LT/HT Power &
Control Cables
Catalogue 2013
HT Power Cables upto 66kV
1.1 kV Power Cables
1.1 kV Copper Control Cables
Index
Manufacturing Process
Introduction
Manufacturing Process
Manufacturing of Cables
Advantages
Cable ranges at a glance
5
6
7
8-9
LT Power & Control Cable
1.1 kV Single Core, PVC Insulated, Un-armoured Cables
1.1 kV Two Core, PVC Insulated, Un-armoured Cables
1.1 kV Three Core, PVC Insulated, Un-armoured Cables
1.1 kV Three & Half Core, PVC Insulated, Un-armoured Cables
1.1 kV Four Core, PVC Insulated, Un-armoured Cables
12
13
14
15
16
1.1 kV Single Core, PVC Insulated, Armoured Cables
1.1 kV Two Core, PVC Insulated, Armoured Cables
1.1 kV Three Core, PVC Insulated, Armoured Cables
1.1 kV Three & Half Core, PVC Insulated, Armoured Cables
1.1 kV Four Core, PVC Insulated, Armoured Cables
17
18
19
20
21
1.1 kV 1.5 sq. mm Copper Cond. PVC Insulated, Un-armoured / Armoured Cables
1.1 kV 2.5 sq. mm Copper Cond. PVC Insulated, Un-armoured / Armoured Cables
22
23
1.1 kV Single Core, XLPE Insulated, Un-armoured Cables
1.1 kV Two Core, XLPE Insulated, Un-armoured Cables
1.1 kV Three Core, XLPE Insulated, Un-armoured Cables
1.1 kV Three & Half Core, XLPE Insulated, Un-armoured Cables
1.1 kV Four Core, XLPE Insulated, Un-armoured Cables
24
25
26
27
28
1.1 kV Single Core, XLPE Insulated, Armoured Cables
1.1 kV Two Core, XLPE Insulated, Armoured Cables
1.1 kV Three Core, XLPE Insulated,Armoured Cables
1.1 kV Three & Half Core, XLPE Insulated,Armoured Cables
1.1 kV Four Core, XLPE Insulated, Armoured Cables
29
30
31
32
33
1.1 kV 1.5 sq mm Copper Cond. XLPE Insulated, Un-armoured / Armoured Cables
1.1 kV 2.5 sq mm Copper Cond. XLPE Insulated, Un-armoured / Armoured Cables
34
35
HT Power Cable
3.3 kV Single Core, XLPE Insulated, Armoured Cables - Non Screened
3.3 kV Three Core, XLPE Insulated, Armoured Cables - Non Screened
38
39
3.3 kV Single Core, XLPE Insulated, Armoured Cables - Screened
3.3 kV Three Core, XLPE Insulated, Armoured Cables - Screened
40
41
3.8/6.6 kV Single Core, XLPE Insulated, Armoured Cables
3.8/6.6 kV Three Core, XLPE Insulated, Armoured Cables
42
43
6.6/6.6 kV& 6.35/11Kv Single Core, XLPE Insulated, Armoured Cables
6.6/6.6 kV& 6.35/11Kv Three Core, XLPE Insulated, Armoured Cables
44
45
11/11kV Single Core, XLPE Insulated, Armoured Cables
11/11kV Three Core, XLPE Insulated, Armoured Cables
46
47
12.7/22 kV Single Core, XLPE Insulated, Armoured Cables
12.7/22 kV Three Core, XLPE Insulated, Armoured Cables
48
49
19/33 kV Single Core, XLPE Insulated, Armoured Cables
19/33 kV Three Core, XLPE Insulated, Armoured Cables
50
51
Basic assumption for current ratings & rating factors
Selection criteria of M/VHV cable size for primary distribution
Standard Drum lengths of Cables
Quality Control & Test
Selection Guide
Handling & Storage
52-53
54
55
56
57
58
Details for BIS Licences
For PVC Cables
For XLPE Cables
For 66kV Cables
IS:1554 (Part-1), 1988
CM/L No.: 81579 82
IS:7098 (Part-1), 1988
CM/L No.: 81896 92
IS:7098 (Part- 3)
CM/L No : 3098967
IS:1554 (Part-2), 1988
CM/L No.: 82594 85
IS:7098 (Part-2), 1985
CM/L No.: 83683 89
Manufacturing of Cables
Advantage
Cables with Aluminium and Copper conductor and polymer insulation are manufactured at Havells India Ltd. (Cable Works) Alwar.
