BUILDING SECTION: LOW VOLTAGE SECTION: MEDIUM VOLTAGE SECTION: HIGH VOLTAGE AND EXTRA HIGH SECTION:

PRODUCT RANGE QICC – a Nexans Company is committed to deliver the highest standard wires and power cables to the local market, GCC and for export. In ...
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PRODUCT RANGE QICC – a Nexans Company is committed to deliver the highest standard wires and power cables to the local market, GCC and for export. In order to fit for the customer demand in the Middle East and for export, QICC – a Nexans Company produces a versatile product range covers most of our customer needs:

BUILDING SECTION: • Flexible wires and cables up to 16 mm2 to IEC 60227, EN 50525, BS 6004 & BS 6500. • Building wires (NYA) to IEC 60227, EN 50525 and BS 6004, from 1.5 mm2 and above. • Halogen Free Flame Retardant wire (HFFR/LSZH) to BS 7211 and EN 50525, with thermo setting insulation which is alternative to wire type (NYA), where the application requires higher standards of safety against the emission of smoke, fumes and toxic gases. The wires coming mainly single core.

LOW VOLTAGE SECTION: • Low Voltage power Cables with PVC and XLPE insulation to IEC 60502-1, BS 5476 and BS 6346. The cables can be single core, and multi core up to 48 cores.

MEDIUM VOLTAGE SECTION: • Medium Voltage cables to IEC 60502-2 up to 18/30 (36) kV and to BS 6622 up to 19/33 (36) kV. • LV cables with HFFR, thermosetting insulation. The cables are produced according to BS 6724, IEC 60502-1and tested to IEC 61034, IEC 60754 & IEC 60332. • MV cables with HFFR to BS 7835. The cables can be single core, and three cores cable.

HIGH VOLTAGE AND EXTRA HIGH SECTION: • High Voltage and Extra High Voltage cables up to 220 kV to IEC 60840 / IEC 62067, with conductor sizes up to 2500 mm2. The cables are single core only.

DESIGN CRITERIA A power cable is an assembly of one or more electrical conductors, usually held together with an overall sheath. The assembly is used for transmission of electrical power. Power cables may be installed as permanent wiring within buildings, buried in the ground, run overhead, or exposed. Flexible power cables are used for portable devices, mobile tools and machinery.

1. CONDUCTOR: Is an object or type of material that permits the flow of electrical current in one or more directions. Conductor materials are: - Plain annealed or tin coated copper conductor (to BS EN 1977, ASTM B3, ASTM B49 &ASTM B 33) - Aluminum (to ASTM B233) The conductor structure is complying with the requirements of IEC 60228 class 2 stranded, non compacted, compacted or compacted sector shaped conductors.

2. INSULATION: The insulating materials used include: 2.1 Polyvinylchloride (PVC): (PVC/A 70 oC) complying with IEC 60502-1 requirements or Types (TI1 70 oC) & Heat Resistant PVC type TI-3 (90 oC to 105 oC) complying with BS EN 50363-3. 2.2 Halogen-Free, Flame Retardant compound (HFFR). 2.3 Cross-linked polyethylene (XLPE): complying with IEC 60502 and GP8 as per BS 7655-1.3 The insulation of building wires is covered by Ultra-violet (UV) resistant Masterbatch.

3. Insulated Core Color Codes: Number of cores 1

Colors to IEC 60502-1 Red or Black

Colors to BS 5467 Brown or Blue

2

Red & Black

Brown & Blue

3

Red, Yellow and Blue

Brown, Black and Grey

4

Red, Yellow, Blue and Black

Blue, Brown, Black and Grey

5

Red, Yellow, Blue, Black and Green / Yellow

Green / Yellow, Blue, Brown, Black and Grey

4. SCREEN DESIGNS: The standard range of QICC Medium Voltage XLPE cables rated up to and including 33 kV incorporates copper wire screens based on fault levels of either 3 kA or 10 kA for 1 second. If either of the standard screen designs does not suit a particular installation, the screen constructions can be tailored in size to meet the specific fault requirements of any operating system.

5. WIRE SCREEN CROSS SECTIONAL AREAS: In the case of three core cables which have screens around each individual core, the total screen cross sectional area is spread evenly over the three cores. There are several other factors which can override the above criteria. Firstly, the screens are designed so that the average gap between the wires does not exceed 4 mm. This result in the screen area being increased above that required for the required fault level in certain cases. Secondly, the screen area is limited to a value so that its fault rating does not exceed that of the conductor. In some cases, the smaller cables in a range have fault levels of less than either 3 kA or 10 kA for 1 second respectively.

6. CABLE ASSEMBLY: The Insulated cores are assembled together to form the laid up cable cores in case of multi core cables. Extruded suitable polymer compound or non-hygroscopic polypropylene filler is applied (when required) between laid up cores to provide a circular shape to the cable.

7. JACKETINGS: There are 3 different types of extruded sheaths: 7.1 Outer sheath It provides protection of the cable from outside. 7.2 Inner sheath It applies under a metallic protection and - optional - under a lead sheath. 7.3 Bedding It separate the sheath applied between a lead sheath and a metallic protection (may also consists of plastic tapes).

The following materials can be used for the sheath:

 Polyvinylchloride (PVC) Type ST2 compounds as specified in IEC 60502-1, or its equivalent PVC Type 9 to BS 7655-4.2.  Polyethylene (PE) compound fulfill and exceed the requirements of Type ST7 IEC 60502-1 for cables that require being abrasion resistant, protected against water ingress and strong Environmental Stress Crack Resistant (ESCR).  Halogen Free Flame Retardant (HFFR) compounds complying with ST8 to IEC 60502-1 or Types LTS 1 & LTS 4 to BS 7655: section 6 for cables installed in intrinsically safe locations and where the cables require being low smoke, low fume and low toxic gas emitting in case of fire. Cables to this category are complying with the requirements of BS 6724.  All cables produced at QICC – a Nexans Company with PVC or HFFR jackets are complying with the flame retardant test to IEC 60332-1 and Ultra-violet (UV) resistant Masterbatch.  Whenever a requirement for more severe tests as IEC 60332-3 is needed, Oil resistant and Hydrocarbon resistant for Oil and Gas projects.

