GCI EHV Catalogue Book

Ext ra Hi gh Vol t age
Cabl e
Connecting the World
Extra Hi gh Vol tage
Ser vi ci ng El ectri c Uti l i ty markets
This catalog features in-depth information on the most comprehensive line of
Extra High Voltage Power Cable available today.
The spec-on-a-page format was developed to meet your needs. It features
up-to-the-minute product Information, from applications and constructions to
detailed technical and specification data.
And, of course, if you need any fur ther data, General Cable's Customer
Service staff provides the answer you need quickly and efficiently.
All information in this catalog is presented solely as a guide product selection and is believed to be
reliable. All printing errors are subject to correction in subsequent releases of this catalog. Although
General Cable has taken precautions to ensure the accuracy of the product specifications at the time
of publication, the specifications of all products contained herein are subject to change without
notice.

E-mail: info@generalcable.co.in
General Cabl e Energy Indi a Pvt Ltd
Corporate office: Centrum Plaza, Level 3, Tower A,
312 S, Golf Course Road, Sector- 53,
Gurgaon-122 002, Haryana.
Phone: (0124) 4326000 Fax: (0124) 4326019
Connectingthe World
I N T ERN A T I ON A L
ISO 9001:2000
CERT I F I CA T I O N
General Cable Corporation, headquar tered in Highland Heights Kentucky, a sales of USD 6.2 billion and over 13000
associates, is a world leader in cable manufacturing with 46 modern production facilities in Nor th America, Europe and
rest of the world and provides service to global network of clients.
General Cable is recognized as world leader in EHV systems, having pioneered and led development of solid dielectric
extruded cable technique over more than 5 decades. General Cable provide its customer with unrivalled know-how and
experience world-wide.
General Cable's complete line of Silec , Phelps dodge, XLPE insulated Extra High Voltage underground energy cable, from
63KV to 550KV and our stateof -the-ar t accessories-such as pre-moulded Joints and terminals- enable us to provide
turnkey design and engineering services for the global, system-engineered electric utility market.
With best in class research and development, superior engineering and manufacturing, leading logistics capabilities, the
broadest product range in all the industry segments, with a strong group of 13 000 associates seamlessly teaming up to
satisf y customers worldwide & differentiates General Cable from all others and makes us the world leader in cable & wire
Industry.
General Cable India, a 100% subsidiary of General Cable Corporation US, is Catering to Indian customer through its state of
the ar t modern facility in 20 acre (Approx 80937 sq. mtrs) situated at the Industrial town of Baddi in the beautiful state of
Himachal Pradesh. The range of products manufactured includes extra high voltage, high voltage, low voltage, and
specialty cables. General Cable has extensive sales network across India.

General Cable India, benefit not only from General Cable's depth and breadth of products and its innovative technology
development and transfer for Indian operations, but can also source the EHV products from its Global production facilities
to suit the Indian utility requirements .
General Cabl e bases its activities on a series of Corporate Val ues which guide all its operations: Customer Sati sfacti on
as an absolute priority; Integri ty in all of its actions; Peopl e as the main source of value; Teamwork as a path to excellence;
Speed of del i ver y as a competitive advantage; and Conti nuous i mprovement as a constant objective.
This philosophy can only be assumed by a global company such as General Cable with extremely broad, diversified range,
able to meet any requirement, however specific, anywhere on the planet.
Worl d Leader i n Extra-Hi gh-Vol tage Cabl e Systems
Aerial view of General Cable factory at Baddi, H.P., India
Connectingthe World
General Cabl e s Gl obal Reach
General Cable serves customers through a global network of 46 manufacturing facilities in 23 countries
and sales representatives and distribution centers worldwide. The Company is solely dedicated to the
production of high-quality energy, industrial, specialty and communications wire and cable products. In
addition to its breadth of product line and strong brand recognition, the Company offers competitive
strengths in such areas as technology, manufacturing, distribution and logistics, and sales and customer
service. This combination enables General Cable to better serve its customers as they expand into new
geographic markets.
International Corp
NSW
General Cabl e Footpri nt General Cabl e Footpri nt
Di r ecti ng Tr affi c without Gridlock
Bui l di ng Br i dges in the Sky
Maki ng Contact with the World
Connectingthe World
General Cable is a leader in the development,
des i gn, manuf ac t ur e, mar ket i ng and
distribution of copper, aluminum and fiber
optic wire and cable for the energy, industrial,
specialty and communications markets.
Our products inspire progress worldwide.....
.
Customers use our value-added products to
create global infrastructure that improves the
standard of living for people everywhere.
Eac h d ay w e r e b u i l d i n g b u s i n es s
momentum-developing ideas into innovative
solutions and industr y- leading products,
expanding geographic access and fur thering
our investment in highly capable associates,
Lean Manufacturing, material science and
technology resources.
General Cable is influencing the world...with more than two-thirds of our
sales generated outside Nor th America and more than 13,000 associates
in 46 manufacturing facilities throughout 23 countries. As the fif th largest
wire and cable manufacturer, we are the One Company Connecting the
World.
Energy Cabl es
Our cables carry energy across the world-through the air, underground
and under the sea. Increasing demand for energy is accelerating
investment in exploration, extraction, power generation, transmission
and distribution-whether based on coal, natural gas, oil, nuclear, wind or
water.
Industri al & Speci al ty Cabl es
We have the competitive product mix and global reach to suppor t the
production of oil, gas and petrochemical; construction of new factories
and maintenance of existing industrial facilities; factory automation; and
special applications such as military, nuclear, marine, mining, transit and
automotive.
Communi cati ons Cabl es
Our cables keep information flowing-facilitating a non-stop stream of
words and images around the world. We meet the high-speed bandwidth
needs of global communications networks from fiber optic, submarine
communications cables, copper and fiber aerial and underground cables
to copper and fiber optic enterprise cables and system solutions.
Indi a Headquar ters
General Cable Energy India Pvt Ltd
Corporate office: Centrum Plaza, Level 3, Tower A,
312 S, Golf Course Road, Sector- 53,
Gurgaon-122 002, Haryana.
Phone: (0124) 4326000 Fax: (0124) 4326019
Worl d Headquar ters
General Cable
4 Tesseneer Drive
Highland Heights, KY
41076-9753 U.S.A
BRAND
Connectingthe World
Qual i ty i s Forethought
General Cable is committed to exceeding our customers expectations for quality and per formance.
We strive to ensure this quality through extensive in-house and third- par ty testing, with strict adherence
to our product specification and industr y standards. At General Cable, quality is not just a process, it
is forethought. It is the forethought of using the best materials and proactive prevention. This level of
quality is best represented in three core steps: Desi gn, Tec hnol ogy and Cont r ol .
General Cable Corporation is committed to developing, producing and marketing product that meet
the per formance, quality, value and safety requirements of our customers by continuously improving all
areas of our business. We apply Lean Sigma Company-wide, seeking innovative ways to differentiate our
products and ser vices and to ser ve as our customers and suppliers most valued business par tner.
Design
Design
Quality
Control
Control
Technology
Technology
Quality
International Corp
NSW
Connectingthe World
Rel y on the Worl d l eader of EHV systems.
Look at our Experi ance & References
Through an ongoing quality assurance initiative, General Cable ensures the quality of product design,
manufacture, installation and expected service life, as well as environmentally sound products, processes
and policies, continuous research and development, combined with process control, quality audits and
prolonged stringent testing, provide an ever-growing range of specialty materials and designs that meet
Utility industry approvals and standards
Fi ve decades of worl d wi de Fi rst by General Cabl e Brands
63 KV
220 KV
400 KV
500 KV
1962 :
1969 :
1985 :
1990 :

