HT and LT cable manufacturing details

Torrent Cables Ltd
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http://www.torrentcables.com/11kv_ht_xlpe.html
Continuous Current rating
Three Core Dimensional Details
Single Core Dimensional Details

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11 kv Cable
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Aluminium
Copper
Continuous Current Rating for
Single Core Cable
(Single End bonding)
When Laid in
When Laid in
Ground
Air
Continuous Current Rating for Single/Three Core Cables

with Aluminium / Copper Conductor
Nominal
Cross
Sectional
Area of
Conductor
Sq.mm.
35
50
70
95
120
150
Tips:
3.Key Manufacturing Process in HT Cable
Manufacturing.
185
240
XLPE Screenings and Insulation by Extrusion

300
Conductors made through stranding process are

subjected to this operation to form cores. The
process requires three extrusion operations, which
are done simultaneously using three extruders but
a common head.
400

Three Core Cable
When Laid in
Ground
When Laid in
Air
amps
amps
amps
amps
115
125
115
140
145
165
150
180
130
150
140
170
170
195
175
215
160
190
170
210
210
240
215
270
190
230
200
255
250
295
260
325
220
260
230
295
280
335
295
375
245
295
255
335
310
380
320
425
275
335
290
385
350
430
370
495
315
395
330
455
400
500
425
580
355
450
375
520
450
570
475
670
400
520
425
610
500
650
540
760
600
485
720
740
600
900
--
550
830
--
670
1010
--
620
950
--
730
1140
--
670
1070
--
790
1250
455
500
The core consists of three concentric layers of
550
extruded material. The first is a layer of black semi
conducting compound formed over the stranded
-630
compacted conductor using the first extruder. Just
-on top of this a layer of white insulation compound
is extruded to form the second layer and finally
-800
through another extruder a layer of black semi
-conducting compound is extruded over insulation
layer. The semi conducting layer formed over
-conductor is called conductor screen and the one
1000
-over insulation is called insulation screen. The three
layers i.e .conductor screen, insulation and
0
C
Ambient
Air
Temperature:
40
insulation screen are formed through a common
0
Ground temperature : 30 C
head known as triple head.
Depth of Laying
3.3 kv to 11 kv Above 11 kv
900 mm
1050 mm
Thermal Resistivity of Soil : 1500 C cm/w
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Maximum Continuous Conductor temperature : 900 C

Single Core Cable laid in Trefoil
Three Core Cable laid Singly
Maximum Conductor Temperature
after Short Circuit : 2500 C
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22/10/2011 12:13 PM
Torrent Cables Ltd
1 of 1
http://www.torrentcables.com/PVC_power_cables_unarmoured1.html
PVC power cables with aluminium conductors

1.1kv Power Cables(Un Armoured)