Essentially cables comprise of conductors, insulation, inner-sheath, armour and outersheath. The brief description of the process is
mentioned as under:
In Havells Cable-polymers used for inner sheath are softer than
insulation or outer sheath & are compatible with temperature
ratings of cables & do not have deleteriocus effect on any other
component of cable.
CONDUCTOR
Havells Cables are available with both aluminum and copper
conductors. It is manufactured with solid/Stranded Circular/
Shaped Aluminium / Copper Conductor. Stranding makes Cables
exible and easy to handle while shaping makes them compact.
Compaction is provided to all stranded conductor constructions
as under:
1. Circular Conductor With one wire in the centre conductor
contains 6, 12, 18, 24, 30... wire layers in either unilay or
opposite helical directions. The conductor is sized upto 92%
compaction.
2. Shaped Conductors In all multicore cables from 16 Sq.
mm size, conductors are shaped. Compaction degree in
multicore power cables is upto 92%.
Thus improving electrical treeing characteristics and mechanical
strength of insulation.
Havells cables are friendly during continuous, emergency and
short circuit conditions.
Though there is no change in basic design of Havells cables yet
the latest manufacturing process gives improved reliability and
compactness to cables. The relative thermal expansion during
short circuit between dielectric and conductor is therefore limited
to minimum both in PVC & XLPE, thus limiting displacement of
cores in cables during short circuit.
Insulation for Havells Cables are strictly manufactured and applied
over conductor in accordance with National and International
specications:
National Specication
IS:5831/IS:7098
3. Segmental Conductor As a special case Havells cables of
1600 sq. mm are made up of segmental conductors.
International Specications
BS:6746/BS:5467/IEC:60502
The conductor is manufactured in equal segments and compacted,
then laid together. This reduces A.C. losses in the large sized
conductor, which are due to skin and proximity effects.
XLPE Cables with rated voltage over 3300V shall be provided with
conductor and insulation screening as follows:
Havells has special construction of conductor to suggest to its
customer for meeting their specic need.
Havells copper conductor cables are of the same construction that
of cables with Aluminium conductor except for high tensile strength,
superior conductivity, better exibility and ease of jointing, copper
cables are used in control, instrumentation, winding, submarine,
mining and ship wiring etc. etc applications.
SCREENING
Conductor
Screen
Semiconducting compound as per is:7098 part 2.
Insulation
Insulation screening shall consist of non-metalic
Screen
Part in combination with metalic part. Non metalic
part shall consist of either semi conducting
compound tape applied hellically or extruded layer
of semi conducting compound, applied directly
over insulation. Over this, metalic part (copper tape)
shall be applied hellically with overlap as per IS:7098
part 2.
All conductors for Havells cables are manufactured strictly in
accordance with National and International specications.
National specications
IS:8130
International specication
IEC:60228 / BS:6360
DIELECTRIC INSULATION
Insulation for Havells cables is strictly as per National and
International specications.
Havells cables are designed and manufactured with polymer
dielectrics to bear thermal and thermomechanical stresses safely
at continuous normal and short circuit temperature conditions.
Havells cables are available with both thermoplastic & thermo
setting insulations.
- PVC Cables
Thermoplastic dielectric
- XLPE Cables
Thermo setting dielectric
Havells PVC cables use PVC compounds that take care of over
load and short circuit current with both coarse & ne protection
systems.
Havells XLPE cables use XLPE compound with anti oxidant
stabilizers and traces of aromatic polynuclear hydrocarbon.
Conductor shall be screened with extruded
To avoid the cavities and voids formation in dielectric particularly
on bending operation of cable, perfect bonding of insulation and
screening is required. To ensure this Havells applying conductor
screen, insulation and insulation screen (non-metalic part) in one
operation through tripple extrusion.
LAYING UP
Cores are tested on line during production both for physical and
electrical characteristics. Control is observed within tight tolerance
limits for dimensions in case pf PVC/XLPE insulation. For multicore
cables cores are laid up on our latest laying up machine equipped
with sector correction equipment. In case of XLPE insulated cores
the same are cured so as to impart the requisite characteristics
both electrical and mechanical and then are laid up.
INNERSHEATH
Laid up cables are provided with inner sheath with high quality
of PVC which acts as bedding for steel wire / strip armouring.
Wherever required, ller cords are provided to maintain the
circularity to laid up cables.
Inner sheath is applied either with extrusion or by wrapping. In
Havells Cables though the inner sheath is closely applied on the
laid up cores, same can be stripped with ease without damaging
insulation.