Qual i ty Assurance Guaranteed
Vol tage Level (KV) 63-161 220-230 330-500
*
Cabl es suppl i ed (km) ? 9312 ? 3598 ? 348
*
Termi nati ons (Nos.) ? 24000 ? 7255 ? 674
*
Joi nts (Nos.) ? 12079 ? 5862 ? 450

*Supplied by General Cable plants in France &Spain (Ref. 2008)
BRAND
Connectingthe World
Our Green Ini ti ati ve symbol recogni zes our rol e
and responsi bi l i ty i n promoti ng sustai nabi l i ty.
The symbol al so refl ects our commi tment to achi evi ng
i ndustr y-l eadi ng standards and respondi ng
proacti vel y to envi ronmental gl obal i ssues.
IN T I N I E A
T E
I R V
G E
Commi tment To Envi ronment - Green Factor y
Compl i ant to Indi an Green Bui l di ng Counci l Rati ng
Commi tment To Envi ronment - Green Factor y
Compl i ant to Indi an Green Bui l di ng Counci l Rati ng
International Corp
NSW
Connectingthe World
Helping to power the world
Energy
BRAND
CONNECTING THE WORLD

Maki ng Cabl es i s about Creati ng
Potenti al
General Cabl e products hel p to i l l umi nate the worl d,
i nspi re progress and open l i nes of communi cati on.
We connect peopl e wi th energy, i nformati on, i deas
and oppor tuni ti es.
For more than a century, General Cable has been a leader in
the development, manufacture, marketing and distribution of
wire and cable-our sole business. Today, we continue to
direct our worldwide resources to deliver maximum value to
customers through a power ful combination of product and
service innovations.
At General Cable we aim to add value to our customers
businesses by understanding and competitively servicing
their needs through customer intimacy operational
excellence.
General Cabl e provi des a si ngl e source sol uti on
The cost effective advantage of a single resource, a single
company that provides one of the broadest product ranges,
highest levels of customer and technical suppor t and
responsive customer-first service.
THE POWER OF ONE
At General Cable, THE POWER OF ONE embodies our
integrated approach to business: one company with the
power of our products, exper tise, systems and people all
focused on one goal - fulfilling our customers needs. It
means one source customers can count on for DATA,
COMMUNICATION, INDUSTRIAL and ENERGY cables. Most
of all, THE POWER OF ONE means one team, well trained and
wholly committed to the highest level of customer
satisfaction.
Manufacturi ng and
l ogi sti cs
With superior engineering and
m a n u f a c t u r i n g o p er a t i o n s ,
i n d u s t r y - l e a d i n g l o g i s t i c s
capabilities, one of the broadest
product ranges in the industry, and
a strong group of employees
seamlessly teaming to satisf y
cust omers, General Cabl e i s
s t r ong, di ver s i f i ed and w el l
positioned to meet the challenges
of tomorrow.
Sal es and Di stri buti on
Network
General Cable has a distribution
network throughout India and a
team of people committed to
meeting the total needs of our
customers- by providing enhanced
di st r i but i on and war ehousi ng
services, and an unprecedented
level of technical suppor t.
Strength, Di versi ty
and Teamwork
Every product reflects our POWER
OF ONE business philosophy. We
have become a leading cable
supplier in Asla pacific through
excellent customer relationships,
the quality of our people and the
highest standards of service.
GENERAL CABLE INDIA
Qual i ty Products, Peopl e and Ser vi ce
ConnectingtheWorld
OUR VISION
Strive for leadership through growth and excellence.
General Cabl e Indi a i s a l eadi ng suppl i er of cabl e sol uti ons for energy, i ndustri al , data, communi cati ons and
speci al i st appl i cati ons. As par t of the US based General Cabl e Corporati on (one of the worl d s l argest wi re
and cabl e manufacturers) we ser ve customers through a gl obal network of for ty si x manufacturi ng faci l i ti es
i n twenty three countri es, wi th sal es and di stri buti on centers worl dwi de.
As par t of a global business we are able to draw on innovative engineering developments, a comprehensive product range
and the best research and technical suppor t available, ensuring our customers are offered a competitive edge.
Extra High Voltage Cable
Connectingthe World
CentrumPlaza, Level 3, Tower A, 312-S, Golf Course Road, Sector-53, Gurgaon-122002, Harayana
Phone : +91 124 432 6000 Fax : +91 124 432 6019
General Cable Energy India Pvt. Ltd.
DESIGN & CONSTRUCTION OVERVIEW
OF EHV CABLE
The EHV Cable has Copper or
Aluminium conductor insulated with
the cross-linked polyethylene,
shielded with metallic screen (metal
sheath or wire shield or both) and
overall PVC or polyethylene
sheathed.
Conductor
Conductor Screen
Insulation
Insulation Screen
Longitudinal Water Barrier
Outer Sheath
Metallic Sheath
The conductor consists of annealed copper or Aluminium stranded wires compacted circular and segmental compacted circular. The wires are
wounded up concentrically. The segmental conductor consists of 4/5/6 segments are wounded up to form compacted circular conductor.
2
Segmental conductor design are recommended for the cross-section over 800 mm toprevent the increase of A. C. Resistance caused by skin
effect.
The conductor screen consists of an extruded
semi-conducting polyethylene is applied over
conductor to minimize electrical stresses. The
semi-conducting material used for conductor
screen has no deleterious effect on the conductor.
Semi-conducting tape is sometimes applied as a
separator.
The insulation material is extruded cross-linked
polyethylene. The conductor screen, the
insulation and the insulation screen mentioned
here are extruded simultaneously in one process
(Triple extrusion and dry-nitrogen cured) to
ensure clean interface and enhanced
performance.
The extrusion process is carried out under strictly
controlled conditions.

