Joints - Sterlite

Sterlite Power
Cable Solutions

Sterlite Medium Voltage (MV) XLPE-insulated Power Cables
Product Applications
Sterlite(R) Medium Voltage (MV) power cables are crosslinked polyethylene (XLPE-insulated) cables that possess very good
electrical, mechanical and thermal characteristics in medium voltage networks. This type of insulation offers excellent chemical
resistant, is non-hygroscopic and is resistant to cold.
Product Applications
Crosslinked polyethylene (XLPE) has become the globally preferred insulation for power cables, both for distribution and
transmission system applications.
Product Benefits
Higher current carrying capacity due to higher permissible continuous conductor temperature
0
Higher Short Circuit rating as it can withstand short circuit temperature up to 250 C
0
Higher temperature to withstand emergency overload up to 130 C
Extremely low dielectric losses
Light-weight
Easier to join and terminate
Smaller bending radius
0
Flexible up to -40 C
Not prone to fatigue damage due to vibration or loading cycles
Typical Product Specifications
Conductor: Electrolytic grade Copper or Aluminum, round, multi-wire stranded, circular and compact in various sizes according to
IS 8130/ IEC 60228.
Conductor Shield: Conductors for cables rated over 3.3 KV are shielded by extruded semi conducting compound which is of
bonded type.
Insulation: Natural, chemically cross linked polyethylene. Thickness is according to relevant IS or IEC standards.
Insulation Shield: Cables rated over 3.3 KV have a non-metallic semi conducting part in combination with a metallic part applied
over the insulation. Non-metallic part is generally made of extruded semi conducting compound and is applied together with
conductor shield. Insulation in one process (wherever required semi conducting tape/ water swellable tape is provided) can be
applied directly over non-metallic insulation screen followed by helically applied bare annealed plain copper tape applied with an
overlap.
Core Identification: It can be provided by coloured strips applied on core or by printed numerals (1, 2&3) or printed strips.
Laying–Up: For multi core cables, the cores are cabled with fillers in the interstices.
Inner Sheath (Common Covering): The laid up cores are provided with a common covering either of tape or extrusion of thickness
as per relevant standard.
Armour: The armour can either be applied directly over core or inner sheath of single core cables and over inner sheath for multi
core cables. Aluminium wire or strip constitutes the armour for single core cables where as GI wire or strip constitutes the armour
for multi core cables.
Outer Sheath: All cables are provided with an extruded inner sheath whose thickness is governed by relevant standard. The PVC of
outer sheath conforms to type ST 2 of IS 5831, wherever required “FR”, “FRLS” or “LSOH” can be provided. The colour of outer
sheath is generally black.
Issued: June 2012 1

Manufacturing Process
To ensure the accuracy and precision of the manufacturing process, Sterlite has a state of-the-art plant with top of the line
machines enabling control of critical process and quality parameters. All Sterlite production lines are backed up with strong quality
assurance systems. This is done by ensuring that all process and test equipments are periodically calibrated with defined
benchmarks.
Quality Tests
The following tests are performed randomly to ensure a better quality:
Degree of Cross linking for the Dielectric Void and contamination test involving microscopic inspection of imperfections of
the insulation
Bonding test of insulation screen with the insulation
Online Diameter and eccentricity measurement and control by X-Ray unit, to ensure consistency and accuracy of Insulated
core.
Further, all Cables produced are subjected to the following routine tests as per IS 7098 (Part-2):1985:
High Voltage test
Conductor Resistance test
Partial Discharge test
Tests on conductors
Tests on Armour
Test for dimensions of insulation and sheath
Physical tests for insulation
Physical tests for outer sheath
Partial Discharge
Bending test followed by partial discharge
Dielectric Power Factor test as a function of voltage
Dielectric Power Factor test as a function of Temperature
Insulation Resistance (Volume Resistivity test)
Heating cycle test
Impulse withstand test
High Voltage test (4 hours)
Flammability
Issued: June 2012 2

