Power cables are used for distribution of electrical current in power stations & in other industrial applications .These cables are available in different Sizes and Types depending on it application in terms of current carrying  capacity, load, application which determine the form & composition of the cable. Power cables for direct burial or exposed installation many also include metal armour in the form of wires spiraled around the cables. The armor may be made of steel or aluminum as per requirement/application.  PVC ARMOURED & UNARMOURED POWER CONTROL CABLES WITH ALUMINIUM & COPPER CONDUCTORS. CONDUCTOR :

The Construction of the Conductors is as follows.

Conductor of nominal area less than 16 mm2 shall be circular only.

Conductor of nominal area 16 mm2 and above may be circular or shaped

INSULATION :

Insulation is of PVC compound conforming to the requirements of type 1 compund of IS: 5831-1970.

CORE IDENTIFICATION :

INNER SHEATH

Cables above two or more cores are provided with a common inner sheath applied either by PVC extrusion or by wrapping with PVC Tape.

ARMOURING :

Where the calculated diameter of inner sheath doesn’t exceed 13.00 mm the armour is of round galvanized steel wires and for calculated diameter of inner sheath above 13.00 mm flat galvanized steel wires are used.

OUTER SHEATH :

The outer heath is of PVC compound confirming to the requiremnets of type 6 compund of IS:5831-1970.

The colour of outer sheath is genereally Black.

CABLE CODE:

The following code is used for easy identification of the cables.

META PLAST 1.1KV SINGLE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED

UNARMOURED & PVC SHEATHED CABLES AS PER IS:1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area	Nominal thickness of Insualtion	Nominal thickness of Outer Sheath	Approx overall diameter	Approx weight of cable	Max. Dc conductor resistance at 200 C	CURRENT RATINGS
						Direct in Ground		In Duct		In Air
						2 cables Amps	3 cables Amps	2 cables Amps	3 cables Amps	2 cables Amps	3 cables Amps
Sq.mm	mm	mm	mm	kg / km	Ohm / km
1 x 1.5	1.1	1.8	7.4	63	19.7	21	17	19	17	18	15
1 x 2.5*	1.2	1.8	8.0	74	11.8	28	24	25	24	25	21
1 x 4*	1.3	1.8	8.7	88	7.39	36	31	33	30	32	27
1 x 6*	1.3	1.8	9.2	101	4.91	44	39	42	37	41	35
1 x 10*	1.3	1.8	10.0	122	2.94	54	51	56	51	56	47
1 x 16	1.3	1.8	11.5	161	1.87	75	66	71	65	72	64
1 x 25	1.5	1.8	12.9	209	1.18	97	86	93	84	99	84
1 x 35	1.5	1.8	14.0	251	0.851	120	100	110	100	120	105
1 x 50	1.5	1.8	15.2	301	0.628	145	120	130	115	150	130
1 x 70	1.5	1.8	17.0	386	0.435	170	140	155	135	185	155
1 x 95	1.6	2.0	19.4	510	0.313	205	175	180	155	215	190
1 x 120	1.6	2.0	20.9	601	0.248	230	195	200	170	240	220
1 x 150	1.8	2.0	22.8	722	0.202	265	220	220	190	270	250
1 x 185	2.0	2.0	25.0	871	0.161	300	240	240	210	305	290
1 x 240	2.2	2.0	27.9	1098	0.122	335	270	270	225	350	335

* If required, cables can be made with stranded conductor also. *Not covered in IS : 1554 (Part 1) 1976

META PLAST 1.1 KV TWIN CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHED
UNARMOURED & PVC SHEATHED CABLES AS PER IS: 1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area	Nominal thickness of Insualtion	Minium thickness of Inner Sheath	Normal thickness Outer Sheath	Approx overallt of cable	Approx weight of cable	Max. Dc conductor resistance at 200 C	CURRENT RATINGS
							Direct in Ground	In Duct	In Air
							Amps	Amps	Amps
Sq.mm	Mm	Mm	Mm	Mm	kg / km	Ohm / km
2 x 1.5	0.8	0.3	1.8	10.4	135	20.0	18	16	16
2 x 2.5*	0.9	0.3	1.8	11.6	194	12.0	25	21	21
2 x 4*	1.0	0.3	1.8	13.0	247	7.54	32	27	27
2 x 6*	1.0	0.3	1.8	14.0	258	5.01	40	34	35
2 x 10*	1.0	0.3	1.8	15.6	351	3.00	55	45	47
2 x 16	1.0	0.3	1.8	16.5	364	1.91	70	58	59
2 x 25	1.2	0.3	2.0	19.4	480	1.20	90	76	78
2 x 35	1.2	0.3	2.0	21.0	600	0.868	110	92	99
2 x 50	1.4	0.3	2.0	23.7	750	0.641	135	115	125
2 x 70	1.4	0.3	2.0	26.3	900	0.443	160	140	150

