Cables selection

Cables selection

Power cables
Introduction
Overhead distribution or transmission becomes difficult in densely populated areas like cities and towns. In such areas it is necessary to use cables laid below the ground surface, these are known as underground cables. All cables are fundamentally similar in that they contain conductors for carrying current, insulation for surrounding the conductor, and some form of covering to provide mechanical and possible corrosion protection to ensure that the insulator may continue to operate is satisfactorily throughout the life of the cable once the cable has been installed. The primary function of cable is to carry energy reliably between source and utilization and source equipment. In carrying this energy, there are heat losses generate in the cable that must be dissipated. The ability to dissipate these losses depends on how the cables are insulated, and this affects their ratings. The selection of conductor size requires consideration of the load current to be carried and the load cycle, emergency overloading requirements and duration, fault clearing time and interrupting capacity of the cable over current protection or source capacity, voltage drop, and ambient temperatures for particular installation conditions. Cable may be installed in raceway, in cable trays, underground in duct or direct buried, in cable bus, or as open runs of cable. In general, Cables are classified according to their uses into the following categories 1! "ower Cables o #ingle core o $ouble cores %often &ine '(eutral). o Triple cores %often *!phase). o +our cores %often *!phase '(eutral). o +ive cores %often *!phase, (eutral ',round). 2! Control ' measurement cables %multi!core with the same color). 3! Telephone cables %in pairs). Electrical power could be transmitted via two methods -verhead lines. .nderground cables. ' we can compare them as a following eature Cost !aintenance Use "ated voltage Overhead line &ower. 2asy. .sed in open country for long distance. .p to highest voltage. Underground cable /igher. $ifficult. .sed in congested industrial areas ' urban areas. .p to ** k0 1&"2 up to 345 k0.

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Cables selection

#hen we use underground cables$ #henever possible, overhead line is preferred. .nderground cable where overhead line can not be used i.e. we use underground cable for the following 8andatory, used inside cities. +or crossing 9ivers '9oads. 9ecommended in architecture designs. .sed for short distances. It is safe from the above ground weather ' traffic problems, so it gives fewer interruptions than the overhead line.

Construction of power cable Conductor

%he main function of the conductor is to carry the transmitted electrical power. %he factors affect choice of the conducting material& o 9eceptivity. o #pecific weight. o Thermal properties. o 8echanical properties. o Chemical properties. o -:idation. o Corrosion. o #oldering problems. o Cost ' Availability. It is a thin layer of carbon black paper. The main function of it is to provide regulation of internal electrical ' magnetic fields.

Internal semiconductor la'er Insulator

E-ternal semiconductor la'er

%he main function of it is to provide insulation for the cable. It is classified into three main categories& o (atural t'pe #uch as +abrics ; 9ubber ; <ood ; "apers. o )'nthetic materials *Pol'mers+ #uch as ! "olyethylene %"2) ! Cross linked "olyethylene %1&"2) ! "olyvinylchloride %"0C) ! "olytetraflouoroethylene %"T+2) ! "olymethlemethacrelate %"88) !"olypropylene %"") !"olyamide !2thylene "olypropylene 9ubber o Oil,Impregnated Paper %he main function of it is to provide regulation of e:ternal electrical ' magnetic fields.

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Cables selection

!etallic sheath
!aterials used for cable sheathing are lead layer, aluminum layer or copper wire. %he main function of it is to provide& o ,ood method of cable earthing. o ,ood path to the fault current.

.edding * illing+
It consists of plastics materials which provide& o 9ound cross!section!area of cables to take largest volume in least space area. o #eparate the metallic sheath from the armored layer to prevent galvanic corrosion. It is a protective non,corrosion la'er which provides& o Carrying earth fault current. o ,ives some protection against mechanical damage both during installation ' in service.

/rmored

E-ternal 0ac1et
It is a protective >acket which saves the cable from the surrounding solid. It could be made of o "0C material. o ?ute impregnated with bitumen.