For FR, FRLS cables , in addition to tests mentioned above, following additional tests are done
Test Function Specification Specified Value
Applicable For
Critical Oxygen index To determine the
percentage of oxygen
required for supporting
combustion of sheathing
material at room temperature
ASTM- D- 2863 Min 29
FR and FRLS
Temperature Index To determine at what
temperature 21 % of Oxygen
will support combustion of
sheathing material
ASTM- D- 2863 Min 250° C
FR FR and FRLS
Smoke Density
To determine visibility (light
transmission) under fire of
sheath material
ASTM- D- 2843 Max 60%
FRLS
Acid Gas generation To measure the amount of
Hydrochloric gas evolved
IEC- 754- I
Max 20% by weight
FRLS
Flammability test
from PVC sheath under
construction
1. To determine ignition 1. Swedish
1. Min 300 mm
FRLS
on group of cables resistance and flame
standard SS unburnt portion from
propagation under specified 4241475
top of 850 mm
conditions
class F3
2. To determine ignition 2. IEC 332- I 2. min unburnt portion FR and FRLS
Flammability
test on group
of cables
Longer Packing Lengths
resistance and flame
propagation under specified
conditions
3. To determine ignition
resistance and flame
propagation especially for a
bunch of cable under
specified conditions
To determine flame
propagation in cable in
installed conditions
3. IEC 332- 3
50 mm from the top of
600+ 25 mm sample after
specified duration
3. min 2.5m unburnt
above burner after
specified duration in
3.5 m sample
FR and FRLS
IEEE- 383 In total burning of 20
minutes at 1500 F of 8 m
cable samples, burning
shall not go the top
FR and FRLS
Larger Take up capacities in Sterlite make it possible to give longer delivery lengths than those mentioned in the catalogue to minimize number of joints
which are a major cause in failures.
The dimensional details, weights and packing are mentioned in Tables 1 to 10.
Issued: June 2012 3

Operating Conditions:
Electrical Parameters of the cables mentioned in Tables 11 to 19 are based on the following operating conditions
0
Maximum permissible conductor : 90 C
temperature for continuous operation
0
Ambient Air Temperature : 40 C
0
Ground Temperature : 30 C
0
Thermal Resistivity of Soil : 150 C cm/watt
Depth of Laying : 90 cms for cables up to 11 KV
: 105 cms for cables above 11 KV
Three single core cables are laid in trefoil formation with screen/Armour bonded at both ends
Multi core cables are laid singly
Rating Factors:
For installations other than standard conditions mentioned above, rating factors have to be applied and have been given in Tables 20 to 25.
Issued: June 2012
4

DIMENSION AND WEIGHT (Tables)
Table 01
Single-core 3.8/6.6 KV Cables
Single wire Armoured cables with Aluminium conductors
Single Core Aluminium Conductor Extruded Semiconducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, PVC type ST 2 inner sheathed, Aluminium wire Armoured, PVC type ST 2 outer sheathed
3.8/6.6 KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code: A2XWaY
Nominal area
of conductor
Sq.mm
50
70
95
120
150
185
240
300
400
630
800
1000
Nominal
Thickness of
insulation
mm
2.8
2.8
2.8
2.8
2.8
2.8
2.8
3.0
3.3
3.5
3.5
3.6
Minimum
Thickness of
inner sheath
mm
0.3
0.3
0.3
0.3
0.3
0.3
0.4
0.4
0.4
0.5
0.5
0.5
Table 02
Three-core 3.8/6.6 KV
strip Armoured cables with Aluminium conductors
Nominal area
of conductor
Sq.mm
25
35
50
70
95
120
150
185
240
300
400
Nominal
Thickness of
insulation
mm
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
3.0
3.3
Minimum
Thickness of
inner sheath
mm
0.4
0.4
0.5
0.5
0.5
0.6
0.6
0.6
0.7
0.7
0.7
Nominal
diameter of
armour
mm
1.6
1.6
1.6
1.6
1.6
1.6
2.0
2.0
2.0
2.0
2.5
2.5
Nominal
Dimension of
armour
mm
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
Minimum
Thickness of
outer sheath
mm
1.4
1.4
1.4
1.4
1.56
1.56
1.56
1.56
1.72
1.88
2.04
2.20
Minimum
Thickness of
outer sheath
mm
1.56
1.72
1.72
1.88
1.88
2.04
2.2
2.2
2.36
2.52
2.84
Approx
overall
dia
mm
24.5
26.0
28.0
29.0
31.0
35.5
35.5
37.7
42.0
49.0
54.0
59.0
Approx
overall
dia
mm
36.0
39.0
42.0
45.5
49.5
53.0
56.5
60.0
65.5
70.2
79.5
Approx
Cable
Weight
kg/km
760
870
1000
1130
1130
1450
1770
2030
2500
3480
4340
5180
Approx
Cable
Weight
kg/km
1650
1900
2190
2610
3040
3510
4000
4575
5465
6390
7950
Standard
packing
length
metres
500
500
500
500
500
500
500
500
500
500
500
500
Three Core Aluminium Conductor Extruded Semiconducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, Taped PVC type ST 2 inner sheathed, Steel strip Armoured, PVC type ST 2 outer sheathed
3.8/6.6 KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code:A2XFY(T)
Standard
packing
length
metres
500
500
500
500
500
500
500
500
500
500
500
Issued: June 2012
5