8. ARMOUR: There are 3 different types of armouring are listed below:  Galvanized round steel wire armour “SWA”: (The wire diameter depends on the cable diameter under armour, min. diameter 0.9 mm).  Single or double layer of steel “STA” : (The minimum thickness of a tape shall be 0.2 mm).  Aluminum or copper wire armour “AWA / CWA”: (The wire diameter depends on the cable diameter under armour, min. diameter 0.9 mm).

9. JACKETING MARKETING: Standard engraving outer Jacket Marking consisting of:

1. 2. 3. 4.

Type designation, size of conductor, rated voltage, standard. Name of manufacturer “QICC-Nexans”. Year, continuous length marking every meter. Any special part no. on request.

10. INSTALLATION

Low voltage cables with both PVC and XLPE insulation are suitable for indoor and outdoor applications. The methods are based on IEC 60364-5-52 or BS 7671 IEE wiring regulation seventeenth edition. Below are the recommendations to be followed in order to get the optimal cable service: 1. Unarmoured cables are not recommended for direct buried applications, except if the quoted cables are designed and produced to pass direct burial test requirements (example, direct burial tests described in UL 1277 and UL 1581). 2. Armoured cables are not recommended for tray applications, as they are heavy in weight and extra loads are exerted on the tray. 3. A PVC jacket is a very stable material against a wide range of chemicals, while HDPE jacketed cables can serve better in wet locations. 4. A recommended minimum bending radius as per the technical data sheet of each group. 5. HFFR cables are not recommended for direct buried applications, as the material is soft and it’s mainly for building proposes.

10.1

CABLE PULLING-IN FORCE:

Care should be taken to prevent damage to insulation or distortion of cable during installation. The pulling force in Newtons should not exceed 0.036 times the circular mil area of the copper cross-sectional area times the number of conductors in the cable when pulling on the conductors utilizing pulling eyes and bolts. Pulling force for multi core cables when utilizing eyes or bolts should not include drain or ground conductors in the copper cross-sectional area. When pulling with a basket weave grip, maximum pulling tension (per grip) should not exceed 4.5kN, or the value calculated for eyes or bolts, whichever is greater. The sidewall pressure should not exceed a maximum of 7.3kN per meter of the inside radius of the bend. Cables should not be pulled in freezing conditions. If conditions are below 0°C, consult the manufacturer. If it is necessary to pull in these conditions, cables should be stored at a temperature above 10°C for 24 h prior to installation, if the cable has been previously stored in an area under 0°C. When installing low smoke cables, additional consideration should be given to handling and lubrication due to their possible lower tear strength and higher coefficient of friction than other marine cable. For more guidance concerning this subject, refer to IEEE Std 576-2001

10.2

Single-conductor ac cables:

To avoid an undesirable inductive effect in ac installations, the following precautions should be observed.

Closed magnetic circuits around single-conductor ac cable should be avoided, and no magnetic material should be permitted between cables of different phases of a circuit. 1. Single-conductor ac cables should not be located closer than 76mm from parallel magnetic material. 2. Single-conductor ac cable should be supported on insulators. Armor, if used, should be grounded only at approximately the midpoint of the cable run. 3. Where single-conductor ac cables penetrate the bulkhead, conductors of each phase of the same circuit should pass through a common nonferrous bulkhead plate to prevent heating of the bulkhead. 4. Single-conductor cables in-groups should be arranged to minimize their inductive effect. This may be accomplished by the transposition of cables in groups of three (one each phase) to give the effect of triplexed cable. This transposition should be made at intervals of not over 15m and need not be made in cable runs of less than 30m.

10.3

Cable continuity and grounding:

All cable should be continuous between terminations; however, splicing is permitted under certain conditions. For cable provided with armor, the armor should be electrically continuous between terminations and should be grounded at each end (multi conductor cables only); except that for final sub circuits, the armor may be grounded at the supply end only.

10.4

Cable locations:

Cable installation should avoid spaces where excessive heat and gases may be encountered such as galleys, boiler rooms and pump rooms, and spaces where cables may be exposed to damage such as cargo spaces and exposed sides of deck houses. Cables should not be located in cargo tanks, ballast tanks, fuel tanks, or water tanks except to supply equipment and instrumentation specifically designed for such locations and whose functions require it to be installed on the tank. Such equipment may include submerged cargo pumps and associated control devices, cargo monitoring, and underwater navigation systems. Unless unavoidable, cables should not be located behind or embedded in structural heat insulation. Where cables are installed behind paneling, all connections should be readily accessible and the location of concealed connection boxes should be indicated. Cables should preferably not be run through refrigerated cargo spaces. Cables should not be located below the faceplate of the vessel s main bottom structural members or within .6m above any double bottom tank top.

10.5

Cable protection:

Cables should be adequately protected where exposed to mechanical damage. Cables should be secured against chafing or displacement due to vibration. Cables in bunkers, and where particularly liable to damage, such as locations in way of cargo ports, hatches, tank tops, and where passing

through decks, should be protected by removable metal coverings, angle irons, or other equivalent means. Where cables pass through insulation, they should be protected by a continuous pipe. For wiring entering refrigerated compartments, the pipe should be of heat-insulating material (fiber or phenolic tubing) joined to the bulkhead-stuffing tube, or a section of such material should be inserted between the bulkhead-stuffing tube and the metallic pipe. Where cables are installed in pipes, the space factor (ratio of the sum of the cross-sectional areas corresponding to the external diameter of the cables to the internal cross-sectional areas of the pipe) shall not be greater than 0.41, except for two cables, where the space factor shall not exceed 0.31, Pipes shall be so arranged or designed to prevent the accumulation of internal condensation.