* If required, cables can be made with stranded conductor also. *Not covered in IS : 1554 (Part 1) 1976

 

META PLAST 1.1 KV THREE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHED UNARMOURED & PVC
SHEATHED CABLES AS PER IS:1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area	Nominal thickness of Insualtion	Minium thickness of Inner Sheath	Normal thickness Outer Sheath	Approx overallt of cable	Approx weight of cable	Max. Dc conductor resistance at 200 C	CURRENT RATINGS
							Direct in Ground	In Duct	In Air
							Amps	Amps	Amps
Sq.mm	Mm	Mm	Mm	Mm	kg / km	Ohm / km
3 x 1.5	0.8	0.3	1.8	10.9	160	20.0	16	14	13
3 x 2.5*	0.9	0.3	1.8	12.2	221	12.0	21	18	18
3 x 4*	1.0	0.3	1.8	13.7	242	7.54	28	23	23
3 x 6*	1.0	0.3	1.8	14.8	320	5.01	35	30	30
3 x 10*	1.0	0.3	1.8	16.5	366	3.00	46	39	40
3 x 16	1.0	0.3	1.8	17.8	436	1.91	60	50	51
3 x 25	1.2	0.3	2.0	21.2	630	1.20	76	63	70
3 x 35	1.2	0.3	2.0	23.1	706	0.868	92	77	86
3 x 50	1.4	0.3	2.0	26.1	903	0.641	110	95	105
3 x 70	1.4	0.3	2.2	29.7	1200	0.443	135	115	130

* If required, cables can be made with stranded conductor also. *Not covered in IS : 1554 (Part 1) 1976

META PLAST 1.1 KV 31/2 CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHED UNARMOURED & PVC SHEATHED
CABLES CONFORMING TO IS :1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area		Nominal thickness of insulation		Minimum thickness of inner sheath	Minimum thickness of Outer sheath			Approx overall diameter	Approx weight of cable	Max. DC conductor resistance at 20°C				CURRENT RATINGS
Sq.mm	Neutral Sq.mm	Main mm	Neutral Smm	Mm		Mm	Mm		Kg/ Km		Main Ohm / km	Neutral Ohm / km	Direct in Ground Amps		In Ducts Amps	In Air Amps
31/2 x 35	16	1.2	1.0	0.3		2.0	23.9		702		1.20	1.91	76		63	70
31/2 x 25	16	1.2	1.0	0.3		2.0	26.2		800		0.868	1.91	92		77	86
31/2 x 50	25	1.4	1.2	0.3		2.2	29.5		1027		0.641	1.20	110		95	105
31/2 x 70	35	1.4	1.2	0.3		2.2	33.5		1550		0.443	0.868	135		115	130

META PLAST 1.1 KV FOUR CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHED UNARMOURED & PVC SHEATHED
CABLES AS PER IS :1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area	Nominal thickness of Insualtion	Minium thickness of Inner Sheath	Normal thickness Outer Sheath	Approx overallt of cable	Approx weight of cable	Max. Dc conductor resistance at 200 C	CURRENT RATINGS
							Direct in Ground	In Duct	In Air
							Amps	Amps	Amps
Sq.mm	Mm	Mm	Mm	Mm	kg / km	Ohm / km
4 x 1.5	0.8	0.3	1.8	11.7	180	20.0	16	14	13
4 x 2.5*	0.9	0.3	1.8	13.1	225	12.0	21	18	18
4 x 4*	1.0	0.3	1.8	14.8	269	7.54	28	23	23
4 x 6*	1.0	0.3	1.8	16.0	316	5.01	35	30	30
4 x 10*	1.0	0.3	1.8	17.9	411	3.00	46	39	40
4 x 16	1.0	0.3	2.0	20.3	532	1.91	60	50	51
4 x 25	1.2	0.3	2.0	23.9	719	1.20	76	63	70
4 x 35	1.2	0.3	2.0	26.0	897	0.868	92	77	86
4 x 50	1.4	0.3	2.2	30.1	1189	0.641	110	95	105
4 x 70	1.4	0.4	2.2	33.9	1548	0.443	135	115	130