DIMENSION AND WEIGHT (Tables)
Table 03
Single-core 6.6/6.6 KV and 6.35/11 KV Cables
Single wire Armoured cables with Aluminium conductors
Single Core Aluminium Conductor Extruded Semiconducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, PVC type ST 2 inner sheathed, Aluminium wire Armoured, PVC type ST 2 outer sheathed
6.35/11 KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code: A2XWaY
Nominal area
of conductor
Sq.mm
50
70
95
120
150
185
240
300
400
630
800
1000
Nominal area
of conductor
Sq.mm
25
35
50
70
95
120
150
185
240
300
400
Nominal
Thickness of
insulation
mm
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
Nominal
Thickness of
insulation
mm
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
Minimum
Thickness of
iinner sheath
mm
0.3
0.3
0.3
0.3
0.3
0.4
0.4
0.4
0.4
0.5
0.5
0.6
Table 04
Three-core 6.6/6.6 KV or 6.35/11 KV
strip Armoured cables with Aluminium conductors
Three Core Aluminium Conductor Extruded Semiconducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, Taped PVC type ST 2 inner sheathed, Steel strip Armoured, PVC type ST 2 outer sheathed
6.35/11 KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code:A2XFY(T)
Minimum
Thickness of
inner sheath
mm
0.4
0.5
0.5
0.5
0.6
0.6
0.6
0.7
0.7
0.7
0.7
Nominal
diameter of
armour
mm
1.6
1.6
1.6
1.6
1.6
2.0
2.0
2.0
2.0
2.0
2.5
2.5
Nominal
Dimension
outer sheath
mm
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
Minimum
Thickness of
outer sheath
mm
1.4
1.56
1.56
1.56
1.56
1.56
1.56
1.56
1.72
1.88
2.04
2.20
Minimum
Thickness of
outer sheath
mm
1.72
1.72
1.88
1.88
2.04
2.20
2.20
2.36
2.52
2.68
2.84
Approx
overall
dia
mm
26.0
27.5
29.5
31.0
32.5
35.0
37.3
39.0
42.5
49.5
54.5
59.0
App
overall
diameter
mm
40.0
42.5
45.5
49.0
53.0
56.5
60.0
64.0
69.0
73.5
80.5
Approx
Cable
Weight
kg/km
840
960
1100
1250
1380
1630
1880
2110
2570
3500
4370
5200
Approx
Cable
Weight
kg/km
1940
2175
2500
2900
3450
3900
4370
5030
5920
6780
8120
Standard
packing
length
metres
500
500
500
500
500
500
500
500
500
500
500
500
Standard
packing length
metres
500
500
500
500
500
500
500
500
500
350
300
Issued: June 2012
6

DIMENSION AND WEIGHT (Tables)
Table 05
Single-core 11/11 KV Cables
Single wire Armoured cables with Aluminium conductors
Single Core Aluminium Conductor Extruded Semi conducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, PVC type ST 2 inner sheathed, Aluminium wire Armoured, PVC type ST 2 outer sheathed 11/11
KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code: A2XWaY
Nominal area
of conductor
Sq.mm
50
70
95
120
150
185
240
300
400
630
800
1000
Nominal area
of conductor
Sq.mm
25
35
50
70
95
120
150
185
240
300
400
Nominal
Thickness of
insulation
mm
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
Nominal
Thickness of
insulation
mm
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
Minimum
Thickness of
inner sheath
mm
0.3
0.3
0.3
0.4
0.4
0.4
0.4
0.4
0.5
0.5
0.6
0.6
Table 06
Three-core 11/11 KV
strip Armoured cables with Aluminium conductors
Three Core Aluminium Conductor Extruded Semi conducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, Taped PVC type ST 2 inner sheathed, Steel strip Armoured, PVC type ST 2 outer sheathed 11/11
KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code:A2XFY(T)
Minimum
Thickness of
inner sheath
mm
0.5
0.6
0.6
0.6
0.6
0.7
0.7
0.7
0.7
0.7
0.7
Nominal
diameter of
armour
mm
1.6
1.6
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.5
2.5
2.5
Nominal
Dimension
of Armour
mm
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
Minimum
Thickness of
outer sheath
mm
1.56
1.56
1.56
1.56
1.56
1.56
1.72
1.72
1.88
2.04
2.20
2.36
Minimum
Thickness of
outer sheath
mm
1.88
2.04
2.20
2.20
2.36
2.36
2.52
2.68
2.84
3.00
3.00
Approx
overall
dia
mm
30.2
31.7
34.2
35.5
37.0
38.8
41.5
43.0
46.5
54.5
58.7
63.0
App
overall
diameter
mm
48.5
51.5
54.5
58.0
62.0
65.5
69.0
73.0
78.0
82.0
89.0
Approx
Cable
Weight
kg/km
1070
1200
1420
1550
1700
1840
2200
2420
2880
4030
4800
5600
Approx
Cable
Weight
kg/km
2670
3010
3360
3800
4390
4880
5430
6120
7080
7970
9360
Standard
packing
length
metres
500
500
500
500
500
500
500
500
500
500
500
500
Standard
packing
length
metres
500
500
500
500
500
500
500
400
350
250
200
Issued: June 2012
7