The insulation screen is applied over the insulation by extruding the semi -conducting compound concentrically and circularly to minimize the
possibility of ionization on the outer surface of the dielectric.

The metallic screen consists of lead sheath and/or wire shield or corrugated aluminium sheath.
Lead sheathed cable has following advantages :
Electrostatic shielding
Fault current carrying capability
Excellent water barrier
Excellent oil and chemical resistance
Excellent sulfides resistance
To protect the metallic sheath from electrical or chemical corrosion, it is covered by PE or PVC. Also there will be overall semi-conducting layer over
this PE or PVC sheath.
Conductor
Insulation
Insulation Screen
Longitudinal Water Barrier
Outer Sheath
Copper Wire Screen
Laminated Radial Water Barrier
Conductor Screen
Metallic Screen
Insulation Screen
Outer Sheath
Insulation
Conductor Screen
Conductor
Connectingthe World
Phone : +91 124 432 6000 Fax : +91 124 432 6019
PRODUCT SELECTION LOCATOR
TECHNICAL INFORMATION 16 - 28
IEC : 60840
2XLyY/2XLy2Y
2XAY/2XA2Y
2XCY/2XC2Y
7 - 9
76/132 (145) KV Copper
Conductor XLPE Cable
IEC : 60840
2XLyY/2XLy2Y
2XAY/2XA2Y
2XCY/2XC2Y
10 - 12
87/161 (170) KV Copper
IEC : 62067
2XLyY/2XLy2Y
2XAY/2XA2Y
2XCY/2XC2Y
13 - 15
127/230 (245) KV Copper
IEC : 60840
2XLyY/2XLy2Y
2XAY/2XA2Y
2XCY/2XC2Y
4 - 6
64/110 (123) KV Copper
2XLyY/2XLy2Y
2XAY/2XA2Y
2XCY/2XC2Y
38/66 (72.5) KV Copper
1 - 3 IEC : 60840
EHV CABLES CABLE TYPE
PAGE
NO.
CABLE
DESCRIPTION
REFERENCE
STANDARD
Connectingthe World
Note: (1) C- Stranded Compacted Circular Conductor.
(2) S- Stranded Compacted Segmental (Milliken) Conductor.
(3) Additional Copper wires screen may be provided if Lead Sheath alone is not sufficient to meet the requirement of earth fault current.
(4) Electrical Parameters are based on Standard Laying Conditions mentioned in Table-1.
(5) Standard delivery Length specified above are for guidance only. Cables can be however supplied as per customer requirements.
(6) Dimensions and weights are subject to industry tolerances.
Conductor : Compact Round/Segmental (Milliken) Copper
Conductor shield : Semi-conducting tape (optional) with extruded
semi-conducting cross-linked polyethylene.
Insulation : Cross-Linked polyethylene.
Insulation Shield : Semi-conducting cross-linked polyethylene.
Synthetic water blocking layer : Semi-Conductive water blocking tape.
Shield & Radial water barrier : Lead Alloy E (Please also refer note (3) below)
Sheath : Black polyethylene (ST-7) or PVC (ST-2)
Construction :
Preferably used for Power transmission
network. Suitable for exposed in Air, direct burial,
open tray & underground duct installation.
Application :
Normal Operation..................................................90C
Emergency* Operation.........................................130C
Short Circuit Operation.......................................250C
Temperature Rating :
* Operation at the emergency overload temperature shall
not exceed 100 hours in 12 consecutive months &not more
than 500 hours during the lifetime of the cable.
Triple-extruded for clean interfaces
Dry nitrogen cure for enhanced performance
Excellent moisture resistance
Super Clean XLPE insulation for Extra-high
dielectric strength
Low dielectric loss
Excellent resistance to treeing
Features & Benefits :
IEC : 60840
Reference Standard :
90 KV (AC) for 30 minutes.
H.V. Test Voltage :
Adventages of Lead Sheath
38/66 (72.5) KV COPPER CONDUCTOR
LEAD SHEATHED CABLE
Shield & Radial water barrier
Conductor shield
Conductor
Insulation
Insulation shield
Synthetic water blocking layer
Sheath
1
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
DIMENSIONS ELECTRICAL PARAMETERS
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
(Sqmm) (mm) (Kg/km) (F/km) cfh (Amp) (Amp) (Mtr./Drum) (Amp) (Amp)
240 C 62.5 8,000 0.0754 0.20 540 530 625 710 500
300 C 65.0 8,500 0.0601 0.21 605 570 710 810 500
400 C 68.0 9,500 0.0470 0.23 695 645 820 945 500
500 C 72.0 11,000 0.0366 0.25 790 735 950 1100 500
630 C 75.0 13,000 0.0283 0.28 900 835 1100 1275 500
800 C 81.0 15,000 0.0221 0.30 1010 960 1245 1460 500
1000 S 87.0 18,000 0.0176 0.33 1180 1125 1500 1760 500
1200 S 92.0 20,000 0.0154 0.36 1280 1210 1650 1940 500
1600 S 100.0 24,500 0.0113 0.40 1470 1440 1910 2285 400
2000 S 106.0 30,000 0.0090 0.44 1630 1590 2130 2600 400
Phone : +91 124 432 6000 Fax : +91 124 432 6019
Connectingthe World
ALUMINIUM SHEATHED CABLE
Application :
Insulation Shield : Semi-conducting cross-linked polyethylene
Shield & Radial water barrier : Corrugated & Seamless Aluminium Sheath
Construction :
Application :
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Adventages of Aluminium Sheath
2
Conductor
Conductor shield
Insulation
Insulation shield
Sheath