Constructional details aluminium

Pvc power cables with aluminum conductors (unarmourded cables)
Minimum
Nominal
conductor nos.of wires in
conductor
area sq.mm.
Sr.no
Main
coreE
1
4 $
6 $
Half
core
-
#
-
#
3
10 $
#
4
16 $
Main
Nominal
thickness of
insulation in
mm
Neutral Main
Minimum thickness
of innersheath in
mm
Nominal thickneness of
outer sheath in mm
Approximate overall
diameter in mm
Approximate weight of
cable in kg/kms.
Nos. of cores
Nos. of cores
Nos. of cores
Nos. of cores
Neutral
2
3.5
3.5
3.5
3.5
0.3
0.3
0.3
1.80
1.80
1.80
14.3
15.0
16.1
232
256
298
0.3
0.3
0.3
1.80
1.80
1.80
14.8
15.6
16.8
250
250
318
0.3
0.3
0.3
1.80
1.80
1.80
15.5
16.3
17.7
280
315
371
0.3
0.3
0.3
1.80
1.80
1.80
16.3
17.2
18.5
305
340
400
0.3
0.3
0.3
1.80
1.80
1.80
16.8
17.8
19.2
307
360
425
0.3
0.3
0.3
1.80
1.80
1.80
18.0
19.0
20.6
335
390
460
0.3
0.3
0.3
1.80
1.80
2.00
20.0
21.2
23.5
415
491
612
0.3
0.3
0.3
2.00
2.00
2.00
24.1
25.5
28.0
592
732
848
25 #
1.2
25 @
16 #
1.2
1.0
0.3
0.3
0.3
0.3
2.00
2.00
2.00
2.00
20.0
23.4
25.4
25.9
461
600
35 @
16 #
1.2
1.0
0.3
0.3
0.3
0.3
2.00
2.00
2.00
2.00
21.5
25.3
27.5
28.2
552
725
825
920
50 @
25 @
1.4
1.2
0.3
0.3
0.3
0.4
2.00
2.00
2.00
2.20
23.9
28.5
31.2
33.0
700
928
1070
1250
70 @
35 @
12
1.4
1.2
0.3
0.4
0.4
0.4
2.00
2.20
2.20
2.20
26.7
32.0
34.8
35.8
871
1230
1415
1570
10
95 @
50 @
15
1.6
1.4
0.4
0.4
0.4
0.4
2.20
2.20
2.20
2.40
30.4
35.7
38.9
40.5
1180
1577
1818
2065
11
120 @
70 @
15
12
1.6
1.4
0.4
0.4
0.5
0.5
2.20
2.20
2.40
2.40
32.4
38.2
42.2
43.2
1384
1860
2262
2485
12
150 @
70 @
15
12
1.8
1.4
0.4
0.5
0.5
0.5
2.40
2.40
2.40
2.60
35.6
42.5
46.2
47.8
1688
2322
2642
3030
13
185 @
95 @
30
15
2.0
1.6
0.5
0.5
0.5
0.6
2.40
2.60
2.60
2.80
39.0
46.7
50.8
53.0
2066
2840
3270
3760
14
240 @ 120 @
30
15
2.2
1.6
0.5
0.6
0.6
0.6
2.60
2.80
3.00
3.00
43.5
52.3
57.2
58.8
2605
3640
4225
4736
15
300 @ 150 @
30
15
2.4
1.8
0.6
0.6
0.6
0.7
2.80
3.00
3.20
3.40
48.0
57.5
62.9
65.0
3222
4430
5135
5902
16
400 @ 185 @
53
30
2.6
2.0
0.7
0.7
0.7
0.7
3.20
3.40
3.40
3.60
54.5
65.0
70.5
73.0
4165
5818
6515
7422
-Extruded Pvc Inner Sheath
-Standard drum length for all sizes : 500mtrs. 5%
# = Stranded Circular Alumimium Conductor
695
760
= Solid Circular Aluminium Conductor
@ =Standard Sector Shaped Aluminum Conductor
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22/10/2011 12:19 PM
Torrent Cables Ltd
2 of 3
http://www.torrentcables.com/control_cables_armoured1.html
Control cables with stranded circular copper conductor
Control cables with solid circular copper conductor

1.1kv Control Cables(Armoured)

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Control cables with stranded circular copper conductor (armoured)
No.of cores
and
conductor
area sq.mm.
C opper
conductor
minimum
no.of wires
Thickness of
insulation
(mm)
2 X 1.5
3 X 1.5
4 X 1.5
Sr.no.
Thickness of innersheath
in mm
Armour size in mm
& type
Minimum
Approximate
Approximate
thickness of
overall diameter weight of cables
outer sheath
(kg./km)
(mm)
(mm)
Extruded
Wrapped
Round
wire
Flat strip
0.8
0.3
1.4
1.24
14.2
420
0.8
0.3
1.4
1.24
14.5
460
0.8
0.3
1.4
1.24
15.5
510
5 X 1.5
0.8
0.3
1.4
1.24
16.5
562
7 X 1.5
0.8
0.3
1.4
1.24
17.1
605
10 X 1.5
0.8
0.3
1.4
1.40
20.9
820
12 X 1.5
0.8
0.3
4 X 0.8
1.24
20.0
700
14 X 1.5
0.8
0.3
4 X 0.8
1.40
21.1
785
16 X 1.5
0.8
0.3
4 X 0.8
1.40
22.0
865
10
19 X 1.5
0.8
0.3
4 X 0.8
1.40
23.1
955
11
24 X 1.5
0.8
0.3
4 X 0.8
1.40
26.3
1175
12
27 X 1.5
0.8
0.3
4 X 0.8
1.40
27.0
1240
13
30 X 1.5
0.8
0.3
4 X 0.8
1.40
27.9
1340
14
37 X 1.5
0.8
0.3
4 X 0.8
1.40
29.7
1545
15
44 X 1.5
0.8
0.3
4 X 0.8
1.56
33.0
1840
16
52 X 1.5
0.8
0.4
4 X 0.8
1.56
35.0
2070
17
61 X 1.5
0.8
0.4
4 X 0.8
1.56
37.0
2340
Thickness of innersheath Armour size in mm