2a'ing of cables
%here are different methods for laying depended on cable type, cable importance ' soil surrounding cable. #uch as Cable supported using brackets above ground level. Cables laid directly in dug in trenches below ground level %direct burial), the depth of trench may be vary between 6 to 6.@m depends on voltage level. .p to 66 k0 hA5.@m BB k0 hA5.7@m 6*4 k0 h A6.55m 445 k0 hA6.@m The bottom of the trench is leveled freed from stones had sharp edge of rock, a layer 65cm thick of clean sand is laid at the bottom of the trench .After laying The cable it is covered once again with a 65cm thick layer of sand. <here the soil conditions not good. A layer of bricks is usually used for protection against mechanical damage and for identification of the cable route. Cables laid in ducts this method for vital cable and for crossing ways. 8an holes are made to maintain ' repair the cable easily when a fault occurs. 8etallic mesh shield it used when the cable is near to railways or duct of pipe lines to prevent galvanic corrosion. Conduits %pipes) which used for buildings %walls ' ceilings). The cables laid in bitumen compound. This method is used where the soil is chemically corrosive to the cable.

or most industrial applications, cables ma' be installed through "ace wa' This method is used in important place like labs, hospitals and in some applications it will be wall mounted. Cable tra's This method is used in industrial loads, it is sealing mounted. %roughs this method is very high e:pensive and used in labs.

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Cables selection

(otes& Pipes or ducts in which cables are installed may be made of ceramic, cast iron, galvanize iron, or cement. These are used for crossing streets or under railway tracks, the size should be sufficiently large to put in additional cables later if required. The cable can be drawn out and replaced without disturbing the earth above. or conduits %pipes) which used for buildings, we have to take the following into consideration o It is prohibited to lay conduits in finished of building floors. o <hen we use any pipe we must have space factor which given by Area of cables (with external diameter) 0.45 Space factor = Internal area of conduct In order to providing !0entilation. !2:pansions 'e:tensions. o It is not recommended to use the fle:ible conduits as possible.

Cable specification
%he cable specification depends on type of conduction, insulation and covering. %he following is a chec1list that can be used in preparing a cable specification o (umber of conductors in the cable. o Conductor size %mm4). o Conductor material. o 0oltage rating and insulation level requirement. o #hielding system requirement. o -uter finish. o Insulation approvals requirements. o Test voltage and partial discharge voltage. o ,round!fault current value and the duration time.

Cable ratings
3oltage "ating %he selection of cable insulation rating is made on the basis of the phase to phase voltage of the system in which the cable is to be applied. The design voltage for the cable may be e:pressed in the form of %.oD.). U power frequency voltage between conductor and earth. Uo & power frequency voltage between conductors for which the cable is designed. Conductor )election& %he selection of conductor size is based on the following considerations o 0oltage!drop limitation. o &oad current criteria. o +ault current criteria. o 2mergency overload criteria. o +requency criteria. o /ot!spot temperature criteria. o &ength of cable in elevated ambient temperature areas.

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Cables selection

)election of cable si4e

%o achieve ma:imum economy in first cost and subsequent appertain of cables, an important aspect is the selection of the optimum size of conductor. )everal factors are involved which are& o Continuous current carrying capacity. o Ability to carry short circuit current. o Cost of losses. o 0oltage drop. %hese factors are based on certain standard conditions such as o Type of conductor material copper or aluminum o Core construction single or multi!core. o Insulation material "0C, 1&"2 E o 8ethod of installation in air or in ground. o #urrounding ambient temperature. o #oil thermal resistively. o $epth of laying. o 8ethod of cable grouping.

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Cables selection

Classification of cables according to voltage

Cables can be classified according to rated voltage as follows 1! &ow voltage cables 2! 8edium voltage cables 3! /igh voltage cables

2ow voltage cables

3556755 3 8 9756:75 3 *)tranded Copper Conductor+ ;escription& )oft annealed solid or stranded copper conductors insulted with "0C compound rated 75F C or =@F C. /pplication or indoor fi:ed installations in dry locations, laid in conduits, as well as in steel support brackets.

#ingle core cable with stranded and "0C Insulated 3556755 3 8 9756:75 3 * le-ible Copper+ ;escription& )oft annealed Copper fine wires bunched in sub ! units or stranded bunched together groups into a main unit, which forms the fle:ible conductor. Insulated with soft "0C 75 FC or =@ FC Compound. /pplication or indoor fi:ed installations in dry locations, where particular fle:ibility is required for electrical panelsG connection or for electrical apparatus they can be laid in groups around steak sheets.

#ingle Core Cable and "0C Insulated 3556755 3 * le-ible Copper+ ;escription )oft annealed Copper fine wires bunched together in sub ! units or stranded bunched groups into a main unit, which forms the fle:ible conductor. These conductors are insulated with "0C compound rated 75 FC and sheathed with "0C compound layer. /pplication& or indoor movable installation in dry location connecting to source power portable electrical appliances operating under unfavorable conditions, such as portable lamps, fans, refrigerators, washing machines, vacuum cleaners, T0 ' house hold heating and ventilating apparatus.