MANUFACTURING CHART

ELECTRICAL CHARACTERISTICS STANDARDS RELATED TO POWER CABLES 1.

THE INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

DOCUMENT NO.

DOCUMENT NAME

IEC 60038

IEC standard voltages - Edition 7.0

IEC 60050-121

AMENDMENT 2 International Electro technical Vocabulary – Part 121: Electromagnetism - Edition 2.0

IEC 60060-1

High-Voltage Test Techniques Part 1: General Definitions and Test Requirements - Edition 2.0; The contents of the corrigendum of March 1992 have been included in this copy

IEC 60183 AMD

Guide to the Selection of High-Voltage Cables - Edition 2.0

IEC 60227-1

Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V “ Part 1: General requirements - Edition 3.0

IEC 60227-2

Polyvinyl Chloride Insulated Cables of Rated Voltages up to and Including 450/750 V - Part 2: Test Methods - Edition 2.1; Edition 2: 1997 Consolidated with Amendment 1: 2003

IEC 60227-3

Polyvinyl Chloride Insulated Cables of Rated Voltages up to and Including 450/750 V - Part 3: Non-Sheathed Cables for Fixed Wiring - Edition 2.1

IEC 60227-4

Polyvinyl Chloride Insulated Cables of Rated Voltages up to and Including 450/750 V - Part 4: Sheathed Cables for Fixed Wiring - Edition 2.1; Edition 2: 1992 Consolidated with Amendment 1: 1997

IEC 60227-5

Polyvinyl Chloride Insulated Cables of Rated Voltages up to and Including 450/750 V - Part 5: Flexible Cables (Cords) - Edition 2.2; Edition 2: Consolidated with Amendments 1:1997 and 2:2003

IEC 60227-6

Polyvinyl Chloride Insulated Cables of Rated Voltages up to and Including 450/750 V - Part 6: Lift Cables and Cables for Flexible Connections - Third Edition

IEC 60227-7

Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V Part 7: Flexible cables screened and unscreened with two or more conductors - Edition 1.1; Edition 1: 1995 Consolidated with Amendment 1: 2003 Electric cables “ Tests on extruded over sheaths with a special protective function - Edition 3.0

IEC 60229 IEC 60230

Impulse Tests on Cables and Their Accessories - First Edition

IEC 60270

High-Voltage Test Techniques - Partial Discharge Measurements - Third Edition; Corrigendum 1, 10/2001

IEC 60287-1-3

Electric Cables - Calculation of the Current Rating - Part 1-3: Current Rating Equations (100% Load Factor) and Calculation of Losses - Current Sharing between Parallel Single-Core Cables and Calculation of Circulating Current Losses - First Edition Electric cables “ Calculation of the current rating – Part 2-1: Thermal resistance “ Calculation of the thermal resistance CORRIGENDUM 1 Edition1.2

IEC 60287-2-1

IEC 60332-3-10

Tests on electric and optical fibre cables under fire conditions “ Part 3-10: Test for vertical flame spread of vertically-mounted bunched wires or cables “ Apparatus - Edition 1.1; Consolidated Reprint

IEC 60332-3-21

Tests on Electric Cables Under Fire Conditions - Part 3-21: Test for Vertical Flame Spread of Vertically-Mounted Bunched Wires or Cables - Category A F/RFirst Edition

IEC 60332-3-22

Tests on electric and optical fiber cables under fire conditions “ Part 3-22: Test for vertical flame spread of vertically-mounted bunched wires or cables “ Category A - Edition 1.1; Consolidated Reprint

IEC 60332-3-23

Tests on electric and optical fiber cables under fire conditions “ Part 3-23: Test for vertical flame spread of vertically-mounted bunched wires or cables “ Category B - Edition 1.1; Consolidated Reprint

IEC 60332-3-24

Tests on electric and optical fiber cables under fire conditions “ Part 3-24: Test for vertical flame spread of vertically-mounted bunched wires or cables “ Category C - Edition 1.1; Consolidated Reprint

IEC 60332-3-25

Tests on electric and optical fiber cables under fire conditions “ Part 3-25: Test for vertical flame spread of vertically-mounted bunched wires or cables “ Category D - Edition 1.1; Consolidated Reprint

IEC 60364-5-52

Low-voltage electrical installations – Part 5-52: Selection and erection of electrical equipment “ Wiring systems - Edition 3.0

IEC 60446

Basic and safety principles for man-machine interface, marking and identification “ Identification of conductors by colours or alphanumerics Edition 4.0

IEC 60502-1

Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) – Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV) - Edition 2.1; Consolidated Reprint Power Cables with Extruded Insulation and Their Accessories for Rated Voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 2: Cables for Rated Voltages from 6 kV (Um = 7,2 kV) and up to 30 kV (Um = 36 kV) - Edition 2 Calculation of the Lower and Upper Limits for the Average Outer Dimensions of Cables with Circular Copper Conductors and of Rated Voltages up to and Including 450/750 V - Edition 2; CENELEC EN 60719: 1993

IEC 60502-2

IEC 60719

IEC 60724

Short-circuit temperature limits of electric cables with rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV) - Edition 3.1; Consolidated Reprint

IEC 60826

Design criteria of overhead transmission lines - Third Edition

IEC 60840

Power cables with extruded insulation and their accessories for rated voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) Test methods and requirements - Third Edition

IEC 60853-3

Calculation of the Cyclic and Emergency Current Rating of Cables Part 3: Cyclic Rating Factor for Cables of all Voltages, with Partial Drying of the Soil First Edition

IEC 60865-1

Short-circuit currents - Calculation of effects - Part 1: Definitions and calculation methods - Second Edition; Corrigendum 1: 03/1995

IEC 60885-1

Electrical test methods for electric cables Part 1: Electrical tests for cables, cords and wires for voltages up to and including 450/750 V - First Edition

IEC 60885-3

Electrical Test Methods for Electric Cables Part 3: Test Methods for Partial Discharge Measurements on Lengths of Extruded Power Cable First Edition First Edition

