 |
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 |
Medium Voltage Cables |  |
|
|
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| Medium Voltage Cables to BS 6622 |  |
Medium Voltage Cables to IEC 60502 | |
Medium Voltage Cables to VDE 0276 |
Medium Voltage Cables to IEC 60502
Three Core Cables to IEC 60502
Application
The three core cables are designed for distribution of electrical power with nominal voltage Uo/U ranging from
1.8/3KV to 26/35KV and frequency 50Hz. They are suitable for installation mostly in power supply stations,
indoors and in cable ducts, outdoors, underground and in water as well as for installation on cable trays for
industries, switchboards and power stations.
Standards
IEC 60502 Part 1(1.8/3KV)
IEC 60502 Part 2(3.6/6KV to 18/30KV)
Construction
Conductor: Plain annealed copper or aluminium complying with IEC 60228 class 1 or 2.
Conductor Screen:
The conductor screen consists of an extruded layer of non metallic, semi-conducting compound applied on top of
a semi-conducting tape. The conductor screen is applied under triple extrusion process over the conductor along
with the insulation and the insulation screen. The extruded semi-conducting compound is firmly bonded to the
insulation to exclude all air voids and can be easily hand stripped on site. The conductor screen is not necessary
for both PVC and EPR/HEPR insulated 1.8/3.6KV and 3.6/6KV cables.
Insulation:
Insulation is of polyvinyl chloride (PVC) intended for 1.8/3.6KV and 3.6/6KV cables, cross-linked polyethylene
compound (XLPE) or ethylene propylene rubber (EPR/ HEPR).
Table 1. Insulation Thickness Of XLPE Or EPR/HEPR Insulation
| Nom. Cross Section Area |
Insulation Thickness at Nom. Voltage | |||||||
|---|---|---|---|---|---|---|---|---|
| 1.8/3kV (Um=3.6)kV |
3.6/6kV (Um=7.2)kV |
6/10KV (Um=12KV) |
8.7/15KV (Um=17KV) |
12/20KV (Um=24KV) |
18/30KV (Um=36KV) |
|||
| mm² | mm | mm | mm | mm | mm | mm | ||
| XLPE/EPR | XLPE | EPR | XLPE/EPR | XLPE/EPR | XLPE/EPR | XLPE/EPR | ||
| Unscr eened |
Scre ened |
|||||||
| 10 | 2.0 | 2.5 | 3.0 | 2.5 | - | - | - | - |
| 16 | 2.0 | 2.5 | 3.0 | 2.5 | 3.4 | - | - | - |
| 25 | 2.0 | 2.5 | 3.0 | 2.5 | 3.4 | 4.5 | - | - |
| 35 | 2.0 | 2.5 | 3.0 | 2.5 | 3.4 | 4.5 | 5.5 | - |
| 50 – 185 | 2.0 | 2.5 | 3.0 | 2.5 | 3.4 | 4.5 | 5.5 | 8.0 |
| 240 | 2.0 | 2.6 | 3.0 | 2.6 | 3.4 | 4.5 | 5.5 | 8.0 |
| 300 | 2.0 | 2.8 | 3.0 | 2.8 | 3.4 | 4.5 | 5.5 | 8.0 |
| 400 | 2.0 | 3.0 | 3.0 | 3.0 | 3.4 | 4.5 | 5.5 | 8.0 |
| 500 - 1600 | 2.2-2.8 | 3.2 | 3.2 | 3.2 | 3.4 | 4.5 | 5.5 | 8.0 |
Insulaton Screen:
The insulation screen consists of an extruded layer of non metallic, semi-conducting compound extruded over
the insulation of each core. The extruded semi- conducting layer shall consist of bonded or cold strippable semi-
conducting compound capable of removal for jointing or terminating. As an option, a semi-conducting tape may
be applied over the individual cores or core assembly as a bedding for the metallic layer. The minimum thickness
is 0.3 mm and the maximum resistivity is 500 Ohm-m at 90°C. The screen is tightly fitted to the insulation to
exclude all air voids and can be easily hand stripped on site. The insulation screen is not necessary for both PVC
and EPR/HEPR insulated 1.8/3.6KV and 3.6/6KV cables. The screen may be covered by semi-conductive water
blocking swellable tape to ensure longitudinal watertightness.
