EHV Catalogue

Extra
High Voltage
(EHV) Cables
Technical Catalogue
Company
Profile
Silvassa Plant
Mysore Plant
Thane Plant
RPG Cables, a division of KEC International Limited has established

itself as one of the leading manufacturers of Power, Control
& Telecommunication cables in India. One of the oldest cable
manufacturing company (1958), we have been serving the
industries with quality cables for over 5 decades. The state-of-the
art manufacturing plants are located at Thane for HT cables upto
33 kV and EHV cables upto 132 kV and Silvassa for LT cables upto
1.1 kV (power and control). The manufacturing facility at Mysore
manufactures LT Power and Control Cables, apart from Telecom Cables
(Fiber Optic & Jelly Filled), Instrumentation, Fire Survival and Signaling
Cables. RPG Cables also offers expertise in Turnkey contracts involving
cable laying, jointing, testing and commissioning. To keep pace with
the changing needs of the customers and requirement of cables for
voltage grades above 132 kV, the company is coming up with a new
manufacturing unit near Halol, Gujarat with capability to manufacture
cables up to 400 kV. The brand name Asian is synonymous with
stringent norms in quality, environment and safety management. The
plants have been ISO 9000 and ISO 14000 certified.
RPG cables has been making major export thrust in keeping with its
global aspirations. We match international quality standards and cables
can be designed to comply with required international standards. The
division has also been given recognition by the Govt. of Maharashtra
for achieving excellence in Exports.
Technical Catalogue
Manufacture
of EHV Cables
RPG Cables commenced the manufacture of
XLPE cables at its Thane Plant in 1978. The
division has already supplied more than 150 Kms
of cables (EHV) with various combinations of
construction ranging from 66 kV to 132 kV and
sizes with both Aluminum and Copper conductors.
The cables can be manufactured according to
most international specifications and designs.
SPECIAL FEATURES OF EHV

XLPE MANUFACTURING LINE
AT RPG CABLES :
Highly sophisticated Dry Cure Line using superclean XLPE compound .

Computerised vulcanizing & cooling systems as well as extruder heating control system.
In line metal detectors for semicon & XLPE materials which ensure removal of ferrous & non ferrous metallic
impurities from compound before extrusion.
In line dust & fine separator for XLPE insulation to have homogenous & extra clean insulation.
Separate pressurized rooms for semicon shielding & XLPE insulation compound to avoid contamination.
Automatic material handling by vacuum loaders.
Pressurised air system with air showers on doors to eliminate dust entry.
Technical Catalogue
ADAVNTAGES OF LEAD SHEATH :

Lead has superior corrosion resistant properties in any environment than that of Aluminium .
Lead sheathed cables can follow bending in contours with ease.
W
ith Aluminium corrugated cable, longitudinal water tightness is lost, eventually increasing
the size ofthe cable due to high temperature developed during sheath extrusion.
Lead sheath is easily solderable.
Minimum life of lead sheath is 40 45 years.
Lead is very dense & easily fusible . It has got very good corrosion resistant property in
all kinds of environment.
SPECIALISED CONTINUOUS LEAD EXTRUDER :

Continuous extrusion free from external impurities which eliminates stop marks
Microprocessor based temperature controller for precise temperature profile
Microprocessor based DC drive system gives uniform Lead thickness, better concentricity.
Electrical system based on programmable logic controllers for reliability.
Elements in
EHV Cables
Typical Cross-Sectional Sketches
Conductor
Aluminium/Copper
Conductor Shielding
INSULATION
INSULATION SHIELDING
COPPER WIRE SHIELD
WATER SWELLABLE TAPE
METAL TAPE MOISTURE BARRIER
OUTER JACKET
Constructional features: EHV CABLES :

Conductor
Insulation
The conductor shall be formed from plain copper or aluminium

complying to IS: 8130 or IEC 228 Publication.The conductor
shall be compacted circular, or segmental compacted circular.
The insulation shall be of dry cured XLPE compound with

a thickness to meet dimensional, electrical and physical
requirements specified . The insulation shall be suitable for
operation in wet or dry locations at conductor temperature not
exceeding 900C for normal condition, 1300C for emergency
overload conditions and 2500C for short circuit conditions.
Conductor Shielding
Conductor Shielding of an extruded semiconducting XLPE
compound shall be applied over the conductor. One or two
layers of semiconducting tape(s) may be applied with an
proper lapping between the conductor and the extruded
semiconducting layer.
Technical Catalogue
Insulation Shielding
Water Swellable Tape
The insulation shielding shall be applied direct upon

the insulation and shall consist of a layer of extruded
semiconducting compound. The extruded semiconducting
compound shall be a thermoset type and firmly and totally
bonded to the insulation.
Water swellable tapes are used in cables to prevent longitudinal

water penetration along the cable. These tapes are used below
and above copper wire screen and below lead sheath. These
tapes are normally semiconducting tapes. However on some
special occasions these are used below outer sheath as well in
which case these are of insulating type.
Copper Wire Shield