* If required, cables can be made with stranded conductor also. *Not covered in IS : 1554 (Part 1) 1976

META PLAST 1.1KV TWIN CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHER ARMOURED & PVC SHEATHED
CABLES AS PER IS : 1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area	Nominal thickness of Insulation	Minimum thickness of Inner sheath	ARMOUR		Nominal thickness of Outer sheath	Approx overall diameter	Approx weight of cable	Max Dc conductor resistance at 20°C	CURRENT RATINGS
			Galv.Round Steel Wire Normal diameter	Galv.Flat Steel Strip Normal thickness
									Direct in Ground	In Ducts	In Air
Sq.mm	mm	mm	mm	mm	mm	mm	Kg/km	Ohm/km	Amps	Amps	Amps
2 x 1.5	0.8	0.3	1.4	--	1.8	13.6	410	20.0	18	16	16
2 x 2.5*	0.9	0.3	1.4	--	1.8	14.8	472	12.0	25	21	21
2 x 4*	1.0	0.3	1.4	--	1.8	16.2	568	7.54	32	27	27
2 x 6*	1.0	0.3	1.4	--	1.8	17.2	632	5.01	40	34	35
2 x 10*	1.0	0.3	1.4	--	1.8	18.3	750	3.00	55	45	47
2 x 16	1.0	0.3	--	0.8	2.0	19.7	770	1.91	70	58	59
2 x 25	1.2	0.3	--	0.8	2.0	21.2	800	1.20	90	76	78
2 x 35	1.2	0.3	--	0.8	2.0	22.9	920	0.868	110	92	99
2 x 50	1.4	0.3	--	0.8	2.0	25.6	1042	0.641	135	115	125

* If required, cables can be made with stranded conductor also. *Not covered in IS : 1554 (Part 1) 1976

META PLAST 1.1KV THREE CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHER ARMOURED & PVC
SHEATHED CABLES AS PER IS : 1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area	Nominal thickness of Insulation	Minimum thickness of Inner sheath	ARMOUR		Nominal thickness of Outer sheath	Approx overall diameter	Approx weight of cable	Max Dc conductor resistance at 20°C	CURRENT RATINGS
			Galv.Round Steel Wire Normal diameter	Galv.Flat Steel Strip Normal thickness
									Direct in Ground	In Ducts	In Air
Sq.mm	mm	mm	mm	mm	mm	mm	Kg/km	Ohm/km	Amps	Amps	Amps
3 x 1.5	0.8	0.3	1.4	--	1.8	14.1	440	20.0	16	14	13
3 x 2.5*	0.9	0.3	1.4	--	1.8	15.4	520	12.0	21	18	18
3 x 4*	1.0	0.3	1.4	--	1.8	16.9	613	7.54	28	23	23
3 x 6*	1.0	0.3	1.4	--	1.8	18.0	680	5.01	35	30	30
3 x 10*	1.0	0.3	--	0.8	2.0	19.4	720	3.00	46	39	40
3 x 16	1.0	0.3	--	0.8	2.0	20.1	766	1.91	60	50	51
3 x 25	1.2	0.3	--	0.8	2.0	23.1	920	1.20	76	63	70
3 x 35	1.2	0.3	--	0.8	2.0	25.0	1047	0.868	92	77	86
3 x 50	1.4	0.3	--	0.8	2.0	28.0	1249	0.641	110	95	105

* If required, cables can be made with stranded conductor also. *Not covered in IS : 1554 (Part 1) 1976

META PLAST 1.1KV 31/2 CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHER ARMOURED & PVC
SHEATHED CABLES AS PER IS : 1554 (PART I) AMENDED UPTO DATE

