XLPE CABLES

CONSTRUCTION

XLPE INSULATED CABLE TO BS 5467:1997

Conductor
Copper conductors are made from high conductivity Copper rods of 8 mm diameter. The rod is drawn to required sizes for the construction of conductors of different areas of cross section conforming to BS 6360.

Single-core cables with cross sectional area 25 sq.mm and above have stranded circular compacted conductors conforming to Table 2 class 2 of BS 6360.

Multi-core cables with cross sectional area upto 16 sq.mm have stranded circular non-cornpact conductors conforming to Table 2 Class 2 of BS 6360. Multi-core cables with cross sectional area 25 sq.mm. and above have stranded shaped conductors conforming to Table 2 Class 2 of BS 6360.

Insulation
Cross linkable polyethylene compound (GP 8) conforming to SS 7655:Section 1.3 is insulated over conductor by extrusion process with required thickness of insulation conforming to SS 5467. XLPE insulation is suitable for a maximum continuous conductor operating temperature of 90° C.

Identification of core colours

No. of cores

  Identification

1

  Red or Black

2

  Red and Black

3

  Red, Yellow and Blue

4

  Red, Yellow, Blue and Black















Laying up

Cores are laid up with right hand lay in the outermost layer in the sequence of above core colours. Interstices, if necessary, are covered with non hygroscopic fillers and covered with a binder tape for compactness and to maintain reasonably round shape.

Bedding

All multi-core cables have either extruded bedding of polymeric material or 2 layers of PVC tape or other synthetic tapes, which is compatible to insulation material and removable without any damage to insulation. Single core armoured cables have extruded PVC bedding.

Bedding

All multi-core cables have either extruded bedding of polymeric material or 2 layers of PVC tape or other synthetic tapes, which is compatible to insulation material and removable without any damage to insulation. Single core armoured cables have extruded PVC bedding.

Armour

Single core cables for use on A.C systems, are armoured with single layer of aluminium wires. Multi-core armoured cables have single layer of Galvanized Steel wire Armour over bedding with left hand lay.

Other armours like steel strip, tape can also be provided against customer specification.

Oversheath

Over sheaths are extruded with Black PVC compound of type 9 of BS 7655:Section 4.2 When specified anti termite properties can be provided on the over sheath.

Packing, storage and handling

Cables for power supplies are always packed in appropriate sizes of strong and seasoned wooden drums designed to withstand long distance transit and preservation in stores.

Power cables of all sizes of single core, Power cables of multi-cores upto 120 sq.mm. are packed in standard lengths of 500 metre + 5% and Power cables of multi-cores of 150 sq.mm. and above are packed in standard lengths of 250 metre 5%.

It is advised that drums are always to be stored in concrete floors to avoid sinking in mud and damages or deterioration of drum flanges and shall not be stored on its flanges horizontal to ground. Drums are designed for easy handling when transported by cranes or mounted on cable drum wheels for laying. Cables in drums shall be stored away from boilers and furnaces.

Customer orientation

Against specific requirement and application, Q-Flx Wires & Cables . can offer cables conforming to either customer specification or other National and International Standards.
Note : Constructional details of cables with cross sectional area from 1.5 sq.mm. to 35 sq.mm. are also provided based on the IEC standard IEC 502-1983. (Ref. table nos. 11 to 17)

Basis of current rating

The ratings are in accordance with ERA Report 69-30 Part V which is in conformity to IEC-287. The ratings of cables in air are based on Ambient Temperature of 30° C to align with the IEE Regulations for electrical installations. The ratings are suitable for a maximum conductor temperature of 90° C

Cables are laid direct in ground with ground temperature 15° C and ground thermal resistivity 120° C cm/W and with a depth of laying of 0.5 m. A close trefoil is assumed with the cables touching. Flat formation is with spacing between cable centers of twice the cable diameter.