Inner Covering & Fillers:
For cables with a collective metallic layer or cables with a metallic layer over each individual cores with additional
collective metallic layers, semi-conducting inner covering and fillers shall be applied over the laid up cores. The
inner covering and fillers are made of non hygroscopic material like polypropylene, except if the cable is to be
made longitudinally watertight. The inner covering is extruded in general but may be lapped if the interstices
between the cores are filled.
The approximate thickness of extruded inner coverings is given in Table 2:
Table 2. Approximate Thickness Of Extruded Inner Coverings
Ficititous Diameter Over Laid Up Cores |
Approx. Thickress of Extruded Inner Covering |
|
|---|---|---|
| mm | mm | |
| > | < | |
| - | 25 | 1.0 |
| 25 | 35 | 1.2 |
| 35 | 45 | 1.4 |
| 45 | 60 | 1.6 |
| 60 | 80 | 1.8 |
| 80 | - | 2.0 |
*The approximate thickness of lapped inner coverings shall be 0.4mm for fictitious diameters over the laid up
cores up to and including 40mm and 0.6mm for larger diameter.
Metallic Layer: The concentric copper screen wire is applied over the insulation, or over the insulation screen or over an inner covering. As an alternative, copper tape(s) with minimum thickness of 0.1mm can be applied with overlap. Total cross section of copper wire screen and copper tape screen layer are shown in Table 3a and 3b.
Table 3a. Total Cross Section and Max. DC Resistance of Copper Wire Screen
Nom. Cross Section Area of Conductor |
Total Cross Section |
Max. DC Resistance at 20℃ |
||||
|---|---|---|---|---|---|---|
3.6/6KV (Um=7.2KV) |
6/10KV (Um=12KV) |
8.7/15KV (Um=17KV) |
12/20KV (Um=24KV) |
18/30KV (Um=36KV) |
||
mm² |
mm |
mm |
mm |
mm |
mm |
Ω |
10 |
10 |
- |
- |
- |
- |
1.075 |
16 |
16 |
16 |
- |
- |
- |
1.075 |
25 |
16 |
16 |
16 |
16 |
- |
1.075 |
35 |
16 |
16 |
16 |
16 |
- |
1.075 |
50 |
16 |
16 |
16 |
16 |
16 |
1.075 |
70 |
16 |
16 |
16 |
16 |
16 |
1.075 |
95 |
16 |
16 |
16 |
16 |
16 |
1.075 |
120 |
16 |
16 |
16 |
16 |
16 |
1.075 |
150 |
25 |
25 |
25 |
25 |
25 |
0.688 |
185 |
25 |
25 |
25 |
25 |
25 |
0.688 |
240 |
25 |
25 |
25 |
25 |
25 |
0.688 |
300 |
25 |
25 |
25 |
25 |
25 |
0.688 |
400 |
35 |
35 |
35 |
35 |
35 |
0.491 |
500 |
35 |
35 |
35 |
35 |
35 |
0.491 |
630 |
35 |
35 |
35 |
35 |
35 |
0.491 |
Table 3b. Total Cross Section and Max. DC Resistance of Copper Tape Screen (0.1mm)
Nom. Cross Section Area of Conductor |
Total Cross Section & Max. DC Resistance |
|||||||||
|---|---|---|---|---|---|---|---|---|---|---|
3.6/6KV (Um=7.2KV) |
6/10KV (Um=12KV) |
8.7/15KV (Um=17KV) |
12/20KV (Um=24KV) |
18/30KV (Um=36KV) |
||||||