Nominal cross sectional area				Nominal thickness of Insulation			Minimum thickness of Inner sheath		ARMOUR		Nominal thickness of Outer sheath		Approx diameter		Approx weight of cable		Max Dc conductor resistance at 20°C			CURRENT RATINGS
									Galv.Flat Steel Strip
																				Direct in Ground		In Ducts		In Air
Main Sq.mm		Neutral Sq.mm			Main Sq.mm	Neutral Sq.mm		Mm		Mm		Mm		Mm		Kg/km		Main Ohm/km	Neutral  Ohm/km		Amps		Amps		Amps
31/2 x 25	16		1.2			1.0	0.3		0.8		2.0		25.8		1048		1.20		1.91	76		63		70
31/2 x 35	16		1.2			1.0	0.3		0.8		2.0		28.1		1221		0.868		1.91	92		77		86
31/2 x 50	25		1.4			1.2	0.3		0.8		2.2		31.4		1529		0.641		1.20	100		95		105

METAPLAST 1.1 KV FOUR CORE, ALUMINIUM CONDUCTOR, PVC INSULATED INNER SHEATHED ARMOURED PVC
SHEATHED CABLES AS PER IS :1554 (PART 1) AMENDED UPTO DATE

* If required, cables can be made with stranded conductor also. *Not covered in IS : 1554 (Part 1) 1976

METAPLAST 1.1 KV ANNEALED HIGH CONDUCTIVITY SOLID COPPER CONDUCTOR 1.5 Sq. mm. PVCINSULATED INNER SHEED, ARMOURED / UNARMOURED &
PVC SHEATHED CONTROL CABLES AS PER IS :1554 (PART 1) AMENDED UPTO DATE

In place of Aluminium Cable if Copper cable are to be used take one size lower than size. Recommended for Aluminium Cable, i.e. for 75 H.P., 70 Sq.mm Aluminium Cable  is recommended. If you desire to use Copper Cable then use 50 sq. mm. Copper Cable for 75 H.P. Motor.

1. Before laying,  the insulation of the cable should be checked with megger as preliminary check against any probable damage.
   
   
2. The drum should be always rolled in the “direction of arrow for rolling” , marked on the drum. In the absence of any such mark, the drum should be rolled in the direction same as that of inside end of the cable and opposite to that of outside end.
   
   
3. Where the cable is to be joined with existing cable, the sequence of cores at the two ends to be joined should be in the oppsite direction, i.e. if at one end it is in clockwise direction, at the other end it should be in anti clockwise direction. This is necessary to avoid the crossing of the cores while jointing. This will also decide the direction in which the cable is to be pulled.
   
   
4. Wherever possible, bending radius of 12 times the overall diameter of the cable should be maintained, but in any case it should not be less than 8 times.
   
   
5. Where the cables are necessarily laid and jointed in very cold regions, both th cable and the ambient temperatures should be above 0°C  and have remained so for the previous 24 hours. During such conditions, the cable should also not be bent to very small radius.
   
   This is due to the reason that at very low temperatures PVC compound become stiff and brittle, and are likely to crack and shatter when stuck hard or bent to small radius.
   
   
6. A joint being the weakest point of the electric power transmission system, all necessaty precautions should be taken. Jointing materials and accessories like conductor  ferrules, solder,       insulating and protective tapes, protective filling compound, joint boxes, etc. of right quality and size should be procured. The application of these materials should be made skillfully for the jointin work. In this connection, it is always advisable that the method and the working instructions of the supplier should be strictly followed.
   
   
7. Armoured cables : All bonding clamps at the joints and terminations and the armour wires should be thoroughly cleaned. The clamps hould be adequately tightened. This is necessary to ensure proper electrical contact, because armour is the only return path for earth fault current.
   
   Unarmoured cable : In case of unarmoured cables, the external metallic earth bonding connector of adequate size should be used.
   
   
8. Earth : All joints, terminations, armour wires and external metallic bonding should be coonected to main earth system at the supplying end by employing metallic connectors.
   
   
9. Filling Compound:           
   a. The design of the box and the composition of the filling compound should provide an effective sealing against entry of moisture to conductor ferrules and armour connectors.
   
   b.If hot pouting protective compounds are used, the temperature of the compound while pouring should not exceed 150°C
   
   
10. Test After installation : After the cable is sistalled, a.d.c. voltage test may be carried out. Each core should be tested at 4 kv against others and the armour, the latters connected to earth.