When a layer of copper wire shield is required, it shall be applied
over the insulation shielding. One or more layers of suitable
seperator or tape may be applied helically over a layer of this
shield.
Lead Alloy
When the lead alloy sheath is required, it shall be applied by
a continuous screw extrusion in high quality, smooth surface
and free from pinholes and any other imperfections including
one associated with oxide inclusions. When the lead sheath
is applied directly over the extruded semi-conducting layer or
inner plastic bedding, suitable non magnetic tape(s) can be
applied under the lead sheath to prevent heat transfer onto
the plastic material during the manufacturing.The lead sheath
can act as screen, moisture barrier and armour.
Corrugated Aluminium Sheath/Metal Tape

Moisture Barrier
When the moisture barrier other than lead is required,
corrugated aluminium sheath or a layer of aluminium
tape laminated on outer side with copolymer is used. It
shall be applied longitudinally over the cable core with an
overlap.
Outer Jacket
The outer jacket shall consist of thermoplastic compound (PVC,
PE or similar materials) extruded continuously over the metallic
layer or moisture barrier. A bitumeneous compound primer shall
be applied under the outer jacket to protect the sheath against
local corrosion when corrugated aluminium sheath or lead alloy
sheath is adopted.
CABLE DESIGN
REQUIREment
CURRENT RATING DETERMINATION
Current rating depends upon :
Installation conditions (ground, air, ducts, depth of burial, etc.)
Environmental effects soil temp, soil thermal resistivity, depth of burial, spacing.
Mutual heating derates cable.
Laying Method Flat Formation, Close Touching Trefoil formation.
Type of Bonding Both End Bonding, Single Point Bonding, Mid Point Bonding, Cross bonding.
Information required for cable design

System Voltage
Route Length requirements
Maximum Air Temperature
Type of Earthing
Site Limitations &

Installation conditions
Ground Thermal resistivity
Impulse Level
Frequency
Termination
Cyclic Load
Fault level & Duration
Max. ground Temperature
Normal Load
D.C. RESISTANCE OF CONDUCTOR

NOMINAL CROSS-SECTIONAL AREA
MAXIMUM RESISTANCE OF CONDUCTOR AT 200C
Sq.mm
Copper Conductor (ohm/km)
Aluminium Conductor (ohm/km)
185
0.0991
0.164
240
0.0754
0.125
300
0.0601
0.100
400
0.0470
0.0778
500
0.0366
0.0605
630
0.0283
0.0469
800
0.0221
0.0367
1000
0.0176
0.0291
1200
0.0151
0.0247
Technical Catalogue
Short Circuit Rating For One Second In Ka.

NOMINAL SIZE OF CONDUCTOR (MM2)
COPPER
ALUMINIUM
150
21.450
14.100
185
26.455
17.390
240
34.320
22.560
300
42.900
28.200
400
57.200
37.600
500
71.500
47.000
630
90.090
59.220
800
114.400
75.200
1000
143.000
94.000
1200
171.600
112.800
TESting of EHV Cables

IS: 7098 / PART 3
IEC 60840
Routine Tests
Acceptance Tests
ROUTINE TESTS
ACCEPTANCE TESTS
Conductor Resistance
Conductor Resistance
High Voltage
Conductor Examination
High Voltage
Annealing test (where applicable)
Partial Discahrge
Conductor resistance and Metallic

screen resistance
Partial Discahrge
Tests for dimensions of insulation
Electrical test on
oversheath
Thickness of insulation and

oversheath
Hot set test for insulation
Thickness of metallic sheath
Voids and Contaminant
Hot set test for insulation
Thickness of metallic sheath
Measurement of capacitance
Thickness of outer sheath
Water penetration test

( if applicable)
Partial Discharge
High Voltage
Measurement of capacitance
Technical particulars Cables with Aluminium Conductors

VOLTAGE GRADE
NO OF CORES
NOMINAL AREA sqmm
TYPE OF CABLE
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
185
240
300
400
A2XLyCY
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
(a) In air......(A) at 40C
391
401
412
455
469
483
514
533
550
592
621
642
(b) In ground(A) at 30C Thermal

Resistivity 1.5 K.m/W
Depth : 1500mm
267
276
294
304
318
339
338
357
381
380
407
435
Approx. Overall Dia. of cable (mm)
61
64
66
69
Approx. Weight of cable (kg / km)
7780
8220
8600
9410
Max. DC Resistance of conductor

at 20C (ohm / km)
0.164
0.125
0.100
0.0778
Max.AC Resistance at 90C (ohm / km)
0.2108
0.2107
0.1610
0.1608
0.1291
0.1289
0.1010
0.1007
Reactance at 50 Hz (ohm / km)
0.1443
0.1925
0.1390
0.1858
0.1349
0.1808
0.1288
0.1729
Approx. Capacitance (microFarad / km)
0.179
0.193
0.205
0.225
Max. Length
1000
950
900
825
TOTAL WT
8109
8570
8962
9802
TOTAL kA for 1 Sec
31.95
31.79
32.05
31.97
Technical particulars Cables with Copper Conductors