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Cables selection

8ulticore Cable with "0C Insulated and "0C #heathed

5<=61 *1<2+ 13 *)ingle core Copper or /luminum Conductor+ ;escription )oft annealed stranded copper or Aluminum conductor, Insulated with "0C compound rated 75 FC and sheathed with "0C Compound layer. /pplication or outdoor and indoor installations in damp and wet locations. They are normally used for power distribution in urban networks, industrial plants, as well as in thermo power and hydropower stations.

#ingle Core Cable, with #tranded Circular Copper Conductors, "0C Insulated and "0C #heathed 5<=61 *1<2+ 13 *!ulticore )tranded Copper Conductors+ ;escription& !ulticore cables of stranded Copper conductors are insulated with "0C compound, assembled together, covered with overall >acket of "0C compound. /pplication or outdoor and indoor installations in damp and wet locations.

8ulticore Cable, with #tranded Copper Conductors "0C Insulated and "0C #heathed 5<=61 *1<2+ 13 *!ulticore )tranded /luminum Conductors+ ;escription& !ulticore cables of stranded Aluminum conductors are insulated with "0C compound, assembled together, covered with overall >acket of "0C compound. /pplication& or outdoor and indoor installations in damp and wet locations.

Multicore Cable, with Stranded Aluminum Conductors PVC Insulated and PVC Sheathed

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Cables selection

5<=61 *1<2+ 13 *!ulticore, cu, /rmored with steel tape+ ;escription& !ulticore cables of stranded Copper conductors are insulated with "0C compound, assembled together, armored with steel tape and covered with overall >acket of "0C compound. /pplication or outdoor installations in damp and wet locations, where mechanical damages are e:pected to occur.

8ulticore Cable, with #tranded Copper Conductors, "0C Insulated, #teel Tape Armored and "0C #heathed. 5<=61 *1<2+ 13 *!ulticore, /l, /rmored with steel tape+ ;escription& !ulticore cables of stranded Aluminum conductors are insulated with "0C compound, assembled together, armored with steel tape and covered with overall >acket of "0C compound. /pplication& or outdoor installations in damp wet locations, where mechanical damages are e:pected to occur.

8ulticore Cable, with #tranded Aluminum Conductors, "0C Insulated, #teel Tape Armored and "0C #heathed 5<=61 *1<2+ 13 *!ulticore , Copper , /rmored with steel wires+ ;escription& !ulticore cables of stranded Copper conductors are insulated with "0C compound, assembled together, armored with steel wires and covered with overall >acket of "0C compound. /pplication& or outdoor installations in damp wet locations where mechanical damages are e:pected to occur.

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Cables selection

8ulticore Cables, with #tranded Copper Conductors, "0C Insulated, #teel <ire Armored and "0C #heathed 5<=61 *1<2+ 13 */luminum Conductors /rmored with )teel #ires+ ;escription& !ulticore cables of stranded Aluminum conductors are insulated with "0C compound, assembled together, armored with steel wires and covered with overall >acket of "0C compound. /pplication& or outdoor installations in damp wet locations where mechanical damages are e:pected to occur.

8ulticore Cables, with #tranded Aluminum Conductors, "0C Insulated, #teel <ire Armored and "0C #heathed 5<=61 *1<2+ 13 *>2PE Insulated and P3C )heathed+ ;escription )oft annealed stranded Copper or Aluminum conductor, Insulated with 1&"2 compound covered with a layer of "0C compound to form the overall >acket. /pplication& or outdoor and indoor installations in damp and wet locations. They are normally used for power distribution in urban networks, in industrial plants, as well as in Thermo power and /ydropower stations.

#ingle Core Cables, with #tranded Circular Copper Conductors, 1&"2 Insulated and "0C #heathed. 5<=61 *1<2+ 13 *!ulticore Copper Conductors with >2PE Insulated+ ;escription& !ulticore cables of stranded Copper conductors are insulated with 1&"2 compound, assembled together and covered with an overall >acket of "0C compound. /pplication or outdoor and indoor installations in damp and wet locations. They are normally used for power distribution in urban networks, in industrial plants, as well as in Thermo ' /ydro power stations.

