1. 1
INTERNSHIP REPORT
ON
STUDY ON INSULATED CABLING SYSTEMS
AT
KEI INDUSTRIES LTD
SUBMITTED BY:
SMRITI TIKOO
14-ECP-015
MTECH (ECE) 1st
Yr
ITM UNIVERSITY, GURGAON
SESSION-2014-15
2. 2
CERTIFICATE
This is to certify that the internship project titled “Study On Insulated Cabling
Systems” submitted by Smriti Tikoo in fulfillment of the requirements of course at
KEI as part of the degree of Master of Technology in Electronics and Communication
of ITM University, session 2014-2015 is a record of bonafide supervision and has not
been submitted anywhere else for any other purpose.
Name of Industrial Experts Name of Faculties
Mr. Arvind Shrowty (Executive Director) Ms. Sharda Vashisht
Mr. Surinder Jain ( Head of Dept)
Mr. Avinash Gautam
3. 3
ACKNOWLEDGEMENT
I hereby acknowledge the guidance and support given to me by my mentors Mr.
Arvind Shrowty, Executive Director of KEI and Mr. Surinder Jain ,Head of EHV
Dept, Mr. Avinash Gautam , Mr Puneet Jain of EHV dept at KEI, for my
internship. I am obliged to them for considering me as a trainee and devoting their
precious time in helping me with the internship project .I would also like to thank the
faculty members of ITM University, Ms Sharda Vashisht for assisting and
encouraging me .
4. 4
ABSTRACT
This report is a study on the different utility cables used in the various industries
manufactured by the one of the leading manufacturers of cables KEI Industries Ltd
.The Organization offers variety of cables keeping in mind the customer specifications
and demands of the market. The report encompasses the details and specifications of
cables offered by KEI as per Indian and International Stds. It also offers the flexibility
of catering to the customer specific requirements. The organization is on the Fortune
500 list and ranks second in the leading Cabling Industries. It offers EHV cables,
Control cables, HT cables, LT cables, Marine and Off shore cables, and many more.
The insulated cabling systems form the basis of power transmission systems be it for
domestic or commercial purposes.
5. 5
TABLE OF CONTENTS
CERTIFICATE
ACKNOWLEDGEMENT
ABSTRACT
1. INTRODUCTION
1.1. Genesis
1.2. Evolution
1.3. Kei cabling solutions spectrum
1.4. Key clients
2. PRODUCTSPROVIDED/MANUFACTURED
3. EHV CABLES
3.1. Type of tests
3.2. Construction
3.3. Construction screening
3.4 Insulation screening
3.5. Type of tests
3.6. Popular constructions
3.7. Selecting a power cable
3.8. Terminations for a polymer cables
3.9 Terminations for oil filled cables
3.10 Joints for polymer cables
3.11.Joints for oil filled polymer cables
3.12.Transition Joints
4. HT CABLES
5. LT CABLES
6.CROSSLINKED POLY ETHYLENE
7. CONTROLCABLES
8. INSTRUMENTATION CABLES
9. THERMOCOUPLE EXTENSION/ COMPENSATING
10. RUBBER CABLES
11. HOUSE WIRES
12. SINGLE/MULTICORE FLEXIBLE WIRES
13. WINDING WIRES
14. STAINLESS STEELWIRES
15. MARINE AND OFF SHORE CABLES
16.SOLAR CABLES
17.CONCLUSION
18.REFERENCES
6. 6
1. INTRODUCTION:
KEI Industries Limited, known for its unique product range across the world is one of
the leading players in the wires and cables industry. KEI manufactures high and low
tension cables (EHV, HT & LT), control and instrumentation cables, house wires and
stainless steel wires. Its unique product range is known pan India and across the
globe. KEI has also been awarded the ′ Superbrand ′ status for the year 2013-2014
further strengthening the consumer ′s trust. To follow the present demands of the
market, KEI set foot into the manufacturing of EHV cables up to 220kV in
collaboration with Brugg Cables, a century old Swiss company.
1.1.Genesis:
1968: Established as a Partnership Company.
1968: Manufacturing of Switchboard Cables for DOT starts.
1985: Manufacturing of Control, Instrumentation and Thermocouple Cables begins.
1993: Manufacturing of PVC/XLPE Power cables up to 3.3 KV added to existing
portfolio.
1.2.Evolution:
1994: Diversified into Stainless Steel drawings with Pilot Plant
1995: Launch of the First IPO, went Public.
1996: Installation of Major SSW plant at Bhiwadi
1997: Installation of another plant at Bhiwadi for LT PVC / XLPE Cables.
2001: Scaling up with manufacture of Rubber Cables up to 11 KV.
