Company Profile EHV Cables

Polycab is one of the leading names in wires and
cables, an ISO 9001:2000 certified company with
Under Writers Laboratories USA, and with a proven
track record of over three decades.
Polycab has achieved a growth of over 0% per
annum in the last 3 years & this growth is attributed to
company’s commitment towards “The total customer
satisfaction in terms of quality & services for the entire
range of its products”.
Dedicated towards continuous improvements,
upgradation of man, machinary & services, Polycab
expanded its facilities from Halol to set up an ultra
modern state of the art plant at Daman in 1996
spread over an area of 35 acres.
Due to rapid industrial & economic growth it
has become necessary to transmit bulk power to
sustain the growth. It is also very important that
while transmitting bulk power logistic & safety
consideration are given due weightage.
The most ideal solution, considering all the aspects
is to transmit bulk power through underground
cables & keeping in line with the basic philosophy
of the organisation, POLYCAB has introduced extra
high voltage cable.

The machineries and equipment are procured

from world renowned manufacturer and these
machines are manned by qualified, experienced and
dedicated professionals. The company is now the
largest manufacturer of HT XLPE, LT power / control, Triple Extrusion Machine
instrumentation, house wires & flexible, specialty
cables, Catv, Lan, Data & Communication Cables.

In addition to catering to various segment of

Indian industry / power utilities, Polycab has made
physical export of different types of cables to various
countries.

EHV Testing Facility

SCHEMATIC DIAGRAM OF TYPICAL EHV CABLES

1. COPPER CONDUCTOR
2. SEMI-CONDUCTING TAPE (optional)
3. EXTRUDED SEMI-CONDUCTING LAYER
4. XLPE INSULATION (Super Clean Compund)
5. INSULATION SHIELD-SEMI CONDUCTING
6. WATER BLOCKING TAPE
7. LEAD SHEATH / POLYAL SHEATH
8. SEMI-CONDUCTING TAP
9. METALLIC SCREEN
10. COUNTER HELIX WITH COPPER TAPE
11. PVC/HDPE OUTER SHEATH
WITH GRAPHITE COATING
 CROSS BONDING METHOD
Two C. C. V. Line for XLPE Cables upto 132 kv
Salient features of EHV / XLPE line
n The only manufacturer in the country to have 2
Dry cure / Dry cooled lines sourced from SCHOLZ
Germany.
n Highly sophisticated extruders for conductor
shield, insulation and insulation shield, employing
a three layer single head triple extrusion method
to eliminate contaminants in the insulating
layers. These are sourced from ROYLE USA.
n Microprocessor based equipments control all the
parameters required for the process within the
specified limits.
n Separate pressurised rooms for semicon shield
& XLPE insulation to avoid contamination & this
material is handled by vacuum loaders.
n Air systems with air showers on doors to eliminate
dust entry.
Metallic Sheath
Metallic Sheath is must for cables above 33 kV as the
cable of voltage grade 66 kV & above are working
with dielectric stress of above 6 kV / mm & at this
level of dielectric stress presence of water triggers
tree formation in the insulation resulting in cable
failure.
Water can enter the cable longitudinally as well as
radially. Longitudinal water entry can be blocked by
using water swellable tape on the core. Lead sheath
can block the entry in radial direction.
Lead sheath is extruded by continuous lead extruder
which is equipped with micro-processor based
temperature controllers & drives to achieve uniform
thickness, better concentricity. Lead sheath in addition
to other electrical & manufacturing advantages has a
life span of minimum 40 to 45 years.
Cable selection / design parameters
Cable design mainly depends on
n System voltage
n Impulse level
n Fault level & duration
n Ground & air temperature
n Thermal resistivity of soil
EHV Testing Lab
 BOTH END BONDING METHOD TYPICAL TRENCH CROSS SECTION
BOTH END BONDING METHOD TYPICAL TRENCH CROSS SECTION
Cables in Trefoil Formation
Cable Termination
Cables in Trefoil Formation
Cable Termination
GL
GL

Excavated earth
Excavated
Backfill earth
Conductor Backfill
Conductor

Pre-warning Tape
Pre-warning Tape
R.C.C. Protection Tile
R.C.C. Protection Tile
BOTH
Screen END BONDING METHOD
Sieved Earth, TYPICAL TRENCH CROSS SECTION
BOTH
Screen END BONDING
Bonding CableMETHOD Sieved
Lightly Earth,
compacted TYPICALCables
TRENCHin TrefoilCROSS
FormationSECTION
Bonding Cable Lightly compacted
Cable Termination Cables in Trefoil Formation
Cable Termination Sieved Earth,
GL Sieved
Firmly Earth,
compacted
Link Box Link Box GL Firmly compacted
Link Box Link Box
Excavated earth
Excavated
Backfill earth
Conductor Backfill
Conductor

Pre-warning Tape
SINGLE POINT BONDING METHOD TYPICAL TRENCH
Pre-warning Tape CROSS SECTION OF
SINGLE POINT BONDING METHOD TYPICAL
R.C.C.TRENCH
Protection Tile CROSS SECTION OF
ROAD
R.C.C. Protection CROSSING
Tile CROSSING
ROAD
Cable Termination Cables in
Sieved Earth, Flat Formation
Cable Termination
Screen Sieved
Cables in Flat Formation
Screen Bonding Cable Lightly Earth,
compacted
Cable sheath Bonding Cable Lightly
GL compacted
Cable sheath
insulated at GL
insulated at
termination Sieved Earth,
termination Sieved
Firmly Earth,
compacted
Link Box Link Box Excavated earth Firmly compacted
Conductor
Link Box Link Box Excavated
Conductor Backfill earth
Backfill

Pre-warning Tape
Pre-warning Tape
R.C.C. Protection Tile
SINGLE
Screen POINT BONDING METHOD
TYPICAL
R.C.C. Protection Tile TRENCH CROSS SECTION OF
SINGLE
Screen POINT BONDING
Bonding Cable METHOD TYPICAL TRENCH CROSS SECTION OF
Bonding Cable
Sieved Earth,
Sieved
ROAD CROSSING PVC /
Lightly Earth, ROAD
Cable Termination
compacted
Lightly compacted Cables in CROSSINGPVC
HDPE/ Pipe
Flat Formation
Cable Termination HDPE Pipe
Cables in Flat Formation
Link Box Link Box with Cable sheath Sieved Earth,
GL Sieved Earth,
Link Box Link Box with Cable
SVL Unit sheath
insulated at GL Firmly compacted
SVL Unit insulated at
termination Firmly compacted
termination
Excavated earth
Conductor Excavated
Conductor Backfill earth
Backfill

Pre-warning Tape
Pre-warning Tape
The complete solution R.C.C. Protection Tile
R.C.C. Protection Tile
Screen
Screen Bonding Cable Sieved Earth, PVC /
Bonding Cable Sieved
Lightly Earth,
compacted PVC
Polycab can provide complete solution to provide assistance in HDPE/ Pipe
Lightly compacted HDPE Pipe
selecting the cables, manufacturing
Link Box the cables Link
toBoxthe
with desired Sieved Earth,
Sieved Earth,
Link Box Link Box with
SVL Unit Firmly compacted
specification & assist / provide turnkey execution of the cable
SVL Unit Firmly compacted

installation.

Polycab Wires Pvt. Ltd

Website: www.polycab.com
Email: ars@polycab.com/ bdg@polycab.com