in mm
& type
No.of cores
and conductor
area sq.mm.
Copper
conductor
minimum
no.of wires
Thickness of
insulation
(mm)
2 X 2.5
3 X 2.5
4 X 2.5
Sr.no.
Minimum
Approximate
Approximate
thickness of
overall diameter weight of cables
outer sheath
(kg./km)
(mm)
(mm)
Extruded
Wrapped
Round
wire
Flat strip
0.9
0.3
1.4
1.24
15.5
500
0.9
0.3
1.4
1.24
16.1
550
0.9
0.3
1.4
1.24
17.0
625
5 X 2.5
0.9
0.3
1.4
1.24
18.2
686
7 X 2.5
0.9
0.3
1.4
1.24
19.0
751
10 X 2.5
0.9
0.3
4 X 0.8
1.24
22.3
861
12 X 2.5
0.9
0.3
4 X 0.8
1.40
22.9
935
14 X 2.5
0.9
0.3
4 X 0.8
1.40
24.0
1030
16 X 2.5
0.9
0.3
4 X 0.8
1.40
25.0
1140
10
19 X 2.5
0.9
0.3
4 X 0.8
1.40
26.1
1270
11
24 X 2.5
0.9
0.3
4 X 0.8
1.40
30.1
1566
12
27 X 2.5
0.9
0.3
4 X 0.8
1.40
30.8
1675
13
30 X 2.5
0.9
0.3
4 X 0.8
1.40
32.3
1845
14
37 X 2.5
0.9
0.4
4 X 0.8
1.56
34.6
2170
15
44 X 2.5
0.9
0.4
4 X 0.8
1.56
38.5
2545
16
52 X 2.5
0.9
0.4
4 X 0.8
1.56
40.5
2860
17
61 X 2.5
0.9
0.4
4 X 0.8
1.56
42.5
3240
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22/10/2011 12:18 PM
Torrent Cables Ltd
2 of 2
http://www.torrentcables.com/PVC_common_design_details.html
Standard Operating Parameters
Current Rating
Short Circuit Rating
Rating Factors
PVC Common design details

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Standard Operating
Parameters
Maximum Conductor
Temperature
70 C (85 C for HR Cable)
Thermal resistivity of soil
150 C.cm./w
Thermal resistivity of PVC
650 C.cm./w
Ground temperature
30 C
Ambient air temperature
40 C
Depth of laying in Cms (Cables

75 cm
laid in ground)
Type of installation
Twin, Three & Multicore Cables Laid singly
3 Cores in close trefoil
formation
Single core Cable
Current Rating (ac) for Three Single Core 650/1100 VOLTS

Unarmoured / Non- Magnetic Armoured Cables according to is : 1554
(Part I) 1988
SR.NO.
Tips:
9.Following care should be taken while
laying the Cable Across Roads, Railway
Tracks or Water Pipe Lines :
Steel, Castlron, Plastics, Cement or earthenware
ducts or cable ducting blocks should be used
where cables cross roads and railways tracks.
Spare ducts for future extension should be
provided & sealed at both ends.
Ensure smooth entry of cable without undue
bending.
LAID DIRECT IN
LAID IN DUCT
LAID IN AIR
GROUND
NOMINAL
CROSS
SECTIONAL
AREA
(sq.mm.) C OPPER ALUMINIUM COPPER ALUMINIUM COPPER ALUMINIUM
(Amps)
(Amps)
(Amps)
(Amps)
(Amps)
(Amps)
1.5
22
17
21
17
20
2.5
30
24
29
24
27
15
21
39
31
38
30
35
27
49
39
48
37
44
35
10
65
51
64
51
60
47
16
85
66
83
65
82
64
25
110
86
110
84
110
84
35
130
100
125
100
130
105
50
155
120
150
115
165
130
10
70
190
140
175
135
205
155
11
95
220
175
200
155
245
190
12
120
250
195
220
170
280
220
13
150
280
220
245
190
320
250
14
185
305
240
260
210
370
290
15
240
345
270
285
225
425
335
16
300
375
295
310
245
475
380
The cable entry and exit should be through bell

mouth or padding.
17
400
400
325
335
275
550
435
18
500
425
345
355
295
590
480
The bending radii of steel or plastic ducts should

not be less than 1.5 m.
19
625
470
390
375
320
660
550
20
800
540
440
405
345
765
640
Single core cables should not be laid individually

in ducts, butall3 cables of the same system
should be laid in one duct.
21
1000
600
490
435
370
860
720
The duct/pipe joints should be covered by collars

to prevent settlement in between pipes.
The diameter of the cable conduit or pipe or duct
should be atleast 1.5 times the outer diameter
of cable. The pipe/duct should be mechanically
strong enough to withstand forces due to heavy
traffic when laid across road/railway tracks.
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22/10/2011 12:18 PM
Torrent Cables Ltd
2 of 3
http://www.torrentcables.com/LT_common_design_details.html

