLPE : 2.3 D = Dia over Insulation d = Dia over conductor 8) Dielectric loss in watts per ( f / km)
2S (mH/km) dm
S = Distance between Cable Centres, dm = Mean Diameter of Sheath 10)
Short Circuit Rating

I2 = K2 S2 loge 1 + T 0 +
where I = Short circuit (R.M.S over duration) in Amps. T = Duration of short circuit in second K = Constant 226 for Copper, 148 for Aluminium, 78 for Steel S = Area of Conductor in mm2
1 = Final Temperature of Conductor or
Armour
0 = Initial Temperature of Conductor or
Armour
= Reciprocal of the temperature coefficient
of resistance of the conductor per o C at 0 o C

= Constant 228 for Aluminium
km/phase
= 2 f x C Uo tan 10 (watt / km per phase)
2 -6
202 for Steel, 234.5 for Copper * source BICC handbook
where C = Capacitance Uo = Power frequency voltage between conductor & earth Tan = Dielectric power factor = 0.0003 for XLPE 9) Voltage Induced in Sheath ES = IXm where I = conductor current (A)
Page 27 of 28
WIRES & CABLES
DIFFERENCE BETWEEN EARTHED / UNEARTHED SYSTEM

Earthed System:
In the initial years, the generators and transformers were having capacities of few MVA and hence fault current was also less. The star point or neutral point was solidly grounded and this is called earthed system.
R
N
Y B
In this system if an earth fault occurs on any of the phases, the voltages of other two healthy phases with respect to the earth remain the same.
Unearthed System:
Today generators of 500 MVA capacity are in commercial use. More over several mega power stations are connected to grid. Due to this, the fault level has increased tremendously. In case of an earth fault, a heavy current flows in to the fault and this may damage the costly generators and power transformers. To reduce the fault current, the star point is connected to the earth through a resistance or a reactance as under:
R N
EARTH
Y VR B
In this case if an earth fault occurs on R phase, the voltage of the faulty phase with respect to the earth (CR) spears across the current limiting resistance or reactance in the earth circuit of the star point and as a result the voltage of the star point which was at earth potential under normal conditions rises to VR. Due to this the
voltages of other two healthy phases (B and Y) with respect to the earth rises by 1.7 times (Vector sum of VR and VB). If the insulation of these phases are not designed for these increased voltages they may develop earth fault. This is called Unearthed System.
Page 28 of 28

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POLYCAB WIRES PVT LTD

WIRES & CABLES

POLYCAB WIRES PVT LTD

WIRES & CABLES

POLYCAB XLPE HIGH VOLTAGE CABLES (H.T.)

* Weights given in the Tables are with PVC Fillers.

POLYCAB WIRES PVT LTD

ROUTINE TEST SET UP

Type Tests: IS:7098 Part 2, IEC:60502, BS:6622, BS:7835

Electrical Type Tests Non-Electrical Type Tests Special Tests

NON-ELECTRICAL TYPE TEST LABORATORY

IMPULSE TEST SET UP

POLYCAB WIRES PVT LTD

WIRES & CABLES

ADVANTAGES OF POLYCAB XLPE CABLES

POLYCAB WIRES PVT LTD

WIRES & CABLES

The details to the above Guidelines are given in tables.

* Conductor meeting requirements of IEC-60228 and BS 6360 can also be manufactured.

POLYCAB WIRES PVT LTD

WIRES & CABLES

25 35 50 70 95 120 150 185 240 300 400

0.12 0.14 0.15 0.16 0.18 0.18 0.20 0.23 0.25

POLYCAB WIRES PVT LTD

WIRES & CABLES

Voltage Grade(kV) 6.6/6.6 & 11/11 6.35/11

25 35 50 70 95 120 150 185 240 300 400

0.133 0.125 0.121 0.116 0.112 0.110 0.105 0.100 0.097

Note: All figures given in various tables are indicative only.

WIRES & CABLES

*Max. Conductor temperature at the end of a short circuit

I a : Current rating at actual operating conditions (amperes)

Is : Current rating at standard operating

POLYCAB WIRES PVT LTD

B). FOR DEPTH OF LAYING (CABLES LAID DIRECT IN THE GROUND)

C). FOR VARIATION IN THERMAL RESISTIVITY OF SOIL

GROUP RATING FACTORS

Number of trefoils in group 2 3 4 5

No. racks/trays in tiers

WIRES & CABLES

GROUP RATING FACTORS

FOR MULTI-CORE CABLES:

45mm 0.90 0.83 0.79 0.76 0.75

POLYCAB WIRES PVT LTD

3.8 / 6.6 KV ( E ) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES

3.8 / 6.6 KV ( E ) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

WIRES & CABLES

POLYCAB WIRES PVT LTD

WIRES & CABLES

WIRES & CABLES

POLYCAB WIRES PVT LTD

11 / 11 KV ( UE ) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES

11 / 11 KV ( UE ) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES

WIRES & CABLES

POLYCAB WIRES PVT LTD

12.7 / 22 KV ( E ) HT XLPE SINGLE CORE ALUMINIUM CONDUCTOR CABLES

WIRES & CABLES

12.7 / 22 KV ( E ) HT XLPE SINGLE CORE COPPER CONDUCTOR CABLES