VOLTAGE GRADE
NO OF CORES
NOMINAL AREA sqmm
TYPE OF CABLE
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
185
240
300
2XLyCY
2XLyCY
2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
(a) In air......(A) at 40C
496
515
531
573
602
622
646
685
710
(b) In ground(A) at 30C Thermal Resistivity 1.5 K.m/W

Depth : 1500mm
335
354
378
379
407
435
418
455
489
61
64
66
8930
9690
10490
0.0991
0.0754
0.0601
Max. DC Resistance of conductor at 20C (ohm / km)

0.1272
0.1270
0.0973
0.0971
0.0781
0.0778
0.1438
0.1918
0.1385
0.1852
0.1338
0.1794
0.181
0.195
0.208
Max. Length
875
800
725
TOTAL WT
9312
10101
10937
Max. Length
875
800
725
31.98
31.82
31.64
TOTAL kA for 1 Sec
Technical Catalogue
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
500
630
800
1000
1200
A2XLyCY
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
682
723
750
774
832
867
876
955
1001
976
1079
1139
1056
1180
1254
427
462
496
473
523
563
521
587
634
567
649
706
600
695
760
73
76
81
85
90
10250
11060
12330
13580
14850
0.0605
0.0469
0.0367
0.0291
0.0247
0.0792
0.0788
0.0623
0.0617
0.0499
0.0491
0.0409
0.0399
0.0360
0.0399
0.1231
0.1656
0.1193
0.1603
0.1148
0.1540
0.1111
0.1489
0.1074
0.1436
0.248
0.267
0.294
0.319
0.348
750
700
625
575
525
10684
11526
12846
14154
15478
31.52
31.53
31.76
31.98
31.84
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
38/66(72.5kV)
400
500
630
800
1000
2XLyCY
2XLyCY
2XLyCY
2XLyCY
2XLyCY
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
734
790
822
831
907
950
931
1036
1093
1035
1171
1247
1135
1302
1399
464
514
554
512
578
627
560
646
706
605
714
786
647
776
860
70
73
77
82
86
11810
13310
15080
17150
19640
0.0470
0.0366
0.0283
0.0221
0.0176
0.0619
0.0614
0.0493
0.0486
0.0395
0.0386
0.0324
0.0313
0.0276
0.0262
0.1281
0.1720
0.1231
0.1656
0.1188
0.1597
0.1143
0.1534
0.1103
0.1479
0.228
0.248
0.270
0.297
0.324
650
575
500
450
400
12303
13871
15709
17872
20463
650
575
500
450
400
31.55
31.52
31.59
31.83
31.64

VOLTAGE GRADE
NO OF CORES
NOMINAL AREA sqmm
TYPE OF CABLE
64/110(123 kV)
64/110(123 kV)
64/110(123 kV)
64/110(123 kV)
240
300
400
500
A2XLyCY
(In Flat
(In Trefoil
Formation)
Formation)
(D+70)
BEB SEB
SEB
A2XLyCY
(In Flat
(In Trefoil
Formation)
Formation)
(D+70)
BEB SEB
SEB
A2XLyCY
(In Flat
(In Trefoil
Formation)
Formation)
(D+70)
BEB
SEB
SEB
A2XLyCY
(In Flat
(In Trefoil
Formation)
Formation)
(D+70)
BEB SEB
SEB
(a) In air......(A) at 40C
454
465
477
513
529
543
592
615
633
683
716
738
(b) In ground(A) at 30C

Thermal Resistivity
1.5 K.m/W
Depth : 1500mm
306
319
337
341
358
379
384
408
432
431
464
493
76
78
82
86
Approx. Weight of cable (kg/km)
10460
10850
11780
12760
Max. DC Resistance of
conductor
at 20C (ohm / km)
0.1250
0.1000
0.0778
0.0605
Max.AC Resistance at 90C

(ohm / km)
0.1609
0.1608
0.1290
0.1289
0.1008
0.1007
0.0790
0.0788
0.1503
0.1914
0.1460
0.1864
0.1393
0.1783
0.1332
0.1709
Approx. Capacitance
(microFarad / km)
0.152
0.160
0.174
0.190
750
725
650
600
TOTAL WT
10903
11303
12279
13293
TOTAL kA for 1 Sec
31.78
31.81
31.86
31.55
Max. Length

VOLTAGE GRADE
NO OF CORES
NOMINAL AREA sqmm
TYPE OF CABLE
64/110(123 kV)
64/110(123 kV)
64/110(123 kV)
240
300
400
2XLyCY
2XLyCY
BEB
SEB
575
597
614
648
680
700
738
784
810
383
408
433
423
457
486
470
516
551
(In Trefoil
Formation)
(a) In air......(A) at 40C
2XLyCY
(In Flat
Formation)
(D+70)
SEB
SEB
(In Flat
Formation)
(D+70)
SEB
BEB
SEB
(In Flat
Formation)
(D+70)
SEB
(In Trefoil
Formation)
BEB
(In Trefoil
Formation)