DIMENSION AND WEIGHT (Tables)
Table 07
Single-core 12.7/22 KV Cables
Single wire Armoured cables with Aluminium conductors
Single Core Aluminium Conductor Extruded Semi conducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, PVC type ST 2 inner sheathed, Aluminium wire Armoured, PVC type ST 2 outer sheathed
12.7/22 KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code: A2XWaY
Nominal area
of conductor
Sq.mm
50
70
95
120
150
185
240
300
400
630
800
1000
Nominal area
of conductor
Sq.mm
25
35
50
70
95
120
150
185
240
300
400
Nominal
Thickness of
insulation
mm
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Nominal
Thickness of
insulation
mm
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Minimum
Thickness of
inner sheath
mm
0.3
0.3
0.4
0.4
0.4
0.4
0.4
0.4
0.5
0.5
0.6
0.6
Table 08
Three-core 12.7/22 KV
strip Armoured cables with Aluminium conductors
Three Core Aluminium Conductor Extruded Semi conducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, Taped PVC type ST 2 inner sheathed, Steel strip Armoured, PVC type ST 2 outer sheathed
12.7/22 KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code:A2XFY(T)
Minimum
Thickness of
inner sheath
mm
0.5
0.6
0.6
0.6
0.7
0.7
0.7
0.7
0.7
0.7
0.7
Nominal
diameter of
armour
mm
1.6
1.6
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.5
2.5
2.5
Nominal
Dimension
of Armour
mm
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
Minimum
Thickness of
outer sheath
mm
1.56
1.56
1.56
1.56
1.56
1.72
1.72
1.72
1.88
2.04
2.20
2.36
Minimum
Thickness of
outer sheath
mm
2.04
2.04
2.20
2.36
2.36
2.52
2.68
2.68
2.84
3.0
3.0
Approx
overall
dia
mm
31.2
32.6
35.2
36.6
38.0
40.2
42.4
44.0
47.7
55.6
59.7
64.0
App
overall
diameter
mm
51.0
53.5
57.0
60.5
64.5
68.0
71.5
75.0
80.0
84.0
91.0
Approx
Cable
Weight
kg/km
1140
1280
1500
1650
1800
2030
2300
2550
3000
4160
4970
5800
Approx
Cable
Weight
kg/km
2900
3200
3590
4100
4650
5175
5750
6380
7360
8280
9670
Standard
packing
length
metres
500
500
500
500
500
500
500
500
500
500
500
500
Standard
packing
length
metres
500
500
500
500
500
500
400
350
300
250
200
Issued: June 2012
8

