3.

Power Carrying Cable and Accessories

3.1. Cables
Wires and cables are the means by which electric power is transmitted from one point to another
point. Copper and aluminum are the two main materials used in the manufacture of wire and cables.
The principle properties of annealed copper and aluminum are given in the table below:
SN Particular Copper Aluminum
1 Density at 20oC 8.89 g/cm3 2.703 g/cm3
o
2 Co-efficient of linear expansions 1710-6/ C 2310-6/oC
3 Resistivity 0.017241 /m 0.02845 /m
Aluminum is much cheaper than copper, but aluminum is mechanically weaker than copper, but
aluminum ismechanically weaker than copper. Therefore, copper is used for wires and cables of
smaller cross-section area so that the wires and cable are safe from the mechanical breaking. But for
wire and cables of larger cross-section aluminum is used for economy. Since aluminum has higher
resistivity with compare to copper. Copper will have higher current carrying capacity than the
aluminum for same cross-section.
Definitions related to wires and cables (as defined in IS code)
a) Conductor: - A material which offers low resistance to the flow of electric current.
b) Wire:- A piece of insulated or uninsulated conductor, uniform in diameter and circular in cross-
section.
c) Solid-Conductor:- A conductor composed of a single wire.
d) Stranded Conductor:-A conductor made up of a number of wired twisted together.
e) Core:-Singleconductor with insulation but without any mechanical protective covering
f) Cable:-A length of one or more than one insulated conductor which laid up together with or
without mechanical protective covering.

3.1.1. Cable Construction

General construction of paper, pvc, rubber insulated lead covered cable.
a) Core: All cables have one central core or a number of cores of stranded copper or aluminum conductors.
Generally, there are one, two, three or four cores (three and half).
b) Insulation: The different insulation used to insulate the conductor is rubber, paper, varnished cambric
and impregnated paper.

i. Rubber: Rubber may be natural and synthetic. Its dielectric strength is 30kV/mm. though it possesses
high insulating qualities but it absorbs moisture readily, soften when heated to a to of 60o to 70oC.
Hence, pure rubber cannot be used as insulating material.
ii. Vulcanized India rubber: It is prepared by mixing India rubber with mineral matter such as Sulphur,
zinc, oxide, red lead etc. Though vulcanization process improves the non-hygroscopic and other
properties like strength, durability, elasticity etc. but it slightly reduces is specific resistance. VIR is a
good electrical insulator, does not absorb moisture from the atmosphere, water proof when new and
under favorable conditions remains so for a number of years. The main drawback with VIR is that
owing to Sulphur, content it attacks copper.
iii. Impregnated paper: It is prepared from wood pulp rages or plant fiber by a suitable chemical process.
It is quite cheap, high dielectric strength (30kV/mm) and high resistivity (10 7-cm). The main
advantage of paper insulation is that it is superior in heat conductivity and is capable to withstand
 higher to without deterioration (50oC to 80oC). The advantages of this property of paper insulated
cables is that a cable of given size can be worked at a higher current density than a VIR cable. The only
disadvantage with paper insulated cable is that it is hygroscopic; it absorbs moisture, which reduces its
insulation resistance. That is why paper insulated cables are always provided with some sort of
protective covering and are never unsealed. Its ends should be temporarily covered with wax or tax,
even if it is required to be left unsused on site while being laid.
Paper insulated cables are used for transfer large power in industrial distribution system at low
voltage in those areas where the joints are to be provided only at terminal apparatus or where the
joints are rare.
iv. Varnished Cambric (Empire Tape): This is cotton cloth impregnated and coated with varnish. It has
very smooth surface. The cambric is lapped in the form of a tape on the conductor. Such cables
require protective covering like lead sheath because it is hygroscopic. Its dielectric strength is
4kV/mm. such cables do not require sealing. This type of insulation is used mainly for machine
connection cables in industry.

c) Metallic Sheath: A metallic sheath is provided over the insulation as so to prevent he entry of the
moisture into the insulating material. The metallic sheath is usually of lead or lead alloy.
d) Bedding: Over the metallic sheath comes a layer of bedding which consists of paper tape compounded
with a fibrous material. Also sometimes jute strands of hessian tap (strong coarse cloth of hemp or jute)
is also used for bedding. The purpose of providing the bedding is to protect the metallic sheath from
mechanical injury from the armoring.
e) Armoring: Armoring is provided to protect from mechanical injury to the cable and it consists of one or
two layers of galvanized steel wires or two layers of steel tape.
f) Serving: Over and above armoring, fibrous material is again provided which is similar to that of bedding
but is called serving.