Depth : 1500mm
77
79
82
11940
12790
14230
0.0754
0.0601
0.0470

at 20C (ohm / km)
0.0972
0.0970
0.0780
0.0778
0.0617
0.0614
0.1498
0.1908
0.1448
0.1850
0.1385
0.1774

Max. Length
0.153
0.162
0.176
650
600
550
TOTAL WT
12439
13329
14827
TOTAL kA for 1 Sec
32.04
31.89
31.93
Technical Catalogue
64/110(123 kV)
64/110(123 kV)
64/110(123 kV)
64/110(123 kV)
630
800
1000
1200
A2XLyCY
A2XLyCY
A2XLyCY
A2XLyCY
BEB
SEB
(In Flat
Formation)
(D+70)
SEB
BEB
SEB
(In Flat
Formation)
(D+70)
SEB
BEB
SEB
(In Flat
Formation)
(D+70)
SEB
BEB
SEB
(In Flat
Formation)
(D+70)
SEB
777
824
852
882
946
984
983
1067
1116
1069
1170
1230
480
525
560
531
590
632
579
653
703
615
701
758
(In Trefoil
Formation)
(In Trefoil
Formation)
(In Trefoil
Formation)
(In Trefoil
Formation)
89
93
97
102
13650
14960
16410
17710
0.0469
0.0367
0.0291
0.0247
0.0621
0.0617
0.0496
0.0490
0.0406
0.0398
0.0356
0.0399
0.1289
0.1655
0.1233
0.1587
0.1192
0.1535
0.1149
0.1479
0.204
0.222
0.239
0.260
575
475
450
425
14225
15591
17097
18449
31.61
31.77
31.78
31.70
64/110(123 kV)
64/110(123 kV)
64/110(123 kV)
64/110(123 kV)
500
630
800
1000
2XLyCY
2XLyCY
2XLyCY
BEB
SEB
838
901
935
942
1030
1075
1053
1166
1226
1153
1294
1371
521
581
623
571
651
702
620
720
782
664
783
856
(In Trefoil
Formation)
SEB
(In Flat
Formation)
(D+70)
SEB
BEB
2XLyCY
(In Flat
Formation)
(D+70)
SEB
(In Trefoil
Formation)
BEB
SEB
(In Flat
Formation)
(D+70)
SEB
BEB
SEB
(In Flat
Formation)
(D+70)
SEB
(In Trefoil
Formation)
(In Trefoil
Formation)
86
89
93
98
15820
17680
19800
22520
0.0366
0.0283
0.0221
0.0176
0.0490
0.0486
0.0391
0.0385
0.0321
0.0313
0.0271
0.0262
0.1332
0.1709
0.1283
0.1648
0.1228
0.1581
0.1184
0.1525
0.190
0.205
0.224
0.243
475
425
375
325
16480
18418
20626
23464
31.55
31.68
31.84
31.94

VOLTAGE GRADE
76/132(145kV)
76/132(145kV)
76/132(145kV)
300
400
500
A2XLyCY
A2XLyCY
A2XLyCY
NO OF CORES
NOMINAL AREA sqmm
TYPE OF CABLE
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(a) In air......(A) at 40C
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
513
527
540
592
613
629
681
712
733
342
358
378
385
408
432
433
464
492
(b) In ground(A) at 30C Thermal Resistivity

1.5 K.m/W
Depth : 1500mm
83
87
90
11830
12820
13650
0.1000
0.0778
0.0605

at 20C (ohm / km)
0.1290
0.1289
0.1008
0.1007
0.0790
0.0787
0.1497
0.1884
0.1429
0.1803
0.1365
0.1728

Max. Length
0.148
0.161
0.175
650
600
575
TOTAL WT
12329
13358
14221
TOTAL kA for 1 Sec
31.57
31.68
31.83

VOLTAGE GRADE
76/132(145kV)
76/132(145kV)
300
400
2XLyCY
2XLyCY
NO OF CORES
NOMINAL AREA sqmm
TYPE OF CABLE
(In Trefoil
Formation)
(a) In air......(A) at 40C
(In Flat
Formation)
(D+70)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
BEB
SEB
SEB
BEB
SEB
SEB
648
678
697
739
781
806
425
457
485
473
517
550

Depth : 1500mm
83
87
13780
15270
Max. DC Resistance of conductor at 20C (ohm / km)
0.0601
0.0470
0.0780
0.0778
0.0617
0.0614
0.1486
0.1870
0.1421
0.1794

