SHYAM CABLE INDUSTRIES

All Types Of Cables Manufacturer Company

Engineering Customized Power Solutions

WELCOME TO

OUR COMPANY
Chapter

Page No.

INTRODUCTION

PRODUCT RANGE

LIST OF GOVERNMENT CLIENTS

LIST OF OTHER REPUTED CLIENTS

LIST OF MACHINERY

LIST OF TESTING EQUIPMENTS

QUALITY CONTROL

CURRENT RATING

PROCESS FLOW CHART (PVC CABLES)

QUALITY ASSURANCE PLAN (PVC CABLES)

10

CONSTRUCTION OF POWER CABLES

14

PROCESS FLOW CHART (RUBBER CABLES)

23

QUALITY ASSURANCE PLAN (RUBBER CABLES)

24

TECHNICAL OF ELASTOMERIC CABLES

26

TECHNICAL OF WELDING CABLES

28

PROPERTIES OF RAW MATERIAL USED

33

TELEPHONE CABLES

40

LIST OF REGISTRATION CERTIFICATE & PERFORMANCE CERTIFICATES

42

LIST OF PURCHASE ORDERS

52

SALIENT FEATURES
1.
Well equipped and most modern laboratory having ISO-9001 and ISI carrying out
extensive tests from raw materials to final products at various stages.
2.

Cables manufacturing conforming to various National and International specifications

having four BIS License: 9968/Pt-I/1988, 1554/Pt-1/1988, 9857/90 & 694/90.

3.

Approval accorded by a number of Organisations and Inspection agencies of International

repute like IFFCO, BHEL, NLC, RSP, BSP, SAIL, ONGC, NTPC, DGS&D, Air Hqs., DGQA
(Naval) LGT, MECON, PDIL etc.

4.

Specialisation in Elastometric / Flexible Cables (Butyl/EPR, PCP /CSP and Silicon Rubber
Cables)

5.

40 successful years of regular supply to numerous Government Departments / Public /

Private Sector Industrial Enterprises.

6.

80% of Production ongoing to Government Department and reputed public Sector

Undertaking all over the country.

CLIENTELE
Our more than 40 years of journey towards service with excellence has given us numerous all over
India in all the sectors of the India Economy, 80% of them in government / Public Sector. Today
hundreds of industrial enterprises rely on Shyam Cable in the key sectors like Steel plants, Power
Projects, Aeronautics, Ordnance factories, Railways, Fertilizer Plants, Atomic Energy, Air Force,
Petroleum, Navy, Shipyards, Mines, Power Stations, Oil & Natural Gas, Port Trusts, Coalfields,
Heavy Engineering, Telecommunication. Electrical and Electronics, Wind Energy and so on.

PRODUCTS
S.No. Type of Cables
upto)

Specification

Size (Including &

No of cores x Area in Sq.mm

1.

Elastomeric Cables
(VIR/TRS, EPR, PCP/CSP &
Silicon Rubber Insulated Cables)

2.

Power & Controls Cables

(Armoured /Unarmoured PVC
Insulated & Sheathed)

3.

Trailing Cables

4.

Welding Cables
(Copper & Aluminium)

5.

PVC Wires/Cables
Lighting Cables
Screened Cables
Instrumentation Cables
Compensating Cables

IS: 9968/88/Pt-1
ISI Marked

1 x 1000
3.5 x 630
61 x 2.5

IS: 1554/88/Pt-1
ISI Marked

1 x 1000
3.5 x 630
61 x 2.5

IS: 9968/88/Pt-1 & Pt-II

Upto 6.6/11 KV

1 x 1000
3.5 x 630
61 x 2.5

IS: 9857/90
ISI Marked

All Sizes

IS: 694/90
ISI Marked

All Sizes

IS: 5608
IS: 8784

6.

FRLS Cables ASTM/D-2843

IS: 1554/88

All Sizes

7.

Telephone Cables
(Armoured /Unarmoured)

ITD-3003
G/WIR-06/02

100 Pairs

8.

Submersible
Flat Cables

IS: 694/90
IS: 9968/88/Pt-1

61 x 2.5
4 x 400

9.

XLPE Cables
(Armoured/ Unarmoured XLPE
Insulated & Sheathed Cables)

IS: 7098

1 x 1000
3.5 x 630
61 x 2.5

10.

Kynar / HMWPE

All Sizes

LIST OF

GOVERNMENT CLIENTS
S A I L / BHILAI STEEL PLANT

BEML

S A I L / BOKARO STEEL PLANT

NTPC

S A I L / ROURKELA STEEL PLANT

ONGC

S A I L / DURGAPUR STEEL PLANT

NALC O

NEYVELI LIGNITE CORP. LTD.

NHPC

B H E L (HARIDWAR & TIRUCHIRAPALLI)

GAIL (INDIA) LIMIITED

DAMODER VALLEY CORPORATION

TRIVENI STRUCTURALS LTD.

R C F (KAPURTHALA)

NATIONAL MINERALS DEVELOPMENT CORP. LTD.

MAZGOAN DOCK LTD.

VISHAKHAPATNAM PORT TRUST

NATIONAL FERTILIZER LIMITED

I F F C O Limited

NUMALIGARH REFINERY LIMITED

URANIUM CORPORATION INDIA LIMITED

THERI HYDRO DEVP. CORP. LTD.

BONGAIGAON REFINERY & PETROCHEMICALS LTD.

CONTAINER CORP. OF IND. LTD.

PANIPAT THERMAL POWER STATION

N.E.E.P.C.O. LIMITED

COAST GUARD

ORDNANCE FACTORIES

NAVAL (MUMBAI, KOCHI, GOA)

HINDUSTAN STEEL WORKS CONS. LTD.

BHARAT HEAVY PLATES & VESSELS LTD.

INDIA AIR FORCE

CHENNAI PORT TRUST

SATLUJ JAL VIDYUT NIGAM LTD.

VISAKHAPATNAM STEEL PLANT

NORTHERN RAILWAYS

MEC0N LTD.

P.D.I.L

INDIAN OIL CORP. LTD.

LIST OF OTHER

REPUTED CLIENTS
RELIANCE INDUSTRIES LIMITED

ENERCON

RELIANCE PETROLEUM LIMITED

GUJARAT AMBUJA CEMENT

ELECON ENGINEERING CO. LTD.

BHUSHAN STEEL LTD.

FENNER INDIA LTD.

JINDAL STAINLESS LTD.

ISGEC

JINDAL PIPE LTD.

DC M SHRIRAM (DAURALA)

SIEMENS LIMITED

BALCO

L&T LTD.

A.B.B. LTD.

ADANI GROUP

ESSAR GROUP

JINDAL STEEL & POWER

PRAKASH INDUSTRIES LIMITED

SUZLON ENERGY LTD.
MUKAND LIMITED
BEEKAY ENGG. CORPORATION
RATHI SUPER STEEL LIMITED
BAJAJ HINDUSTAN LTD.
MONNET ISPAT & ENERGY LTD.
SIMPLEX ENGG. & FOUNDRY WORKS (P) LTD.