DIMENSION AND WEIGHT (Tables)
Table 09
Single-core 19/33 KV Cables
Single wire Armoured cables with Aluminium conductors
Single Core Aluminium Conductor Extruded Semi conducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, PVC type ST 2 inner sheathed, Aluminium wire Armoured, PVC type ST 2 outer sheathed 19/33
KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code: A2XWaY
Nominal area
of conductor
Sq.mm
50
70
95
120
150
185
240
300
400
630
800
1000
Nominal area
of conductor
Sq.mm
50
70
95
120
150
185
240
300
400
Nominal
Thickness of
insulation
mm
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
Nominal
Thickness of
insulation
mm
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
Minimum
Thickness of
inner sheath
mm
0.4
0.4
0.4
0.4
0.4
0.5
0.5
0.5
0.5
0.6
0.6
0.7
Table 10
Three-core 19/33 KV
strip Armoured cables with Aluminium conductors
Three Core Aluminium Conductor Extruded Semi conducting compound screened, XLPE insulated, Semi conducting compound
screened, helical copper tape wrapped, Taped PVC type ST 2 inner sheathed, Steel strip Armoured, PVC type ST 2 outer sheathed 19/33
KV cable conforming to IS 7098 (Part-2):1985 with latest amendments. Code:A2XFY(T)
Minimum
Thickness of
inner sheath
mm
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
Nominal
diameter of
armour
mm
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.5
2.5
2.5
2.5
3.15
Nominal
Dimension
of Armour
mm
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
4 x 0.8
Minimum
Thickness of
outer sheath
mm
1.56
1.56
1.72
1.72
1.72
1.88
1.88
2.04
2.04
2.36
2.36
2.52
Minimum
Thickness of
outer sheath
mm
2.52
2.68
2.84
2.84
3.00
3.00
3.00
3.00
3.00
Approx
overall
dia
mm
36.5
38.2
40.2
41.6
43.0
45.1
47.3
50.4
53.7
61.2
64.6
70.5
App
overall
diameter
mm
69.5
73.5
77.5
80.5
84.0
88.0
92.5
96.5
103.0
Approx
Cable
Weight
kg/km
1470
1600
1800
1960
2100
2340
2630
3070
3500
4700
5410
6560
Approx
Cable
Weight
kg/km
5050
5660
6310
6840
7480
8190
9190
10080
11600
Standard
packing
length
metres
500
500
500
500
500
500
500
500
500
500
500
500
Standard
packing
length
metres
500
500
500
500
400
350
300
250
200
Issued: June 2012
9

ELECTRICAL PARAMETERS (Tables)
Table 11
PERMISSIBLE MAXIMUM SHORT CIRCUIT RATINGS FOR XLPE CABLES
Conductor Area
Sq.mm
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Short circuit rating for 1 second duration
Copper Conductor Aluminium Conductor
KA
2.28
3.57
5.0
7.15
10.0
13.58
17.16
21.45
26.45
34.32
42.9
57.2
71.5
90.0
114.28
142.85
KA
1.51
2.36
3.30
4.72
6.60
8.96
11.32
14.16
17.46
22.65
28.32
37.76
47.20
59.47
75.52
94.40
For duration other than 1 second, short circuit may be calculated from the following formula : Isc = I/t
Isc=Short circuit current during time t in Amperes
I = Short circuit during time of 1 second, as given in above table
t = Short circuit current duration in seconds
Note: For large currents , the force between the conductors must be considered specially when single core cables are used
Table 12
CAPACITANCE
Conductor Area
Sq.mm
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
CAPACITANCE
3.8/6.6 KV
6.6/6.6 KV &
6.35/11 KV
11/11 KV
µF/Km
µF/Km
µF/Km
0.22
0.18
0.135
0.24
0.20
0.148
0.27
0.22
0.165
0.31
0.25
0.184
0.35
0.28
0.205
0.38
0.31
0.222
0.42
0.34
0.239
0.46
0.37
0.260
0.51
0.41
0.286
0.51
0.44
0.306
0.53
0.49
0.343
0.56
0.55
0.380
0.63
0.61
0.421
0.69
0.67
0.462
0.75
0.75
0.508
12.7/22 KV
µF/Km
0.128
0.139
0.155
0.173
0.192
0.208
0.224
0.243
0.266
0.285
0.319
0.353
0.391
0.428
0.471
19/33 KV
µF/Km
-
-
0.121
0.134
0.147
0.158
0.169
0.182
0.199
0.211
0.235
0.258
0.284
0.310
0.339
Issued: June 2012
10