|
Total Cross Section |
Max. DC |
Total Cross Section |
Max. DC |
Total Cross Section |
Max. DC |
Total Cross Section |
Max. DC |
Total Cross Section |
Max. DC |
mm² |
mm |
Ω |
mm |
Ω |
mm |
Ω |
mm |
Ω |
mm |
Ω |
10 |
4.2 |
4.122 |
- |
|
- |
|
- |
|
- |
- |
16 |
4.6 |
3.778 |
5.20 |
3.306 |
- |
|
- |
|
- |
- |
25 |
5.0 |
3.420 |
5.68 |
3.029 |
6.47 |
2.657 |
7.2 |
2.390 |
- |
- |
35 |
5.4 |
3.161 |
6.09 |
2.824 |
6.89 |
2.498 |
7.6 |
2.261 |
- |
- |
50 |
5.9 |
2.903 |
6.58 |
2.616 |
7.37 |
2.334 |
8.1 |
2.125 |
9.9 |
1.738 |
70 |
6.6 |
2.616 |
7.23 |
2.380 |
8.02 |
2.145 |
8.7 |
1.967 |
10.5 |
1.630 |
95 |
7.3 |
2.369 |
7.91 |
2.174 |
8.71 |
1.975 |
9.4 |
1.824 |
11.2 |
1.531 |
120 |
8.0 |
2.153 |
8.64 |
1.991 |
9.43 |
1.823 |
10.2 |
1.694 |
12.0 |
1.438 |
150 |
8.5 |
2.013 |
9.19 |
1.871 |
9.99 |
1.722 |
10.7 |
1.606 |
12.5 |
1.374 |
185 |
9.4 |
1.838 |
9.88 |
1.741 |
10.82 |
1.590 |
11.4 |
1.509 |
13.2 |
1.303 |
240 |
10.4 |
1.656 |
10.96 |
1.569 |
11.76 |
1.463 |
12.5 |
1.378 |
14.3 |
1.204 |
300 |
11.4 |
1.508 |
11.84 |
1.452 |
12.64 |
1.361 |
13.4 |
1.287 |
15.2 |
1.134 |
400 |
12.6 |
1.362 |
12.92 |
1.332 |
13.71 |
1.254 |
14.4 |
1.192 |
16.2 |
1.059 |
500 |
13.9 |
1.237 |
14.34 |
1.199 |
15.14 |
1.136 |
15.5 |
1.110 |
17.7 |
0.974 |
630 |
15.3 |
1.121 |
16.68 |
1.031 |
16.57 |
1.038 |
17.3 |
0.995 |
19.1 |
0.901 |
Separation Sheath (for armoured cable):
The separation sheath comprises a layer of extruded PVC, PE or LSZH applied over the laid up cores under the
armour. PVC is normally of grade ST2 and PE of grade ST7. The nominal thickness is calculated by 0.02Du +
0.6mm where Du is the fictitious diameter under the sheath in mm. For cables without a lead sheath, the
nominal separation sheath thickness shall not be less than 1.2mm. For cables where the separation sheath is
applied over the lead sheath, the nominal separation sheath thickness shall not be less than 1.0mm.
Tabel 4. Separation Thickness
| Cores Diameter | Approx. Thickress of Inner Sheath |
|
|---|---|---|
| mm | mm | |
| > | < | |
| 35 | 45 | 1.4 |
| 45 | 60 | 1.6 |
| 60 | 80 | 1.8 |
| 80 | - | 2.0 |
Lapped Bedding (for armoured lead sheathed cable):
The lapped bedding applied to the lead sheath consists of either impregnated/synthetic compounded paper
tapes or a combination of two layers of these paper tapes followed by a few layers of compounded fabulous
materials. The thickness is around 1.5mm.
Armour (for armoured cable):
The armour is applied over the inner covering helically. It consists of either flat galvanized steel wire armour
(strip), round galvanized steel wire armour, and double steel tape armour.