Minimum installation radius

Circular copper conductors = 6 D
Shaped copper conductors = 8 D
(D is the tabulated overall diameter of the cable)

Conditions of laying

1. Continuous operating temperature of conductor 90° C
2. Ambient Temperature 30° C
3. Ground Temperature 15° C
4. Depth of laying in ground 0.5 m
5. Thermal resistivity of ground 12011 C cm/W

Note : High operating temperature make the cable too hot to handle and reduce the expected service life. Under service condition, if long life is not expected, eg. because of possibility of mechanical damages or when a high surface temperature can be tolerated, the current rating for 25° C ambient temperature may be used upto 40°C.


XLPE - Insulated and PVC - Sheathed single core unarmoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997


Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

kg/km

ohm/km

m


50


70

95

120

150

185


1.0


1.1

1.1

1.2

1.4

1.6


1.4


1.4

1.5

1.5

1.6

1.6


14.2


16.2

18.3

20.2

22.4

24.7


540


750

1020

1220

1530

1950


0.387


0.268

0.193

0.153

0.124

0.0991


500±5%


500±5%

500±5%

500±5%

250±5%

250±5%

XLPE - Insulated and PVC - Sheathed single core armoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Extruded
Bedding

Diameter
of
armour
wire

Thicknes
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum Conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

mm

mm

kg/km

ohm/km

m


50


70

95

120

150

185


1.0


1.1

1.1

1.2

1.4

1.6


0.8


0.8

0.8

0.8

1.0

1.0


1.6


1.6

1.6

1.6

1.6

1.6


1.5


1.5

1.6

1.6

1.7

1.8


18.5


20.2

22.3

24.2

27.4

30.0


695


980

1290

1515

1908

2320


0.387


0.268

0.193

0.153

0.124

0.0991


500±5%


500±5%

500±5%

500±5%

250±5%

250±5%

XLPE - Insulated and PVC - Sheathed 2 core unarmoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

kg/km

ohm/km

m


10


16

25

35

50

70


0.7


0.7

0.9

0.9

1.0

1.1


1.8


1.8

1.8

1.8

1.8

1.9


15.4


17.6

20.5

23.8

25.6

30.4


395


560

745

980

1245

1700


1.83


1.15

0.727

0.524

0.387

0.268


500±5%


500±5%

500±5%

500±5%

500±5%

500±5%

XLPE - Insulated and PVC - Sheathed 2 core unarmoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Extruded
Bedding

Diameter
of
armour
wire

Thicknes
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum Conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

mm

mm

kg/km

ohm/km

m


10


16


25


35

50

70


0.7


0.7

0.9

0.9

1.0

1.0


0.8


0.8

0.8

1.0

1.0

1.0


0.9


1.25

1.25

1.6

1.6

1.6


1.5


1.5

1.6

1.7

1.8

1.9


18.0


20.4

20.4

23.3

25.8

29.0


695


960

1200

1820

2160

2270


1.83


1.15

0.727

0.524

0.387

0.268


500±5%


500±5%

500±5%

500±5%

500±5%

500±5%

XLPE - Insulated and PVC - Sheathed 3 core unarmoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

kg/km

ohm/km

m


10


16

25

35

50

70

95

120

150

185


0.7


0.7

0.9

0.9

1.0

1.1

1.1

1.2

1.4

1.6


1.8


1.8

1.8

1.8

1.8

1.9

2.0

2.1

2.2

2.4


17.0


18.5

19.8

22.0

24.0

28.6

32.0

34.8

38.5

44.0


520

690

950

1250

1580

2200

3000

3740

4600

5680


1.83


1.15

0.727

0.524

0.387

0.268

0.193

0.153

0.124

0.0991


500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

250±5%

250±5%

XLPE - Insulated and PVC - Sheathed 3 core armoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Extruded
Bedding