Continuous Current Rating
Maximum short circuit rating of conductor for a duration of one second Rating Factor
LT-XLPE Common Design Details

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Maximum conductor temperature for continuous operations ( C)
PVC
70
XLPE
90
Ambient air temperature ( C)
40
40
Ground temperature ( C)
30
30
Thermal resistivity of soil ( C cm/watt)
150
150
Thermal resistivity ( C cm/w)
650
350
Depth of laying
75 cm
75cm
Cables are installed singly

Minimum bending radious ( for Multi core cables) times cable diameter.
Maximum conductor temperature During short circuit ( C)
12
12
160
250
Continuous current rating of 3 or 4 core cables armoured and unarmoured laid direct in
the ground or in air 1100 volts grade with Aluminium conductor.
3, 3.5 or 4 core cables to
IS : 1554 (Pt.1)
(PVC)
When Laid in
Approx.
Size
Voltage
Ground
Air
drop
sq. mm.
amps
amps
v/km/A
Tips:
6.Type of Tests conducted on Finished
Cables
Routine Tests
Routine tests are tests conducted on each and
every finished length of a cable. Routine tests
mean tests conducted on a cable to assess its
suitability during routine service condition.
25
35
50
70
95
120
150
185
240
300
400
76
92
110
135
165
185
210
235
275
305
335
70
86
105
130
155
180
205
240
280
315
375
2.50
1.80
1.30
0.94
0.68
0.55
0.46
0.37
0.30
0.27
0.22
3, 3.5 or 4 core cables to

IS : 7098 (Pt. 1)
(XLPE)
When Laid in
Approx.
Size
Voltage
Ground
Air
sq. mm.
drop
amps
amps
v/km/A
25
35
50
70
95
120
150
185
240
300
400
94
114
133
164
196
223
249
282
327
368
418
96
117
142
179
221
257
292
337
400
455
511
2.68
1.95
1.44
0.99
0.78
0.58
0.47
0.40
0.31
0.26
0.22
Type Tests
Type tests consist of a number of tests
conducted on a piece of cable (not on the entire
drum length) cut from a finished cable drum
length. The purpose of these tests is to confirm
the suitability of a cable against the type, which
has been constructed for a particular application.
The sample taken for type tests represents the
entire lot of cable manufactured of a particular
type.
Acceptance Tests
Acceptance tests also consist of a number of
tests conducted on few pieces of cables drawn
from a manufactured lot. These tests are
conducted during client's witness of test
programme on a manufactured lot in order to
decide about the lotto be shipped for usage or
not.
Special Tests
Special tests are those tests which do not get
covered under routine or type or acceptance
tests. Generally special tests are conducted to
assess a particular property or a set of
properties, which have been built in the cable to
exhibit desired requirement during its operation.
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22/10/2011 12:16 PM
Torrent Cables Ltd
2 of 3
http://www.torrentcables.com/single_two_three_unarmoured_cables.html
Single core
Two core
Three Core
Three & Half Core
Four Core
LT-XLPE UnArmoured Cables

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SINGLE CORE UNARMOURED CABLES - 1100 VOLTS ALUMINIUM CONDUCTOR WITH XLPE INSULATION
Single Core unarmoured Cables
Nominal
Area of
Conductor
Delivery
length with
+/- 5%
tolerance
Standard
Max DC
resistance
at 20C
AC
resistance
at
Operating
Temp
90C
Nominal
Thickness
of
Insulation
Nominal
diameter
of round
Alu. Wire
Approx.
Overall
diameter
of cable
Approx
weight of
finished
cables
sq.mm.
mm.
mm.
mm.
kg/km
meters
ohms/km
ohms/km
25
0.9
1.8
13.0
177
1000
1.2000
1.536
35
0.9
1.8
14.0
209
1000
0.8680
1.111
50
1.0
1.8
15.0
258
1000
0.6410
0.820
70
1.1
1.8
17.0
337
1000
0.4430
0.567
95
1.1
1.8
17.0
401
1000
0.3200
0.410
120
1.2
1.8
21.0
535
1000
0.2530
0.324
150
1.4
2.0
23.0
642
1000
0.2060
0.264
185
1.6
2.0
25.0
774
500
0.1640
0.210
240
1.7
2.0
27.0
968
500
0.1250
0.160
300
1.8
2.0
30.0
1162
500
0.1000
0.128
400
2.0
2.2
33.0
1491
500
0.0778
0.100
Conductor : Stranded Compacted Circular. ( Except 25 sq.mm. Stranded circular)