Above fig represents the 3-core belted cables, each of the conductors is insulated from the other with
impregnated paper. Surrounding the three conductors is again provided a belt of paper and interstices
between them are filled with fibrous insulating material. Over belt is provided a metallic sheath, then
a layer of braiding armoring and finally serving.
3.1.2. Types of Cable
According to construction:
a) Multi-core cable: A cable containing more than three cores not arranged concentrically.
b) Concentric cable: A cable containing two or more separate conductors arranged concentration with
insulation between them.

c) Flexible cord: A flexible cable having conductor of small cross-sectional area. Two flexible cords
twisted together are known as twin twisted flexible cord.

d) Flexible cable: A cable containing one or more cores, each formed of a group of wires, the diameters
of wires being sufficiently small to affored flexibility.
 According to voltage:
a) Low Tension (L.T.) cables for operating voltage up to 1kV.
b) High Tension (H.T.) cables for operating voltage up to 11kV.
c) Super Tension (S.T.) cables for operating voltage up to 33kV.
d) Extra High Tension (EHT) cables for operating voltage up to 132kV.
e) Extra Super Tension (EST) cables for operating voltage up to 132 kV.
According to Designation
AVV – Aluminum conductor PVC insulated PVC sheathed
ATRV – Aluminum conductor PVC insulated single round steel armuored and PVC sheathed
AVFV – aluminum conductor PVC insulated flat steel strip armoured and PVC sheathed
CVV – Copper armored and PVC sheathed
CTRV - Copper armuored and PVC sheathed
CVFV - Copper armoured and PVC sheathed

3.1.3. Installation of cable

The mode of installation determines the type of cables to be used. For underground installation, armored
cables are used to prevent damage on account of accidental digging. In general, armored cables are
recommended where there is a possibility of mechanical damage. The paper insulated lead covered (PILC)
cable are generally installed in the following ways:
i. Directly in the ground
ii. In a duct or pipe
iii. Air

Laying of Underground Cables

Before laying cable under the ground, its route should be surveyed. The cable to be underground must have the
following properties:
i. The moisture of the soil should not entre the core of the cable
ii. It must have high insulation resistance.
iii. It should be able to withstand the heat produced due to the flow of current.
 iv. It should not be capable of being damaged while handling or laying in the ground. So due to reason
armored cables are usually used.

The steps involved in the laying of underground distribution system are as follows:
a) Selecting the routeof the cable i.e. planning
b) Trenching and laughing of cable
c) (Laying: - Pulling of cables, methods of laying, road crossing, clearance from communication cable etc.)

a) Route of Cable
As a rule the shortest possible route having minimum bends is chosen. The cable route depends on factors
such as obstruction caused by building and the crossing of roads. Wherever possible it is desirable to lay the
cables along the roads so that fault detection and repair is easy to carry out.
b) Laying Cables in Trenches i) direct laying in trenches includes the following scope of work: digging out
trench, delivery of cable drums to the installation site, placing it in the trench and back filling of the trench.

In this method of laying cables a trench about 1.2m deep and 50cm wide is dug, a layer pf about 10cm thickness
of fine sand is spread and the cable is laid over this sand bed. The sand does not allow the moisture to affect the
cables and thus protects the cable from decay on the sides the bricks are placed and after laying of cables the
trench is covered by putting bricks and earth.
In cases, when more than one cable is to be laid in the same trench, the minimum spacing between any two
adjacent parallel cables should be 100mm and at least 50mm between the trench wall and the cable.

Where cable jointing sleeves are expected to be located, the trenches shall be expanded to form pits. This pit for
single jointing sleeve shall be 1.5m wide and 2.5m long.
Several cables with sleeves laid in parallel in one trench
a) Position of cable ends to be joined together in a sleeve
b) Cable extra length at sleeve insulated
c) Mutual position of several cables with sleeves mounted
3.1.4. Locating cable faults
In an industrial plant, a variety of cable faults can occur. Faults in cables cause interruption of supply.
Therefore, they should be attended to immediately for restoration of supply. In the underground cable, there
are three types of faults:
a) Short-circuit Fault: While handling the cable the insulation between two cores cable is damaged then the
current flow from one core to another core directly. Such faults are known as short circuit fault.
b) Open-circuit fault: When any conductor or core of cables is broken in the length of opened joint while
pulling out then there is no flow of current from the cable, such fault is called open circuit fault.
c) Earth fault (Ground fault): When the insulation of the cable gets damaged then the current flow from
core to earth directly through cable sheath. Such a fault is called ground or earth fault.

For lifting the earth fault or short circuit fault in underground cables, “Murray loop test” methods are
performed. It is based on the principle of Wheatstone bridge.