LIST OF

MACHINERY
PVC Extruders (150 mm)

Kneader

PVC Extruders (100 mm)

PVC Mixtures

PVC Extruders (75 mm)

Rubber Mixing Mills

PVC Extruders (40 mm)

M.S. Vulcanisers Complete with

Rubber Extruders (100 mm)

Rubber Extruders (75 mm)
Rubber Extruders (40 mm)
Tray and stand.
Bale Cutting Machine
Wire Stranding & Trapping Machines
Taping Heads
High Speed Bunching Machine
Armouring Machines
Braiding Machines of various sizes
Core Printing Machine
Sequential length marking machine
M. S. Trolley
Laying Machines
Spooling Machines
High Speed Bunching
Welding Machine
Oil Fired Boiler

LIST OF

TESTING EQUIPMENTS

AC High Voltage Tester 10 KV

Single Pan Electrical Balance

AC High Voltage Tester 30 KV

Mandral for Bending Test

Double Kelvin Bridge

Dombell Die with Stand

Million Meghohms Meter

Tear Resistance Attachment

Hot Deformation Test Apparatus

Air & Oxygen Bomb Apparatus

Volumetric Test Apparatus

Oxygen Cylinder

Annealing Test Apparatus

Meggar

Hot Water Bath

Spark Tester

DC High Voltage

Air Compressor

Hydraulic Press

Tensile Testing Machine

Capacitance Meter

Travelling Microscope

Flamability Test Apparatus

Flame Resistance Test Apparatus

Standard Resistance Box

Hot set Test Apparatus

Micrometer

Humidity Conditioning Chamber

Digital Milliohm Meter

Ozone Test Apparatus

Air Hot Oven

Cold Band Test Apparatus

Fault Locator

Smoke Density

Physical Balance

Oxygen Index

Multimeter

Halogen Acid Gas Generation

Ageing Oven

Swedish Chimney

Ageing Air Oven

Ladder Test

QUALITY CONTROL
QUALITY CONTROL
1.
2.
3.

Raw Material Control.

Process Control & Continuous on-line testing.
Product Control.

Shyam Cables maintains very high standards of product quality through a very strict and efficient
quality control system mainly.
RAW MATERIAL CONTROL
All raw materials under go rigorous testing for the conformity and stability in the
manufacturing process. A highly qualified and experienced group of Chemists ensure that
no sub-standard material is used in processing of cables.
PROCESS CONTROL
Process is controlled and checked by a team of experts and any deviations from standard
process in immediately checked and corrective action is taken.
PRODUCT CONTROL
100% testing and checking is done for cables. So that they are capable of giving
satisfactory services in actual use. Our engineers ensure the cable conform to the
standards is specified and results are well within relevant values.
Elastometric Insulated Cables for working voltage upto and insulating 1100 Volts as per IS9968 - Part - I/1988 ISI Marked and upto as per IS:9968 Part - II/81.
The elastometric insulated cables for fixed wiring, flexible cables and flexible cords for
electric power and lighting for operation at voltage upto an including 6.6 K.V. is
manufactured as per the requirements specified in IS: 9968 (Part-II) 1981.
The type of cables covered under this standard are as follows:1)
For Fixed Wiring.
a)
Braided and Compounded/Varnished.
b)
Elastomeric sheathed (general purpose)
c)
Elastomeric with earth community conductor (ECC)
2)
For Fixed Wiring.
a)
Braided and Varnished.
b)
Elastomeric sheathed (Heavy Duty)
3)
For Flexible Cords.
a)
Braided.
b)
Elastomeric sheathed (general purpose)
c)
Unlinkable flexible cords.

CURRENT RATINGS
The current ratings in table 1 & 2 based on the normal conditions of installation as described below :
0
1. Maximum condr. Temperature
70 C
5. Thermal resistivity of soil
0
2. Ambient air temperature
40 C
6. Thermal resistivity of cable
0
3. Ground temperature
30 C
7. Max. short-circuit conductor temp.
4. Depth of laying (for cable
8. Max. Ambient Air Temperature
laid directly in ground )
75 cm (1.1 KV)

150 C cm/watt
0
650 C cm/watt
0
160 C
0
55 C

Installation method and rating factors are given in tables 1 to 6.

Table -1
Rating for variations in ground temperature for cables laid directly in ground and in ducts
0

Ground temperature C
Rating factor

15

20

25

30

35

40

45

50

55

1.17

1.12

1.06

1.0

0.94

0.87

0.79

0.70

0.80

Table -2
Rating factors for variation in amblent air temperature
0

Air temperature C
Rating factor

25

30

35

40

45

50

55

1.25

1.16

1.09

1.00

0.90

0.80

0.69

Table- 3
Rating factors of groups of twin and multicore cables laid directly in ground in horizontal formation
No. of cables

Rating factor for axial spacing

Touching

15 cm

30 cm

45 cm

60 cm

2 cables

0.78

0.81

0.85

0.88

0.90

3 cables

0.68

0.71

0.77

0.81

0.83

4 cables

0.61

0.65

0.72

0.76

0.79

6 cables

0.53

0.58

0.66

0.71

0.78

8 cables

0.48

0.54

0.62

0.67

0.72

Table -4
Rating factors of groups of twin and multicore cables laid directly in ground in tier formation
Rating factor for axial spacing

No. of cables
Touching

15 cm

30 cm

45 cm

60 cm

4 cables

0.60

0.67

0.73

0.76

0.78

6 cables

0.51

0.57

0.63

0.67

0.69

8 cables

0.45

0.51

0.57

0.59

0.61

Table -5
Rating factors for variation in depth of laying in ground
Depth of laying
Rating factor upto 25 sq.
mm.

75

90

105

120

150

150& above

1.00

0.99

0.98

0.97

0.96

0.95

Table 6
Group-rating factors for cables installed in ground, separated by more than 7 cms.
No of cables

Single core D.C cables & multicore power cables

1.0

0.90

0.80

0.75

0.70

0.65

Single core A.C. cables

1.0`

0.80

0.75

0.70

0.65

0.60

PROCESS FLOW

CHART FOR PVC CABLES

10

QUALITY ASSURACE

CHART FOR PVC CABLES

11

QUALITY ASSURACE

CHART FOR PVC CABLES

12

QUALITY ASSURACE

CHART FOR PVC CABLES

13

QUALITY ASSURACE

CHART FOR PVC CABLES

14

POWER & CONTROL CABLE AS PER IS-1554 (PART-I) 1988

1.1 K.V Grade, Copper/Aluiminum Conductor, PVC/HR PVC Insulated
core laid up and PVC Inner Sheath, G.I. Steel Wire/Strip armoured
and Overall PVC/HR PVC/FRLS PVC sheathed Cable ISI MARKED
Material :
Copper conductors are of annealed high conductivity copper wires
IS:8130/1984.
Aluminium conductors are of aluminium wire complying to IS-8130-1984.

complying to

Insulation :
It is of PVC compound conforming to the requirements of Type - A,B,C, of IS-5831-84
Inner Sheath : (Common Covering)
a)
Vulcanised or unvulcanised rubber
b)
Thermoplastic material
c)
Proofed or plastic tape
Armoured :
a)
Galvanised round steel wire
b)
Galvanised steel strip
Outer Sheath :
The outer sheath is of PVC compund conforming to the requirements of Type ST-1, ST-2
of IS-5831-1970
Conductor :
(Nominal Cross Sectional/Area in mm )
2

Copper
1.5
2.5 to 6
10 and above

Aluminium

Solid/Stranded

1.5
2.5 to 10
6 and aboveStranded

Solid
Solid
Stranded

THE CABLES AMPACITY

Standard Conditions of installation for which the current carrying capacity
is given in the ensuing tables are :
Conductor temperature
Thermal resistivity of soil
Thermal resistivity of PVC
Ambient temperature
Ground temperature
Depth of laying cable

15

:
:
:
:
:
:

70 C Maximum
150 C cm/w
650 C cm/w
40 C
30 C
75 cm in the ground
0

UNARMOURED CONTROL CABLE IS : 1554 (Pt - I ) - 1988

A p p ro x .
N et.
W eig h t
of
C a b les
K g /k m

S ta n d a rd
D eliv ery
L en g th
in M trs.