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
(Sqmm) (mm) (Kg/km) (F/km) $') (Amp) (Amp) (Mtr./Drum) (Amp) (Amp)
240 C 67.0 4,500 0.0754 0.20 525 490 600 675 500
300 C 70.0 5,000 0.0601 0.21 595 555 685 770 500
400 C 74.0 6,000 0.0470 0.23 670 630 780 890 500
500 C 79.0 7,000 0.0366 0.25 765 715 895 1025 500
630 C 81.0 9,000 0.0283 0.28 880 810 1025 1190 500
800 C 88.0 11,000 0.0221 0.30 965 930 1150 1350 500
1000 S 95.0 13,000 0.0176 0.33 1120 1080 1360 1620 500
1200 S 100.0 15,000 0.0151 0.36 1200 1150 1465 1750 500
1600 S 108.0 20,000 0.0113 0.40 1355 1315 1655 2035 400
2000 S 115.0 23,000 0.0090 0.44 1470 1435 1805 2275 400
Phone : +91 124 432 6000 Fax : +91 124 432 6019
Connectingthe World
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Application :
Metallic Insulation Screen : Copper Wires applied Helically with open
Helix of copper tape
Synthetic water blocking layer : Non-Conductive water blocking tape.
Radial water barrier : Aluminium Laminated tape
Construction :
COPPER WIRE SHIELDED CABLE
3
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
Metallic Insulation Screen
Radial water barrier
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
240 C 59.0 4,000 0.0754 0.20 530 485 610 695 500
300 C 61.0 5,000 0.0601 0.21 600 545 695 795 500
400 C 65.0 6,000 0.0470 0.23 685 615 800 925 500
500 C 68.0 7,000 0.0366 0.25 780 730 930 1075 500
630 C 72.0 8,000 0.0283 0.28 885 830 1065 1250 500
800 C 76.0 10,000 0.0221 0.30 980 930 1210 1430 500
1000 S 81.0 12,000 0.0176 0.33 1175 1090 1475 1730 500
1200 S 86.0 14,000 0.0151 0.36 1270 1175 1610 1895 500
1600 S 94.0 17,000 0.0113 0.40 1465 1375 1885 2245 500
2000 S 100.0 21,000 0.0090 0.44 1630 1530 2110 2555 400
Phone : +91 124 432 6000 Fax : +91 124 432 6019
Connectingthe World
64/110 (123) KV COPPER CONDUCTOR
LEAD SHEATHED CABLE
Conductor shield : Semi-conducting tape (optional) with extruded.
Construction :
Application :
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
4
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
(Sqmm) (mm) (Kg/km) (F/km) (Amp) (Amp) (Mtr./Drum) (Amp) (Amp)
240 C 74.0 9,500 0.0754 0.16 535 500 620 695 500
300 C 77.0 10,500 0.0601 0.17 605 560 705 995 500
400 C 80.0 12,000 0.0470 0.18 690 655 815 925 500
500 C 84.0 13,000 0.0366 0.19 785 745 940 1070 500
630 C 88.0 15,000 0.0283 0.21 890 845 1085 1245 500
800 C 93.0 17,000 0.0221 0.23 1000 950 1230 1425 500
1000 S 98.0 20,000 0.0176 0.25 1175 1110 1490 1720 500
1200 S 103.0 23,000 0.0151 0.27 1270 1235 1610 1870 500
1600 S 110.0 28,000 0.0113 0.30 1455 1415 1870 2205 400
2000 S 117.0 33,000 0.0090 0.33 1610 1565 2090 2505 400
2500 S 125.0 39,000 0.0072 0.37 1700 1650 2200 2645 300
Phone : +91 124 432 6000 Fax : +91 124 432 6019
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
240 C 80.0 6,000 0.0754 0.16 520 490 590 660 500
300 C 84.0 7,000 0.0601 0.17 590 550 675 755 500
400 C 87.5 8,000 0.0470 0.18 670 640 775 875 500
500 C 92.0 9,000 0.0366 0.19 760 725 890 1010 500
630 C 96.0 10,000 0.0283 0.21 860 820 1020 1170 500
800 C 102.0 12,000 0.0221 0.23 960 915 1145 1335 500
1000 S 107.0 14,000 0.0176 0.25 1110 1055 1345 1580 500
1200 S 113.0 17,000 0.0151 0.27 1190 1180 1450 1720 500
1600 S 119.0 21,000 0.0113 0.30 1340 1330 1635 1995 400
2000 S 127.0 26,000 0.0090 0.33 1460 1445 1790 2235 400
2500 S 135.0 32,000 0.0072 0.37 1540 1525 1885 2360 300
Connectingthe World
Application :
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Construction :
Conductor
Conductor shield
Insulation
Insulation shield
Sheath
5
Phone : +91 124 432 6000 Fax : +91 124 432 6019
Connectingthe World
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Application :
Construction :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
6
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
240 C 70.0 5,000 0.0754 0.16 530 495 605 685 500
300 C 73.0 5,500 0.0601 0.17 600 560 695 785 500
400 C 76.0 6,500 0.0470 0.18 680 650 800 910 500
500 C 79.0 7,500 0.0366 0.19 775 740 925 1055 500
630 C 82.0 9,000 0.0283 0.21 885 840 1065 1225 500
800 C 88.0 11,000 0.0221 0.23 995 945 1210 1410 500
1000 S 93.0 13,000 0.0176 0.25 1170 1105 1465 1695 500
1200 S 98.0 15,000 0.0151 0.27 1265 1230 1595 1850 500
1600 S 105.0 18,000 0.0113 0.30 1455 1415 1860 2185 500
2000 S 112.0 22,000 0.0090 0.33 1620 1570 2090 2490 400
2500 S 119.0 26,000 0.0072 0.37 1700 1655 2200 2625 400
Phone : +91 124 432 6000 Fax : +91 124 432 6019
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
240 C 81.0 11,000 0.0754 0.14 530 495 615 680 500
300 C 83.0 12,000 0.0601 0.15 600 560 705 780 500
400 C 86.0 13,000 0.0470 0.16 685 640 810 905 500
500 C 90.0 14,000 0.0366 0.17 780 730 935 1050 500
630 C 94.0 16,000 0.0283 0.19 890 840 1080 1225 500
800 C 100.0 19,000 0.0221 0.21 1000 940 1225 1400 500