ELECTRICAL PARAMETERS (Tables)
Table 13
CURRENT RATING
Cable
size
mm²
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Cable
size
mm²
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
Ground
96
115
135
165
195
225
250
285
330
370
420
480
540
610
680
Ground
98
115
140
170
200
225
250
285
325
365
410
465
520
560
600
3.3 kV (E) & (UE)
Duct
86
100
120
145
175
200
220
250
285
325
370
420
470
530
580
Table 14
CURRENT RATING
3.3 kV (E) & (UE)
Duct
87
105
120
150
175
200
220
250
285
320
360
400
445
485
510
Single core XLPE Insulated Unarmoured Cables laid in trefoil formation (Solid Bonded)
Aluminium (Amp) Copper (Amp)
Air
105
125
150
190
235
275
310
360
425
495
580
690
800
930
1060
Air
110
135
160
200
245
285
325
375
440
500
590
680
780
880
970
6.6kV (E),11kV(E)
& 11kV(UE)
Ground
97
115
135
165
200
225
250
285
330
370
425
485
550
620
690
Ground
99
115
140
170
200
225
250
285
325
365
410
455
510
550
590
Duct
86
100
120
145
175
195
220
250
285
325
375
420
475
530
590
Duct
87
105
120
145
175
195
220
245
280
315
355
395
435
470
500
Air
110
135
160
200
245
285
320
370
455
510
600
700
810
940
1070
6.6kV (E),11kV(E)
& 11kV(UE)
Air
115
140
165
210
255
295
330
380
450
510
590
680
780
870
960
22kV(E) & 33kV (E) 3.3kV
Ground
-
115
135
165
195
225
250
280
325
370
420
480
550
610
680
Ground
-
115
135
165
195
225
250
280
320
355
400
445
495
540
570
Duct
-
100
120
145
170
195
215
245
280
320
360
410
470
520
580
Duct
-
100
120
145
170
195
215
240
275
305
345
380
420
460
490
Air
-
140
170
210
255
295
330
380
450
520
610
710
820
950
1080
Single core XLPE Insulated Armoured Cables laid in trefoil formation (Solid Bonded)
Aluminium (Amp) Copper (Amp)
22kV(E) & 33kV (E) 3.3kV
Air
-
145
170
215
260
300
340
385
450
510
600
680
770
870
950
Ground
125
150
175
215
255
290
320
365
420
470
530
600
670
740
800
Ground
125
150
175
215
255
290
325
360
415
460
510
560
610
660
680
Duct
110
130
155
190
225
255
285
320
370
410
465
520
580
640
690
Duct
115
135
155
190
225
255
285
315
360
400
445
485
530
570
580
Air
130
160
195
245
300
350
400
460
550
630
740
860
980
1120
1250
Air
140
170
205
260
315
365
415
475
560
640
730
840
940
1040
1100
Ground
125
150
175
215
255
290
325
365
420
475
540
610
680
750
820
Ground
125
150
175
215
255
290
320
360
410
455
510
550
600
640
670
6.6kV (E),11kV(E)
& 11kV(UE)
Duct
110
130
155
190
225
255
285
320
370
415
465
520
590
640
700
6.6kV (E),11kV(E)
& 11kV(UE)
Duct
110
130
155
190
225
250
280
315
355
395
435
475
520
540
570
Air
140
175
205
260
315
365
415
480
560
650
760
880
1010
1140
700
Air
150
180
215
270
325
375
425
485
570
640
730
830
930
1010
1090
22kV(E) & 33kV (E)
Ground
-
150
175
210
255
290
320
360
420
470
530
600
680
750
820
22kV(E) & 33kV (E)
Ground
-
150
175
215
250
285
315
355
400
445
495
540
580
630
650
Duct
-
130
150
185
220
250
280
315
365
410
460
520
580
640
700
Duct
-
130
150
185
220
245
275
305
350
380
425
460
500
530
550
Air
-
180
215
270
330
380
430
490
580
660
770
890
1020
1160
1290
Air
-
185
220
275
335
385
430
490
570
650
740
830
920
1020
1080
Issued: June 2012
11