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TWO / THREE CORE UNARMOURED CABLES - 1100 VOLTS ALUMINIUM CONDUCTOR WITH XLPE INSULATION
Nominal
Area of
Conductor
Two core unarmoured Cable

3 core unarmoured C able
AC
Standard
(Shaped C ond.)
(Shaped Cond.)
resistance
Delivery
Nominal
Max DC
Approx.
Approx
at
length
Thickness Minimum Nominal Approx.
Minimum Nominal Approx.
resistance
Weight
weight
Operating
with
of
Thickness Thickness Overall
Thickness Thickness Overall
at 20C
of
of
Temp
+/- 5 %
Insulation of inner of outer diameter
of inner of outer diameter
finished
finished
90C
tolerance
sheath of cable
sheath
sheath of cable
sheath
cable
cables
sq.mm.
mm.
mm.
mm.
mm.
kg/km
mm.
mm.
mm.
kg/km
25
0.90
0.3
2.0
20.0
295
0.3
2.0
23.0
411
meters ohms/km ohms/km

500
1.2000
1.536
35
0.90
0.3
2.0
22.0
377
0.3
2.0
25.0
525
500
0.8680
1.111
50
1.00
0.3
2.0
24.0
496
0.3
2.0
28.0
686
500
0.6410
0.820
70
1.10
0.3
2.0
27.0
669
0.4
2.2
32.0
983
500
0.4430
0.567
95
1.10
0.4
2.2
30.0
912
0.4
2.2
35.0
1253
500
0.3200
0.410
120
1.20
0.4
2.2
32.0
1167
0.4
2.2
37.0
1587
500
0.2530
0.324
150
1.40
0.4
2.2
36.0
1413
0.5
2.4
42.0
2001
500
0.2060
0.264
185
1.60
0.5
2.4
40.0
1786
0.5
2.6
46.0
2467
500
0.1640
0.210
240
1.70
0.5
2.6
44.0
2252
0.6
2.8
51.0
3163
500
0.1250
0.160
300
1.80
0.6
2.8
48.0
2784
0.6
3.0
56.0
3841
500
0.1000
0.128
400
2.00
0.6
3.0
54.0
3539
0.7
3.2
63.0
4948
500
0.0778
0.100
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Single core
Two core
Three Core
Three & Half Core
Four Core
LT-XLPE Armoured Cables

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SINGLE CORE ARMOURED CABLES - 1100 VOLTS ALUMINUM CONDUCTOR WITH XLPE INSULATION
Hard drawn Aluminium round wire Armoured
Nominal
Area of
Conductor
Standard
Delivery
Max DC
length with
resistance
+/- 5 %
at 20C
tolerance
AC
resistance
at
Operating
Temp 90C
Nominal
Thickness
of
Insulation
Nominal
diameter
of round
Alu. Wire
Minimum
Thickness
of outer
sheat
Approx.
Overall
diameter
of cable
Approx.
Weight of
finished
cable
sq.mm.
mm.
mm
mm.
mm.
kg/km
meters
ohms/km
ohms/km
25
1.2
1.4
1.24
14.5
259
1000
1.2000
1.536
35
1.2
1.4
1.24
15.0
295
1000
0.8680
1.111
50
1.3
1.4
1.24
17.0
354
1000
0.6410
0.820
70
1.4
1.4
1.24
18.0
445
1000
0.4430
0.567
95
1.4
1.6
1.40
19.0
544
1000
0.3200
0.410
120
1.5
1.6
1.40
23.0
694
1000
0.2530
0.324
150
1.7
1.6
1.40
25.0
817
1000
0.2060
0.264
185
1.9
1.6
1.40
26.0
965
500
0.1640
0.210
240
2.0
1.6
1.40
29.0
1188
500
0.1250
0.160
300
2.2
1.6
1.56
32.0
1428
500
0.1000
0.128
400
2.4
2.0
1.56
36.0
1844
500
0.0778
0.100
Conductor : Stranded Compacted Circular. (Except 25 sq. mm. Stranded circular)
TWO CORE ARMOURED CABLES - 1100 VOLTS ALUMINIUM CONDUCTOR WITH XLPE INSULATION
Flat galvenised steel strip Armoured
( shaped cond)
Galvenised round steel wire