1000 S 104.0 22,000 0.0176 0.23 1170 1100 1470 1680 500
1200 S 109.0 25,000 0.0151 0.25 1265 1225 1600 1845 400
1600 S 116.0 30,000 0.0113 0.28 1450 1405 1855 2170 400
2000 S 123.0 35,000 0.0090 0.30 1600 1550 2065 2460 400
2500 S 131.0 41,000 0.0072 0.33 1690 1630 2175 2595 300
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LEAD SHEATHED CABLE
Construction :
Application :
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
7
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
240 C 90.0 7,000 0.0754 0.14 520 490 590 650 500
300 C 93.0 7,700 0.0601 0.15 585 550 670 745 500
400 C 95.0 8,700 0.0470 0.16 665 635 770 860 500
500 C 98.0 10,000 0.0366 0.17 755 715 885 995 500
630 C 103.0 11,500 0.0283 0.19 860 815 1010 1150 500
800 C 108.0 13,500 0.0221 0.21 960 945 1135 1315 500
1000 S 110.0 15,000 0.0176 0.23 1105 1095 1335 1555 500
1200 S 120.0 18,000 0.0151 0.25 1185 1170 1440 1695 400
1600 S 127.0 22,500 0.0113 0.28 1335 1325 1630 1975 400
2000 S 133.0 26,000 0.0090 0.30 1455 1435 1780 2210 400
2500 S 140.0 33,000 0.0072 0.33 1530 1515 1875 2330 300
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Application :
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Construction :
Conductor
Conductor shield
Insulation
Insulation shield
Sheath
8
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
240 C 77.0 6,000 0.0754 0.14 525 495 600 675 500
300 C 79.0 7,000 0.0601 0.15 595 555 690 775 500
400 C 82.0 8,000 0.0470 0.16 675 635 795 895 500
500 C 85.0 9,000 0.0366 0.17 770 715 910 1035 500
630 C 88.0 11,000 0.0283 0.19 875 810 1045 1200 500
800 C 94.0 12,000 0.0221 0.21 980 935 1185 1375 500
1000 S 100.0 15,000 0.0176 0.23 1145 1090 1420 1650 500
1200 S 104.0 16,000 0.0151 0.25 1235 1215 1546 1800 500
1600 S 112.0 20,000 0.0113 0.28 1415 1390 1785 2125 500
2000 S 118.0 24,000 0.0090 0.30 1570 1535 2000 2420 400
2500 S 126.0 28,000 0.0072 0.33 1655 1615 2110 2550 400
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dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Application :
Construction :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
9
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
300 C 88.0 12,000 0.0601 0.14 600 560 760 775 500
400 C 91.0 13,500 0.0470 0.15 685 650 805 900 500
500 C 94.0 15,500 0.0366 0.16 780 735 930 1045 500
630 C 100.0 17,500 0.0283 0.18 885 835 1075 1215 500
800 C 104.0 20,000 0.0221 0.19 995 940 1220 1390 500
1000 S 109.0 23,000 0.0176 0.22 1170 1130 1465 1670 500
1200 S 114.0 26,000 0.0151 0.24 1260 1220 1590 1825 400
1600 S 121.0 31,000 0.0113 0.26 1445 1400 1845 2155 400
2000 S 128.0 36,000 0.0090 0.28 1600 1540 2060 2445 300
2500 S 135.0 43,000 0.0072 0.31 1680 1620 2170 2575 300
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LEAD SHEATHED CABLE
Construction :
Application :
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
10
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
300 C 97.0 8,000 0.0601 0.14 585 560 670 740 500
400 C 100.0 9,000 0.0470 0.15 665 635 770 855 500
500 C 103.0 10,000 0.0366 0.16 755 720 880 990 500
630 C 108.0 12,000 0.0283 0.18 855 810 1010 1150 500
800 C 113.0 14,000 0.0221 0.19 955 940 1135 1310 500
1000 S 117.0 17,000 0.0176 0.22 1100 1090 1330 1550 500
1200 S 125.0 19,000 0.0151 0.24 1180 1165 1430 1685 400
1600 S 132.0 23,000 0.0113 0.26 1330 1310 1630 1970 400
2000 S 139.0 28,000 0.0090 0.28 1450 1420 1775 2200 300
2500 S 145.0 34,000 0.0072 0.31 1525 1500 1870 2315 300
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Application :
dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Construction :
Conductor
Conductor shield
Insulation
Insulation shield
Sheath
11
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
300 C 83.0 8,000 0.0601 0.14 590 555 685 765 500
400 C 86.0 9,000 0.0470 0.15 675 630 790 890 500
500 C 89.0 10,000 0.0366 0.16 765 715 910 1030 500
630 C 94.0 11,500 0.0283 0.18 870 830 1045 1195 500
800 C 98.0 13,000 0.0221 0.19 980 930 1180 1370 500
1000 S 103.0 15,500 0.0176 0.22 1145 1080 1415 1640 500
1200 S 108.0 17,000 0.0151 0.24 1235 1210 1535 1790 500
1600 S 116.0 20,500 0.0113 0.26 1405 1385 1765 2100 500
2000 S 123.0 24,500 0.0090 0.28 1555 1525 1975 2385 400
2500 S 130.0 29,000 0.0072 0.31 1635 1605 2080 2510 400
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dielectric strength
Low dielectric loss
IEC : 60840
H.V. Test Voltage :
Application :
Construction :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
12
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
400 C 103.0 18,000 0.0470 0.14 680 640 795 870 500
500 C 107.0 19,000 0.0366 0.15 770 745 915 1010 500
630 C 111.0 22,000 0.0283 0.16 880 850 1095 1175 500
800 C 116.0 24,000 0.0221 0.17 985 950 1200 1345 400
1000 S 122.0 28,000 0.0176 0.19 1155 1110 1430 1610 400