IEC 60889

Hard-Drawn Aluminum Wire for Overhead Line Conductors - First Edition

IEC 60949 AMD 1

AMENDMENT 1 Calculation of thermally permissible short-circuit currents, taking into account non-adiabatic heating effects - Edition 1.0

IEC 60986

Short-circuit temperature limits of electric cables with rated voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV) - Edition 2.1; Consolidated Reprint

IEC 61089

Round Wire Concentric Lay Overhead Electrical Stranded Conductors - First Edition; Amendment 1-1997; Replaces 60207 thru 60210: 1966

IEC 62067

Power cables with extruded insulation and their accessories for rated voltages above 150 kV (Um = 170 kV) up to 500 kV (Um = 550 kV) – Test methods and requirements - Edition 1.1 * Consolidated Reprint

IEC GUIDE 104

Preparation of Safety Publications and the Use of Basic Safety Publications and Group Safety Publications - Third Edition

IEC TR 61597

Overhead Electrical Conductors - Calculation Methods for Stranded Bare Conductors - Edition 1

IEC TS 61394

Overhead Lines - Characteristics of Greases for Aluminium, Aluminium Alloy and Steel Bare Conductors - Edition 1.0; Includes Access to Additional Content

2.

THE BRITISH STANDARD (BS) DOCUMENT NO.

DOCUMENT NAME

BS 5099

Electric cables - Voltage levels for spark testing

BS 5467

Electrical cables - Thermosetting insulated, armoured cables for voltages of 600/1 000 V and 1 900/3 300 V Electric cables - PVC insulated, non-armoured cables for voltage up to and including 450/750 V, for electric power, lighting and internal wiring.

BS 6004 BS 6469-99.1

Insulating and sheathing materials of electric cables

BS6724

Electric cables - Thermosetting insulated, armoured cables for voltages of 600/1 000 V and 1 900/3 300 V, having low emission of smoke and corrosive gases when affected by fire

BS 7211

Electric cables - Thermosetting, insulated, non-armoured cables for voltages up to and including 450/750V, for electric power, lighting and internal wiring, and having low emission of smoke and corrosive gases when affected by fire Specification for Insulating and sheathing materials for cables. Section 6. General application thermoplastic types.

BS 7655 BS 7655

Specification for Insulating and sheathing materials for cables. Section 1.2 General 90°C application

BS 7655-0

Specification for insulating and sheathing materials for cables

BS 7655-1.3

Specification for Insulating and sheathing materials for cables.

BS 7655-4.2

Specification for Insulating and sheathing materials for cables - Part 4. PVC sheathing compounds - Section 4.2: General application

BS 7835

Electric cables - Armoured cables with thermosetting insulation for rated voltage from 3.8/6.6kv to 19/33kv having low emission of smoke and corrosive gases when affected by fire - requirements and test methods.

BS 7846

Electric cables - Thermosetting insulated, armoured, fire resistance cables of rated 600/1 000 V, having low emission of smoke and corrosive gases when affected by fire - Specification.

BS 7870-4.10

LV and MV polymeric insulated cables for use by distribution and generation utilities - Part 4: Specification for distribution cables with extruded insulation for rated voltage of 11kV and 33 kV - Section 4.10: Single -core 11kV and 33kV cables. LV and MV polymeric insulated cables for use by distribution and generation utilities - Part 4: Specification for distribution cables with extruded insulation for rated voltage of 11kV and 33 kV - Section 4.11: Single -core 33kV lead sheathed cables. LV and MV polymeric insulated cables for use by distribution and generation utilities - Part 4: Specification for distribution cables with extruded insulation for rated voltage of 11kV and 33 kV - Section 4.20: Three -core 11kV cables.

BS 7870-4.11

BS 7870-4.20

BS 7889

Electric cables - Thermosetting insulated, unarmored cables for a voltage of 600/1 000 V

BS 7970

Electric cables - metallic wire foil sheat constructions of power cables having XLPE insulation for rated voltage from 66 kv (Um = 72.5 kv) to 132 kv (Um = 145 kv)

BS EN 10257-1:

Zinc or Zinc alloy coated non-alloy steel wire for armoring either power cables or telecommunication cables

BS EN 50267-2-1

Common test methods for cables under fire conditions - Test on gases evolved during combustion of materials from cables.

EN50525-2-31

Electric cables Low voltage energy cables of rated voltages up to and including 450/750 V (U0/U) Part 2-31: Cables for general applications Single core non-sheathed cables with thermoplastic PVC insulation

EN50525-3-41

Electric cables Low voltage energy cables of rated voltages up to and including 450/750 V (U0/U) Part 3-41: Cables with special fire performance Single core non-sheathed cables with halogen-free cross linked insulation and low emission of smoke

BS EN 50363-3

Insulating, sheathing and covering materials for low voltage energy cables Part 3: PVC insulating compounds

BS EN 50363-4-1

Insulating, sheathing and covering materials for low voltage energy cables

BS EN 50363-5

Insulating, sheathing and covering materials for low voltage energy cables

BS EN 60230 BS EN 60332-1-2

Impulse test on cables and their accessories Test on electric and optical fiber cables under fire conditions - Part 1-2: Test for vertical flame propagation for a single insulated wire or cable - Procedure for 1kW pre-mixed flame

BS EN 60332-2-2

Test on electric and optical fiber cables under fire conditions - Part 1-2: Test for vertical flame propagation for a single small insulated wire or cable Procedure for diffusion flame

BS EN 60332-3-24

Test on electric and optical fiber cables under fire conditions

BS EN 60811-1-1

Insulating and sheathing materials of electric and optical cables - Common Test methods - Part 1-1: General application - Measurement of thinness and overall dimensions - Test for determining the mechanical properties

BS EN 60811-1-2

Common test methods for insulating and sheathing materials of electric and optical cables Insulating and sheathing materials of electric and optical cables - Common Test methods

BS EN 60811-1-3 BS EN 60885-3

Electrical test methods for electric cables

BS EN 61034-2

Measurement of smoke density of cables burning under defined condition Part 2: Test procedure and requirements.