2002: Established JFTC Plant at Silvassa
2005: Upgraded JFTC Plant in Silvassa to manufacture existing cable range -
Rebalancing Act
2006: Expansion of Bhiwadi unit to manufacture up to 33 kV HT XLPE Cables with
Dry curing inert nitrogen gas and with triple extrusion (Single cross head) process.
2006: Introduced ERP Baan S/W system in the organization to ensure Transparency
and efficacy.
2007: Upgrading Bhiwadi Unit to manufacture HT power cable up to 132 kV & LT
cable.
2007: Proud recipient of Corporate Governance Rating
2007: Setting up of 100% EOU at Chopanki
2008: Successfully commissioned 100% EOU at Chopanki
2009: Enhanced HT Cable Capacity at Bhiwadi up to 132 KV
2010: Entered into a technical collaboration agreed with M/s Brugg Kabel AG,
switzerland to manufacture EHV cables up to 220kV and diversified into EPc
business.
7. 7
2010 : Proud recipient of Business Super brand Award for Industry Validated
2011 : Certification of ISO 9001:2008, OHSAS 18001:2007, OHSAS 14001:2004
2011 : Receipt of EHV cable order from KPTCL worth Rs75 Crores
2011: Successful redemption of FCCBs in November.
2012: Receipt of EHV order of Rs.138 crores from Uttar Pradesh Rajkiya nirman
Nigam Ltd.
2012: Proud recipient of Super Brand status for consumer validated.
2013-14: New office at Singapore, Nigeria, Kazakhstan.
Manufacturing sites: Bhiwadi( Rajasthan), sislvassa(Union territory of D&NH),
Chopanki (Rajasthan)
Figure 1
8. 8
1.4.Kei Cabling Solutions Spectrum :-
KEI has earned a formidable reputation by nurturing relationships, ensuring timely
execution of orders and becoming a reliable partner in executing client projects.
Repeat orders received year after year from satisfied customers bear testimony to our
uncompromised quality and customer commitment. Our cost-effective quality and
reliable products range that meets rigorous technical requirements of our customers
has made us an undisputed industry leader. KEI has invested in building an intelligent
infrastructure which ensures clients receive products that conform to their stringent
requirements.KEI is perhaps one of the few companies in India to offer customers a
unique range of specialty cables such as fire survival cables, zero halogen cables and
braided cables. An ability to utilize more than 90% of its resources makes KEI one of
the most efficient players in the industry. KEI enjoys a unique flexibility to switch
production between HT and LT cables depending on prevailing market conditions and
demands. An an ISO:9001:2008, ISO:14001:2004 & OHSAS:18001:2007 certified
company; KEI carries out stringent quality control measures under surveillance of a
competent team of technocrats and quality enablers. Continuous Product Innovations
and cutting-edge R&D at KEI's in-house labs is what contributes towards constant
evolution in our offerings and services. All KEIs cables and wires are of a superior
quality, a reason why they have been accredited and certified by Testing Agencies
across the globe.
1.5.Key Clients: The company has a longstanding presence in the sector which has
resulted in an esteemed clientele cutting across various sectors. The list comprises of
the biggest names in the industry. Just go ahead and search to find out more about our
long list of satisfied clients. Clientele as per following categories:
9. 9
Sector specific: - Power/ transmission/ coal field projects, Cement project,
Fertilizers/ refineries/petro chemicals/ paper projects.
Country specific:-MEW EDD BAHRAIN, SEWA, FEWA-UAE, NEPCO, PEC
YEMEN, JT METRO JV(DUBAI), GASCO, PDD OMAN, KNPC KUWAIT,
QATAR PETROLEUM , SOHAR ALUNIUM, TECHNIP, PETROFAC ETC.
2.Products Provided/Manufactured By KEI:
It manufactures cables suiting the needs of clients be it Select the copper core or
aluminium core; whether armoured or unarmored cable is required , find them all
here confirming to different standards. It also provides custom-manufactured
speciality cables.
EHV Cables
HT Cables
LT Cables
Control Cables
Instrumentation Cables
Thermocouple Extension/Compensating
Rubber Cables
House Wires
Single/Multicore Flexible Wires
Winding Wires
Stainless Steel Wires
Marine & offshore cables
Solar Cables.
10. 10
3.EHV Cables:
In the Indian terminology all cables rated 66 KV & above are designated as Extra
High Voltage cables. Available with aluminum & copper conductor and various
combination of metal sheath namely poly-aluminum sheath / lead sheath / aluminum
sheath in combination with or without copper wire screens. The standard covers the
requirement of single core cross linked polythene insulated armoured and unarmoured
and thermoplastic outer sheathed cables for 3 phase ac earthed system for electric
supply for voltage grades.