ELECTRICAL PARAMETERS (Tables)
Table 15
CURRENT RATING
Cable
size
mm²
25
35
50
70
95
120
150
185
240
300
400
Table 16
REACTANCE OF SINGLE CORE XLPE CABLES
Cable
size
mm²
50
70
95
120
150
185
240
300
400
500
630
800
1000
Ground
94
115
135
165
195
220
245
280
320
360
410
3.3 kV (E) & (UE)
Duct
80
94
110
140
165
185
210
235
270
305
350
UNARM
0.113
0.105
0.100
0.097
0.095
0.091
0.089
0.088
0.086
0.085
0.082
0.081
0.080
Three core XLPE Insulated Armoured Cables
Aluminium (Amp) Copper (Amp)
Air
99
120
145
185
225
255
295
340
400
460
535
3.8/ 6.6 KV
ARM
/Km /Km
0.128
0.119
0.114
0.111
0.108
0.105
0.101
0.097
0.094
0.091
0.089
0.088
0.087
6.6kV (E),11kV(E)
& 11kV(UE)
Ground
95
115
130
160
190
220
245
275
315
355
400
Duct
82
97
115
140
165
190
210
240
275
310
350
APP REACTANCE AT 50Hz assuming cables in trefoil touching
UNARM
0.117
0.109
0.104
0.101
0.098
0.096
0.092
0.090
0.087
0.085
0.082
0.081
0.080
Air
105
125
150
190
230
260
295
335
395
450
520
6.6/ 6.6KV &
6.35/ 11 KV
ARM
/Km /Km
22kV(E) & 33kV (E) 3.3 kV (E) & (UE)
Ground
-
110
130
160
190
215
240
270
310
350
395
0.128
0.119
0.114
0.111
0.107
0.105
0.101
0.099
0.095
0.092
0.089
0.088
0.087
Duct
-
98
115
140
170
190
215
240
275
310
355
Air
-
130
155
190
230
265
300
340
400
455
530
UNARM
11/ 11 KV
ARM
/Km /Km
0.127
0.118
0.113
0.110
0.107
0.103
0.099
0.097
0.093
0.091
0.088
0.086
0.084
Ground
120
145
170
210
250
285
315
355
410
460
520
Duct
100
120
145
175
210
240
270
300
350
390
440
0.137
0.128
0.124
0.120
0.116
0.111
0.108
0.106
0.101
0.098
0.095
0.093
0.091
Air
125
155
190
235
290
330
375
435
510
590
670
UNARM
12.7/ 22 KV
ARM
/Km /Km
0.130
0.121
0.116
0.112
0.109
0.105
0.101
0.099
0.095
0.093
0.089
0.087
0.085
Ground
120
145
170
210
250
280
310
350
400
445
500
6.6kV (E),11kV(E)
& 11kV(UE)
Duct
105
125
150
180
215
240
270
305
350
390
440
0.139
0.130
0.125
0.121
0.117
0.113
0.109
0.106
0.102
0.100
0.097
0.094
0.092
Air
135
165
195
240
295
335
380
430
500
570
650
UNARM
19/ 33 KV
ARM
/Km /Km
0.143
0.134
0.128
0.124
0.120
0.116
0.111
0.109
0.104
0.100
0.097
0.095
0.092
22kV(E) & 33kV (E)
Ground
-
145
170
205
245
275
305
345
395
440
495
Duct
-
125
150
180
215
245
275
305
350
390
440
Air
-
0.149
0.139
0.134
0.129
0.125
0.121
0.116
0.115
0.109
0.107
0.103
0.099
0.098
165
200
245
300
340
385
435
510
580
660
Issued: June 2012
12

ELECTRICAL PARAMETERS (Tables)
Table 17
REACTANCE OF 3 CORE CABLES
Conductor
Area
mm²
25
35
50
70
95
120
150
185
240
300
400
Table 18
DIELECTRIC LOSSES
Conductor
Area
mm²
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
REACTANCE OF 3 CORE CABLES
3.8/ 6.6 KV
6.6/ 6.6KV &
6.35/ 11 KV
11/ 11 KV 12.7/ 22 KV 19/ 33 KV
/Km /Km /Km /Km /Km
0.101
0.108
0.123
0.126
0.143
0.097
0.104
0.118
0.121
0.137
0.093
0.099
0.112
0.115
0.130
0.087
0.093
0.104
0.107
0.121
0.084
0.089
0.100
0.103
0.116
0.082
0.087
0.097
0.100
0.112
0.080
0.085
0.094
0.097
0.108
0.078
0.082
0.091
0.093
0.104
0.076
0.080
0.088
0.090
0.101
0.076
0.078
0.086
0.088
0.098
0.075
0.076
0.083
0.085
0.094
3.8/ 6.6 KV
6.6/ 6.6KV &
6.35/ 11 KV
DIELECTRIC LOSSES
11/ 11 KV 12.7/ 22 KV 19/ 33 KV
w/ pH/Km w/ pH/Km w/ pH/Km w/ pH/Km w/ pH/Km
3.943
9.883
20.561
25.923
46.097
4.367
10.892
22.450
28.250
49.810
4.959
12.293
25.063
31.464
54.909
5.632
13.884
28.016
35.094
60.634
6.344
15.566
31.127
38.913
66.628
6.929
16.946
33.673
42.038
71.514
7.555
18.422
36.390
45.369
76.709
8.264
20.091
39.457
49.129
82.556
9.180
22.246
43.413
53.976
90.075
9.299
23.910
46.461
57.709
95.855
9.680
27.036
52.184
64.715
106.680
10.219
30.061
57.714
71.484
117.115
11.382
33.474
63.946
79.108
128.852
12.545
36.883
70.168
86.720
140.552
13.518
40.777
77.270
95.407
153.891
Issued: June 2012
13

