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 |
|