BS EN 62230 BS EN ISO 14001

Electric cables - Spark-test method Environmental management systems - Requirements with guidance for use

BS EN ISO 6892-1

Metallic materials - Tensile testing Part 1: Method of test at ambient temperature.

BS EN ISO 9001

Quality management system - Requirements

BS OSHAS 18001

Occupational health and safety management system - requirements

BS 7655: Section 6.1

Specification for Insulating and sheathing materials for cables

SELECTION OF CABLES: It is essential to consider the specific system and installation conditions to be able to select the right cable. The following criteria should be taken into account to choose the suitable cable.

1. Cable Laying: Depending on the nature of the cable system (fixed or mobile) a rigid or flexible cable should be selected. The appropriate protection of a cable will be determined taking into account the mechanical stress and presence of chemical, oils or hydrocarbons.

2. Ambient and ground Temperature The quality of the material used to manufacture a cable shall be determined according to the maximum and minimum temperatures to which the cable will be submitted.

3. Nature of Conductors Copper or aluminum conductors can be used.  For equal current rating aluminum cross-section = 1.28 copper cross-section  For equal ohmic resistance aluminum cross-section = 1.65 copper cross-section  For copper, sector shaped conductors are available On request from 70 mm2 and above

4. Maximum operating voltage. 5. Insulation level.

6. Load to be carried. 7. Frequency. 8. Magnitude and duration of possible overload “Emergency current”. 9. Magnitude and duration of short-circuit current for conductor and screen. 10.Length of line. 11.Voltage drop. 12.Chemical and physical properties of soil. 13.Min. and Max. ambient air temperatures and soil temperature. 14.Specification and requirements to be follow.

VOLTAGE: The VOLTAGE Is the electric potential difference between two points, or the difference in electric potential energy of a unit charge transported between two points, The standard rate voltage are defined by three values Uo / U (Um), where : Uo = rated rms power frequency voltage, core to screen or sheath. U

= rated rms power frequency voltage, core to core.

Um = max. rms power frequency voltage, core to core.

Uo / U (kV) Um (kV)

0.6/1 1.8/3 3.6/6 6/10 8.7/15 12/20 18/30 38/66 76/132 127/220 1.2 3.6 7.2 12 17.5 24 36 72.5 145 245 Cable design for 6/10, 12/20 and 18/30 kV is applicable for 6.35/11, 12.7/22 and 19/33 kV respectively.

METALS USED FOR CABLES: Electrical Properties:

Metal Copper (annealed) Copper (hard drawn) Tin copper Aluminum Lead

Relative Conductivity 100 97 95 - 97 61 8

Electrical Resistivity at 20 °C ohm. m (10-8) 1.7241 1.777 1.741 - 1.814 2.8264 21.4

Temperature Coefficient of Resistance per °C 0.00393 0.00393 0.00393 0.00403 0.0040

Unit

Copper

Aluminum

Lead

8890.00

2703.00

11340.00

17.00 1083.00 3.80

23.00 659.00 2.40

29.00 327.00 0.34

225.00

70-90

-

Physical Properties: Property Density at 20 °C

kg / m

3

Coeff. thermal expansion Melting point Thermal conductivity

Per °C x 10 °C W/cm °C

Ultimate tensile strength

Mn/m2

-6

ELECTRICAL CALCULATION GUIDE 1. NOMINAL VOLTAGE

4. INDUCTANCE

The Nominal voltage is to be expressed with two

L=K+0.2 ln ( 2s/d) mH/km

values of alternative current Uo/U in V (volt)

L : Inductance

Uo/U : Phase to earth voltage

K :Constant depends on number of wires of conductor

Uo U

d: Conductor diameter

: Voltage between conductor and earth : Voltage between phases (conductors)

2. RESISTANCE

mH/km

S : Axial spacing between cables (Trefoil formation ) S : 1.26 x axial spacing between cables ( Flat formation)

5. REACTANCE

The Values of conductor DC resistance are dependent on temperature as given by :

The inductive reactance per phase of a cable may be

Rt=R20x[l+α20(t-20)]

/km

Rt : conductor DC resistance at t ° C

/km

X = 2 π f L x 10-3

/km

R20 : conductor DC resistance at 20 ° C

/km

X: Reactance

/km

t : operating temperature

°C

α : resistance temperature coefficient

obtained by the formula:

f : Frequency

Hz

L : Inductance

= 0.00393 for copper

mH/km

6. IMPEDANCE

= 0.00403 for aluminum Generally DC resistance is based on IEC 60228

R2ac  X 2

/km

To calculate AC resistance of the conductor

Z=

at the operating temperature as the following:

Z :Phase impedance of cable

RAC = Rt x[ 1+ ys + yp ]

Rac : AC resistance at operating temperature /km

ys : skin effect factor

X : Reactance

/km

/km

yp : proximity effect

7. INSULATION RESISTANCE

Generally AC resistance is based on IEC 60287

R=

3. CAPACITANCE

1000 * LN (D/d) 2*π

μF/km C : Operating capacitance

μF/km

D : Diameter over insulation

mm

d : Conductor diameter

mm

Єr :Relative permittivity of insulation material Єr = 4.8 for PVC Єr = 2.3 for XLPE

R : Insulation resistance at 20° C

MΩ.km

D : Insulated conductor diameter d : Conductor diameter

mm mm

8.CHARGING CURRENT

11. VOLTAGE DROP

I = Uo x 2Π f x C x 10-6

When the current flows in conductor, there is a voltage

I : Charging current

A/km

drop between the ends of the conductor. For low voltage

Uo : voltage between phase and earth

V

cable network of normal operation.