1200 S 126.0 30,000 0.0151 0.20 1245 1195 1555 1760 400
1600 S 134.0 36,000 0.0113 0.23 1425 1400 1800 2070 300
2000 S 140.0 42,000 0.0090 0.24 1525 1545 2000 2345 300
2500 S 148.0 47,000 0.0072 0.27 1655 1625 2110 2465 300
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LEAD SHEATHED CABLE
Construction :
Application :
dielectric strength
Low dielectric loss
IEC : 62067
H.V. Test Voltage :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
13
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
400 C 110.0 10,000 0.0470 0.14 660 640 760 835 500
500 C 114.0 12,000 0.0366 0.15 745 725 865 965 500
630 C 118.0 14,000 0.0283 0.16 845 825 990 1110 500
800 C 125.0 15,000 0.0221 0.17 945 915 1115 1270 500
1000 S 130.0 16,000 0.0176 0.19 1090 1060 1310 1505 500
1200 S 135.0 21,000 0.0151 0.20 1165 1130 1405 1630 400
1600 S 142.0 26,000 0.0113 0.23 1315 1325 1600 1900 400
2000 S 150.0 30,000 0.0090 0.24 1440 1425 1760 2145 300
2500 S 160.0 35,000 0.0072 0.27 1515 1500 1850 2255 300
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Application :
dielectric strength
Low dielectric loss
IEC : 62067
H.V. Test Voltage :
Construction :
Conductor
Conductor shield
Insulation
Insulation shield
Sheath
14
Nominal
Area of
Conductor
Approx.
Capacitance
Flat Trefoil
Standard
Delivery
Length
Duct Direct
Buried
Air
Current Rating
Max DC
Conductor
Resistance
at20C
Approx.
Cable
Wt.
Approx.
Overall
Cable
Diameter
400 C 98.0 10,000 0.0470 0.14 670 635 780 865 500
500 C 102.0 11,000 0.0366 0.15 760 720 895 1000 500
630 C 106.0 12,500 0.0283 0.16 865 845 1030 1160 500
800 C 111.0 14,500 0.0221 0.17 970 945 1170 1325 500
1000 S 115.0 17,000 0.0176 0.19 1130 1100 1390 1585 500
1200 S 120.0 19,000 0.0151 0.20 1220 1185 1515 1735 500
1600 S 128.0 23,000 0.0113 0.23 1400 1355 1750 2040 400
2000 S 134.0 27,000 0.0090 0.24 1545 1490 1950 2310 400
2500 S 142.0 31,000 0.0072 0.27 1625 1570 2050 2430 300
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dielectric strength
Low dielectric loss
IEC : 62067
H.V. Test Voltage :
Application :
Construction :
Conductor shield
Conductor
Insulation
Insulation shield
Sheath
15
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TECHNICAL INFORMATION
S.NO. INFORMATION
PAGE
NO.
16
1 Short Circuit Current Rating 17
2 Standard Laying Conditions & Rating Factors 18
3 Sheath Bonding Methods 19-20
4 Method of Installation 21
5 Checklist for Specifications 22
6 Metric Conversion Factors 23
7 Recommended Reel Handling Practices 24
8 Recommended Cable Handling Practices 25
9 Recommended Cable Storage Practices 26
10 Installation Feed-In Setups 27-28
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SHORT CIRCUIT CURRENT
RATINGS
The short circuit capacity of the conductor and metallic sheath or shield of a cable are related principally
to their heat capacities and are limited by the maximum temperature permitted under short circuit. The
calculation is based on following :-
17
I = x 226
S
S
t
In
+234.5
f
+234.5
i
Where,
I =Permissible Short Circuit Current (A)
S
=Factor to allow for heat loss into
the Adjacent Components
S =Cross-Sectional Area of Conductor (sqmm)
t =Duration of Short circuit (s)
=Final Temperature (250C)
=Initial Temperature (90C)
I = x 41
S
S
t
In
+230
f
+230
i
Where,
S
S =Cross-Sectional Area of sheath (sqmm)
I = x 226
S
S
t
In
+234.5
f
+234.5
i
Where,
S
S =Cross-Sectional Area of Screen (sqmm)
Copper Conductor
Lead Sheath
Copper Screen
Aluminium Sheath
I = x 148
S
S
t
In
+228
f
+228
i
Where,
S
S =Cross-Sectional Area of sheath (sqmm)
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STANDARD LAYING CONDITION
& RATING FACTORS
RATING FACTORS FOR VARIATION IN AMBIENT AIR TEMPERATURE WHEN CABLE LAID IN AIR
Air Temperature (C)
Rating Factor
20c 25c 30c 35c 40c 45c 50c
1.2 1.16 1.10 1.05 1.0 0.94 0.88
RATING FACTORS FOR VARIATION IN GROUND TEMPERATURE WHEN CABLE LAID DIRECT IN GROUND
Air Temperature (C)
Rating Factor
15c 20c 25c 30c 35c 40c 45c
1.08 1.04 1.0 0.96 0.91 0.87 0.83
RATING FACTORS FOR VARIATION IN THERMAL RESISTIVITY OF SOIL
Thermal Resistivity of Soil
(cm/W)
Rating Factor
0.7 1.0 1.2 1.5 2.0 2.5 3.0
1.14 1.0 0.93 0.84 0.74 0.67 0.61
0.50 ~0.70
0.71 ~0.90
0.91 ~1.10
1.11 ~1.30
1.31 ~1.50
1.09
1.05
1.03
1.01
1.00
Rating Factor Depth of Laying (m)
RATING FACTORS FOR VARIATION IN DEPTH OF LAYING
TABLE-1
STANDARD LAYING CONDITION
GROUND TEMPERATURE : 25C
DEPTH OF LAYING : 1.5 m
SOIL THERMAL RESISTIVITY : 1.0C-m/W
AMBIENT TEMPERATURE : 40C
MAX. CONDUCTOR TEMPERATURE : 90C
METHOD OF INSTALLATION : FLAT (S =2 X OD)
S =DISTANCE BETWEEN CABLES
OD =CABLE DIAMETER
FREQUENCY : 50HZ
18
TABLE-2
RATING FACTORS
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E E
The simplest, known as solid bonding, involves bonding both