1 1 .8

185

1000

23

20

1 2 .3

190

1000

21

17

1 .8

1 3 .2

225

1000

21

17

0 .3

1 .8

1 4 .1

260

1000

16

14

0 .8

0 .3

1 .8

1 5 .1

295

1000

15

13

0 .8

0 .3

1 .8

1 5 .1

315

1000

14

13

1 0 x 1 .5

0 .8

0 .3

1 .8

1 8 .4

425

1000

13

11

1 2 x 1 .5

0 .8

0 .3

1 .8

1 8 .9

480

1000

12

10

1 4 x 1 .5

0 .8

0 .3

1 .8

1 9 .8

535

1000

11

10

1 6 x 1 .5

0 .8

0 .3

1 .8

2 0 .7

595

1000

11

1 9 x 1 .5

0 .8

0 .3

2 .0

2 2 .5

720

1000

10

2 4 x 1 .5

0 .8

0 .3

2 .0

2 5 .8

880

1000

2 7 x 1 .5

0 .8

0 .3

2 .0

2 6 .3

960

1000

3 0 x 1 .5

0 .8

0 .3

2 .0

2 7 .2

1040

1000

3 7 x 1 .5

0 .8

0 .3

2 .0

2 9 .1

1230

1000

2 x 2. 5

0 .9

0 .3

1 .8

1 3 .0

230

1000

32

27

3 x 2. 5

0 .9

0 .3

1 .8

1 3 .6

240

1000

27

24

4 x 2. 5

0 .9

0 .3

1 .8

1 4 .6

290

1000

27

24

5 x 2. 5

0 .9

0 .3

1 .8

1 5 .7

335

1000

23

19

6 x 2. 5

0 .9

0 .3

1 .8

1 6 .9

385

1000

21

18

7 x 2. 5

0 .9

0 .3

1 .8

1 6 .9

420

1000

20

17

10 x 2. 5

0 .9

0 .3

1 .8

2 0 .8

570

1000

18

15

12 x 2. 5

0 .9

0 .3

2 .0

2 2 .2

690

1000

17

14

14 x 2. 5

0 .9

0 .3

2 .0

2 3 .2

775

1000

16

13

16 x 2. 5

0 .9

0 .3

2 .0

2 4 .3

860

1000

15

13

19 x 2. 5

0 .9

0 .3

2 .0

2 5 .5

985

1000

14

12

24 x 2. 5

0 .9

0 .3

2 .0

2 9 .4

1215

1000

13

11

27 x 2. 5

0 .9

0 .3

2 .0

3 0 .0

1330

1000

12

10

30 x 2. 5

0 .9

0 .3

2 .0

3 1 .0

1450

1000

12

10

37 x 2. 5

0 .9

0 .3

2 .2

3 4 .1

1790

1000

11

N o. of
C ro res
& C ro ss
S ectio n a l
A rea N O
x m m 2.

T h ick n ess
of PV C
in su ta io n
(N o m .)

T h ick n ess
of PV C
In n ersh ea th
(M in )

T h ik n ess o f
PV C
o u tersh ea th
(N o m .)

mm

mm

mm

2 x 1 .5

0 .8

0 .3

1 .8

3 x 1 .5

0 .8

0 .3

1 .8

4 x 1 .5

0 .8

0 .3

5 x 1 .5

0 .8

6 x 1 .5
7 x 1 .5

A p p ro x .
O .D .

mm

C u rren t R a tin g
D irect in
In
G ro u u n d A ir/D u ct
A m p s.
A m p s.

Construction
1. Solid/ Stranded annealed copper conductor & Tinned / Bare
2. General Purpose /HR PVC insulation
3. Cores laid up (filled if needed )
4. FRLS / General Purpose PVC inner Sheath
5. FRLS / General Purpose PVC Outer sheath
Max Conductor D.C Resistance at 20 Deg C Conductor Size:
1.5 sq mm -12.1 Ohm /km (Bare, 12.2 Q/km (Tinned)
2.5 sq mm -7.41 Ohm /km (Bare, 7.56 Q/km (Tinned)
*Dimensions specified are with stranded conductor

16

1 CORE ALUMINIUM PVC ARMOURED POWER CABLES

Type

No. of
cores
&Cross
Section
al Area

Min
no. of
Wires

Thickness
of PVC
insulation
(nom)

Nominal
Dimension
s of
Armour
Wire (mm)

Mm

17

Min
Thickness
of PVC
Outer
Sheath

Overall
Deamte
r
(Approx
)

(mm)

Approx
Net Wt
of cable

Max.D.
C
Resista
nce at
70

Max AC
Resista
nce at
70

Ohms/k
m
8.8900

0.158

0.47

(Kg/Km)

Approx
Reactance
at 50Hz

Approx.
Capacit
ance

Km

160

Ohms
/km
7.4100

Km

Ayway

1Cx4

1.30

1.40

1.24

(mm)
11

Ayway

1Cx6

1.30

1.40

1.24

12

180

4.6100

5.5300

0.148

0.56

Ayway

1Cx10

1.30

1.40

1.24

13

210

3.0800

3.7000

0.138

0.67

Ayway

1Cx16

1.30

1.40

1.24

14

240

1.9100

2.2900

0.128

0.81

Ayway

1Cx25

1.50

1.40

1.24

15

310

1.2000

1.4400

0.120

0.87

Ayway

1Cx35

1.50

1.40

1.24

16

360

0.8680

1.0400

0.114

1.00

Ayway

1Cx50

1.70

1.40

1.24

18

450

0.6410

0.7700

0.110

1.03

Ayway

1Cx70

12

1.70

1.40

1.40

20

560

0.4430

0.5300

0.103

1.21

Ayway

1Cx95

15

1.90

1.60

1.40

22

720

0.3200

0.3800

0.101

1.27

Ayway

1Cx120

15

1.90

1.60

1.40

24

830

0.2530

0.3000

0.096

1.42

Ayway

1Cx150

15

2.10

1.60

1.40

27

980

0.2060

0.2500

0.094

1.42

Ayway

1Cx185

30

2.30

1.60

1.40

28

1160

0.1640

0.2000

0.092

1.44

Ayway

1Cx240

30

2.50

1.60

1.56

31

1450

0.1250

0.1500

0.090

1.53

Ayway

1Cx300

30

2.70

2.00

1.56

35

1710

0.1000

0.1200

0.088

1.56

Ayway

1Cx400

53

3.00

2.00

1.56

39

2190

0.0778

0.0934

0.088

1.56

Ayway

1Cx500

53

3.40

2.00

1.72

40

2730

0.0605

0.0726

0.087

1.57

Ayway

1Cx630

53

3.90

2.00

1.88

48

3440

0.0469

0.0563

0.086

1.57

Ayway

1Cx800

53

3.90

2.00

1.88

52

4120

0.0367

0.0440

0.083

1.75

Ayway

1Cx1000

53

3.90

2.50

2.04

57

5090

0.0291

0.0349

0.082

1.94

1 CORE ALUMINIUM PVC UNARMOURED POWER CABLES

Type

No. of
cores
&Cross
Sectional
Area

Min
no. of
Wires

Thickness
of insulation
(nom)

Nom.
Thickness
of Outer
Sheath

Overall
Diameter
(Appro)

Net Wt of
cable
(approx)

Max.D.C
Resistan
ce at
0
20 C

Max AC
Resistance
0
at 90 C

Approx
Reactanc
e at 50Hz

Approx.
Capacita
nce

Mm

(mm)

(mm)

(Kg/Km)