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Cables selection

8ulticore Cables, with #tranded, Copper Conductors, 1&"2 Insulated and "0C #heathed

5<=61 *1<2+ 13 *!ulticore with )tranded /luminum Conductors, >2PE Insulated+ ;escription !ulticore cables of stranded Aluminum conductors are insulated with 1&"2 compound, assembled together and covered with an overall >acket of "0C compound. /pplication& or outdoor and indoor installations in damp and wet locations. They are normally used for power distribution in urban networks, in industrial plants, as well as in Thermo power and /ydropower stations.

8ulticore Cables, with #tranded, Aluminum Conductors, 1&"2 Insulated and "0C 5<=61 *1<2+ 13 *!ulticore Cables, with )tranded Copper Conductors, >2PE Insulated, )teel %ape /rmored and P3C )heathed+ ;escription& !ulticore cables of stranded Copper conductors are insulated with 1&"2 compound, assembled together, armored with steel tape and covered with an e:ternal ?acket of "0C compound. /pplication or outdoor installations in damp wet locations where mechanical damages are e:pected to occur.

8ulticore Cables, with #tranded Copper Conductors, 1&"2 Insulated, #teel Tape Armored and "0C #heathed. 5<=61 *1<2+ 13 *!ulticore Cables, with )tranded /luminum Conductors, >2PE Insulated, )teel %ape /rmored and P3C )heathed+ ;escription !ulticore cables of stranded Aluminum conductors are insulated with 1&"2 compound, assembled together, armored with steel tape and covered with an overall >acket of "0C compound. /pplication&

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Cables selection

or outdoor installations in damp wet locations where mechanical damages are e:pected to occur.

8ulticore Cables, with #tranded Aluminum Conductors, 1&"2 Insulated, #teel Tape Armored and "0C #heathed 5<=61 *1<2+ 13 *!ulticore#ith )tranded Copper Conductors, >2PE Insulated steel #ire /rmored and P3C )heathed+ ;escription& !ulticore cables of stranded Copper conductors are insulated with 1&"2 compound, assembled together, armored with steel wires and covered with an overall >acket of "0C compound. /pplication& or outdoor installations in damp wet locations where mechanical damages are e:pected to occur.

8ulticore Cables, with #tranded Copper Conductors, 1&"2 Insulated, #teel <ire Armored and "0C #heathed 5<=61 *1<2+ 13 *!ulticore with )tranded /luminum Conductors, >2PE Insulated )teel #ire /rmored and P3C )heathed) ;escription& !ulticore cables of stranded Aluminum conductors are insulated with 1&"2 compound, assembled together, armored with steel wire and covered with an overall >acket of "0C compound. /pplication& or outdoor installations in damp wet locations where mechanical damages are e:pected to occur.

8ulticore Cables, with #tranded, Aluminum Conductors, 1&"2 Insulated, #teel <ire Armored and "0C #heathed

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Cables selection

!edium voltage cables

B615 *12+ 13 *!ulticore with )tranded Copper Conductors, >2PE Insulated, )teel #ire /rmored and P3C )heathed) ;escription& )tranded circular compacted Copper conductor, semi conducting layer as conductor screen, 1&"2 insulated, semi conducting layer as non metallic insulation screen, Copper tape or wire as metallic insulation screen, three cores assembled together with non!/ygroscopic "olypropylene fillers, wrapped with polyester tape and "0C sheathed. /pplication& %hese cables are generally suitable for direct burial or for installation on trays or ducts.

8ulticore Copper Conductors 1&"2 Insulated and "0C #heathed =615 *12+ 13 *!ulticore with )tranded /luminum Conductor, >2PE Insulated, )teel #ire /rmored and P3C )heathed+ ;escription& )tranded circular compacted Aluminum conductor, semi conducting layer as conductor screen, 1&"2 insulated, semi conducting layer as non metallic insulation screen, Copper tape or wire as metallic insulation screen, three cores assembled together with non hygroscopic "olypropylene fillers, wrapped with polyester tape and "0C sheathed. /pplication& %hese cables are generally suitable for direct burial or for installation on trays or ducts.

8ulticore Aluminum Conductors, 1&"2 Insulated and "0C #heathed =615 *12+ 13 *!ulticore Copper or /luminum Conductors, >2PE Insulated, )teel %ape /rmored and P3C )heathed+

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Cables selection

;escription& )tranded circular compacted Copper or Aluminum conductor, semi conducting layer as conductor screen, 1&"2 insulated, semi conducting layer as non metallic insulation screen, Copper tape or wire as metallic insulation screen, three cores assembled together with non hygroscopic polypropylene fillers, wrapped with polyester tape, covered with a layer of "0C compound as a bedding, steel tape armored and "0C sheathed.