Table 1 Voltage Grades
System’s Voltage –U(kV) Rated Voltage- U˳/U(kV) Highest System’s Voltage-
Um(kV)
66 38/66 725
110 64/110 123
132 76/132 145
220 127/220 245
Cables covered under this std are suitable for use where the combined ambient
temperature and temperature rise ,due to load result in conductor temperature not
exceeding 90°C under normal operation and 250˚C under short circuit operation.
3.1Important Tests and Terms carried out on Cables:
1. Routine test:-Tests carried out by manufacturer on all finished cable lengths to
demonstrate integrity of the cable.
2. Type Tests:- These tests are required to be made before supply o a type of
cable on a general commercial basis in order to demonstrate satisfactory
performance characteristic to meet the intended application. These tests are of
the such nature that after they are made they need to be repeated unless changes
11. 11
are made in the cable materials on design which might change the performance
characteristics.
3. Acceptance test:-Tests carried out on samples taken from the lot for purpose
of acceptance of the lot.
4. Optional Tests: Special tests to be carried out , when required ,by the
agreement between purchaser and the supplier.
5. Earthed System :An electrical system in which the neutral point or a midpoint
connection is earthed in such a manner that even under fault conditions , the
maximum voltage that can occur between any conductor and earth does not
exceed 80 percent of nominal system voltage.
6. Longitudinally Watertight Cable: Cables to meet requirements to prevent the
propagation of water along the length of cable.
7. Radially Watertight Cable:-Cables to meet the requirements to prevent the
radial propagation of water.
Materials Required for various parts of EHV cables:-
Conductor:-Composed of plain copper wires complying with IS 8130:1984.
Insulation: The insulation shall be of cross linked polythene conforming to
the requirements of Table.
Screening:-The screening shall consist of one or more of the following:
a) Non –metallic semi-conducting tape;
b) Non-metallic semiconducting compound , and
c) Non –magnetic metallic tape, wire, strip or sheath. The semi-conducting
compound shall be suitable of the cable and compatible with the insulating
material.
12. 12
Table 2: Properties of XLPE Insulation
Property Requirement
(i)Tensile strength before ageing 125 N/ sq mm(min)
(ii)Elongation at break before ageing 200%
(iii)Ageing in air oven
a)Treatment temperature duration 135±3°C
168h
b)Variation from corresponding values
before ageing
Tensile strength ±25%(max)
Elongation after cooling ±25%(max)
(iv)Hot Set
a)Treatment temperature time under load
mechanical stress
b)Elongation under load ±175%(max)
c)Permanent Elongation after cooling 15%(max)
(iv)Shrinkage
a)Treatment temperature duration 130±3˚C
6h
b)Shrinkage 4%(max)
Moisture Barrier:
Laminated Tape: This shall be plastic coated non-ferrous metal tape
longitudinally applied suitably sealed.
Lead Alloy Sheath:- The metallic sheath shall be of lead Alloy E
conforming to requirements.
Water Blocking Tape/Powder: This shall be synthetic non-woven
tape / synthetic powder with suitable water swellable absorbdent. The
tape /powder can be either non conducting or semi conducting.
Inner Sheath: The inner sheath shall be of PVC compound or
thermoplastic polythene compound. The PVC compound shall
conform to Type ST2 of IS 5851.
The thermoplastic polythene compound shall conform to the following
properties:
a)Tensile strength before ageing (min).
b)Elongation at break(min)
-before ageing 300%
-after ageing in air oven at 110±2˚C for 14 days
c)Hot deformation test –115±2 for 6 hours
-Max depth of indentation 50%
d)Carbon black content 25±0.5%
13. 13
Armour: It shall be of non-magnetic material wires.
Outer Sheath: The outer sheath may be of PVC compound or
thermoplastic polyethylene compound.
Table 3: Nominal Thickness XLPE Insulation
3.1CONSTRUCTION
Conductor: It shall be of stranded circular compacted construction
complying with the requirements of Class 2 of IS 8130. 1984. Where
necessary , segmental construction is permissible.
Table 4 Nominal cross section of conductor.
Voltage Grade U˳/U (kV) Smallest Nominal Cross Section
of Conductor( sq mm)
38/66 95
64/110 150
76/132 185
127/220 400
Voltage Grade U˳/U(kV) Nominal Thickness in (sq mm)
38/66 11
64/110 16
76/132 18
127/220 27
14. 14
3.2Conductor Screening: The conductor screening shall consist of a layer of
semi conducting compound extruded over the conductor. Semi- conducting
barrier tape tapes with suitable overlap may be applied between the conductor
and extruded conductor screening . Such barrier tape/ tapes when used shall be
compatible with the insulating material and suitable for operating temperature
of the cable. The minimum thickness of extruded conductor screening shall be
0.8mm.