Max. Length
0.150
0.162
550
500
TOTAL WT
14359
15910
TOTAL kA for 1 Sec
31.65
31.75
Technical Catalogue
76/132(145kV)
76/132(145kV)
76/132(145kV)
76/132(145kV)
630
800
1000
1200
A2XLyCY
A2XLyCY
A2XLyCY
A2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
776
819
846
882
942
977
986
1065
1110
1074
1167
1222
482
526
559
534
591
631
583
655
702
621
703
757
93
97
101
106
14790
16140
17280
18870
0.0469
0.0367
0.0291
0.0247
0.0620
0.0617
0.0495
0.0490
0.0405
0.0398
0.0354
0.0346
0.1320
0.1673
0.1262
0.1604
0.1219
0.1551
0.1173
0.1494
0.187
0.204
0.219
0.237
475
450
450
400
15406
16823
18004
19664
31.77
31.86
31.63
31.62
76/132(145kV)
76/132(145kV)
76/132(145kV)
76/132(145kV)
500
630
800
1000
2XLyCY
2XLyCY
2XLyCY
2XLyCY
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
(In Trefoil
Formation)
(In Trefoil
Formation)
(In Flat
Formation)
(D+70)
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
838
897
929
944
1025
1067
1056
1162
1217
1160
1293
1363
523
582
622
574
652
700
625
722
781
670
786
855
90
94
98
102
16710
18810
20980
23400
0.0366
0.0283
0.0221
0.0176
0.0490
0.0486
0.0391
0.0385
0.0320
0.0312
0.0270
0.0261
0.1365
0.1728
0.1314
0.1666
0.1257
0.1598
0.1211
0.1540
0.175
0.189
0.206
0.222
450
400
375
325
17408
19604
21862
24375
31.83
31.84
31.94
31.78
VOLTAGE GRADE : 38/66(72.5kV) & TYPE : A2XLyCY

Conductor / Conductor-Screen/XLPE Insulation/Insulation-Screen / Semicon WS Tape/ Lead Sheath / Semico Tape /
Copper Wire Screen / PVC Sheath / Graphite Coating
Aluminium Conductor & Combined Screen(Lead+Copper Wire) fault Level 31.5kA for One Second
NOMINAL AREA sqmm
185
240
In Flat
Form
D+70
In Trefoil
Form
300
In Flat
Form
D+70
In Trefoil
Form
In Trefoil
Form
400
In Flat
Form
D+70
In Trefoil
Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
Air (40C)(A)
391
401
412
455
469
483
514
533
550
592
621
642
Ground (30C)(A)
TRS-1.5 K.m/W
Depth-1500mm
267
276
294
304
318
339
338
357
381
380
407
435
Approx. Overall Dia.(mm)
61
64
66
69
Approx. Weight (kg / km)
7780
8220
8600
9410
Max. DC Resistance at
20C (ohm / km)
0.164
0.125
0.100
0.0778
Max.AC Resistance at
90C(ohm / km)
0.2108
0.2107
0.1610
0.1608
0.1291
0.1289
0.1010
0.1007
Reactance at
50 Hz (ohm / km)
0.1443
0.1925
0.1390
0.1858
0.1349
0.1808
0.1288
0.1729
Approx. Capacitance
(mFarad / km)
0.179
0.193
0.205
0.225
Max. Length
1000
950
900
825
VOLTAGE GRADE : 38/66(72.5kV) & TYPE : 2XLyCY
Conductor / Conductor-Screen/XLPE Insulation/Insulation-Screen / Semicon WS Tape/Lead Sheath / Semico Tape /

Copper Conductor & Combined Screen(Lead+Copper Wire) fault Level 31.5kA for One Second
NOMINAL AREA sqmm
185
240
In Flat
Form
D+70
In Trefoil
Form
300
In Flat
Form
D+70
In Trefoil
Form
In Flat
Form
D+70
In Trefoil
Form
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
Air (40C)(A)
496
515
531
573
602
622
646
685
710
Ground (30C)(A)
TRS-1.5 K.m/W
Depth-1500mm
335
354
378
379
407
435
418
455
489
61
64
66
8930
9690
10490
0.0991
0.0754
0.0601
Max. DC Resistance at
20C (ohm / km)
Max.AC Resistance at
90C(ohm / km)
0.1272
0.1270
0.0973
0.0971
0.0781
0.0778
0.1438
0.1918
0.1385
0.1852
0.1338
0.1794
Approx. Capacitance (mFarad / km)