Diameter
of
armour
wire

Thicknes
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
Conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

mm

mm

kg/km

ohm/km

m


10


16

25

35

50

70

95

120

150

185


0.7


0.7

0.9

0.9

1.0

1.1

1.1

1.2

1.4

1.6


0.8


0.8

1.0

1.0

1.0

1.0

1.2

1.2

1.4

1.4


1.25


1.25

1.6

1.6

1.6

1.6

2.0

2.0

2.5

2.5


1.5


1.6


1.7

1.8

1.8

1.9

2.1

2.2

2.3

2.4


20.0


21.6

23.6

25.7

28.5

32.2

37.0

40.4

45.5

49.8


870

1055

1485

1855

2305

3050

4190

5050

6450

7790


1.83


1.15

0.727

0.524

0.387

0.268

0.193

0.153

0.124

0.0991


500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

250±5%

250±5%

XLPE - Insulated and PVC - Sheathed 4 core unarmoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

kg/km

ohm/km

m


10


16

25

35

50

70

95

120

150

185


0.7


0.7

0.9

0.9

1.0

1.1

1.1

1.2

1.4

1.6


1.8


1.8

1.8

1.8

1.8

2.0

2.1

2.2

2.4

2.6


17.0


21.6

22.5

24.4

27.2

32.0

35.9

40.0

45.0

50.0


575


860

1150

1560

2070

2990

4020

5060

6135

7640


1.83


1.15

0.727

0.524

0.387

0.268

0.193

0.153

0.124

0.0991


500±5%


500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

250±5%

250±5%

XLPE - Insulated and PVC - Sheathed 4 core armoured cable
with stranded copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thickness
of
Extruded
Bedding

Diameter
of
armour
wire

Thicknes
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
Conductor
Resistance
at 20° C

Standard
Packing

Sq.mm

mm

mm

mm

mm

mm

kg/km

ohm/km

m


10


16

25

35

50

70

95

120

150

185


0.7


0.7

0.9

0.9

1.0

1.1

1.1

1.2

1.4

1.6


0.8


0.8

1.0

1.0

1.0

1.2

1.2

1.4

1.4

1.4


1.25


1.25

1.6

1.6

1.6

2.0

2.0

2.5

2.5

2.5


1.5


1.6

1.7

1.8

1.9

2.1

2.2

2.3

2.4

2.6


21.4


23.4

26.1

28.6

32.6

38.4

42.7

47.9

52.4

57.8


1020


1420

1910

2400

2960

4260

5460

6975

8530

10170


1.83


1.15

0.727

0.524

0.387

0.268

0.193

0.153

0.124

0.0991


500±5%


500±5%


500±5%

500±5%

500±5%

500±5%

500±5%

500±5%

250±5%

250±5%

XLPE - Insulated and PVC - Sheathed 4 core unarmoured cable
with reduced neutral conductors and with stranded
copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thicknes
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
Conductor
Resistance
at 20° C

Standard
Packing

Phase

Neutral

Phase

Neutral

 

 

 

Phase

Neutral

 

Sq.mm

Sq.mm

mm

mm

mm mm kg/km

ohm/km

ohm/km

m


25


35

50

70

95

120

150

185


16


16

25

35

50

70

70

95


0.9


0.9

1.0

1.1

1.1

1.2

1.4

1.6


0.7


0.7

0.9

0.9

1.0

1.1

1.1

1.1


1.8


1.8

1.8

1.9

2.0

2.2

2.3

2.4


22.0


23.6

26.9

31.0

35.6

40.0

43.0

48.8


11600


1400

1830

2580

3560

4500

5480

6860


0.727


0.524

0.387

0.268

0.193

0.153

0.124

0.0991


1.15


1.15

0.727

0.524

0.387

0.268

0.268

0.193


500±5%


500±5%

500±5%

500±5%

500±5%

500±5%

250±5%

250±5%

XLPE - Insulated and PVC - Sheathed 4 core armoured cable
with reduced neutral conductors and with stranded
copper conductors 600 / 1000 V to BS 5467 : 1997

Norminal
Conductor
Area

Thickness
of
Insulation

Thicknes
of
Extruded
Bedding

Diameter
of
Armour
Wire

Thicknes
of
Oversheath

Approx.
Overall
Diameter

Approx.
Weight

Maximum
Conductor
Resistance
at 20° C

Standard
Packing

Phase

Neutral

Phase

Neutral

 