/pplication& %hese cables are generally suitable for direct burial or for installation on trays or ducts.

8ulticore Copper or Aluminum Conductors, 1&"2 Insulated, #teel Tape Armored and "0C #heathed. =615 *12+ 13 *!ulticore Copper or /luminum Conductors, >2PE Insulated, )teel #ire /rmored and P3C )heathed+ ;escription& )tranded circular compacted Copper or Aluminum conductor, semi conducting layer as conductor screen, 1&"2 insulated, semi conducting layer as non metallic insulation screen, Copper tape or wire as metallic insulation screen, three cores assembled together with non hygroscopic "olypropylene fillers, wrapped with polyester tape, covered with a layer of "0C compound as a bedding, steel wire armored and "0C sheathed. /pplication %hese cables are generally suitable for direct burial or for installation on trays or ducts.

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Cables selection

8ulticore Copper or Aluminum Conductors, 1&"2 Insulated, #teel <ire Armored and "0C #heathed

?igh voltage cables

3@6== *:2<7+ 13 *)ingle Core Copper Conductor, >2PE Insulated, Copper )creened and ?;PE )heathing+ ;escription )tranded circular compacted copper conductor, semi conducting layer as conductor screen, 1&"2 insulated, semi conducting layer as non metallic insulation screen, copper tape, wire or both as metallic insulation screen to achieve the required cross sectional area to withstand the earth fault current, longitudinal water blocking tapes to protect the screen area from any longitudinal water penetration, copolymer aluminum tape to protect the cable from any radial water penetration and /$"2 sheathed.

#ingle Core Copper Conductor, 1&"2 Insulated, Copper #creened and /$"2 #heathing. 3@6== *:2<7+ 13 *)ingle Core Copper Conductor, >2PE Insulated, 2ead )creened and ?;PE )heathing+ ;escription& )tranded circular compacted copper conductor, semi conducting layer as conductor screen, 1&"2 insulated, semi conducting layer as non metallic insulation screen, semi conducting water blocking tape applied helically, lead screened with suitable thickness to withstand the earth fault current and /$"2 sheathed.

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Cables selection

#ingle Core Copper Conductor, 1&"2 Insulated, &ead #creened and /$"2 #heathing

;esign of underground cables under stud'

)everal factors are considered in selecting cable si4e, such as& o Continuous current carrying capacity. o Ability to carry short!circuit current. o Cost of losses. Continuous current carr'ing capacit'& Current carrying capacity or Ampacity of cable is defined as the ma:imum allowable current, which may flow through cable conductor without damaging the conductor or its insulation. !able rated current !able Ampacit" = % A) O erall rating factor O erall rating factor ( F ) = F 6 F 4 F * F 3 #here F 6 9ating factor of soil temperature. F 4 9ating factor of soil thermal resistivity. F * grouping factor. F 3 9ating factor of buried depth. (ote& or cables installed in air there is only one rating factor % F ) which is called Gthe air temperature rating factorG 8ost cable manufacturers issue catalogues which contain ratings for the cables which they supply. ?owever these ratings are based on certain standard conditions such as& o Type of conductor material, copper or aluminum. o Core construction, single!core or multi!core depends on the rated current in cable. o Insulation material, "0C, 1&"2 E o 8ethod of installation, in air or in ground %direct buried or in duct). o #urrounding ambient temperature. o #oil thermal resistivity.

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Cables selection

o $epth of laying. o 8ethod of cable grouping. All of these previous factors should be taken into consideration in order to get the current carrying capacity of the cable under actual operating conditions. )hort,circuit current %he most important factor for the cable selection is the capability of cable to carry the short circuit current. The permissible rise in temperature during period of short circuit is 6@5FC in "0C cable and 4@5FC in 1&"2 cables. The electrodynamics load induced due to short circuit reduces the time that cable can be withstood. In addition the symmetrical short circuit increases the armored and the outer sheath losses of the cable. Cost of losses One important factor for cable selection is the cost of losses, which means that the cost of power which dissipated in the cable core resistance. Cable manufacturers issue catalogues which contain resistance, inductance ' capacitance for the cables which they supply.

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