Armoured ( shaped cond)
AC
Standard
resistance
Delivery
Nominal Minimum
Max DC
Nominal
at
length
Thickness Thickness
resistance
Area of
Operating
with
of inner Nominal Minimum Approx. Approx Nominal Minimum Approx. Approx.
of
at 20C
Conductor
Weight
diameter
weight
Temp
+/- 5 %
Insulation sheath dimension Thickness Overall
Thickness Overall
of
of round
of
90C
tolerance
of outer diameter
of outer diameter
of flat
finished
g.s.
finished
sheath of cable
of cable
sheat
strip
cable
Wire
cables
sq.mm.
mm.
mm
mm.
mm.
mm.
kg/km
mm.
mm.
mm.
kg/km
25
0.90
0.3
4 x 0.8
1.40
21.0
527
1.6
1.40
22.0
741
meters ohms/km ohms/km

500
1.2000
1.536
35
0.90
0.3
4 x 0.8
1.40
22.0
633
1.6
1.40
24.0
866
500
0.8680
1.111
50
1.00
0.3
4 x 0.8
1.40
25.0
788
1.6
1.40
26.0
1050
500
0.6410
0.820
70
1.10
0.3
4 x 0.8
1.56
28.0
1024
1.6
1.56
29.0
1318
500
0.4430
0.567
95
1.10
0.4
4 x 0.8
1.56
31.0
1285
2.0
1.56
33.0
1822
500
0.3200
0.410
120
1.20
0.4
4 x 0.8
1.56
33.0
1574
2.0
1.56
35.0
2156
500
0.2530
0.324
150
1.40
0.4
4 x 0.8
1.72
37.0
1899
2.0
1.72
39.0
2546
500
0.2060
0.264
185
1.60
0.5
4 x 0.8
1.72
40.0
2295
2.0
1.88
43.0
3047
500
0.1640
0.210
240
1.70
0.5
4 x 0.8
1.88
44.0
2813
2.5
2.04
48.0
4031
500
0.1250
0.160
300
1.80
0.6
4 x 0.8
2.04
49.0
3402
2.5
2.20
52.0
4741
500
0.1000
0.128
400
2.00
0.6
4 x 0.8
2.36
55.0
4281
2.5
2.36
58.0
5738
500
0.0778
0.100
Extruded PVC inner sheath
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Conductor resistance and Short Circuit Carrying Capacity Group Rating Factor for Single and Multi Core Cables
Group Rating Factors for Single/Multicore Cables
Rating Factor for Ambient Air/Ground Temperature variation
HT Common design details

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Conductor Resistance and Short Circuit Current Carrying Capacity

Nominal
Cross
Sectional
Area
Maximum
DC
Resistance
Approx.AC
Resistance
0
at 90 C
at 200 C
Aluminium Conductor
ohms/km
ohms/km
0.8680
1.137
0.6410
0.840
0.4430
0.580
0.3200
0.419
0.2530
0.331
0.2060
0.270
0.1640
0.215
0.1250
0.164
0.1000
0.131
0.0778
0.102
0.0605
0.079
0.0467
0.061
0.0367
0.048
0.0292
0.038
sq.mm
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Maximum
DC
Resistance
Approx.AC
Resistance
Short Circuit Current

for Conductor
at 90 C
at 200 C
Copper Conductor
ohms/km
ohms/km
0.5240
0.6864
0.3870
0.5070
0.2680
0.3511
0.1930
0.2528
0.1530
0.2004
0.1240
0.1624
0.0991
0.1298
0.0754
0.0988
0.0601
0.0787
0.0470
0.0616
0.0366
0.0479
0.0283
0.0371
0.0210
0.0280
0.0176
0.0231
Aluminium
ka/sec
3.29
4.70
6.58
8.93
11.28
14.10
17.39
22.56
28.20
37.60
47.00
59.22
75.20
94.00
Copper
ka/sec
5.01
7.15
10.01
13.58
17.16
21.45
26.46
34.32
42.90
57.20
71.50
90.09
114.40
143.00
Group Rating Factor for Single and Multi Core Cables