The inner sheath dimensions are maintained strictly in accordance
with laid down specication .
Specication
For PVC Cables
IS:1554 (Part-I & II)
For XLPE Cables
IS:7098 (Part-I & II)
FINAL TESTING
Each Havells Cable is tested for all applicable Routine Tests.
From a lot of Cable one cable of each type is tested for Type tests,
as per relevant specications.
Havells conduct its testing at Havells India Ltd. cable plant at Alwar
for acceptance test as per specication.
Testing of Havells Cables are carried out as per Havells Work
Standards for testing, besides applicable standards.
ADVANTAGES OF PVC CABLES
1. A non-hygroscopic insulation almost unaffected by moisture.
2. Non-migration of compound permitting vertical installation.
3. Complete protection against most forms of electrolytic and
chemical corrosion.
ARMOURING
Mechanical protection to the cable is provided with armouring.
Havells single core cables are armoured with Aluminium or
Aluminium alloy wire/strips, thus avoiding magnetic hysteresis
losses on A. C. System.
4. A tough and resilient sheath with excellent re - resisting
qualities.
5. Good ageing characterstics.
6. Not affected by vibration.
Multicore cables are provided with galvanised steel wire/strips.
Havells cables are provided with galvanised wire armouring, where
cables are to run vertically and are subjected to stresses.
ADVANTAGES OF XLPE CABLES
Havells Mining cables are armoured with steel wire and tinned
copper wires, so as to provide conductivity of armour more than
75% of main conductor of cable.
2. Higher Short Circuit Rating.
Havells cables armour wires/strips are of low resistivity material
and meet the requirements of IS:3975.
Havells armoured cables are with almost 95% armour coverage.
OUTER SHEATH
All Havells Cables are provided with PVC/polymer outer sheath.
Havells Cables are manufactured with various characteristics of
sheathing compounds.
General purpose sheathing Compound
ST1
1. Higher Current Rating.
3. Longer Service Life.
4. For a short time it can withstand maximum 130oC and is
favourable to endure short circuit stresses.
5. It is less sensitive to the setting of the network protection.
6. Because of the thermosetting process taking place due the
effect of cross linking, the crack resistance is increased.
7. Due to the chemical cross-linking internal stresses are
reduced. Consequently the material is less sensitive during
manufacturing process to the setting of the cooling gradient.
Heat resistant Compound for sheath (H.R.) ST2
8. The thermal resistivity of cross-linked material is favourably low,
compared to thermoplastic material.
Fire Retardant Low
IEC 754 Part I
9. The low dielectric loss is a signicant advantage.
Smoke Compound
IEC 60332 Part I& III
(FRLS)
IEEE-383
10. The excellent mechanical features of the insulation improves
the protection against external effects.
ASTM-2843
ASTM-2863
Flame Retartant Compound (FR)
to EIL Specn.
Ultra Voilet Radiations Resistance Compound to ASTM G-53.
Anti Rodent and Anti Termite Compound.
PVC compounds used for Havells Cables are of various grades to
meet specications IS: 5831.
In order to be identied, Havells Cables have their name embossed/
printed/indented on outersheath at regular intervals on the outer
sheath of Havells Cables, Voltage Grade, cable size, trade name &
year of manufacture are embossed, as desired.
Cables are sequentially marked for length at every metre throughout
its length.
11. The resistance of the XLPE to acids, alkalies is outstanding and
is often compensating the adverse environmental inuences.