 

 

 

 

Phase

 

Sq.mm

Sq.mm

mm

mm

mm mm mm mm kg/km

ohm/km

ohm/km

m


25


35

50

70

95

120

150

185


16


16

25

35

50

70

70

95


0.9


0.9

1.0

1.1

1.1

1.2

1.4

1.6


0.7


0.7

0.9

0.9

1.0

1.1

1.1

1.1


1.0


1.0

1.0

1.2

1.2

1.2

1.4

1.4


1.6


1.6


1.6

2.0

2.0

2.0

2.5

2.5


1.7


1.8

1.9

2.0

2.1

2.2

2.4

2.5


26.4


27.9

31.6

36.6

41.0

45.8

50.8

56.0


1750


2100

2750

3900

4900

6040

7590

9130


0.727


0.524

0.387

0.268

0.193

0.153

0.124

0.0991


1.15


1.15

0.727

0.524

0.387

0.268

0.268

0.193


500±5%


500±5%

500±5%

500±5%

500±5%

500±5%

250±5%

250±5%

Current rating of XLPE - Insulated armoured cables
with copper conductor 600 / 1000 V to BS : 5467 : 1989

Norminal
Conductor
Area

In Air

In Ground



Sq.mm

*Single Core

2 Core

3 or 4 Core

*Single core

2 Core

3 or 4 Core

Trefoil

Flat

Trefoil

Flat

A

A

A

A

A

A

A

A


10


16

25

35

50

70

95

120

150

185


-


-

-

-

222

285

346

402

463

529


-


-

-

-

288

358

425

485

549

618


90


115

152

188

228

291

354

410

472

539


78


99

131

162

197

251

304

353

406

463


-


-

-

-

231

284

340

386

431

485


-


-

-

-

242

295

350

395

434

482




141


183

219

259

317

381

433

485

547




119


152

182

217

266

319

363

406

458

* Single core cables with Aluminium wire armour, 3 phase circuit Refer conditions for laying factors

Current rating of XLPE - Insulated unarmoured cables
with copper conductor 600 / 1000 V to BS : 5467 : 1989

Norminal
Conductor
Area

In Air

In Ground



Sq.mm

*Single Core

2 Core

3 or 4 Core

*Single core

2 Core

3 or 4 Core

Trefoil

Flat

Trefoil

Flat

A

A

A

A

A

A

A

A


10


16

25

35

50

70

95

120

150

185


-


-

-

-

209

2701

330

385

445

511


-


-

-

-

274

351

426

495

570

651


115


149

185

225

289

352

410

473

542

641


100


127

158

192

246

298

346

399

456

538


-


-

-

-

231

284

340

386

431

485


-


-

-

-

242

295

350

395

434

482




141


183

219

259

317

381

433

485

547




119


152

182

217

266

319

363

406

458

* Single core cables with Aluminium wire armour, 3 phase circuit Refer conditions for laying factors

Voltage drop at maximum conductor operating temperature in V/A/km for XLPE - Insulated cables
with copper conductor for rated voltages 600/1000V

Nominal Conductor area

** Single Core

2 core or 2 single
core

3 or 4
Core

Trefoil

Flat*

Sq.mm

V

V

V

V


10


16

25

35

50

70

95

120

150

185


4.0


2.5

1.65

1.15

0.87

0.62

0.47

0.39

0.39

0.28


4.0


2.5

1.65

1.15

0.90

0.70

0.58

0.51

0.45

0.41


4.7


2.9

1.9

1.35

1.00

0.69

0.52

0.42

0.35

0.29


4.0


2.5


1.65

1.15

0.87

0.60

0.45

0.37

0.30

0.26

* Adjacent cores have spacing twice the cable diameter
** Single core cables are aluminium wire armoured, 3 phase circuit
Refer conditions for laying factors