Single Core
Multi Core
Number of Cables
in Group
2
3
4
5
6
Spacing between Cables in mm

Touching
0.76
0.79
0.64
0.67
0.58
0.61
0.53
0.56
0.50
0.53
SINGLE CORE:
150
0.81
0.82
0.72
0.73
0.65
0.68
0.61
0.63
0.56
0.60
200
0.83
0.86
0.72
0.77
0.67
0.72
0.63
0.68
0.60
0.65
300
0.85
0.87
0.77
0.78
0.72
0.74
0.68
0.70
0.66
0.68
400
0.87
0.88
0.79
0.80
0.75
0.79
0.71
0.76
0.69
0.74
450
0.88
0.89
0.81
0.82
0.76
0.80
0.73
0.77
0.72
0.76
600
0.90
0.92
0.83
0.86
0.80
0.83
0.77
0.81
0.76
0.80
800
0.92
0.94
0.86
0.89
0.84
0.87
0.81
0.85
0.80
0.84
MULTI CORE:
A. Group Rating factors for Circuit of three Single core cables in Trefoils laid B. Group Rating factors for cables laid in Horizontal formation.
direct in Ground in Horizontal formation.
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Continuous Current rating
Three Core Dimensional Details
Single Core Dimensional Details

33 kv Cable
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Aluminium
Copper
Single Core Cable
(Single End bonding)
When Laid in
When Laid in
Ground
Air
Continuous Current Rating for Single/Three Core Cables

with Aluminium / Copper Conductor
Nominal
Cross
Sectional
Area of
Conductor
Sq.mm.
35
50
70
95
120
150
Tips:
5.Key Manufacturing Process in HT Cable
Manufacturing.
185
240
Wet (Steam/Hot Water) Cure Process

The chemistry of
C-Si-O-Si-C linkage.
cross
linking
leads
300
to
400
The cores are cooled in water, post extrusion.

The cross linking
environment.
takes
place
in
wet
500
Curing is done by batch process.

630
Because of batch process, there is a limitation to

drum length of cable.
800
The plant and machinery are not very expensive.

Losses are less in case of equipment
/process malfunctioning.
This does not require very large factory space.
1000

Three Core Cable
When Laid in
Ground
When Laid in
Air
amps
amps
amps
amps
110
130
115
140
145
165
150
185
130
155
135
170
170
200
175
225
160
190
165
215
205
245
215
275
190
230
195
255
245
300
250
340
215
265
225
295
275
340
290
390
240
300
250
330
305
385
325
440
270
340
280
380
345
435
365
500
310
400
325
450
395
510
420
590
350
455
370
520
440
580
470
680
395
530
420
610
495
660
530
780
445
610
480
710
550
750
590
900
--
--
550
820
--
--
660
1020
--
--
610
950
--
--
730
1140
--
--
680
1080
--
--
790
1240
Ambient Air Temperature: 400 C
Ground temperature : 300 C

The process requires an associated curing
Thermal
Resistivity of Soil : 1500 C cm/w
arrangement in the form of steam y chamber or
water tank etc.
Maximum Continuous Conductor temperature : 900 C
Single Core Cable laid in Trefoil
Curing is restricted to insulation only, semi Three Core Cable laid Singly
conducting layers are of y thermoplastic Maximum Conductor Temperature
compound based.
after Short Circuit : 2500 C
Depth of Laying
3.3 kv to 11 kv Above 11 kv
900 mm
1050 mm
Because of batch curing, extremely difficult to

crossing cores.beyond 33 kV. Chances of
non-uniform cross linking cannot be ruled out.
Maintenance expenses are comparatively lower.
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PVC power cables with aluminium sector shaped conductors
PVC power cables with aluminium conductors

1.1kv Power Cables(Armoured)

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Constructional details aluminium

Pvc power cables with aluminum sector shaped conductors (armourded cables)
Sr.no.
Nominal
conductor
area
sq.mm.
Minimum
nos. of
wires in
conductor
Minimum
Nominal
Nominal
Minimum thicknass of
thickness of thickness of
diameter/dimension of
outer sheath in mm
insulation in innersheath
G.I.armouring in mm
in mm
mm
Nos.of cores
Main Half
Main NeutralL Main Neutral
core core
2 3 3.5 4
1
25
16
1.2
Number.of cores
2
3.5
Number.of cores
2
4.0 x 4.0 x 4.0 x 4.0 x

