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Training – Introduction
Course Scope It covers all types of power cables, from wiring and flexible cables for general use to distribution, and transmission. It includes information on materials, design principles, installation and standards, and it contains extensive tables of data on commonly used cable types. Voltage – Current - Resistance Ohm’s Law Conductivity Resistivity -: Voltage Any electric equipment is denoted by its operating voltage , cables are denoted as U0/UKV where :_ Uo :- is the rated power frequency voltage between conductor and earth or metallic screen for which cable is designed. U : is the rated power frequency voltage between conductors for which the cable is designed For example : Saying 0.6/1 (1.2) Kv cable means that Uo (Phase voltage) = 0.6 Kv U ( Line voltage) = 1 Kv
Cable is defined by its line voltage as when
saying 15 kv cables we mean 8.7/15 Kv IEC Voltages 45 KV 0.6/1 KV 66 KV 1.8/3 KV 3.6/6 KV 110 KV 6/10 KV 132 KV 8.7/15 KV 150 KV 12/20 KV 220 KV 18/30 KV 275 KV 330 KV 400 KV 500KV Power cables 1- Overhead transmission lines O.H.T.L 2- Under ground power cables High voltage Low voltage Medium voltage Types of overhead conductors 1. ACC ( ALL CU. CONDUCTOR) AAC -2 (ALL AL. CONDUTOR) 3 – AAAC (ALL AL. ALLOY COND.) ASCR (ALL ALLOY STEEL RIENFORCED) – 4 :Comparison between O.H. conductors &U.G. cables )2 O.H. CONDUCTOR U.G. CABLES - Widely in transmission - Widely used in side towns where safety is requires Network & distribution net work in urban areas - Out door application - Both outdoor & Indoor (inside industrially residential & Building, wiring & lighting application) - Considered of less cost -Considered of higher cost compared with O.H conductors compared with underground cables Duration of an outage can be longer . Duration of an outage is less since the failure tends to be more difficult to locate and repair. Cable replacing due to load growth . Conductor replacing is easier with some limits is not easier. Therefore UGC should be applied in areas where sharp load . growth would not be expected - Include processes of - Includes processes of 1) Drawing section 1) Drawing section 6) Armoring section 2) Stranding section 2) Stranding section 7) Separation section 3) Insulation section 8) Lead section 4) Assembly section 9) Sheathing section 5) Bedding section UNDER GROUND CABLES
LOW VOLTAGE CABLES :Voltage Grades of L.V. Cables 300/500 V [Both sheath & non-sheath cable (insulated wires)]
450/750 V [non-sheathed cables (insulated
wires)]
600/1000 V or 0.6/1 kV (Sheathed cables)
Material of Conductors 1) Copper: Soft annealed copper conductor
2) Aluminum: Aluminum conductor (H12)
- Copper has excellent electrical and
mechanical properties but it is more expensive than Aluminum as it is cheaper and lighter . Types & Shapes of Conductors Solid round conductors )1
Flexible conductor )2
Stranded round conductor )3
Compacted round conductor )4
Sector shape conductor )5
:Sizes of Conductors (mm2) 1.5 25 240 2 35 300 2.5 50 400 3 70 500 4 95 630 6 120 800 10 150 1000 16 185 Types of Insulation Poly Vinyl chloride ( PVC ) : Thermo Plastic material Maximum operating temp. is 70 °C Maximum S.C. temp. 160 °C for C.S.A. 300mm2 Maximum S.C. temp. 140 °C for C.S.A. >300mm2
Cross linked polyethylene ( XLPE ):
Thermosetting material Maximum operating temp. is 90 °C Maximum S.C. temp. 250 °C
Ethylene propylene Rubber ( EPR ) :
Thermosetting material Maximum operating temp. is 90 °C Maximum S.C. temp. 250 °C Cores Identification Colors of cores are usually as following: Single core : Natural, Red, etc… 2 cores : Red & Black 3 cores : Red, Yellow & Blue 4 cores : Red, Yellow, Blue & Black 5 cores : Red, Yellow, Blue, Black & Green Grounding wire : Green & Green/Yellow More than 5 : (Black + No. or White + No. ,etc…)
Cores identification can be as per customer
Assembly Process The insulated cores assembly together with suitable lay length (right hand).
Polypropylene filler (if necessary) to fill the
space between cores to make the assembled shape round .
Then wrapped with suitable tape to form a
compact round cable Bedding Process The main function of the Bedding is to give mechanical protection for insulation in case of armored cables only.
Material : Extruded poly vinyl chloride ( PVC ) when there is higher mechanical hazard we use polyethylene ( PE ) Armouring Process
The Armouring is used as mechanical
protection for direct burial cables.
It is used as an earthing conductor in
some Networks . Armouring Process
Material :
The steel is the suitable material for multi-core cables
Steel is applied in one of the following forms :
a) Tapes : Double tapes are applied helically around the bedding of cables with 50 % gap.
b) Wires : Number of wires with the specified
diameter is to cover the bedding surface helically .
In case of single core cables steel is replaced with non
magnetic material like Aluminum to reduce the magnetic losses (eddy current) . Sheath Process It is outer jacket of the cable , its main function is mechanical protection.
Material : Poly Vinyl Chloride (PVC) , When there is higher mechanical hazard we can use Polyethylene (PE) colour: Black or as per customer requirements Special characteristics may be included such as: Anti-Termite resistant Oil resistant Chemical resistant Acids & Alkaline resistant … etc. In case of mechanical hazard we can use polyethylene materials such as High Density Polyethylene [HDPE]