Max. Length
0.181
0.195
0.208
875
800
725
Technical Catalogue
500
In Trefoil
Form
630
In Flat
Form
D+70
In Trefoil
Form
800
In Flat
Form
D+70
In Trefoil
Form
1000
In Flat
Form
D+70
In Trefoil
Form
1200
In Flat
Form
D+70
In Trefoil
Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
682
723
750
774
832
867
876
955
1001
976
1079
1139
1056
1180
1254
427
462
496
473
523
563
521
587
634
567
649
706
600
695
760
73
76
81
85
90
10250
11060
12330
13580
14850
0.0605
0.0469
0.0367
0.0291
0.0247
0.0792
0.0788
0.0623
0.0617
0.0499
0.0491
0.0409
0.0399
0.0360
0.0399
0.1231
0.1656
0.1193
0.1603
0.1148
0.1540
0.1111
0.1489
0.1074
0.1436
0.248
0.267
0.294
0.319
0.348
750
700
625
575
525
400
In Trefoil
Form
500
In Flat
Form
D+70
In Trefoil
Form
630
In Flat
Form
D+70
In Trefoil
Form
800
In Flat
Form
D+70
In Trefoil
Form
1000
In Flat
Form
D+70
In Trefoil
Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
734
790
822
831
907
950
931
1036
1093
1035
1171
1247
1135
1302
1399
464
514
554
512
578
627
560
646
706
605
714
786
647
776
860
70
73
77
82
86
11810
13310
15080
17150
19640
0.0470
0.0366
0.0283
0.0221
0.0176
0.0619
0.0614
0.0493
0.0486
0.0395
0.0386
0.0324
0.0313
0.0276
0.0262
0.1281
0.1720
0.1231
0.1656
0.1188
0.1597
0.1143
0.1534
0.1103
0.1479
0.228
0.248
0.270
0.297
0.324
650
575
500
450
400
VOLTAGE GRADE : 64/110 (123 kV) & TYPE : A2XLyCY

NOMINAL AREA sqmm
240
In Trefoil
Form
300
In Flat
Form
D+70
In Trefoil
Form
400
In Flat
Form
D+70
In Trefoil
Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
Air (40C)(A)
454
465
477
513
529
543
592
615
633
Ground (30C)(A) TRS-1.5 K.m/W

Depth-1500mm
306
319
337
341
358
379
384
408
432
76
78
82
10460
10850
11780
Max. DC Resistance at 20C (ohm / km)
0.1250
0.1000
0.0778
Max.AC Resistance at 90C(ohm / km)
0.1609
0.1608
0.1290
0.1289
0.1008
0.1007
Reactance at 50 Hz(ohm / km)
0.1503
0.1914
0.1460
0.1864
0.1393
0.1783
0.152
0.160
0.174
750
725
650
Max. Length
VOLTAGE GRADE : 64/110(123 kV) & TYPE : 2XLyCY

Copper Conductor & Combined Screen(Lead+Copper Wire) fault Level 31.5kA for One Second
NOMINAL AREA sqmm
240
In Trefoil
Form
300
In Flat
Form
D+70
In Trefoil
Form
400
In Flat
Form
D+70
In Trefoil
Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
Air (40C)(A)
575
597
614
648
680
700
738
784
810

Depth-1500mm
383
408
433
423
457
486
470
516
551
77
79
82
11940
12790
14230
0.0754
0.0601
0.0470
0.0972
0.0970
0.0780
0.0778
0.0617
0.0614
0.1498
0.1908
0.1448
0.1850
0.1385
0.1774

Max. Length
0.153
0.162
0.176
650
600
550
Technical Catalogue
500
630
In Flat
Form
D+70
In Trefoil
Form
800
In Flat
Form
D+70
In Trefoil
Form
1000
In Flat
Form
D+70
In Trefoil
Form
In Trefoil
Form
1200
In Flat
Form
D+70
In Trefoil Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
683
716
738
777
824
852
882
946
984
983
1067
1116
1069
1170
1230
431
464
493
480
525
560
531
590
632
579
653
703
615
701
758
86
89
93
97
102
12760
13650
14960
16410
17710
0.0605
0.0469
0.0367
0.0291
0.0247
0.0790
0.0788
0.0621
0.0617
0.0496
0.0490
0.0406
0.0398
0.0356
0.0399
0.1332
0.1709
0.1289
0.1655
0.1233
0.1587
0.1192
0.1535
0.1149
0.1479
0.190
0.204
0.222
0.239
0.260
600
575
475
450
425
500
In Trefoil
Form
630
In Flat
Form
D+70
In Trefoil
Form
800
In Flat
Form
D+70
In Trefoil
Form
1000
In Flat
Form
D+70
In Trefoil
Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
838
901
935
942
1030
1075
1053
1166
1226
1153
1294
1371
521
581
623
571
651
702
620
720
782
664
783
856
86
89
93
98
15820
17680
19800
22520
0.0366
0.0283
0.0221
0.0176
0.0490
0.0486
0.0391
0.0385
0.0321
0.0313
0.0271
0.0262
0.1332
0.1709
0.1283
0.1648
0.1228
0.1581
0.1184
0.1525
0.190
0.205
0.224
0.243
475
425
375
325
VOLTAGE GRADE : 76/132(145kV) & TYPE : A2XLyCY

NOMINAL AREA sqmm
300
In Trefoil Form
400
In Flat
Form
D+70
500
In Flat
Form
D+70
In Trefoil
Form
In Trefoil Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
Air (40C)(A)
513
527
540
592
613
629
681
712
733

Depth-1500mm
342
358
378
385
408
432
433
464
492
83
87
90
11830
12820
13650
0.1000
0.0778
0.0605
0.1290
0.1289
0.1008
0.1007
0.0790
0.0787
0.1497
0.1884
0.1429
0.1803
0.1365
0.1728

Max. Length
0.148
0.161
0.175
650
600
575
VOLTAGE GRADE : 76/132(145kV) & TYPE : 2XLyCY