3.4.Insulation: The insulation shall be extruded cross linked
polyethylene(XPLE), refer XPLE properties table. The average thickness of
insulation shall be not less than the nominal value (t1) specified in the
table.The smallest of the measured values of thickness of insulation shall not
fall below the nominal value (t1) specified in the table by not more than 0.1 t1.
3.5 Insulation Screening: The insulation screening shall consist of two parts
namely, metallic and non metallic.
Non –metallic Part:-It shall consist of a layer of semi-conducting
compound extruded directly over the insulation .Conductor screening
insulation and insulation screening shall be extruded in one operation. The
minimum thickness of extruded insulation screening .Such barrier
tape/tapes when used shall be compatible with insulating material and
suitable for operating temperature of the cable.
Metallic –Part:-The metallic part of the screening shall consist of Copper
wires /Copper tape(s) helically applied over lead alloy sheath or non-
metallic screening. The diameter of copper wire in the screening shall be
not less than 0.8mm .The perpendicular gap be more than 4.0mm.The
nominal thickness of the tape shall not be less than 0.1mm.The minimum
thickness shall not fall below the nominal value by more than
10%.Abinder tape of copper shall be applied over the wire screen . The
nominal thickness of the tape shall be not less than 0.1mm .The minimum
thickness shall not fall below the nominal value by more than 10%.Where
the lead Alloy sheath is provided over the non-metallic part of the
15. 15
insulation screening as moisture barrier , it shall form the metallic part of
the screening.
Moisture Barrier: The moisture barrier shall be provided as given below:
a)Water blocking tape/ powder shall be suitably applied; and
b) Laminate tape shall be applied longitudinally with overlap and sealed;
or metallic sheath of lead alloy ‘E’ shall be applied by extrusion.
Metallic Sheath: It shall consist of extruded metallic sheet of Lead Alloy
‘E’ and thickness not less than 19mm.
Inner Sheath:-For armoured cables the inner sheath can be applied on
moisture barrier or the metallic screen. The thickness of inner sheath
should not less than 9mm.
Armour: It shall consist of non- magnetic metallic wires helically applied
over inner sheath.
Table 5 Dimensions of armour wire
Calculated
diameter of
armour
Nominal diameter
of round wire
(mm)
Above Up to & including
- 40 20
40 55 250
55 70 315
70 - 400
The armour shall be applied as closely as possible. The direction of lay armour
shall be left hand. Joints in armour wires shall be made by welding and surface
irregularities shall be removed. A joint in any wire shall be atleast 300mm
from the nearest joint in any other armour wire in the completed cable .
16. 16
Outer Sheath: The outer sheath shall be applied by extrusion. It shall be
applied :
a) over the moisture barrier or metallic screen unarmoured cables , and
b) over the armour for armoured cables. A binder tape may be applied under
the outer sheath. The colour of the outer sheath shall be black.
-The thickness of outer sheath –under Unarmoured cables :the thickness of
outer sheath of unarmoured cables determined by taking the average of a
number of measurements shall not be less than the nominal value specified in
the table and the smallest of the measured values shall be not less than the
minimum value specified 1.72mm.For armoured cables –the thickness of outer
sheath at any point for armoured cables shall not be less than the minimum
value of 1.72mm.
Table 6 :Thickness Of Outer sheath
Calculated
diameter under
outer sheath
Thickness of
outer sheath
for
unarmoured
cables
Minimum
outer sheath
for armoured
cable
Above Up to &
including
Nominal Minimum
- 40 2.4 1.72 1.72
40 45 2.6 1.88 1.88
45 50 2.8 2.04 2.04
50 55 3.0 2.20 2.20
55 60 3.2 2.36 2.36
60 65 3.4 2.52 2.52
65 70 3.6 2.68 2.68
70 75 3.8 2.84 2.84
75 - 4.0 3.0 3.0
17. 17
3.5TYPE TESTS:-
a)Test on conductor
I)Annealing test (for copper)
II)Resistance Test
b)Physical test on insulation
I)Test for thickness and dimensions of insulation
II)Tensile strength and elongation at break
III)Thermal ageing in air oven
IV)Hot set test
V)Shrinkage test
VI)Void and contaminants test
c)Resistivity test for semi-conducting layers
d)Test for concentric metallic screen.