Ohms
/km

Ohms/km

Km

Km

Ayy

1CX4

1.00

1.80

100

7.4100

8.8900

0.137

0.58

Ayy

1CX6

1.00

1.80

110

4.6100

5.5300

0.127

0.68

Ayy

1CX10

1.00

1.80

10

130

3.0800

3.7000

0.118

0.83

Ayy

1CX16

1.00

1.80

11

160

1.9100

2.2900

0.110

1.01

Ayy

1CX25

1.20

1.80

12

220

1.2000

1.4400

0.105

1.05

Ayy

1CX35

1.20

1.80

13

260

0.8680

1.0400

0.100

0.22

Ayy

1CX50

1.40

1.80

15

330

0.6410

0.7700

0.098

1.22

Ayy

1CX70

12

1.40

1.80

17

410

0.4430

0.5300

0.091

0.43

Ayy

1CX95

15

1.60

1.80

19

530

0.3200

0.3800

0.088

1.47

Ayy

1CX120

15

1.60

2.00

21

640

0.2530

0.3000

0.086

1.62

Ayy

1CX150

15

1.80

2.00

23

770

0.2060

0.2500

0.085

1.62

Ayy

1CX185

30

2.00

2.00

25

920

0.1640

0.2000

0.084

1.62

Ayy

1CX240

30

2.20

2.00

28

1160

0.1250

0.1500

0.082

1.72

Ayy

1CX300

30

2.40

2.00

30

1390

0.1000

0.1200

0.080

1.74

Ayy

1CX400

53

2.60

2.20

35

1760

0.0778

0.0934

0.080

1.81

Ayy

1CX500

53

3.00

2.20

39

2200

0.0605

0.0726

0.079

1.76

Ayy

1CX630

53

3.40

2.40

44

2620

0.0469

0.0563

0.077

1.77

Ayy

1CX800

53

3.40

2.40

48

3430

0.0367

0.0440

0.077

1.98

Ayy

1CX1000

53

3.40

2.60

53

4180

0.0291

0.0349

0.076

2.20

18

2 CORE ALUMINIUM PVC ARMOURED POWER CABLES

Type

No. of
cross &
Cross
Sectional
Area

Min no.
of Wires

Thickne
ss of
PVC
insulati
on
(nom)
Mm

19

Min
Thic
knes
s of
PVC
Oute
r
She
ath(
mm)

Nominal
Dimension of
Armour
Strip Wire
(mm)

Min. Thickness OF
pvc outer
strength
Strip Wire
Armour Armour

Overall Diameter
(approx)
Strip Wire
Armour Armour

Appox Net Wt. of

cable
Strip wire
Armour

(mm)

Max.D.
C
Resista
nce at
20

Max
AC
Resist
ance
at 70

Approx
Reacta
nce at
50Hz

(mm)

Approx.
Capacit
ance

Km
Km
(Kg/Km)

Ohms
/km

Ohms
/km

Aywy

2CX1.5

0.8

0.3

1.40

1.24

13.5

390

18.10

21.72

0.126

0.14

Aywy

2CX2.5

0.9

0.3

1.40

1.24

15.0

450

12.10

14.52

0.119

0.15

Aywy

2CX4

1.0

0.3

1.40

1.24

16.5

550

7.41

8.89

0.116

0.16

Aywy

2CX6

1.0

0.3

1.40

1.24

17.5

640

4.61

5.53

0.110

0.19

Aywy

2CX10

1.0

0.3

1.40

1.24

19.0

745

4.08

3.70

0.100

0.22

Aywy/
Ayfy

2CX16

1.0

0.3

4X0.8

1.60

1.40

1.40

20.5

22.5

565

830

1.91

2.29

0.097

0.29

Aywy/
Ayfy

2CX25

1.2

0.3

4X0.8

1.60

1.40

1.40

21.0

23.0

700

905

1.20

1.44

0.097

0.32

Aywy/
Ayfy

2CX35

1.2

0.3

4X0.8

1.60

1.40

1.40

22.5

24.0

810

1040

0.868

1.04

0.097

0.37

Aywy/
Ayfy

2CX50

1.4

0.3

4X0.8

1.60

1.40

1.56

25.0

27.0

1000

1290

0.641

0.77

0.094

0.37

Aywy/
Ayfy

2CX70

12

1.4

0.3

4X0.8

1.60

1.56

1.56

28.0

29.5

1230

1510

0.443

0.53

0.090

0.44

Aywy/
Ayfy

2CX95

15

1.6

0.4

4X0.8

2.00

1.56

1.56

31.5

34.0

1520

2060

0.320

0.38

0.090

0.44

Aywy/
Ayfy

2CX120

15

1.6

0.4

4X0.8

2.00

1.56

1.72

33.5

36.5

1765

2360

0.253

0.30

0.087

0.49

Aywy/
Ayfy

2CX150

15

1.8

0.4

4X0.8

2.00

1.72

1.72

37.0

39.5

2080

2700

0.206

0.25

0.087

0.49

Aywy/
Ayfy

2CX185

30

2.0

0.5

4X0.8

2.00

1.88

1.88

41.0

43.0

2500

3175

0.164

0.20

0.087

0.49

Aywy/
Ayfy

2CX240

30

2.2

0.5

4X0.8

2.50

2.04

2.04

45.5

49.0

3075

4230

0.125

0.15

0.087

0.50

Aywy/
Ayfy

2CX300

30

2.4

0.6

4X0.8

2.50

2.20

2.20

50.0

53.5

3760

4950

0.100

0.12

0.086

0.52

Aywy/
Ayfy

2CX400

53

2.6

0.7

4X0.8

3.15

2.36

2.52

55.5

60.5

4560

6560

0.0778

0.09

0.086

0.53

3 CORE ALUMINIUM PVC ARMOURED POWER CABLES

Type

No. of
cores
&Cross
Section
al Area

Min
no. of
Wires

Thick
ness
of
PVC
insula
tion
(nom)
(mm)

Min
Thi
ckn
ess
of
PV
C
Out
er
She
ath(
mm
)

Nominal
Dimension of
Strip/Wire
Armour

Min. Thickness
OF pvc outer
strength
Strip/ Wire
Armour

Overall
Diameter
(approx)
Strip/Wire
Armour

Appox Net Wt.

of cable
Strip/wire
Armour

Max.
D.C
Resist
ance
at 20

Max
AC
Resi
stan
ce at
70

Approx
Reactan
ce at
50Hz

Approx
Capaci
tance

(mm)

(mm)

(mm)

(Kg/Km)