C : Capacitance to neutral

μF/km We recommend voltage drops not to exceed:

9. DIELECTRIC LOSSES

D = 2 π f C Uo 2 tan δ 10-6

watt/km/phase

D : Dielectric losses

watt/km/phase

Uo : Voltage between phase and earth

V

C : Capacitance to neutral

μF/km



3 % for lighting wire systems



5 % for driving force wire systems



10 % on starting time for motors

To calculate voltage drop as the following:

tan δ : Dielectric power factor

1. In DC

10. CABLE SHORT CIRCUIT CAPACITY

ISC(t) = ISC(1) / √t

kA

ISC(t): Short circuit for t second ISC(1): Short circuit for 1 second

kA kA

Data about short circuit are tabulated from table 9 to table 11

∆ =

2. For single phase circuit AC:

∆ =

(

∅+

∅)

3. For three phase circuit AC:

∆ =√

(

∆u : Voltage drop

∅+

V

Rc : conductor resistance in D.C. at operating temperature (/km) Ra : conductor resistance in A.C. at operating temperature (/km) L : core inductance (H/km) ω : pulsation equal to 2 π f (314 for f= 50 Hz) I : Load current

∅)

A

/km

X : Reactance ℓ : Length

km

cosΦ : Power factor - Relation between cosΦ and sinΦ as following:





1.0

0.9

0.8

0.71

0.6

0.5

0.0

0.44

0.6

0.71

0.8

0.87

CURRENT RATING ASSUMPTIONS: THE ELECTRIC CURRENT: is a flow of electric charge. In electric circuits this charge is often carried by moving electrons in a wire. It can also be carried by ions in an electrolyte, or by both ions and electrons such as in a plasma. The calculation of the current ratings, Current rating equations(100% load factor) and calculation of losses are based on IEC 60287 series , and the values of Current ratings for underground applications (In Duct or Direct Buried) are derived from the latest issue of ERA Report ‘Current Rating Standards 69.30 Part V’. and the values of current ratings are verified with the tabulated value in IEC 60364-5-52. The Current Carry Capacity calculated based on one circuit installed thermally isolated from other circuits or any other heat source. Ambient Air Temperature Ambient Ground Temperature of laying in ground Soil Thermal Resistivity

: 30 °C : 20°C Depth : 0.70 m :2.5 °K.m/W

For other installation conditions or any value of different air/ ground temperature, depth of laying, different soil thermal resistivity the customer is divided to multiply the tabulated current rating by the de-rating factor values as in tables 1 to 8.

DERATING FACTORS 1. INSTALLATION CONDITIONS FOR CABLES IN AIR Table 1: Rating factors for ambient air temperatures other than 30 °C to be applied to the current-carrying capacities for cables in the air:

Ambient temperature a °C

a

Insulation PVC

XLPE and EPR

Mineral a PVC covered or bare and exposed to touch 70 °C

Bare not exposed to touch 105 °C

10 1,22 1,15 1,26 1,14 15 1,17 1,12 1,20 1,11 20 1,12 1,08 1,14 1,07 25 1,06 1,04 1,07 1,04 30 1,00 1,00 1,00 1,00 35 0,94 0,96 0,93 0,96 40 0,87 0,91 0,85 0,92 45 0,79 0,87 0,78 0,88 50 0,71 0,82 0,67 0,84 55 0,61 0,76 0,57 0,80 60 0,50 0,71 0,45 0,75 65 – 0,65 – 0,70 70 – 0,58 – 0,65 75 – 0,50 – 0,60 80 – 0,41 – 0,54 85 – – – 0,47 90 – – – 0,40 95 – – – 0,32 For higher ambient temperatures, consult the manufacturer.

2. INSTALLATION CONDITIONS FOR DIRECT BURIAL CABLES For a cable installed direct buried, the following tables will be used to calculate the current rates based on the actual soil thermal resistivity, Ground ambient temperature and the Depth of Laying. Table 2: Rating factors for ambient ground temperatures other than 20 °C to be applied to the current-carrying capacities for cables in ducts in the ground:

Ground temperature °C 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Insulation

PVC 1,10 1,05 1,00 0,95 0,89 0,84 0,77 0,71 0,63 0,55 0,45 – – – –

XLPE and EPR 1,07 1,04 1,00 0,96 0,93 0,89 0,85 0,80 0,76 0,71 0,65 0,60 0,53 0,46 0,38

Table 3: Rating factors for cables buried direct in the ground or in buried ducts for soil thermal resistivities other than 2,5 K·m/W to be applied to the current-carrying capacities for reference method D:

Thermal resistivity, K·m/W Correction factor for cables in buried ducts Correction factor for direct buried es factors given have been NOTE 1 Thecabl correction

0,5 1,2 8 1,8 averaged 8

0,7 1 1,2 1,1 0 1,6 81,5 2over the range

1,5 2 2,5 1,1 1,0 1 5 1,2 1,1 1 of 8 conductor 2 sizes and

3 0,9 6 0,9 types 0 of

installation included in Tables B.52.2 to B.52.5. The overall accuracy of correction factors is within ± 5 %. NOTE 2 The correction factors are applicable to cables drawn into buried ducts; for cables laid direct in the ground the correction f actors for thermal resistivities less than 2, 5 K·m/W will be higher. W here more precise values are required they may be calculated by methods given in the IEC 60287 series. NOTE 3 The correction factors are applicable to ducts buried at depths of up to 0,8 m. NOTE 4 It is assumed that the soil properties are uniform. No allowance had been made for the possibility y of moisture migration which can lead t o a region of high thermal resistivity around t he cable. If partial drying out of the soil is foreseen, the permissible current rating should be derived by the methods specified in the IEC 60287 series.