I)Test for concentric copper wire
II)Test for concentric copper tape
e)Test for metallic sheath
f)Test for armouring material
i)Dimensions
ii)Tensile strength and elongation at break
iii)Wrapping test
iv)Resistivity test
g)Physical tests for outer sheath
1)Measurement of thickness
2)PVC sheath
i)Tensile strength and elongation at break
ii)Thermal ageing in air oven
iii)Loss of mass
iv)Heat shock test
v)Hot deformation test
vi)Shrinkage test
vii)Thermal stability
3)PE sheath
i)Carbon black content
ii)Tensile strength elongation at break before and
after ageing
iii)Hot detormation
h)Flammability Test(for PVC outer sheathed
cables only)
j)Water tightness test
k)i)Thermal ageing on complete cable sample
ii)Tensile strength and elongation break for
insulation and outer sheath
iii)Resistivity test for semi-conducting layer
m) Bending test followed by PD test
n) Dielectric power factor and capacitance
18. 18
measurement at ambient temperature
p)Dielectric power factor and measurement at
elevated temperature
q)Load cycle test followed by PD measurement
r)Impulse withstand followed by HV test
Acceptance Test: The following shall constitute acceptance
tests:
a) Conductor resistance test
b) Annealing test
c) Test for dimensions of insulation
d) Hot set test for insulation
e) Void and contaminants test
f) Test for thickness of metallic sheath
g) Test for thickness of outer sheath
h) Partial discharge test
j) High voltage test
k) Measurement of capacitance
NOTE — Partial discharge test shall be carried out on
full drum length
Routine Test: The following shall be carried out as
routine test:
a) Conductor resistance test
b) Partial discharge test
c) High voltage test
Optional Test: Cold impact test shall constitute the optional test.
Integrated Optical Fiber Unit: The optical fibers in power cables can be used for
measuring the actual temperature along with the cable line or for data transmission.
Fiber units are normally embedded under the lead sheath or between the screen wires.
The temperature monitoring provides continuous monitoring of cable temperatures,
detecting hot spots, delivering operational status, condition assessments and power
circuit rating data. Ideal for use in high voltage cables, it provides reliable temperature
measurements and is immune to electromagnetic interference.
19. 19
Standard Specifications: KEI MANUFACTURES Extra high voltage according to
various international or national standards. Such as IEC: 60840, IEC:62067,
IS:7098(P-3)/93.Cable are also designed specially to customer’s requirement.
3.6.POPULAR CONSTRUCTIONS:
(A)Single Core XPLE insulated power cable with copper wire screen and foil
laminated sheath:
1. Conductor: Longitudinally watertight segmental stranded stranded and
compacted Copper or Aluminum.
2. Binder Tapes: Semiconducting water blocking tapes compound.
3. Conductor Screen: Extruded semiconducting copolymer compound.
4. Insulation: Extruded super clean XPLE compound.
5. Insulation Screen: Extruded semiconducting copolymer compound.
6. Bedding: Semiconducting water blocking tapes.
7. Metallic Screen: A layer of copper wire helix and a copper contact tape in
open helix.
8. Separation Tape: Semiconducting water blocking tapes and binder tapes.
9. Radial Water Barrier: Aluminium or copper foil laminate.
10. Outer Sheath: Extruded PE of HFFR.
20. 20
Figure 2
(B)Single Core XPLE insulated power cable with Lead sheath/ corrugated
Aluminium sheath
1. Conductor: Longitudinally watertight segmental stranded or compared
Circular Copper or Aluminum.
2. Binder Tapes: Semiconducting water blocking tapes compound.
3. Conductor Screen: Extruded semiconducting copolymer compound.
4. Insulation: Extruded super clean XPLE compound.
5. Insulation Screen: Extruded semiconducting copolymer compound.
6. Bedding: Semiconducting water blocking tapes.
7. Metallic Screen : A layer of copper wire helix and a copper contact tape in
open helix (if required).
8. Water Blocking Tape.
9. Metallic Sheath: Extruded Lead, alloy E/Corrugated Aluminium.
10. Outer Sheath: Extruded PE, PVC or HDFR.
21. 21
The electrical properties and continuous current rating apply for Lead sheathed cable
with our normal sheath thickness. The thickness of sheath and especially the cross
section of Copper screen can be adjusted according to required short-circuit rating of
sheath or screen. Where loading is cyclic , appreciable increase in current capacities
may be justified. In cable circuits having no magnetic saturating materials the positive
and negative sequence impedances are equal and can be deduced from tabulated
effective resistance and inductance values corrected as required for frequencies other
than 50Hz. Zero sequence impedance for solidity bonded systems can be roughly
esteemed as the sum of the resistances of conductor , sheath and a reactance of 0.05 to
0.1ohms/km depending on the proportion of diameters of sheath and conductor at 50
to 60Hz. For single point bonded systems , the zero sequence , impedance depends on
the ground wires and any other grounded metallic objects along the cable route .