ends of the cable screen/sheath circuit to earth, as shown here.
Whilst this arrangement keeps the voltages on the sheath low it
unfortunately provides a very good path for induced currents to
flow in the sheath. Depending on the geometry of the installation
these currents can be high and therefore lead to large sheath
losses and lower current ratings. For cables where all three
phases are within the sheath then this will often be the best
arrangement.
S S
E
Mid Point Bonding :
The circuit length can be doubled if the bonding point is moved to
the mid-point of the circuit as shown here. This arrangement is
known as mid-point bonding has the same benefits and
limitations as end-point bonding except that the circuit length can
be greater. The mid-point bonding may be at a joint, as shown
here, or by using a special sheath bond attachment.
S E
For shorter circuit lengths, it may be acceptable to bond only at

one end to earth. The arrangement shown here, known as end-
point bonding, involves bonding at one end of the cable circuit to
earth and the other end is bonded to sheath voltage limiters. This
arrangement allows the voltage to rise but the sheath voltage
limiters form a conducting path to earth prevent the voltage rise
too much (under fault conditions). By limiting the circuit length the
induced voltage on the sheath at the end farthest from the earth
bond can be kept below an acceptable value during normal
operation. And no induced currents can flow during normal
operation.
Single Point Bonding (End Point Bonding) :
SHEATH BONDING METHODS
19
This Engineering Recommendation deals with the earthing of cable screens which constitute an insulated three phase line,
installed either in a service gallery, in an indoor installation or directly buried. To reduce the losses on the line and optimize the
transport capacity, connection systems tend to be adopted which reduce the intensity of the currents induced on the screens.
These systems involve specific connections of the screens to each other and to earth and give rise to permanent current and
current surges on the screen circuits which must be considered.
Scope
This Recommendation describes the systems and components used in the connections of the screen/sheath circuits of three
phase power lines for voltages equal to or greater than 66 kV, made up of single-core cables with metallic screen and insulating
sheath. Specific means may be required to withstand the permanent current and current surges which can occur between different
parts of the screen/sheath circuit, and between the same and the earth. Various Sheath Bonding methods are given below :
Introduction
Both Ends Bonding (Solid Bonding) :
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J OINT WITH SECTIONALISING
INSULATION
CONCENTRIC
LEADS
LOCKABLE LINK BOX
WITH SHEATH
VOLTAGE LIMITERS
J OINT BAY EARTH
SYSTEM
Cross-Bonding :
E E E X X X X
Minor Section
Major Section
For longer circuit lengths, this arrangement, known as cross
bonding, is commonly used for EHV Systems. The circuit is
divided into major and minor sections such that there are three
minor sections of approximately equal length in each major
section. Both ends of a major section are bonded to earth and the
other two positions within the major section are bonded to sheath
voltage limiters. Because this would allow induced currents to
flow in the sheath the cables are rearranged as shown and the
sheaths are "crossed over" so that they remain at the same
geometry, see below. This means that the induced currents are
effectively cancelled due to the phase shift.
In this diagram, the colours represent the sheath
connections and not phases. So, for example, as
phase 1 enters from the left in the top position the
sheath is represented in magenta, phase 1 is then
transposed to the middle position to exit on the
right and the sheath is now represented in yellow.
The sheath of phase 1 on the left is shown bonded
via the link box to the sheath of phase 3 on the right
such that, in effect, the sheath both enters and
exits in the top position whilst the phases are
transposed.
20
SHEATH BONDING METHODS
Note : E stands for directly earthed
S stands for Sheath Voltage Limiter (SVL)
X stands for Link Box (LB) with SVL
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METHOD OF INSTALLATION
21
Installation :
Laying conditions play a major role for reliable and
optimized performance of EHV cable system. Extreme
care to be taken while dealing with an EHV cable
installation so that it can serve to its useful life.
Specialized installation method for EHV cables are
furnished here. Respect Bending radius as improper
bending will result in insulation being unduly stressed.
Also attention need to be paid for soil conditions under
direct burial for improvement of heat dissipation
properties.
Direct Burial Installation
(Trefoil Formation)
Protection Tile
Backfill
1
5
0
0
3
0
0
5
0
600
Sand Filling
G.L.
Warning Tape
To ensure safety during cable
installation and reliability once the
cable is installed, you should confirm
the following prior to installation:
The cable selected is proper for
your 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 authority.
Next, you must identify any existing
cable damage and prevent any
further damage from occurring. This
is done through proper cable
inspection, handling and storage.
Overview
Inspect every cable reel for damage
before accepting the shipment. Be
particularly alert for cable damage if:
A reel is laying flat on its side
Several reels are stacked
Other freight is stacked on a reel
Nails have been driven into reel
flanges to secure shipping
blocks
A reel flange is damaged
A cable covering is removed,
stained or damaged
A cable end seal is removed or
damaged
A reel has been dropped
(Hidden damage likely)
Cable Inspection
Remove all nails and staples from
the reel flanges before moving a
reel, and avoid all objects that could
crush, gouge or impact the cable
when moving. NEVER use the cable
as a means to move a reel.
When unreeling, observe
recommended bending radii, use
swivels to prevent twisting and avoid
overruns.
Cabling Handling
Pre-installation Instructions :
Road Crossing
(Trefoil Formation)
G.L.
Backfill
Sand Filling
RCC Tile
HDPE Pipe
1
5
0
0
4
0
0
5
0
Concrete
War ng Tape
ni
The following minimum bending radius should be
observed, so that the cable and especially the
insulation are not unduly stressed.
25 x OD for cables with PVC outer sheath,
30 x OD for cables with HDPE outer sheath,
where, OD is the Overall Diameter of the cable
Bending Radius :
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Size (sqmm)
Conductor Type (metal)
Insulation
EPR
XLPE
Other
Insulation Level
Earthed
Unearthed
Metallic Sheath
Lead Alloy
Corrugated Aluminum
Smooth Aluminum
Other
Metallic Shielding
Bare/Coated
Helical copper tapes
Helical wires
Longitudinal drain wires
Other
J acket
HDPE
PVC
Other
Color
Voltage rating
Temperature rating
Approvals
Standards
ISS
BSS
J IS
AEIC
CANENA
CSA
ICEA
IEC
Other