Ohms
/km

Ohm
s/km

Km

Km

Aywy

3Cx1.5

0.8

0.3

1.40

1.24

14.0

420

18.10

21.72

0.126

0.14

Aywy

3Cx2.5

0.9

0.3

1.40

1.24

15.0

500

12.10

14.52

0.119

0.15

Aywy

3Cx4

1.0

0.3

1.40

1.24

16.5

595

7.41

8.89

0.116

0.41

Aywy

3Cx6

1.0

0.3

1.40

1.24

17.5

685

4.61

5.53

0.110

0.47

Aywy

3Cx10

1.0

0.3

1.40

1.40

19.5

830

3.08

3.70

0.100

0.56

Aywy/
Ayfy

3Cx16

1.00

0.3

4x0.8

1.60

1.40

1.40

19.5

21.0

680

890

1.91

2.29

0.097

0.76

Aywy/
Ayfy

3Cx25

1.2

0.3

4x0.8

1.60

1.40

1.40

22.5

24.0

880

1120

1.20

1.44

0.097

0.86

Aywy/
Ayfy

3Cx35

1.2

0.3

4x0.8

1.60

1.40

1.40

24.0

25.5

1025

1305

0.868

1.04

0.097

0.98

Aywy/
Ayfy

3Cx50

1.40

0.3

4x0.8

1.60

1.56

1.56

27.5

29.0

1310

1605

0.641

0.77

0.094

1.02

Aywy

3Cx70

12

1.6

0.4

4x0.8

2.00

1.56

1.56

30.5

33.0

1630

2160

0.443

0.53

0.090

1.18

Aywy/
Ayfy

3Cx95

15

1.6

0.4

4x0.8

2.00

1.56

1.72

34.5

37.5

1990

2645

0.320

0.38

0.090

1.20

Aywy/
Ayfy

3Cx120

15

1.6

0.4

4x0.8

2.00

1.72

1.72

38.0

40.5

2375

3050

0.253

0.30

0.087

1.31

Aywy/
Ayfy

3Cx150

15

1.8

0.5

4x0.8

2.00

1.88

1.88

41.5

44.0

2825

3560

0.206

0.25

0.087

1.31

Aywy/
Ayfy

3Cx185

30

2.0

0.5

4x0.8

2.50

1.88

2.04

45.5

49.0

3365

4590

0.164

0.20

0.087

1.31

Aywy/
Ayfy

3Cx240

30

2.2

0.6

4x0.8

2.50

2.20

2.20

52.0

55.5

4250

5620

0.125

0.15

0.087

1.34

Aywy/
Ayfy

3Cx300

30

2.4

0.6

4x0.8

2.50

2.36

2.36

56.5

60.0

5140

6650

0.100

0.12

0.086

1.41

Aywy/
Ayfy

3Cx400

53

2.6

0.7

4x0.8

3.15

2.52

2.68

64.5

69.5

6270

8720

0.0778

0.09

0.086

1.45

20

3.5 CORE ALUMINIUM PVC ARMOURED POWER CABLES

Type

No. of
cores
&Cross
Sectional
Area

Min
no. of
Wires

Thickne
ss of
PVC
insulatio
n (nom)

Mm

21

Mi
n
Thi
ckn
ess
of
PV
C
Ou
ter
Sh
eat
h(
m
m)

Nominal
Dimension of
Armour
Strip Wire

(mm)

Min. Thickness
OF pvc outer
strength
Strip Wire
Armour Armour

Overall
Diameter
(approx)
Strip Wire
Armour
Armour

Appox Net Wt.

of cable

(mm)

(Kg/Km)

Strip wire
Armour

Max.D
.C
Resist
ance
at 20

Max
AC
Resist
ance
at 70

Appro
x
React
ance
at
50Hz

Ohms/
km

Km

Approx
.
Capaci
tance

(mm)
Km
Ohms
/km

Aywy/
Ayfy

3.5Cx
25/16

6/6

1.2/1.0

0.3

4x0.8

1.60

1.40

1.40

25.0

26.5

1000

1260

1.2000

1.44

0.097

0.86

Aywy/
Ayfy

3.5Cx
35/16

6/6

1.2/1.0

0.3

4x0.8

1.60

1.40

1.40

26.0

27.5

1170

1450

0.8680

1.04

0.097

0.98

Aywy/
Ayfy

3.5Cx
50/25

6/6

1.4/120

0.3

4x0.8

1.60

1.56

1.56

29.5

31.0

1470

1805

0.6410

0.77

0.094

1.02

Aywy/
Ayfy

3.5Cx
70/35

12/6

1.4/1.2

0.4

4x0.8

2.00

1.56

1.56

33.5

36.0

1810

2405

0.4430

0.53

0.090

1.18

Aywy/
Ayfy

3.5Cx
95/50

15/6

1.6/1.4

0.4

4x0.8

2.00

1.56

1.72

37.5

40.0

2305

3015

0.3200

0.38

0.090

1.20

Aywy/
Ayfy

3.5Cx
120/70

15/12

1.6/1.4

0.5

4x0.8

2.00

1.72

1.88

41.0

43.0

2760

3545

0.2530

0.30

0.087

1.31

Aywy/
Ayfy

3.5Cx
150/70

15/12

1.8/1.4

0.5

4x0.8

2.00

1.88

1.88

45.5

48.0

3215

4030

0.2060

0.25

0.087

1.31

Aywy/
Ayfy

3.5Cx
185/95

30/15

2.0/1.6

0.5

4x0.8

2.50

2.04

2.04

50.0

53.5

3900

5300

0.1640

0.20

0.087

1.31

Aywy/
Ayfy

3.5Cx
240/120

30/15

2.2/1.6

0.6

4x0.8

2.50

2.20

2.36

57.0

60.0

4840

6390

0.1250

0.15

0.087

1.34

Aywy/
Ayfy

3.5Cx
300/150

30/15

2.4/1.8

0.6

4x0.8

3.15

2.36

2.52

61.5

66.0

5835

8210

0.1000

0.12

0.086

1.41

Aywy/
Ayfy

3.5Cx
400/185

53/30

2.6/2.0

0.7

4x0.8

3.15

2.68

2.68

70.0

75.0

7250

9900

0.0778

0.09

0.086

1.45

4 CORE ALUMINIUM PVC ARMOURED POWER CABLES

T ype

No. o f
c ores
& Cros s
Sec tion
al A rea

Min
no.
of
W ir
es

T hick ne
s s of
P VC
ins ulatio
n ( nom)
Mm

Min
T hi
c kn
es s
of
PV
C
O ut
er
S he
a th(
mm
)

Nom ina l
Dim ension of
A rm our
Strip /W ire

Min. Thic kness

O F pvc o uter
strength
Strip/W ire
Ar mour

O vera ll
Diam eter
(approx)
Strip/ W ire
A rm our

Appo x Net
W t. of cable

(m m )

(m m)

( mm )

(K g/K m)

S trip /wir e
Arm our

M ax.D.
C
Res is t
ance at
20

M ax
AC
Resi
s tan
ce at
70

Ap pro
x
R eact
anc e
at
50Hz

A ppr
ox .
Capa
c itan
ce

Ohm s
/km

O hm
s/km

Km

Km

A yw y

4CX 1 .5

0.8

0 .3

1.40

1.24

14 .5

470

18 .100 0

21 .72

0.126

0.14

A yw y

4CX 2 .5

0.9

0 .3

1.40

1.24

16 .0

560

12 .100 0

14 .52

0.119

0.15

A yw y

4C X 4

1.0

0 .3

1.40

1.24

17 .5

675

7.4100

8.89

0.116

0.41

1.0

0 .3

1.40

1.24

19 .0

800

4.6100

5.53

0.110

0.47

1.0

0 .3

4x0.8

1.60

1.40

14 0

21.5

23 .0

80 0

1 030

3.0800

3.70

0.100

0.56

1.0

0 .3

4x0.8

1.60

1.40

1.40

23.0

25 .0

83 0

1 050

1.9100

2.29

0.097

0.76

1.2

0 .3

4x0.8

1.60

1.40

1.40

25.0

27 .0

1075

1 350

1.2000

1.44

0.097

0.86

1.2

0 .3

4x0.8

1.60

1.40

1.40

27.5

30 .0

1280

1 620

0.8680

1.04

0.097

0.98

1.4

0 .4

4x0.8

2.00

1.56

1.56

32.0

34 .5

1620

2 175

0.6410

0.77

0.094

1.02

12

1.4

0 .4

4x0.8

2.00

1.56

1.56

36.5

38 .0

2010

2 660

0.4430

0.53

0.090

1.18

A yw y

4C X 6

A yw y
/A yfy

4CX 10

A yw y
/A yfy

4CX 16

A yw y
/A yfy

4CX 25

A yw y
/A yfy

4CX 35

A yw y
/A yfy

4CX 50

A yw y
/A yfy

4CX 70

A yw y
/A yfy

4CX 95

15

1.6

0 .4

4x0.8

2.00

1.72

17 2

40.0

42 .5

2550

3 280

0.3200

0.38

0.090

1.20

A yw y
/A yfy

4C X 120

15

1.6

0 .5

4x0.8

2.00

1.88

1.88

44.5

47 .0

3040

3 840

0.2530

0.30

0.087

1.31

A yw y
/A yfy

4C X 150

15

1.8

0 .5

4x0.8

2.50

1.88

2.04

48.0

51 .0

3580

4 880

0.2060

0.25

0.087

1.31

A yw y
/A yfy

4C X 185

30

2.0

0 .6

4x0.8

2.50

2.04

2.20

53.0

57 .0

4340

5 810

0.1640

0.20

0.087

1.31

A yw y
/A yfy

4C X 240

30

2.2

0 .6

4x0.8

2.50

2.36

2.36

60.0

64 .0

5460

7 050

0.1250

0.15

0.087

1.34

A yw y
/A yfy

4C X 300

30

2.4

0 .7

4x0.8

3.15

2.52

2.68

60.5

71 .0

6630

9 260

0.1000

0.12

0.086

1.41

A yw y
/A yfy

4C X 400

53

2.6

0 .7

4x0.8

3.15

2.84

2.84

73.0

78 .0

8185

11020

0.0778

0.09

0.086

1.45

22

ARMOURED CONTROL CABLE IS: 1554 (Pt-I) -1988

No. of
Crores
&Cross
Sectional
Area NO
x mm 2.