3. INSTALLATION CONDITIONS FOR CIRCUIT GROUPS Table 4: Rating factors for one circuit or one multi-core cable or for a group of more than one circuit:

Number of circuits or multi-core cables

Item

Arrangement (cables touching)

1

2

3

4

5

6

7

8

9

1

Bunched in air, on a surface, embedded or enclosed

1,00

0,80

0,70

0,65

0,60

0,57

0,54

0,52

0,50

Single layer on wall, floor or unperforated cable tray systems

1,00

3

Single layer fixed directly under a wooden ceiling

0,95

0,81

0,72

0,68

0,66

0,64

0,63

0,62

0,61

4

Single layer on a perforated horizontal or vertical cable tray systems

1,00

0,88

0,82

0,77

0,75

0,73

0,73

0,72

0,72

Single layer on cable ladder systems or cleats etc.,

1,00

2

5

12

16

20

0,45

0,41

0,38

To be used with currentcarrying capacities, reference B.52.2 to B.52.13 Methods A to F

0,85

0,79

0,75

0,73

0,72

0,72

0,71

0,70 B.52.2 to B.52.7 No further reduction factor for more than nine circuits or multicore cables

Method C

B.52.8 to B.52.13 0,87

0,82

0,80

0,80

0,79

0,79

0,78

0,78

Methods E and F

NOTE 1

These factors are applicable to uniform groups of cables, equally loaded.

NOTE 2

W here horizontal clearances between adjacent cables exceeds twice their overall diameter, no reduction factor need be applied.

NOTE 3

The same factors are applied to: – groups of two or three single-core cables; – multi-core cables.

NOTE 4 If a system consists of both two- and three-core cables, the total number of cables is taken as the number of circuits, and the corresponding f actor is applied to the tables for two loaded conductors for the two-core cables, and to the tables f or three loaded conductors for the three-core cables. NOTE 5 If a group consists of n single-core cables it m ay either be considered as n/2 circuits of two loaded conductors or n/ 3 circuits of three loaded conductors.

Number of circuits

Table 5: Rating factors for more than one circuit, cables laid directly in the ground – Single-core or multi-core cables: Cable to cable clearancea Nil (cables touching)

One cable diameter

0,125 m

0,25 m

0,5 m

2

0,75

0,80

0,85

0,90

0,90

3

0,65

0,70

0,75

0,80

0,85

4

0,60

0,60

0,70

0,75

0,80

5

0,55

0,55

0,65

0,70

0,80

6

0,50

0,55

0,60

0,70

0,80

7

0,45

0,51

0,59

0,67

0,76

8

0,43

0,48

0,57

0,65

0,75

9

0,41

0,46

0,55

0,63

0,74

12

0,36

0,42

0,51

0,59

0,71

16

0,32

0,38

0,47

0,56

0,38

20

0,29

0,35

0,44

0,53

0,66

a

a Multi-core cables

a

a Single-core cables

NOTE 1 Values given apply to an installation depth of 0,7 m and a soil thermal resistivity of 2,5 K·m /W . They are average values for the range of cable sizes and types quoted for Tables B.52.2 to B.52.5. The process of averaging, together with rounding off, can result in some cases in errors up to ± 10 %. (W here m ore precise values are required they may be calculated by methods given in IEC 60287 -2-1.) NOTE 2 In case of a thermal resistivity lower than 2, 5 K·m /W the corrections factors can, in general, be increased and can be calculated by the methods given in IEC 60287-2-1. NOTE 3 If a circuit consists of m parallel conductors per phase, then for determining the reduction factor, this circuit should be considered as m circuits.

Table 6: Rating factors for more than one circuit, cables laid in ducts in the ground: A) Multi-core cables in single-w a y ducts Number of cables

Duct to duct clearance a Nil (ducts touching)

0,25 m

0,5 m

1,0 m

2 3

0,85 0,75

0,90 0,85

0,95 0,90

0,95 0,95

4

0,70

0,80

0,85

0,90

5

0,65

0,80

0,85

0,90

6

0,60

0,80

0,80

0,90

7

0,57

0,76

0,80

0,88

8

0,54

0,74

0,78

0,88

9

0,52

0,73

0,77

0,87

10

0,49

0,72

0,76

0,86

11

0,47

0,70

0,75

0,86

12

0,45

0,69

0,74

0,85

13

0,44

0,68

0,73

0,85

14

0,42

0,68

0,72

0,84

15

0,41

0,67

0,72

0,84

16

0,39

0,66

0,71

0,83

17

0,38

0,65

0,70

0,83

18

0,37

0,65

0,70

0,83

19

0,35

0,64

0,69

0,82

20

0,34

0,63

0,68

0,82

B)

Single-core cables in non-magnetic single-w a y ducts

Number of single- core circuits of two or three cables

a

Duct to duct clearance b

Nil (ducts touching)

0,25 m

0,5 m

1,0 m

2 3

0,80 0,70

0,90 0,80

0,90 0,85

0,95 0,90

4

0,65

0,75

0,80

0,90

5

0,60

0,70

0,80

0,90

6

0,60

0,70

0,80

0,90

7

0,53

0,66

0,76

0,87

8

0,50

0,63

0,74

0,87

9

0,47

0,61

0,73

0,86

10

0,45

0,59

0,72

0,85

11

0,43

0,57

0,70

0,85

12

0,41

0,56

0,69

0,84

13

0,39

0,54

0,68

0,84

14

0,37

0,53

0,68

0,83

15

0,35

0,52

0,67

0,83

16

0,34

0,51

0,66

0,83

17

0,33

0,50

0,65

0,82

18

0,31

0,49

0,65

0,82

19

0,30

0,48

0,64

0,82

20

0,29

0,47

0,63

0,81

Multi-c ore cables

b Single-core cables

NOTE 1 Values given apply t o an installation depth of 0,7 m and a soil t herm al resistivity of 2,5 K·m/W . They are average values for the range of cable sizes and types quoted for Tables B.52.2 to B.52.5. The process of averaging, together with rounding off, can result in some cases in errors up to ±10 %. W here m ore precise values are required they may be calculated by methods given in the IEC 60287series. NOTE 2 In case of a thermal resistivity lower than 2, 5 K·m/W the corrections factors can, in general, be increased and can be calculated by the methods given in IEC 60287-2-1. NOTE 3 If a circuit consists of n parallel conductors per phase, then for determining the reduction factor this circuit shall be considered as n circuits