NOMINAL AREA sqmm
300
In Trefoil Form
400
In Flat
Form
D+70
In Trefoil Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
Air (40C)(A)
648
678
697
739
781
806
Ground (30C)(A) TRS-1.5 K.m/W Depth-1500mm
425
457
485
473
517
550
83
87
13780
15270
0.0601
0.0470
0.0780
0.0778
0.0617
0.0614
0.1486
0.1870
0.1421
0.1794

Max. Length
0.150
0.162
550
500
Technical Catalogue
630
In Trefoil Form
800
In Flat
Form
D+70
In Trefoil Form
1000
In Flat
Form
D+70
In Trefoil Form
1200
In Flat
Form
D+70
In Trefoil Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
776
819
846
882
942
977
986
1065
1110
1074
1167
1222
482
526
559
534
591
631
583
655
702
621
703
757
93
97
101
106
14790
16140
17280
18870
0.0469
0.0367
0.0291
0.0247
0.0620
0.0617
0.0495
0.0490
0.0405
0.0398
0.0354
0.0346
0.1320
0.1673
0.1262
0.1604
0.1219
0.1551
0.1173
0.1494
0.187
0.204
0.219
0.237
475
450
450
400
630
800
1000
500
In Trefoil Form
In Flat
Form
D+70
In Trefoil Form
In Flat
Form
D+70
In Trefoil Form
In Flat
Form
D+70
In Trefoil Form
In Flat
Form
D+70
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
BEB
SEB
SEB
838
897
929
944
1025
1067
1056
1162
1217
1160
1293
1363
523
582
622
574
652
700
625
722
781
670
786
855
90
94
98
102
16710
18810
20980
23400
0.0366
0.0283
0.0221
0.0176
0.0490
0.0486
0.0391
0.0385
0.0320
0.0312
0.0270
0.0261
0.1365
0.1728
0.1314
0.1666
0.1257
0.1598
0.1211
0.1540
0.175
0.189
0.206
0.222
450
400
375
325
Process Flow
Chart
MATERIAL
COPPER
SEMICONDUCTING CROSS - LINKED POLYETHYLENE
CROSS LINKED POLYETHYLENE
SEMICONDUCTING CROSS - LINKED POLYETHYLENE
WIRE DRAWING
CONDUCTOR DRAWING
CONDUCTOR SHIELDING (EXTRUSION AND VULCANISING)
CROSS LINKED POLYETHYLENE INSULATION (EXTRUSION AND VULCANISING)
INSULATION SHIELDING (EXTRUSION AND VULCANISING)
SEMI CONDUCTING WATER SWELLABLE TAPE
ANNEALED COPPER TAPE
TAPING
INSULATION METALLIC SHIELDING
TAPING
SEMI CONDUCTING WATER SWELLABLE TAPE
LEAD ALLOY SHEATHING / COPPER SCREENING
PVC TYPE ST - 2
METALLIC SHIELDING
PVC SHEATHING (EXTRUSION)

WITH GRAPHITE COATING
TESTING FINISHED CABLE
PACKING
Technical Catalogue
Laying
Methods
Both End Bonding Method
Cable Termination
typical trench cross section

Cables in Trefoil Formation
G.L.
Conductor
Excavated earth
Backfill
Bonding
Cable
R.C.C.
Protection Tile
EHV Cable in
close touching
trefoil formation
50
single point bonding method
300
Link Box
Pre-warning
Tape
Link Box
1500
Screen
Cable Termination
Cable sheath
insulated at
termination
600
Conductor
Bonding
Cable
Screen
Link Box with

SVL Unit
Link Box
typical trench cross section

road crossing
Cables in Flat Formation
G.L.
Excavated earth
Backfill
cross-bonding method
Cable terminations
Conductor
Pre-warning Tape
1500
Screen separation
R.C.C. Protection Tile

Screen
SVL
Cross-bonding
of screens
Sieved compacted
Earth
765
Direct earthing
PVC / HDPE Pipe
EVH Cable in
flat formation
KEC
International
Ltd.
KEC is one of the oldest players in the industry and global leader in the Infrastructure Engineering, Procurement and
Construction space. Established in 1945, KEC has a significant presence in the segments of Power Transmission & Distribution,
Cabling, Railway, Telecom and Water Resource management. KECs strengths lie in Engineering, Design, Manufacture and
Testing, supply of transmission towers, telecom towers, cables and Construction of turnkey infrastructure projects. KECs
focused approach towards project management enables the creation of world class products, innovative solutions, customized
to overcome extreme terrain and climate. With proven technical prowess in handling mega projects and superior project
management expertise, KEC has made an indelible mark on the world map by constantly and consistently reengineering itself
to retain its position of leadership in the areas of quality, technology, capacity and capability.
rpg
Enterprises
RPG Enterprises is one of Indias largest business conglomerates. Since its inception in 1979, RPG Enterprises has been one
of the fastest growing business houses in India. RPG Enterprises has diverse businesses under its fold ranging from Power,
Tyres, Infrastructure, IT to Pharma. The Groups management comprises individuals extensively qualified and experienced in
their domain areas. RPGs wide ranging business invite growing returns and high esteem in the eyes of all its stakeholders.
The Group lives by values of keen entrepreneurial skills, performance and excellence.
Corporate office
6th Floor, RPG House, 463. Dr. Annie Besant Road, Worli, Mumbai - 400 030. India
Tel. +91-22-66670300, 24937244 | Fax No. +91-22-24930206
email: powercables@kecrpg.com | telecomcables@kecrpg.com | exportcables@kecrpg.com
Sales Offices
Delhi
Mumbai
Pune
Chennai
N-83,1st Floor,(Above PNB )