Table 5. Round Armour Wire Diameter
| Fictitious Diameter Under the Armour | Armour Wire Diameter | |
|---|---|---|
| mm | mm | |
| > | < | |
| - | 10 | 1.25 |
| 10 | 15 | 1.25 |
| 15 | 25 | 1.6 |
| 25 | 35 | 2.0 |
| 35 | 60 | 2.5 |
| 60 | - | 3.15 |
Table 6. Armour Tape Thickness
| Fictitious Diameter Under the Armour | Galvanized Steel / Steel | Aluminum / Aluminium Alloy | |
|---|---|---|---|
| mm | mm | mm | |
| > | < | ||
| - | 30 | 0.2 | 0.5 |
| 30 | 70 | 0.5 | 0.5 |
| 70 | - | 0.8 | 0.8 |
For flat wire armour and fictitious diameter under the armour greater than 15mm, the nominal thickness of the
flat steel wire diameter shall be 0.8mm.Cables with fictitious diameter under the armour up to and including
15mm, flat wire armour will not be used. The tape armour is applied helically in two layers so that the outer tape
is approximately central over the gap of the inner tape. If tape armour is used, the inner covering shall be
reinforced by taped bedding.
Over Sheath:
Overall sheath comprises a layer of extruded either thermoplastic compound (PVC ST3 type or PE ST7 type) or
elastomeric compound (polychlorprene CSP or chlorosulfonated PE). The nominal oversheath thickness is
calculated by 0.035D+1 where D is the fictitiuous diameter immediately under the oversheath in mm. For
unarmoured cables and cables with the oversheath not applied over the armour, metallic screen or concentric
conductor, the nominal oversheath thickness shall not be less than 1.4mm. And for cables with oversheath
applied over the armour, metallic screen or concentric conductor, the nominal oversheath thickness shall not be
less than 1.8mm.
PHYSICAL PROPERTIES:
Operating Temperature: up to 70°C (PVC insulation); up to 90°C (XLPE or EPR insulation)
Temperature Range: -5°C ( PVC sheath ); -20°C ( PE sheath )
Short Circuit Temperature( 5 seconds maximum duration ): 140-160 °C (PVC insulation);
250°C (XLPE or EPR insulation)
Bending Radius: 15 x OD
Table 7. Nominal /Operating /Testing Voltages
| Rated Voltage Uo/U | Operating Voltage (Um) | Testing Voltage (rms) |
|---|---|---|
| 1.8/3KV | 3.6KV | 6.5KV |
| 3.6/6KV | 7.2KV | 12.5KV |
| 6/10KV | 12KV | 21KV |
| 8.7/15KV | 17.5KV | 30.5KV |
| 12/20KV | 24KV | 42KV |
| 18/30KV | 36KV | 63KV |
*21/35KV and 26/35kV power frequency voltage test can be made under the following conditions: 2.5Uo x
30mins or 3.0Uo x 15mins. Numbers in brackets refer to the test values for 3.0Uo x 1.5mins.