Thic
kne
ss
of
PVC
Insu
latio
n
(No
m)
mm

Standa
rd
Deliver
y
Length
in
Mtrs.

Thick
ness
of
Inners
heath
(min)
Extru
ded
mm

STRIP ARMOURED CABLE

Strip
Size
Mm

2 x 1.5
3 x 1.5
4 x 1.5
5 x 1.5
6 x 1.5
7 x 1.5
10 x 1.5
12 x 1.5
14 x 1.5
16 x 1.5
19 x 1.5
24 x 1.5
27 x 1.5
30 x 1.5
37 x 1.5
2 x 2.5
3 x 2.5
4 x 2.5
5 x 2.5
6 x 2.5
7 x 2.5
10 x 2.5
12 x 2.5
14 x 2.5
16 x 2.5
19 x 2.5
24 x 2.5
27 x 2.5
30 x 2.5
37 x 2.5

23

0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9

0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.4

4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8
4x0.8

Thicknes
s PVC
Outer
Sheath
(Min)
Mm

Approx.
OD

1.24
1.40
1.40
1.40
1.40
1.40
1.40
1.40

1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.56
1.56

WIRE ARMOURED CABLE

Approx.
Net
weight
of cable
Kg/km

Roun
d
WireD
ia

19.5
20.8
21.7
23.1
26.4
26.9
27.8
29.7

760
830
920
1040
1250
1355
1430
1670

21.8
22.8
23.8
24.9
26.1
30.0
30.6
32.0
34.7

900
1020
1130
1210
1355
1655
1770
1940
2300

1.4
1.4
1.4
1.4
1.4
1.4
1.4
1.8
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.2
2.2

Mm

Current
Rating

Thickness
PVC Outer
Sheath
(Min)
Mm

Approx.
OD

1.24
1.24
1.24
1.24
1.24
1.24
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.24
1.24
1.24
1.24
1.24
1.24
1.40
1.40
1.40
1.40
1.40
1.56
1.56
1.56
1.56

13.6
14.1
15.0
15.9
16.9
16.9
20.6
21.5
22.4
23.3
24.7
28.0
28.5
29.4
31.3
14.8
15.4
16.4
17.5
18.7
18.7
23.4
24.4
25.4
26.5
27.7
32.0
32.6
33.6
37.1

Mm

Approx.
New
Weight
of cable
Kg/km

Direct
in
Groun
d

mm

In Air/
Duct.
Amps

Amps

415
430
490
545
604
630
835
950
1040
1130
1265
1510
1610
1700
1960
500
520
590
660
745
780
1110
1240
1340
1455
1605
1970
2100
2250
2900

1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000

23
21
21
16
15
14
13
12
11
11
10
9
9
9
8
32
27
27
23
21
20
18
17
16
15
14
13
12
12
11

20
17
17
14
13
13
11
10
10
9
9
8
8
7
7
27
24
24
19
18
17
15
14
13
13
12
11
10
10
9

PROCESS FLOW CHART

FOR RUBBER CABLES

24

QUALITY ASSURACE CHART

FOR RUBBER CABLES

25

QUALITY ASSURACE CHART

FOR RUBBER CABLES

26

TABLE- 3
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR) INSULATED OVERALL
PCP, CSP/TRS SHEATHED FLAT THREE CORE (WITHOUT ECC) CABLE
ISI MARKED AS PER IS : 9968/Pt-1/1988

Nominal Cross
Sectional Area

Nominal of
Insulation

Thickness of Sheath
Flat
Flat

Nominal cross
Sectional Area of
Earth

mm2

mm

Twin
mm

Three Continuity Conductor

mm
mm

1.0
1.5
2.5
4
6
10
16

1.0
1.0
1.0
1.0
1.0
1.2
1.2

1.0
1.0
1.10
1.20
1.20
1.3
1.4

1.0
1.1
1.1
1.2
1.2
1.4
1.4

of Conductor
2

1.0
1.5
1.5
1.5
2.5
4.0
6.0

TABLE- 2
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR) INSULATED OVERALL
PCP, CSP/TRS SHEATHED SINGLE-CORE CIRCULAR TWIN CORE THREE CORE THREE & FOUR
CORE CABLE ISI MARKED AS PER IS: 9968/Pt-1/1988

Nominal Cross
Sectional Area
of Conductor
mm
1
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630
2

27

Thickness
of Insulation

Single
Core

Twin
Core

Three
Core

Four
Core

mm
1.0
1.0
1.0
1.0
1.0
1.20
1.20
1.40
1.40
1.6
1.6
1.8
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.0

mm
1.0
1.0
1.0
1.0
1.0
1.1
1.1
1.2
1.2
1.3
1.4
1.4
1.5
1.6
1.7
1.8
1.90
2.0
2.2
2.3

mm
1.0
1.0
1.1
1.20
1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.2
2.4
2.6
2.8
3.0
3.2
-

mm
1.0
1.1
1.1
1.2
1.2
1.4
1.4
1.6
1.7
1.8
2.0
2.2
2.3
2.5
2.7
3.0
3.2
3.4
-

mm
1.1
1.1
1.1
1.2
1.3
1.4
1.5
1.7
1.7
2.0
2.1
2.4
2.5
2.7
2.9
3.2
3.5
3.8
-

TABLE-4
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR)/SILICON INSULATED
OVERALL PCP, CSP/TRS SHEATHED CABLE SINGLE TWIN, THREE AND FOUR-CORE GLASS
FIBRE BRAIDED AND VARNISHED CABLES AND CORDS ISI MAREKED AS PER IS: 9968/Pt1/1988
Nominal Cross-Sectional
Area of Conductor
mm2
0.50
0.75
1
1.5
2.5
4
6
10
16
25
35
50

Thickness of Insulation
Cables for Fixed
Flexible cables or
Wiring
Cords
mm
mm
1.0
1.0
1.0
1.0
1.0
1.2
1.2
1.2
1.4
1.6

1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.2
1.2
1.2
1.4
1.6

TABLE-5
1100 V GRADE, FLEXIBLE ATC CONDUCTOR, ELASTOMERIC (EPR/VIR)/SILICON INSULATED
OVERALL PCP, CSP/TRS SHEATHED CABLE SINGLE-CORE, CIRCULAR TWIN, THREE-CORE,
FOUR-CORE AND FIVE CORE
ISI MARKED AS PER IS: 9968/Pt-1/1988
Nominal Cross
Sectional Area
of Conductor

Thickness
of Insulation
(ft)

Single
Core

Thickness of Sheath (ts)

Twin
Three
Four
Core
Core
Core

Five
Core

6
16
10
25
35
50
70
95
120
150
185
240
300

1.0
1.2
1.2
1.20
1.4
1.60
1.6
1.80
1.8
2.0
2.2
2.4
2.6

1.6
1.9
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.5
3.6

2.0
2.5
2.4
3.2
3.3
3.5
3.6
3.8
4.0
4.2
4.3
4.6
4.9

2.50
3.2
2.9
-

2.1
2.7
2.5
3.3
3.4
3.6
3.7
4.0
4.1
4.3
4.5
4.8
5.1

2.50
2.9
2.7
3.4
3.5
3.7
3.9
4.1
4.3
4.5
4.8
5.1
5.4

28

WELDING CABLES
COPPER/ALUMINIUM WELDING CABLES WITH HOFR
COVERING/GENERAL PURPOSE ELECTROMETRIC SHEATHED AS
PER IS-9857/1990 ISI MARKED
The welding cable is suitable for use where combination of ambient temperature and
temperature rise due to load results a conductor temperature not exceeding 60 C for
general purpose rubber copound cables and 85C for general purpose HOFR compound
cables. (Heat resisting, oil resisting and flame retardant).
Copper Conductor
Copper Conductor is of annealed high conductivity copper wire complying to
IS-8130-1984.
Aluminium Conductor
Aluminium Conductor is of Aluminium wire complying to IS-8130-1976.