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CHECKLIST FOR SPECIFICATIONS
22
Testing Procedures
ISS
BSS
J IS
AEIC
CAN ENA
CSA
ICEA
IEC
Other
Special Requirements (if any)
Flame-retardant
Sunlight-resistant
Other
Documentation
Certificates of Compliance
Certified Test Reports
Drawings
Warranties
Other
System Characteristics
Shipping Details
Cut lengths
Installation Recommendation
Lagging
Returnable reels
Other
Identification
Cable
Circuit
Reel
Fault Current Requirement
Conductor
Metallic Sheath
Metallic Wire Shield
Note: This checklist must be
accompanied by exact system
details about the environment and
electrical characteristics.
Checklist for Specifications

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METRIC CONVERSION FACTORS
Inches Millimeters 25.4
Millimeters Inches 0.03937
Inches Centimeters 2.54
Centimeters Inches 0.3937
Feet Meters 0.3048
Meters Feet 3.2808
Kilofeet (1000 ft) kilometers 0.3048
kilometers kilofeet (1000 ft) 3.2808
Square Inches Square Millimeters 645.16
Square Millimeters Square Inches 0.00155
Square Inches Square Centimeters 6.4516
Square Centimeters Square Inches 0.155
Square Inches Circular Mils 1,273,240
-7
Circular Mils Square Inches 7.854 x 10
4
Circular Mils Square Millimeters 5.066 x 10
Square Millimeters Circular Mils 1973.51
Square Feet Square Meters 0.0929
Square Meters Square Feet 10.764
Pounds Kilograms 0.4536
Kilograms Pounds 2.2046
Pound/Kilofeet Kilograms/Kilometer 1.4882
Kilograms/Kilometer Pounds/Kilofeet 0.6720
Ohms/Kilofeet Ohms/Kilometer 3.2808
Ohms/Kilometer Ohms/Kilofeet 0.3048
Microfarads/Kilofeet Microfarads/Kilometer 3.2808
Microfarads/Kilometer Microfarads/Kilofeet 0.3048
Insulation Resistance:
MegohmsKilofeet MegohmsKilometer 0.3048
MegohmsKilometer MegohmsKilofeet 3.2808
Pounds/Square Inch Kilo Pascal* 6.895
Kilo Pascal* Pounds/Square Inch 0.1432
Pounds (force) Newtons 4.448
* 1 Pascal =1 newton/m2
To Convert From To Multiply By
Length
Area
Weight
Electrical
Mechanical
23
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RECOMMENDED REEL
HANDLING PRACTICES
How to Handle Cable Reels
24
Upended heavy reels will often arrive
damaged. Refuse or receive subject to
inspection for hidden damage.
Reels can be hoisted with a shaft
extending through both flanges.
Do not lift by top flange. Cable or reel
will be damaged.
Lower reels fromtruck using
hydraulic gate, hoist or fork lift.
LOWER CAREFULLY.
Never allow forks to touch cable surface
or reel wrap.
Always load with flanges on edge and
chock and block securely.
Never drop reels.
Cradle both reel flanges between forks.
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RECOMMENDED CABLE
HANDLING PRACTICES
25
Unloading and Moving of Reels:
Cable reels are never shipped upended (flat side down). Cable reels that arrive in this manner should be rejected or
received only after a thorough inspection for damage.
See Recommended Reel Handling Practiceson the following pages.
Upon receipt, a cables protective covering and/or lagging should be inspected for evidence of damage during shipment.
If evidence of damage is found, a report should immediately be made to the carrier.
Under no circumstances should reels be dropped from the delivering vehicle to the ground.
Unloading and reel handling should be accomplished so that the equipment used does not contact the cable surface,
and in the case of protective wrap, that the equipment does not contact the protective wrap.
If unloading and reel handling is accomplished by crane, either a cradle supporting the reel flanges or a shaft through
the bore hole should be used. If a fork lift is utilized, the forks must lift the reel at 90 to the flanges and the forks must
be long enough to make complete lifting contact with both flanges. Under no circumstances should the forks come into
contact with the cable surface or the protective wraps.
When a reel of cable is rolled from one point to another, care must be taken to see that there are no objects on the
surface area which could contact or damage the cable surface or protective wrap.
If an inclined ramp is used for unloading, the ramp must be wide enough to contact both flanges completely. The
stopping of the reels at the bottom shall be accomplished by using the reel flanges and not the surface of the cable.
Connectingthe World
Phone : +91 124 432 6000 Fax : +91 124 432 6019
RECOMMENDED CABLE
STORAGE PRACTICES
26
Finished cables have no established shelf-life. Moisture and atmospheric conditions can cause exposed conductors to
oxidize and discolor. Uncovered/unsheltered cable will degrade due to exposure to direct sunlight and/or the elements. If
the cables are protected, there should be no degradation of the insulation.
In general, any cable for use indoors should be stored indoors. Any cable suitable for installation outdoors is suitable for
storage outdoors. Cables stored outdoors should have the ends sealed to prevent moisture ingress into the cable.
Cables should be stored in a sheltered area. While on the reel, cable should be covered with Masonite or a dark film
wrap (to block the suns rays and shield from the elements).
Cables with a cold temperature marking i.e. 10C, 25C, or 40C may be stored in low ambient temp. area. Cables
without a cold temperature marking should not be stored in the low temp. area.
Cable reels must remain in the upright position. Cable reels must not be stored on their sides. Reels must not be
stacked.
Cable reels should be stored with the protective covering or lagging in place. If a length of cable has been cut
from the reel, the cable end should be immediately resealed to prevent the entrance of moisture. If a part length is
returned to storage, the reels protective covering should be restored.
Wooden reels should be stored off the ground to prevent rotating. Reels should be stored on a flat, hard surface so that
flanges do not sink into the earth. The weight of the reel and cable must be carried at all times by the reel flanges.
Cable reels and lagging must not be stored for an extended time period sitting in direct contact with water or
dampness. Timbers or metal supports must be placed under the reel flanges to provide elevated storage of the reels
away from the direct contact with water or damp soil.
Reels should be stored in an area where construction equipment, falling or flying objects or other materials will not
contact the cable.
Cable should be stored in an area where chemicals or petroleum products will not be spilled or sprayed on the cable.
Cable should be stored in an area away from open fires or sources of high heat.
If the reels are relocated, they should be handled as suggested in the Recommended Reel Handling Practicessection,
and inspection made on each reel during the relocation.
If the cables are stored in a secure area and not exposed to the effects of the weather, an annual inspection
should be satisfactory.
Where the reels are exposed to the weather, a bimonthly inspection should be performed to observe any sign of
deterioration.
If the reels are exposed in a non-secure area, policing of the area at frequent intervals may be required depending on
circumstances.
Records of delivery date, manufacturer, installation date, any extenuating circumstances, along with all test
reports should be kept on file.
Storage and Storage Maintenance:
Connectingthe World
Phone : +91 124 432 6000 Fax : +91 124 432 6019
Cable Feed-In Setups
The following diagrams illustrate various cable feed-in setups:
INSTALLATION
FEED-IN SETUPS
The feed-in setup should unreel the
cable with a natural curvature
(Figure 1) as opposed to a reverse
Scurvature (Figure 2).
27
Connectingthe World
Phone : +91 124 432 6000 Fax : +91 124 432 6019
INSTALLATION
FEED-IN SETUPS
Cable Feed-In Setups (continued)
Single Sheaves may be
used only for GUIDING cables.
Arrange multiple blocks to hold
bending radii whenever cable
is deflected.
.
Remember to use the radius of the
surface over which the cable is bent,
not the outside flange diameter of the
pulley. A 10 inchcable sheave typically
has an inside (bending) radius
of 3 inches.
The pulleys must be positioned to ensure that
the effective curvature is smooth and deflected
evenly at each pulley. Never allow a polygon
curvature to occur (Figure 3).
The fit of a pulley around the cable is also
important when pulling heavy weights
(i.e. pulleys at the top of a vertical drop).
For pulling around bends,
use conveyor sheave
assemblies of the
appropriate radius series
28
Connectingthe World
Connectingthe World
Helping to Power the World
ConnectingtheWorld
General Cable Energy India Pvt Ltd
Corporate office: Centrum Plaza, Level 3,
Tower A,312 S, Golf Course Road, Sector- 53,
Gurgaon-122 002, Haryana, India
Phone: (0124) 4326000 Fax: (0124) 4326019
Factory:
Village Bhatouli Khurd, Baddi
Dist. - Solan, Pin - 173205
Himachal Pradesh, India
Energy

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Ext ra Hi gh Vol t age

CONNECTING THE WORLD

The simplest, known as solid bonding, involves bonding both

For shorter circuit lengths, it may be acceptable to bond only at

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