3.7.SELECTING A POWER CABLE: Different kinds of power cable construction
are required to transport electrical energy from the power station to the consumer. The
following factors are important when selecting a suitable cable construction:
Maximum operating voltage
Insulation level frequency
Load to be carried
Daily load curve
Magnitude and duration of possible overloads currents phase –to -phase and
phase to earth and cable line (whether directly or via a transformation)
Insulation level of equipment (bare conductor, insulators, arresters, etc.)
Voltage Drop
Length of line
Profile of line
22. 22
Mode of Installation
-Underground (Whether directly or in ducts )
- In air( if in a tunnel , the dimensions and the mode of ventilation of tunnel)
Chemical and physical properties of the soil
Maximum and minimum ambient air and soil temperatures , bearing in mind
nearby hot water pipes and other factors liable to heat the cables .
Specifications and requirements to be met .The cross-sectional area can be
calculated based on the capital costs of the cable and its running costs incurred
by the power losses in the cable.
Voltages Used :
Rated Voltage: The voltage which forms the basis for certain operating
characteristics and test conditions is called the rated voltage and test conditions is
called the rated voltages and is denoted U˳/U where
U˳=The voltage between the conductor and earth or earthed metallic cover
(Concentric conductor , screen, armoring , metal sheath)
U= The voltage between the phase conductors .
Operating Voltage:
Um=The maximum continuously permissible operating voltage of the network at
any time or any art of the network, excluding temporary fluctuations such as those
occurring during switching or faults.
23. 23
3.8.Terminations For Polymer Cables: The terminations for polymer cables are
are designed to be used independently of any type of polymer cable or cable
manufacturer from 7.25 to 550Kv and up to a conductor cross section of
2500mm².
Figure 3
24. 24
Termination Design: Terminations for polymer cables consist of a stress cone
with deflector, an insulating compound, an insulator a corona shield and a
terminal stud.
Properties of SiR stress cone: Stress cones are pre moulded sleeves which ensure
field grading between the outer semiconducting layer and the insulation. Made of
silicone rubber they combine outstanding electrical and mechanical properties
with excellent interface behavior .The electrical properties are designed to
minimize stress, whilst mechanical properties ensure optimum level of surface
pressure on the cable. The optimum surface pressure remains constant throughout
the lifetime of the termination. The deflectors are made of solid semiconducting
material. Although costly, this ensures that they function properly at voltage loads
and guarantees a long and reliable lifetime .For optimum electrical stress
distribution, stress cones are designed with help of computer simulations.
Quality in Production and Testing for Reliable devices: Our stress cones are
one piece and fabricated in -house in an extremely clean surrounding. To ensure
best quality, the fabrication is made computerized machines. For zero failure
production, every part is tested several times in the fabrication process. The stress
cones must pass a final acceptance test. Each device is certified individually. This
ensures that every stress cone leaving our factory is 100% reliable.
25. 25
Advantages of prefabricated and pretested SiR test cones are:
Very High breakdown strength of >23kmkV/mm at 50/60 Hz.
Excellent temperature stability of between -50 and +180°C.
Very high life exponent n>>40.
Excellent field grading performance at high frequency with deflectors of
solid material.
Optimum electrical stress distribution due to computer based design.
Zero failure guarantee with final high voltage pretesting.
Void free – contact pressure on the cable surface at normal and elevated
load conditions due to excellent elasticity of SiR.
Easy installation due to excellent mechanical properties and elasticity , no
mechanical forces needed.
Four Termination Types Available: For outdoor applications porcelain and
composite insulators. Terminations for SF6 gas insulated switchgears (GIS) or
transformers are made of epoxy resin insulators. Each type of termination has
specific insulating compound, which can be chosen according to customer
specifications –oil SF6.The corona shield is designed to minimize electrical
stress.The following fout types are:
Outdoor terminations with porcelain insulators.
Outdoor Terminations with composite insulators.
GIS terminations.
Transformer Terminations.
26. 26
Outdoor terminations with porcelain insulators: Excellent
resistance against ultraviolet radiation. Resistant against bird-
picking. Excellent track record in numerous countries and climate
zones. In service for more than 40 years at Brugg Cableith
outstanding results.
Outdoor Terminations with composite insulators: It is light
weight , easy to handle , resistant against UV radiation. Excellent
hydrophobic behavior , explosion proof and earthquake proof and
excellent track record in numerous countries and climate zones.
GIS Terminations: These were developed using for use in SF6
gasinsulated switch gears(GIS).Made with cast resin body,
they designed to fit perfectly into your GIS .It is light weight,
easy to handle , classically tried and tested design with high
tolerances for cables and applications. Excellent track record
in numerous countries and climate zones.
Figure 4
Figure 5
Figure 6
27. 27
Transformer Terminations: Have a cast resin body
and are designed to fit perfectly into the transformer.