Nominal Area
of Conductor
mm
16*
25
35
50
70
95
120**
2

TABLE-1
THICKNESS OF COVERING
Redial Thickness
of Covering (tc)
mm
2.00
2.00
2.00
2.20
2.40
2.60
2.80

* For copper conductor only

** For aluminium conductor only

29

TABLE-2
CURRENT RATINGS OF GENERAL PURPOSE RUBBER
COMPOUND COVERED CABLE WITH COPPER CONDUCTIOR
Nominal Area
of Conductor 100%
mm

16
25
35
50
70
95

Current Rating as a maximum duly cycle of

85%
60%
30%
20%

94
125
156
197
248
299

102
136
169
214
269
342

121
161
201
254
320
386

172
228
285
360
453
546

210
279
349
440
555
669

Ambient Air Temperature = 30oc

Maximum Conductor temperature = 60oc

TABLE - 3
CURRENT RATINGS OF GENERAL PURPOSE HOFR COMPOUND
COVERED CABLES WITH COPPER CONDUCTOR
Nominal Area
of Conductor
mm
16
25
35
50
70
95

Current Rating at a Maximum duly cycle of

100%
85%
60%
30%
A

135
177
221
279
352
424

146
192
240
303
382
460

174
228
285
360
454
547

Ambient Air Temperature = 30oc

A
246
343
403
509
643
774

Maximum Conductor temperature = 90oc

30

TABLE -4
CURRENT RATING OF GENERAL PURPOSE RUBBER COMPOUND
COVERED CABLE WITH ALUMINIUM CONDUCTOR
Nominal Area
of Conductor
mm

25
35
50
70
95
120

Current Rating as a maximum duly cycle of

100%
85%
60%
30%
20%
A

100
123
155
196
237
283

108
133
168
213
257
307

129
159
200
253
306
365

183
225
283
358
433
517

224
275
347
438
530
633

Ambient Air Temperature = 30oc

Maximum Conductor temperature = 60oc

TABLE- 5

CURRENT RATINGS OF GENERAL PURPOSE HOFR COMPOUND

COVERED CABLE WITH ALUMINIUM CONDUCTOR
Nominal Area
of Conductor

Current Rating as a maximum duly cycle of

100%
85%
60%
30%

mm
25
35
50
70
95
120

Ambient Air Temperature = 30oc

31

A
144
176
222
280
339
404

A
156
191
241
304
368
438

A
186
227
287
361
438
522

A
263
321
405
511
619
738

Maximum Conductor temperature = 60oc

TABLE - 6
VOLTAGE DROP IN COPPER CONDUCTORS AT NORMAL
AND ELEVATED TEMPERATURES
Nominal Area
of Conductor

DV Voltage Drop/100/A1/210 m of Cable at

20 C

60 C

90 C

mm

16

1.19

1.438

1.587

25

0.780

0.922

1.018

35

0.552

0.655

0.773

50

0.390

0.456

0.503

70

0.276

0.321

0.355

95

0.244

0.244

0.269

TABLE - 7
VOLTAGE DROP IN ALUMINIUM CONDUCTORS AT NORMAL
AND ELEVATED TEMPERATURES
Nominal Area

DC Voltage Drop/100A/10 m of Cable at

Sectional Area
of Conductor

20 C

60 C

90 C

mm

25

1.23

1.427

1.574

35

0.901

1.045

1.153

50

0.634

0.735

0.811

70

0.445

0.516

0.570

95

0.334

0.387

0.428

120

0.256

0.297

0.328

32

Table 3
STRANDED COPPER AND ALUMINIUM CONDUCTORS
(WEIGHT & DC RESISTANCE AT 200C )

Nominal Area of
Conductor
(sq. mm)

1.0
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630

33

Annealed plain Copper

Appox. Weight Max.d.c.resist0
(kg\km)
ance at 20 C
(ohms/km)

9.0
13.3
22.4
36.1
54.0
90.8
145
229
317
429
620
860
1086
1334
1673
2199
2759
3528
4445
5744

18.1
12.1
7.41
4.61
3.08
1.83
1.15
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

Approx.
(kg\km)

2.70
4.1
6.8
10.4
16.4
27.7
43.9
69.5
96.4
131
189
262
331
406
409
669
839
1073
1353
1746

Aluminium
Max.d.c.resist0
ance at 20 C
(ohms/km)

29.9
18.1
12.1
7.41
4.61
3.08
1.91
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

TABLE -4
FLEXIBLE COPPER CONDUCTORS

Nominal Area of
Conductor
(sq. mm)

Approx.
Weight
(kg\km

1.0
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
300
400
500
630

9.5
14.0
23.5
37.9
56.7
95.3
152
240
333
450
651
903
1140
1401
1757
2309
2897
3704
4670
6031

Max. D.C.resistance at 200C (ohms/km)

Annealed plain Copper Annealed tinned
Cooper
19.5
13.3
7.98
4.95
3.30
1.91
1.21
0.780
0.554
0.386
0.272
0.206
0.161
0.129
0.106
0.0801
0.0641
0.0486
0.0384
0.0287

20.0
13.7
8.21
5.09
3.39
1.95
1.24
0.795
0.565
0.393
0.277
0.210
0.164
0.132
0.108
0.0817
0.0654
0.0495
0.0391
0.0292

34

TABLE -5
TEMPERATURE CORRECTION FACTORE FOR
CONDUCTOR RESISTANCE AT DIFFERENT TEMPERATURES

Temperature( C)
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90

35

Temperature correction factor for

Copper and Aluminium conductor
0.94
0.96
0.98
1.00
1.02
1.04
1.06
1.08
1.10
1.12
1.14
1.16
1.18
1.20
1.22
1.24
1.26
1.28

VOLTAGE DROP CALCULATIONS

An approximate check can be made on voltage drop by means of the following formulae:
For d.c. and single phase a.c. two wire system:
=

2xIxLxRxt
1000

For three phase a.c. system :

=

1.732 x I x L x R x t
1000

Where I = Current in Amperes.

L = Length of cable run in metres (one conductor only).
R = Resistance in ohms of one conductor only from table 3-4.
T = temperature correction factor from table 5.
Notes:
1) Resistance values for copper and aluminium conductors are shown in table 3 and 4.
2). for conductor cross section above 70sqmm an allowance must be considered for skin and proximity
effect.

USEFUL 3 PHASE FORMULA

KW

=
KVA x power factor
KW =
HP x 746
1000 x efficiency
Line Amps x Line Volts x 1.732 x power factor
1000

HP

Line Amps x Line Volts x 1.732 x efficiency x p.f.