Cable range at a glance
Application
Cables for Power
Supply to
Residential,
Commercial &
Industrial units
Type & Size
PVC/XLPE Power cables for 1.1
& 3.3 kv for Electrical Substations
as per IS:1554 - I & 2
Sizes:
Single Core 10-1000 sq. mm
Multicore 6-630 sq. mm
Cable range at a glance
Options
Conductor - Stranded / Solid, Circular /
Shaped Aluminium / Copper
Insulation - PVC / HR PVC
Inner Sheath - PVC / HR PVC / FRLS / PVC
Unarmoured / Armoured - G.S. Round Wire/
Flat Strip or Aluminum Wire / Flat Strip
Outer Sheath - PVC/ HR PVC/ FRLS PVC
Heavy Duty
XLPE
Power cables for
Power
Generation
Distribution
XLPE Power cables
upto 19/33 kv grade 33 kv (E)
as per IS:7098 - I & II
Sizes :
Single Core : 25 - 1000 sq. mm
Multicore : 25 - 400 sq. mm
Conductor - Circular/Shaped - Aluminum/Copper
Insulation - XLPE
Innersheath - PVC / HR PVC / FRLS
Unarmoured / Armoured - G.S Round Wire /
Flat Strip or Aluminum Wire / Flat Strip
Outersheath - PVC / HR PVC / FRLS
Heavy Duty
copper
cables for Coal
Mines
Stranded bright annnealed
electrolytic copper conductor, PVC/
XLPE insulated / PVC sheathed
upto and including 3.3 kv as per
IS: 1554 - I&II / IS: 7098 - I & II
Sizes :
Multicore 25 to 400 sq. mm
Conductor - Circular / Shaped
Insulaton - PVC / XLPE
Innersheath- PVC / HR PVC / FRLS
Unarmoured/Armoured- Round Wire/Flat Strip
with conductivity not less than 75% of the phase
Conductor
Outer Sheath - PVC/ HR PVC / FRLS
PE/XLPE insulated 1.1 kv to 33 kv
as per IS:14255 & IS:7098-II
Conductor - Stranded Circular compacted
Aluminium
Insulation - PE/XLPE
Messenger conductor - All Aluminium Alloy-Bare/
Insulated
Street Light Cond. - Stranded Circular
Compacted Aluminium, Bare/Insulated
Arial Bunched /
Bundled required
for over head
power
distribution
Fire Survival
Cables for re
hazardous/ prone
areas
Copper Control
Cables for Power
Switch yard
Control /
Relay Equipment
Railway ignaling
Cables
Telecom / Switch
board cables for
Indoor
Telephones
Coaxial cables
for
Telcom /
Microwave /
CATV / MATV
industry
Annealed electrolytic copper
conductor, heat barrier, XLPE, LSZH
inner sheath G.S. wier and LSZH
outer sheath as per IS 7098-I/ BS
7846 testing as per IEC 331 &
BS 6387
Conductor - Solid/Stranded, Plain /Tinned
Heat Barrier - Mica Tape
Insulation - XLPE
Innersheath - Zero Halogen
Armoured - G.S. Round Wire/ Flat Strip
Outersheath - Zero Halogen
Annealed electrolytic copper
conductor, PVC/XLPE insulated,
PVC sheathed 650/ 1100V
grade as per IS: 1554-I & IS: 7098-I
Sizes :
1.5 / 2.5 sq. mm upto 61 core
4 & 6 Sq. mm upto 4 core
Conductor - Solid/Stranded, Plain /Tinned
Insulation - PVC/HR PVC/XLPE
Innersheath - PVC/HR PVC/FRLS/Zero Halogen
Unarmoured / Armoured - G.S. Round Wire /
Flat Strip
Outersheath - PVC/HR PVC/FRLS/Zero Halogen
Additional Option : Overall shielding with
Aluminum mylar tape with 100% coverage & 25%
overlap on laid up cores for static noise rejection.
Annealed Bare Copper conductor,
PVC insulated cores laid up PVC
sheath as per IRS-S-63/89 RDSO
& related specications
Sizes :
1.5 & 2.5 sq. mm upto 61 core
4 & 6 sq. mm upto 4 core
Screened/Unscreened - Aluminum mylar tape
Unarmoured/Armoured - G.S. Round Wire /
Flat Strip/Galvanised Tape
Additional Option :
Insulation/Inner/Outer Sheath - PVC
Inner/Outer sheath - PVC
Annealed Copper conductor,
PVC Insulated as per DOT TEC
Spec No: G/WIR-06/02
Sizes :
0.4 / 0.5 / 0.6 / 0.7 / 0.9 mm
Conductor - Tinned / Plain
Insulation - PVC / HR PVC / Nylon
Innersheath - PVC/ HR PVC/ FRLS Zero Halogen
Unarmoured / Armoured - G.S. round wire /
Flat Strip
Outer sheath - PVC/HR PVC/FRLS
AdditIonal Option - Individual / Overall pair/