ELECTRICAL PARAMETERS (Tables)
Table 19
RESISTANCES
Conductor
Area
mm²
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
D C RESISTANCE AT 20° C A C RESISTANCE AT 90° C
ALUMINIUM COPPER ALUMINIUM COPPER
1.20
0.868
0.641
0.443
0.320
0.253
0.206
0.164
0.125
0.100
0.0778
0.0605
0.0469
0.0367
0.0291
0.727
0.524
0.387
0.268
0.193
0.153
0.124
0.0991
0.0754
0.0601
0.0470
0.0366
0.0283
0.0221
0.0176
1.53
1.11
0.818
0.565
0.409
0.323
0.264
0.210
0.161
0.129
0.102
0.082
0.065
0.931
0.671
0.496
0.344
0.248
0.197
0.160
0.129
0.099
0.080
0.064
0.052
0.042
Issued: June 2012
14

RATING FACTORS
Table 20
RATING FACTORS FOR DEPTH OF LAYING
(For cables laid directly in ground)
Depth of laying
(mm)
500- 750
750- 900
900- 1050
1050- 1200
1200- 1500
1500- 1800
1.1 KV
Cables
1.00
0.98
0.96
0.94
0.92
0.90
3.3, 6.6,11 KV
Cables
-
1.00
0.99
0.98
0.96
0.95
22 & 33 KV
Cables
-
-
1.00
0.99
0.98
0.96
Table 21
GROUP RATING FACTORS FOR MULTI CORE CABLES OR GROUPS OF SINGLE CORE CABLES IN HORIZONTAL FORMATION
(For cables laid directly in ground)
Number of cables or group of single core
cables in same trench
Spacing between cables or groups touching
70 mm
250 mm
2 3
4 5
6
0.79
0.85
0.87
0.69
0.75
0.79
Table 22
GROUP RATING FACTORS FOR MULTI CORE CABLES OR GROUPS OF SINGLE CORE CABLES IN AIR ON LADDER SUPPORTS, METAL TRAYS , WALLS
etc WITH MAINTAINED SPACING BETWEEN CABLES OR GROUPS
Number of cables or group of single core cables
Vertically
1
2
3
0.93
0.83
0.76
0.63
0.68
0.75
0.58
0.64
0.72
0.55
0.60
0.69
1 2
Horizontally
3 4
5
1.00
0.89
0.80
0.87
0.79
0.72
0.84
0.76
0.70
0.83
0.75
0.69
4 0.77 0.72 0.68 0.67 0.66
Table 23
RATING FACTORS FOR VARIATION IN GROUND TEMPERATURE
(For cables laid directly in ground)
GROUND TEMPERATURE ° C
RATING FACTOR
15
1.12
20
1.08
Table 24
RATING FACTORS FOR VARIATION IN AMBIENT AIR TEMPERATURE
AIR TEMPERATURE ° C
RATING FACTOR
20
1.18
25
1.14
Table 25
RATING FACTORS FOR VARIATION IN THERMAL RESISTIVITY OF SOIL
Voltage rating of cables
1.1 & 3.3 KV
6.6, 11 & 22 KV
33 KV
25
1.04
30
1.10
30
1.0
35
1.05
35
0.96
40
1.0
40
0.91
45
0.95
45
0.87
50
0.89
Thermal resistivity of soil (° C cm/W)
100
1.18
120
1.08
150
1.0
200
0.88
250
0.81
0.16 1.08 1.0
0.90 0.83
0.12 1.07 1.0
0.90 0.83
50
0.82
55
0.84
300
0.74
0.76
0.78
6
0.82
0.74
0.68
0.65
Issued: June 2012
15

PROCESS FLOW CHART: XLPE INSULATED POWER CABLES (upto 33 kV GRADE)
RAW MATERIALS
ALUMINIIUM/ COPPER
WIRE DRAWING
A
CONDUCTOR STRANDING
XLPE COMPOUND
SEMICONDUCTING COMPOUND XLPE TRUE TRIPLE EXTRUSION
COPPER TAPE
COL. IDENTIFICATION TAPE
FILLERS
PVC TAPE/
PVC COMPOUND
GALVANISED STEEL
FLAT STRIPS/
ROUND WIRES
(A-I QUALITY CHECKPOINTS)
3 CORE
B
C
COPPER TAPING
D
LAYING UP OF CORES
E
INNER SHEATHING
(TAPED/ EXTRUDED)
F
ARMOURING
G
1 CORE
PACKING
OUTER SHEATHING H
I
Issued: June 2012
16

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About Sterlite
Sterlite Technologies Limited is a leading global
provider of connectivity solutions for the
telecom & power industries.
Equipped with a suite that includes power
conductors, power cables, optical fibers, fiber
cables, data cables and a comprehensive
telecom solutions portfolio, Sterlite's vision is to
'Connect every home on the planet'. Sterlite is
also executing multi-million dollar power
transmission system projects, pan-India.
email: communications@sterlite.com
RECYCLABLE June 2012