746

36

TABLE-8
PROPERTIES OF METALS USED IN CABLE

Annealed
Copper
8.89

Tensile strength
(Approx.)

Kg/mm2

25

12 to 15

Melting point

Deg. C

1083

659

23 to 40

2 to 6

15

30

7000

19000

1600

Properties

Unit

Specific gravity

Elongation
Youngs Modules
of Elasticity

37

Kg/mm2

Co-efficient of
linear expansion

Deg. C

Specific heat

K cal/kg0C

Thermal resistivity

103

9 to 15.5

Aluminium

Steel

Lead

2.703

7.86

11.37

30 to 50

1.8

1400

327

0.093

0.217

0.114

29
10-6
0.031

C cm/watt

0.25

0.48

2.20

2.96

Specific electrical
resistance at 200C

Microhm/cm

1.7241

2.8264

1405

21.0

Temp. co-efficiect
of resistance at
20oC

Per deg.C

0.00393

0.00403

0.0042

0.0042

17

10-6

23

10-6

11.5

10-6

TABLE 9
PERFORMANCE AND SELECTION OF COMMONLY USED THERMOPLASTIC CABLES
INSULATING AND SHEATHING MATERIALS

General
purpose
PVC
insulation
ty pe A to
IS5831/84

Material

General
purpose
PVC
insulation
ty pe B to
IS5831/84

Heat
resisting
PVC
insulation
ty pe C to
IS5831/84

Max. cond. Tem. For

0
continous operation ( C)

General
purpose
PVC
sheath
ty pe ST 1
to IS5831/84

70

Heat resisting
PVC sheath
ty pe ST 2 to
IS-5831/84

Low
Temp.
PVC

Special
Heat
resistin
g PVC

105

Poly tertre
f luro
ethy lene
(PTFE)

Fluorinated
ethy len
e
propy le
ne
(FEP)

70

260

200

Poly ethy lene

90

70

160

160

160

160

130

500

250

-20

-15

-40

-30

-60

-75

-75

Oil

Water

Chemical

Solv ents

Abrasions

70

70

85

160

160

160

-20

-15

-15

Coronaz

Weather

Max. cond. Temp . at

the termination of
0
shorty circuit ( C)
0

Min. working temp. ( C)

Resistance to Ozone

Flame resistance
Electricals

Insulation resistance

NA

NA

Voltage breakdown

NA

NA

A.C.Losses

NA

NA

E- EXCELLENT : G- GOOD: F FAIR: P- POOR: NA- NOT APPLICABLE

38

TABLE 10
PERFOMANCE AND SELECTION OF COMMONLY USED ELASTOMERIC CABLES
INSULATING AND SHEATHING MATERIALS

Natureal
Rubber
(VIR
&TRS)in
cluding
blends with
SBR

M aterial

Max. cond. Tem. For

continous operation
(0 C)

Heat
Resist-ing
Natural
rubber
HRVIR

Ethylene
propylen
e rubber
EPR

Polychlo
roprene
rubber
PCP

90

Nitrile
Butadiene
rubber
blend with
PVC
(NBRPVC)

Chlorosulp
h-onated
polyethylen
e rubber
CSP

90

Silicon
rubber

150/180

90

90

200

200

200

250

350

-50

-40

-30

-35

-40

-55

NA

NA

Weather

Oil

P/F

Water

Chemical

Solvents

Abrasions
Flame resistance
Electrical
Insulation resistance

P/F

NA

NA

Vo ltage breakdown

NA

NA

A.C.Losses

NA

NA

60

75

200

200

-55

-55

Corona

Max. cond. Temp . at

the termination of
shortly circuit (0 C)
Min. working temp.
(0 C)
Resistance to Ozone

90

250

E- EXCELLENT : G- GOOD: F FAIR: P- POOR: NA- NOT APPLICABLE

39

Cross
linked
Polyethy
lene
(XLPE)

TELEPHONE CABLES
1.

Telephone Switch Bard Multicore Cables are being extensively used by

Telephone Depart ment, Govt.Departments, railway and other industries in
their telecommunication network.

2.

Conductor : Annealed tinned-electrolytic copper conductors, PVC colour coded

as per ITO Specification D-3003 ITD-S/WS-1138 or S/WS-1148 each wire twisted
with its mate wire in a right hand lay and each such pair twisted with its make wire
in a right hand lay and each such pair twisted with respect to all other airs in
concentric layers so as to supress cress talk. The conductors shall be 0.5, 0.6, 0.7
or 0. 9 mm Dia. and Cables are manufactured in one pair size to 100 pairs as per
costomers requirements.

3.

Insulation : Hard Grade PVC with nominal radial thickness.

4.

Colour Scheme : As per I.T.I.D. 3003,ITD S/WS-113B OF S/WB-114B.

5.

Armouring : The armouring shall consist of galvanised steel wires having nominal
diameter of 1.4 mm for Cables having inner sheathed diameter uto 13mm in
Cables where the diameter of inner sheathing exceeds 13 mm, steel striof size 4 x
0.8 mm is to be used.

6.

Sheathing : The outer sheath shall be extruded PVC Compound specially

designed to afford high degree of mechanical chemical and Thermal Properties.
RECOMMENDATIONS FOR INSTALLATION
The following are some of the salient factors which should be kept in view during
installation of PVC Insulated Heavy Duty Cables :

1.

Before laying, the insulation of the cable should be checked with megger as a
preliminary check against any probably damage.

2.

The drum should be always rolled in the "direction of arrow for rolling" marked on
the drum. In the absence of any such mark, the drum should be rolled in the
direction same as that of inside and of the cable and opposite to that of the outside
end.

3.

Where the cable is to be jointed with existing cable, the sequence of cores at the
two ends to be jointed should be in the opposite direction i.e. If at one end it is in
clockwise direction, at the other end it should be in anticlockwise direction. This is
necessary to avoid the crossing of cores while jointing. This will also decide the
direction in which the cable is to be pulled.

4.

Wherever possible bending radius of 12 times the overall diameter of the cable
should be maintained, but in any case it should not be less than 8 times.

40

5.

6.

7.

Where the cables are necessarily laid and jointed in very cold regions both the
cable and the ambient temperature should be above OC and have remained so
for the previous 24 hours. During such conditions, the cable should also not be
bent to ver small radius.
A joint being the weakest point of the electric power transmission system, all
necesaary precautions shuld be taken. Jointing materials and accessories like
conductiors ferules, solder, insulating and protective tapes, protective filling
compound, joint boxes etc. of right quality and sized should be procured. The
application of these materials should be made skilfully for joining work. In this
connection, it is always advisable that the method and the working instructions of
the supplier should be strictly followed.
Armoured Cables : All bonding clamps at the joints and terminations and the
armour wires should be thoroughly cleaned. The clamps should be adequately
tightened. This is necessary to ensure proper electrical contact, because armour
is the only return path for earth fault current.
Unarmoured Cables : In case of unarmoured cables, the external metallic earth
bodding connector of adequate sizes should be used.

8.

Earth : All joints, terminations, armour wires and external metallic bonding should
be connected to earth. Wherever possible, armour at one end of the cable should
be connected to main earth system at the supplying end by employing metallic
connectors.
Precautions should be taken to eliminate the chemical and bimetallic corrosion of
the earth connectors or bonds.

9.

Filling Compunds :
a) The design of the box and the cimposition of the filling compound should
provide an effective saving against entry of moisture to conductor ferrules and
a hour connector.
b) If not pouring protective compounds, are used, the temperatures of the
compound whicl pouring should not exceed 100 C.
0

10.

Test after installion : After the cable is installed, a voltage test may be carried out.
Each core should be tested at 4KV against others and the armour, the latters
connected to the earth.
The voltage should be injcreased gradually to full value and maintained
continuously for 15 minutes. No breakdown of insulation occur during the test.

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