Shielding / Screening
Available in specied RG
& UR Series as per MIL-C-17 /
BS: 2316 / IS: 5608 / IS: 11967
Sizes : Suitable for Impedance
of 50 / 75 / 100 / 125 ohms
Conductor - Plain / Tinned / Copper Clad Steel /
Silver Plated
Insulation - Solid / Foam / Semi air spaced
Screen - Single / Double braid
Sheath - PVC / HR PVC / FRLS / P.E
Cross Sectional View
Outer-Sheath
Armouring
Application
Type & Size
Options
Stranded Plain copper, PVC
insulated & PVC sheathed of
1.1kV grade as per IS: 694
Sizes : 3 core - 1.5 to 50 sq. mm
Insulation - PVC / HR PVC
Sheathing - PVC / HR PVC
Trinned cooper XLPO insulated &
LSZH sheathed 1100 Vac/ 1800
Vdc as per TUV specications
2PFG - 1169/08-2007
Conductor - Flexible trinned copper
Insulation - Cross linked polyolen compound
Sheath - XLPO/ LSZH compound
PVC Sheathed 225/650/
1100 V grade cables as per
BS: 5308 / DIN VDE 0815 &
816 / IS: 1554 / IEC: 189
Sizes:
0.5/0.75/1.0/1.5 sq. mm
Conductor - Standed / Solid, plain / tinned
Insulation - PVC / HR PVC / P.E / Zero Halogen
Shielding - Individual Pair / over all pairs
Drain wire - Solid Stranded
Innersheath - PVC / HR PVC
Zero Halogen
Unarmoured/Armoured-G.S. Round Wire, Flat
Strip Outersheath - PVC / HR PVC/ FRLS /
Zero Halogen
Flexible & Cord
Cables for
appliances,
Machine Tools &
Equipment Wiring
Multistrand, exible, bright
annealed electrolytic copper
conductor, PVC insulated and
sheathed upto 1100V as per IS:694
Sizes : Single, Two, Three or
Four core upto 25 sq. mm
Insulation - PVC / HR PVC / FRLS /
Zero Halogen
Unsheathed /Sheathed - PVC / HR PVC /
FRLS / Zero Halogen
Wiring Cables for
electrical industry
Multistrand Flexible, upto 1100V
grade PVC Cables as per IS: 694
Sizes :
Single core 1.0 - 630 sq. mm
Conductor - Bright Annealed Copper
Insulation - PVC/ HR PVC/ FRLS PVC /
Zero Halogen
Energy Cables
for Power Supply
to Telephone
Exchanges /
UPS /
Battery Backup /
Equipments
PVC Flexible Cables upto 1.1kv
grade as per IS:694
Sizes :
1.0 upto 240 sq. mm
Single / Multi Core
Conductor - Stranded / Solid bright
annealed Copper
Insulation - PVC / HR PVC / FRLS /
Zero Halogen
Air Field Lighting
Cables
Stranded plain annealed copper,
PVC insulated & PVC
sheathed of 5 kV grade
Sizes :
Single core 6 /16 sq.mm
and 2 x 6, 16 & 25
Insulation - PVC / XLPE
Flat cables for
Submersible
Pumps & Motors
Inner-Sheath
Cross Sectional View
Insulation
Conductor
Sheath
Insulation
Aluminium /
Copper Conductor
Solar cable for
Solar plant
PVC Outer-Sheath
Armouring
PVC Inner-Sheath
Filler
Stranded Conductor
Conductor Screening
XLPE Insulation
Insulation Screening
Metallic Screening
Instrumentation
Signal Cables for
Process control &
Instrumentation
Outer-sheath
Armour (outer layer)
Seprator (PVC tape)
Armour (inner layer)
Inner-Sheath
Conductor - Flexible trinned copper
Insulation - XLPO linked poly compound
Sheath - XLPO/ LSZH compound
Drain Wire
Outer Sheath
Armour
Inner Sheath
Drain Wire
Individual Pair Shield
Conductor
Insulation
Insulation
Conductor
Outer Sheath
Cu Tape Screening
Insulation Screening
Conductor
Insulation
Filler
Sheath
XLPE Insulation
Conductor Screening
Conductor
AAA
Messenger
Conductor
Insulation
Conductor
Conductor
Glass Mica Tape
Insulation
Inner Sheath
Armour
Outer Sheath
Outer Sheath
Armour
Inner Sheath
Conductor
Insulation
Color Skin
Natural PVC
Multistrand Flexible
Copper Conductor
Insulation
Conductor
Sheath
Outer Sheath
Armour
Inner Sheath
Conductor
Insulation
Outer Sheath
Armour
Inner Sheath
Conductor
Insulation
P.E. Insulation
Sheath
Braid
Inside View - Cable Factory
LT POWER &
CONTROL CABLE
LT POWER & CONTROL CABLE
FEATURES
XLPE INSULATED CABLE
s (IGHER CURRENT RATING