Light weight and easy to handle , classically tried and
tested design with high tolerances for cables and their
application. Excellent track record in numerous
countries and climate zones.
3.9.Terminations for oil filled cables :Terminations for oil filled cables are designed
to be used independently of any type of oil filled cable or cable manufacturer from
72.5 kV to 420kV and up to a conductor cross section of 2500mm².
Termination design: Terminations for oil filled cable consist of paper taped stress
cone , an insulating liquid , an insulator , a corona shield and terminal stud .
Prefabricated stress cones: The prefabricated paper-taped stress cones are tried and
tested design that has been used for terminations of Brugg cables for 70 years. The
main advantage is that the coils for stress cone are prefabricated in a clean and dry
environment at the factory. After a high quality process of taping , drying and
impregnation, the coils are stored and delivered in sealed and oil- filled containers.
Consequently, the coils remain dry in any degree of humidity and oil –impregnated
for the installation. For the best solutions the prefabricated cones are made as per
customer specifications.
29. 29
Advantages of prefabricated design:
High degree of quality and reliability due to production of prefabricated paper-
taped coils in a clean dry environment.
Very good thermal stabality of up to 85˚C.
Excellent field grading performance at normal frequency and higher frequency
load.
Can be applied under the super vision of the Brugg personnel.
Excellent track record in all environment , laying condition and climate zones.
In service for more than 70years at Brugg cable with outstanding results.
The four termination types available are same as for the polymer cables .
3.10.Joints for polymer cables: These are designed to be used independently of any
type of polymer cable or cable manufacturer from 72.5 to 550kV and up to conductor
cross section of 2500m².
Figure 8
30. 30
Joint Design: It consists of polymer cables of conductor clamp, an insulation body
with semi conductive deflectors and middle electrode, a moisture barrier, a
mechanical protection and connections of outer conductor.
Variety of Conductor Clamps: Conductor clamps connect both conductor ends of
the cable. Their main task is to ensure a low contact resistance during lifetime. Our
joints are designed to suit all common types of conductor clamps. Due to their main
advantages, such as being easy to apply, we recommend the use of screwed conductor
clamps.
Outstanding Protection for Sir Insulation Body: The insulation body consists of
semi conductive deflectors at both sides, semi conductive middle electrode and
insulation compound. It ensures field grading between the semiconducting layers of
the cable and conductor clamp. Made of silicone rubber (SiR), the insulation body
combines outstanding electrical and mechanical properties with excellent interface
behavior.The electrical properties are designed to minimize stress, whilst mechanical
properties ensure an optimum level of surface pressure on the cable. The optimum
surface pressure remains constant throughout the lifetime of the joint. The field
grading deflectors and middle electrodes are made of solid semiconducting material.
Although costly, this ensures that they function properly at all voltage loads and
guarantees a long and reliable lifetime. For optimum electrical stress distribution, the
insulation body is designed with the computer simulations.
Quality in Production And Testing For Failure Free Devices: Our insulation
bodies are one piece and fabricated in house in an extremely clean surrounding. To
ensure best quality, the fabrication is made with computerized machines. For zero
failure, every part is tested several times in the fabrication process. The insulation
bodies must pass a final acceptance test. Each device is certified individually. This
ensures that every joint leaving is factory is 100% reliable.
31. 31
Main Advantages Of Prefabricated And Pretested Sir Stress Cones Are:
Very high breakdown strength of > 23kV/ mm at 50/60 Hz.
Excellent temperature stability of between -50 and +180°C.
Very high life exponent of >>40.
Excellent field grading performances at higher frequency with deflectors
and middle electrode of solid material.
Optimized electrical stress distribution due to computer based design.
Zero failure guarantee with final high voltage pretesting.
Void –free contact pressure on the cable surface at normal and elevated
load conditions due to excellent elasticity of SiR.
Easy to install due to excellent mechanical properties and elasticity , no
mechanical forces needed.
Moisture Protection Shield: Our standard joints are equipped with real transverse
moisture barrier made of metal shield .This gives 100% moisture protection to the
joint and results in prolonged lifetime making it highly reliable. In its basic version,
the barrier is a metal sheet. In the sophisticated version , the moisture barrier is metal
tube .
Variety of Designs For metallic protection: High reliability and a long lifetime are
further ensured by the first rate mechanical protection of the joint. Suited to the
diverse applications of the customer, we offer a wide variety of mechanical protection
designs. Basic protection is provided by heat sink cover. For a higher degree of
protection, steel or copper housing and /or a box of Polyester can be chosen. The
polyester protection box is filled with an insulating compound, giving excellent
sealing to the joint . The different designs of mechanical protection enable to select
the best technical and cost efficient solution for application.