Three Core 1.8/3KV (Um=3.6KV) Dimensional Data
|
|
Unarmoured Cables |
Steel Round-Wire Armoured Cables |
||||||||
Nom. Cross- Section Area |
Nom. Insulation Thickness |
Nom. Sheath Thickness |
Approx. Overall Diameter |
Approx. Weight |
Nom. Bedding Thickness |
Armour Wire Size |
Nom. Sheath Thickness |
Approx. Overall Diameter |
Approx. Weight |
||
CU |
AL |
CU |
AL |
||||||||
mm² |
mm |
mm |
mm |
kg/km |
mm |
mm |
mm |
mm |
kg/km |
||
10 |
2.0 |
1.8 |
23 |
650 |
460 |
1.2 |
1.6 |
1.8 |
28 |
1480 |
1290 |
16 |
2.0 |
1.8 |
24 |
840 |
540 |
1.2 |
1.6 |
1.9 |
29 |
1720 |
1410 |
25 |
2.0 |
1.8 |
26 |
1160 |
680 |
1.2 |
1.6 |
1.9 |
32 |
2130 |
1650 |
35 |
2.0 |
1.8 |
29 |
1490 |
820 |
1.2 |
2.0 |
2.1 |
36 |
2810 |
2140 |
50 |
2.0 |
1.9 |
32 |
1900 |
1000 |
1.2 |
2.0 |
2.2 |
39 |
3340 |
2450 |
70 |
2.0 |
2.0 |
36 |
2580 |
1290 |
1.2 |
2.0 |
2.3 |
42 |
4200 |
2910 |
95 |
2.0 |
2.2 |
40 |
3440 |
1640 |
1.3 |
2.5 |
2.4 |
47 |
5620 |
3820 |
120 |
2.0 |
2.3 |
43 |
4220 |
1950 |
1.3 |
2.5 |
2.5 |
51 |
6580 |
4310 |
150 |
2.0 |
2.4 |
46 |
5090 |
2290 |
1.4 |
2.5 |
2.7 |
54 |
7680 |
4870 |
185 |
2.0 |
2.5 |
50 |
6240 |
2730 |
1.5 |
2.5 |
2.8 |
58 |
9060 |
5560 |
240 |
2.0 |
2.7 |
56 |
8030 |
3430 |
1.6 |
2.5 |
3.0 |
64 |
11200 |
6600 |
300 |
2.0 |
2.8 |
60 |
9890 |
4100 |
1.6 |
2.5 |
3.1 |
69 |
13590 |
7500 |
400 |
2.0 |
3.1 |
68 |
12530 |
5150 |
1.8 |
3.15 |
3.4 |
78 |
17260 |
9880 |
500 |
2.2 |
3.3 |
75.7 |
16680 |
7510 |
1.8 |
3.15 |
3.5 |
84.3 |
21780 |
13025 |
630 |
2.4 |
3.5 |
84.9 |
21770 |
10040 |
1.8 |
3.15 |
3.8 |
94.6 |
27400 |
16050 |
|
Steel Flat Wire Armoured Cables |
Double Steel Tape Armoured Cables |
||||||||||
Nom. Cross- Section Area |
Nom. Bedding Thickness |
Armour Wire Size |
Nom.Sheath Thickness |
Approx. Overall Diameter |
Approx. Weight |
Nom. Bedding Thickness |
No of Steel Tapes x Nom Tape Thickness |
Nom. Sheath Thickness |
Approx. Overall Diameter |
Approx. Weight |
||
CU |
AL |
CU |
AL |
|||||||||
mm² |
mm |
mm |
mm |
mm |
kg/km |
mm |
mm |
mm |
mm |
kg/km |
||
10 |
1.2 |
0.8 |
1.8 |
24.5 |
1245 |
1065 |
1.2 |
2 x 0.2 |
1.8 |
23.6 |
925 |
750 |
16 |
1.2 |
0.8 |
1.8 |
27.1 |
1565 |
1280 |
1.2 |
2 x 0.2 |
1.8 |
26.2 |
1205 |
925 |
25 |
1.2 |
0.8 |
1.8 |
29.7 |
1975 |
1525 |
1.2 |
2 x 0.2 |
1.9 |
29.0 |
1590 |
1145 |
35 |
1.2 |
0.8 |
1.9 |
32.5 |
2420 |
1805 |
1.2 |
2 x 0.2 |
1.9 |
31.6 |
1985 |
1370 |
50 |
1.2 |
0.8 |
2.0 |
35 |
2860 |
2080 |
1.2 |
2 x 0.2 |