Pratap Building, Cannaught Place,
New Delhi - 110 001. India
6th Floor, RPG House, 463.

Dr. Annie Besant Road, Worli,
Mumbai - 400 030. India
Flat No.9, KSHITIJ ,1st Floor, 769/6,

Lane No.7, Prabhat Road, Deccan
Gymkhana, Pune - 411 004. India
Bhavani Mansion No.3, 4th Lane,

Nungambakkam High Road,
Chennai - 600 034. India
Tel. +91-11-66098598, 599

Fax No. +91-11-66098597
Tel. +91-22-66670300, 24937244

Fax No. +91-22-24930206
Tel. +91-20-64706061, 6065

Fax No. +91-20-2436178
Tel. +91-44-28332920, 28332918

Fax No. +91-44-28224917
Kolkata
Vadodara
Hyderabad
Bangalore
Halwasiya Mansion, Ground Floor,

6/2, Moira Street,
Kolkata - 700 017. India
421, Center Point,

R.C.Dutta Road, Alkapuri,
Vadodara - 390 007. India
406 & 407, Maheshwari Chambers,

Erramanzil, Somajiguda,
Hyderabad - 500 082. India
C/o. CEAT Limited, Jasmine Mansion,

4th Floor, 19, J. C. Road,
Bangalore - 560 002. India
Tel. +91-33-64590654
Fax No. +91-33-22906720
Tel. Tel. +91-265-3015454

Fax No. +91-265-3015454
Tel. +91-40-30901642
Fax No. +91-40-30901642
Tel. +91-80-22124444
Fax No. +91-80-22124444
April 2011

EHV Catalogue

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EHV Catalogue

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Extra

RPG Cables, a division of KEC International Limited has established

SPECIAL FEATURES OF EHV

Highly sophisticated Dry Cure Line using superclean XLPE compound .

ADAVNTAGES OF LEAD SHEATH :

SPECIALISED CONTINUOUS LEAD EXTRUDER :

Constructional features: EHV CABLES :

The conductor shall be formed from plain copper or aluminium

The insulation shall be of dry cured XLPE compound with

Water Swellable Tape

The insulation shielding shall be applied direct upon

Water swellable tapes are used in cables to prevent longitudinal

Copper Wire Shield

Corrugated Aluminium Sheath/Metal Tape

Information required for cable design

Route Length requirements

Maximum Air Temperature

Site Limitations &

Ground Thermal resistivity

Fault level & Duration

Max. ground Temperature

D.C. RESISTANCE OF CONDUCTOR

MAXIMUM RESISTANCE OF CONDUCTOR AT 200C

Copper Conductor (ohm/km)

Aluminium Conductor (ohm/km)

Short Circuit Rating For One Second In Ka.

TESting of EHV Cables

Annealing test (where applicable)

Conductor resistance and Metallic

Tests for dimensions of insulation

Thickness of insulation and

Hot set test for insulation

Thickness of metallic sheath

Voids and Contaminant

Hot set test for insulation

Thickness of metallic sheath

Thickness of outer sheath

Water penetration test

Technical particulars Cables with Aluminium Conductors

(a) In air......(A) at 40C

(b) In ground(A) at 30C Thermal

Approx. Overall Dia. of cable (mm)

Approx. Weight of cable (kg / km)

Max. DC Resistance of conductor

Max.AC Resistance at 90C (ohm / km)

Reactance at 50 Hz (ohm / km)

Approx. Capacitance (microFarad / km)

TOTAL kA for 1 Sec

Technical particulars Cables with Copper Conductors

(a) In air......(A) at 40C

(b) In ground(A) at 30C Thermal Resistivity 1.5 K.m/W

Approx. Overall Dia. of cable (mm)

Approx. Weight of cable (kg / km)

Max. DC Resistance of conductor at 20C (ohm / km)

Reactance at 50 Hz (ohm / km)

Approx. Capacitance (microFarad / km)

TOTAL kA for 1 Sec

Technical particulars Cables with Aluminium Conductors

(a) In air......(A) at 40C

(b) In ground(A) at 30C

Approx. Overall Dia. of cable (mm)

Approx. Weight of cable (kg/km)

Max.AC Resistance at 90C

Reactance at 50 Hz (ohm / km)