1.40
0.8
0.8
0.8
0.8
1.0
0.3 0.3 0.3 0.3
1.0
4.0 x 4.0 x 4.0 x 4.0 x

1.40
0.3 0.3 0.3 0.3
0.8
0.8
0.8
0.8
1.2
4.0 x 4.0 x 4.0 x 4.0 x

1.40
0.3 0.3 0.3 0.4
0.8
0.8
0.8
0.8
1.2
4.0 x 4.0 x 4.0 x 4.0 x

1.56
0.3 0.4 0.4 0.4
0.8
0.8
0.8
0.8
Approximate overall
diameter in mm
Approximate weight
cable in kg/kms.
Number.of cores
Number.of cores
3.5
3.5
3.5
1.40
1.40
1.40
20.4
23.8
25.8
27.0
675
855
975
10
(1.6) (1.6) (1.6) (1.6) (1.40) (1.40) (1.40) (1.40) (21.8) (25.3) (27.2) (28.0) (901) (1125) (1265) (13
2
35
16
1.2
1.40
1.40
1.40
22.0
25.6
27.9
29.1
785
1005
1130
12
(1.6) (1.6) (1.6) (1.6) (1.40) (1.40) (1.40) (1.56) (23.2) (27.3) (29.2) (30.7) (1030) (1295) (1445) (16
3
50
25
1.4
1.56
1.56
1.56
24.5
29.3
31.8
33.5
970
1275
1450
16
(1.6) (1.6) (1.6) (2.0) (1.56) (1.56) (1.56) (1.56) (26.0) (30.9) (33.2) (35.2) (1275) (1605) (1805) (22
4
70
35
12
1.4
1.56
1.56
1.56
27.0
32.3
35.0
36.5
1195
1570
1780
19
(1.6) (2.0) (2.0) (2.0) (1.56) (1.56) (1.56) (1.56) (28.3) (34.6) (37.4) (38.0) (1500) (2165) (2430) (26
4 0 x 4 0 x 4 0 x 4 0 x
-Wrapped thermoplastic tape inner sheath
-Standard drum length for all sizes : 500 mtrs. 5 %
-Values written in bracket are for g.i. wire armoured cables
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HT and LT cable manufacturing details

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Torrent Cables Ltd

Continuous Current rating

Three Core Dimensional Details

Single Core Dimensional Details

Continuous Current Rating for Single/Three Core Cables

XLPE Screenings and Insulation by Extrusion

Conductors made through stranding process are

Continuous Current Rating for

Thermal Resistivity of Soil : 1500 C cm/w

Maximum Continuous Conductor temperature : 900 C

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PVC power cables with aluminium conductors

1.1kv Power Cables(Un Armoured)

Constructional details aluminium

-Extruded Pvc Inner Sheath

-Standard drum length for all sizes : 500mtrs. 5%

# = Stranded Circular Alumimium Conductor

= Solid Circular Aluminium Conductor

@ =Standard Sector Shaped Aluminum Conductor

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Control cables with stranded circular copper conductor

Control cables with solid circular copper conductor

1.1kv Control Cables(Armoured)

Control cables with stranded circular copper conductor (armoured)

Thickness of innersheath Armour size in mm

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Standard Operating Parameters

Short Circuit Rating

PVC Common design details

70 C (85 C for HR Cable)

Thermal resistivity of soil

Thermal resistivity of PVC

Ambient air temperature

Depth of laying in Cms (Cables

Single core Cable

Current Rating (ac) for Three Single Core 650/1100 VOLTS

The cable entry and exit should be through bell

The bending radii of steel or plastic ducts should

Single core cables should not be laid individually

The duct/pipe joints should be covered by collars

Torrent Cables Ltd

Standard Operating Parameters

LT-XLPE Common Design Details

Standard Operating Parameters

Ambient air temperature ( C)

Thermal resistivity of soil ( C cm/watt)

Thermal resistivity ( C cm/w)

Cables are installed singly

3, 3.5 or 4 core cables to

Torrent Cables Ltd

Three & Half Core

LT-XLPE UnArmoured Cables

Conductor : Stranded Compacted Circular. ( Except 25 sq.mm. Stranded circular)

Two core unarmoured Cable

meters ohms/km ohms/km

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