2.0 |
34.1 |
2400 |
1605 |
70 |
1.2 |
0.8 |
2.1 |
38.7 |
3685 |
2525 |
1.2 |
2 x 0.5 |
2.2 |
39.5 |
3570 |
2410 |
95 |
1.3 |
0.8 |
2.2 |
42.9 |
4695 |
3080 |
1.3 |
2 x 0.5 |
2.3 |
43.7 |
4570 |
2950 |
120 |
1.3 |
0.8 |
2.3 |
46.4 |
5650 |
3585 |
1.3 |
2 x 0.5 |
2.4 |
46.1 |
5510 |
3440 |
150 |
1.4 |
0.8 |
2.4 |
49.6 |
6630 |
4085 |
1.4 |
2 x 0.5 |
2.6 |
50.6 |
6500 |
3955 |
185 |
1.5 |
0.8 |
2.6 |
54.1 |
7990 |
4820 |
1.5 |
2 x 0.5 |
2.7 |
54.9 |
7825 |
4650 |
240 |
1.6 |
0.8 |
2.7 |
59.2 |
10060 |
5790 |
1.6 |
2 x 0.5 |
2.8 |
60.0 |
9825 |
5600 |
300 |
1.6 |
0.8 |
2.9 |
64.6 |
12230 |
6865 |
1.6 |
2 x0.5 |
3.0 |
65.4 |
12030 |
6660 |
400 |
1.8 |
0.8 |
3.1 |
71.0 |
15200 |
8280 |
1.8 |
2 x 0.5 |
3.2 |
71.8 |
14970 |
8055 |
500 |
1.8 |
0.8 |
3.3 |
79.5 |
19090 |
10255 |
1.8 |
2 x 0.8 |
3.5 |
80.5 |
18880 |
10035 |
630 |
1.8 |
0.8 |
3.6 |
89.8 |
24400 |
12920 |
1.8 |
2 x 0.8 |
3.8 |
92.3 |
25070 |
13620 |
Electrical Data
Nom. Cross- Section Area |
D C Resistance CU / AL |
A C Resistance CU / AL |
Short Circuit Rating of Conductor CU / AL |
Capaci- tance |
Charging Current |
Reactance |
Inductance |
mm² |
µΩ/m |
µΩ/m |
kA |
pF/m |
mA/m |
µΩ/m |
nH/m |
10 |
1830/3080 |
2330/3920 |
1.4/0.9 |
160 |
0.25 |
101 |
390 |
16 |
1150/1910 |
1460/2420 |
2.2/1.4 |
180 |
0.27 |
98 |
370 |
25 |
727/1200 |
929/1538 |
3.6/2.3 |
220 |
0.29 |
95 |
350 |
35 |
524/868 |
668/1113 |
5.0/3.2 |
250 |
0.31 |
92 |
330 |
50 |
387/641 |
494/822 |
6.8/4.4 |
270 |
0.33 |
88 |
310 |
70 |
268/443 |
343/568 |
9.8/6.3 |
310 |
0.35 |
84 |
290 |
95 |
193/320 |
248/410 |
13.3/8.5 |
350 |
0.38 |
81 |
270 |
120 |
153/253 |
196/325 |
17.2/11.0 |
380 |
0.46 |
79 |
250 |
150 |
124/206 |
159/265 |
21.2/13.5 |
420 |
0.50 |
77 |
260 |
185 |
99/164 |
128/211 |
26.6/17.0 |
460 |
0.56 |
76 |
250 |
240 |
75/125 |
98/161 |
34.9/22.3 |
510 |
0.61 |
74 |
240 |
300 |
60/100 |
80/130 |
43.8/28.0 |
570 |
0.68 |
73 |
250 |
400 |
47/78 |
64/102 |
57.3/36.6 |
590 |
0.70 |
71 |
240 |
500 |
37/60 |
57/81 |
72.3/46.2 |
610 |
0.72 |
69 |
230 |
630 |
28/47 |
42/64 |
91.2/58.3 |
630 |
0.74 |
67 |
220 |
Three Core 3.6/6KV (Um=7.2KV)
Three Core 6/10KV (Um=12KV)
Three Core 8.7/15KV (Um=17.5KV)
Three Core 12/20KV (Um=24KV)
Three Core 18/30KV (Um=36KV)
Current Rating for Three Core 3.6/6KV(Um=7.2 )KV to 18/30KV(Um=36KV)
Current Rating Conditions:
Ground Temperature: 20°C
Ambient Temperature (air): 30°C
Depth of Soil: 0.8 m
Thermal Resistance of Soil: 1.5K•m/W