Table 7: Rating factors for group of more than one multi-core cable to be applied to reference current-carrying capacities for multi-core cables in free air:

Method of installation in Table A.52. 3 IEC 60364-5-52 Touching

Perforat ed cable tray systems

31

Spaced

(not e 3)

Numb er of trays or ladder s

Number of cables per tra y or ladder

1

2

3

4

6

9

1

1,00

0,88

0,82

0,79

0,76

0,73

2

1,00

0,87

0,80

0,77

0,73

0,68

3

1,00

0,86

0,79

0,76

0,71

0,66

6

1,00

0,84

0,77

0,73

0,68

0,64

1

1,00

1,00

0,98

0,95

0,91



2

1,00

0,99

0,96

0,92

0,87



3

1,00

0,98

0,95

0,91

0,85



1

1,00

0,88

0,82

0,78

0,73

0,72

2

1,00

0,88

0,81

0,76

0,71

0,70

1

1,00

0,91

0,89

0,88

0,87



2

1,00

0,91

0,88

0,87

0,85



1

0,97

0,84

0,78

0,75

0,71

0,68

2

0,97

0,83

0,76

0,72

0,68

0,63

3

0,97

0,82

0,75

0,71

0,66

0,61

6

0,97

0,81

0,73

0,69

0,63

0,58

1

1,00

0,87

0,82

0,80

0,79

0,78

2

1,00

0,86

0,80

0,78

0,76

0,73

3

1,00

0,85

0,79

0,76

0,73

0,70

6

1,00

0,84

0,77

0,73

0,68

0,64

Touching

Vertical perforated cable tray systems

31

(not e 4) Spaced Touching Un perforat ed cable tray systems

31

Touching Cable ladder systems, cleats, etc. (not e 3)

32 33 34

Spaced 1

1,00

1,00

1,00

1,00

1,00



2

1,00

0,99

0,98

0,97

0,96



3

1,00

0,98

0,97

0,96

0,93



NOTE 1 Values given are averages for the cable types and range of conductor sizes considered in Tables A.52.8 to A.52.13. The spread of values is generally less than 5 %. NOTE 2 Factors apply to single layer groups of cables as shown above and do not apply when cables are installed in more than one layer touching each other. Values for such installations may be significantly lower and has to be determined by an appropriate method. NOTE 3 Values are given for vertical spacing between cable t rays of 300 mm and at least 20 mm between cable trays and wall. For closer spacing the factors should be reduced. NOTE 4 Values are given for horizontal spacing between cable t rays of 225 mm with cable trays mounted back t o back. For closer spacing the factors should be reduced.

Table 8: Rating factors for groups of one or more circuits of single-core cables to be applied to reference current-carrying capacity for one circuit of single- core cables in free air

Method of installation in Table A.52. 3 IEC 60364-5-52

Number of trays or ladders

Number of threephase circuits per tray or ladder

1

2

3

1

0,98

0,91

0,87

2

0,96

0,87

0,81

3

0,95

0,85

0,78

1

0,96

0,86



2

0,95

0,84



Use as a multiplier to currentcarr yi ng capacit y for

Touching Perforat ed cable tray systems

31

(not e 3)

Vertical perforat ed cable tray systems

31

Touching

(not e Cable 4) ladder systems,

32

1

1,00

0,97

0,96

cleats, etc.

33

2

0,98

0,93

0,89

(not e 3)

34

3

0,97

0,90

0,86

Three cables in horizontal formation

Three cables in vertical formation

Touching

Touching

Three cables in horizontal

Perforat ed cable tray systems

1

1,00

0,98

0,96

2

0,97

0,93

0,89

3

0,96

0,92

0,86

1

1,00

0,91

0,89

2

1,00

0,90

0,86

32

1

1,00

1,00

1,00

33

2

0,97

0,95

0,93

34

3

0,96

0,94

0,90

31

(not e 3)

Vertical perforat ed cable tray systems (not e Cable 4) ladder systems, cleats, etc. (not e 3)

Spaced 31

Three cables in trefoil formation

NOTE 1 Values given are averages f or t he c able types and range of conductor sizes considered in Table B. 52.8 to B.52.13. The spread of values is generally less than 5 %. NOTE 2 Factors are given for single layers of cables (or trefoil groups) as shown in the table and do not apply when cables are installed in more than one layer touching each other. Values f or such installations may be significantly lower and should be determined by an appropriate method. NOTE 3 Values are given for vertical spacing between cable trays of 300 mm and at least 20 mm between cable trays and wall. For closer spacing the factors should be reduced. NOTE 4 Values are given for horizontal spacing between cable trays of 225 mm with cable trays mounted back to back. For closer spacing the factors should be reduced. NOTE 5 For circuits having more than one cable in parallel per phase, each three phase set of conductors should be considered as a circuit for the purpose of this table. NOTE 6 If a circuit consists of m parallel conductors per phase, then for determining the reduction factor this circuit should be considered as m circuits.

SHORT CIRCUIT RATING – CONDUCTORS The permissible short-circuit currents as presented in figures 1 to 6 are calculated in accordance with IEC 60724:2008. The calculation method neglects heat loss and is accurate enough for the majority of practical cases. Any error is on the safe side. However, caution should be exercised when using large size conductors and an installation radius less than 8 x cable diameter where high deforming forces may occur. Where such conditions cannot be avoided, it is recommended to reduce the short circuit rating by 15% or contact SCC technical department. The following formulae have been derived from 60724:2008 Figure 1

Ik  (0.155/ t) * S

Figure 2

Ik  (0.1038/ t) * S

Figure 3

Ik  (0.075/ t) * S

Figure 4

Ik  (0.068/ t) * S

Figure 5

Ik  (0.143/ t) * S

Figure 6

Ik  (0.0937/ t) * S

I k S

: Short-circuit current (kA) : Duration of short-circuit current t (sec.) : Cross-sectional area of conductor (mm2)

Maximum Short circuit temperature for cable components: Material Insulation

Item

Temp. °C

PVC insulation

140 For C.S.A.