32. 32
Protection designs for polymer cable joints are :
Metal sheet with heat shrink cover .
Metal sheet with protection box.
Cu- tube with coating of high density polyethylene(HDPE coating).
Cu-tube with protection box.
Steel housing.
Steel housing protection box.
These polymer joints are specific to Brugg stds.
Figure 9
33. 33
Table 7
Advantages Heat Shrink
Cover:
Extremely
compact
dimensions.
Total sealing
against
moisture. Cost
effective
Protection
Box: Good
mechanical
protection in
different
environments.
Total sealing
against
moisture.
Cu- tube with
HDPE
coating:
Compact
dimensions.
High degree of
mechanical
protection.
Total sealing
protection.
Steel housing
and
protection
box: Highest
degree of
mechanical
protection.
Total sealing
against
moisture.
Application For limited
dimensions,
such as small
manholes. In
tunnels or
concrete
manholes
without
permanent
water ingress.
In all types of
laying such as
tunnels,
concrete pits or
directly buried
installations. In
buried
installations
with humid
soil.
In all types of
laying such as
tunnels,
concrete pits or
directly buried
installations. In
installations
with
permanent
humidity or
shallow water.
In all types of
laying, such as
in tunnels,
concrete pits or
directly buried
installations. In
installations
with
permanent
humidity or
shallow water.
¹description for joints of voltage level 145kV
²description for joints of voltage level 550kV
³description for joints of all other voltage levels
34. 34
High Flexibility in earthing: Earthing of joints can be made according to
customer specifications .All joints are designed so that direct or indirect earthing ,
straight through connection or cross bonding can be released.
Figure 10
Slip –on Joints: Are joints most frequently applied when it comes to any type of
polymer cable. These joints at Brugg cables profit from the outstanding properties
of the prefabricated one piece and pretested SiR slip –on insulation bodies. All
joints are designed and tested according to international standards, such as IEC
60840 or IEEE Std 404-2000 .
35. 35
Advantages:
Very compact dimensions
100% failure free pretested one- piece SiR slip-on bodies.
Total moisture barrier with standard use of metal sheet.
High variety in application with different types of mechanical protection
design.
Easy to handle and fast and easy to install.
No preload needed during transport or storage due to design with SiR slip-
on bodies.
Excellent track record in all environments, laying conditions and climate
zones.
At service for more than 20 years at Brugg Cables with outstanding
results.
Profit from advantages of our slip –on joints for polymer cables. All joints for
polymer cables are designed to be used independently of any type of polymer cable or
cable ,manufacturer from 7.25 to 550kV and up to a conductor cross section of
2500mm² .
3.11.Joints for oiled filled cables:Our joints are for oil- filled cables are designed to
be used independently of any type of oil- filled cable or cable manufacturer from 72.5
to 420kV and up to a conductor cross section 2500mm².
36. 36
Figure 11
Joint Design: Joints for oil filled cables consist of a conductor clamp, a paper taped
insulation , a moisture barrier , a mechanical protection and an earthing link.
Prefabricated Coils: The prefabricated coils are a tried and tested design that has
been used for Brugg Cables joints for more than 50 years.The main advantage is that
the coils are stored and delivered in sealed and oil – filled containers .Consequently ,
the coils remain dry in any degree of humidity and oil pregnated for tapping during
installation.
37. 37
Advantages of paper taped design:
High quality and reliability of the paper-taped coils .
Very good thermal stability of up to 85°C.
Excellent field grading performances at normal frequency and higher
frequency load .
Can applied under supervision of Brugg Personnel
Excellent track record in all environment laying conditions and climatic
zones.
Joints for oil – filled cables are:
Straight through joints
Stop joints
Moisture Protection with metal housing: Joints for oil-filled cables come with a
standard metal housing. This acts as radial moisture barrier. Together with mechanical
protection of the joint, it guarantees a prolonged lifetime making it highly reliable.
Straight through joints for oil filled cables: A wide range of straight through joints
is offered by Brugg cables for oil filled –cables.
38. 38
Figure 12
Advantages:
Tried and tested design.
Total moisture barrier due to metal shield
Available with different types of mechanical protection.
Can be applied under supervision of Brugg Personnel
Usable with a standard pressure of 10 bar , higher pressure values for special
applications possible.
Excellent track record in different laying and climatic zones.
Profit from the advantages of our joints for oil –filled cables. All joints for oil
filled cables are designed to be used independently of any type of oil filled
cable or cable manufacturer from 72.5 to 420kV and up to conductor cross
section of 2000mm².
Stop Joints for oiled filled cables: These joints are used to limit the oil
pressure of cables that have to overcome differences in height .All joints are
designed according to international standards IEC 60141-1.
39. 39
Advantages:
Tried and tested design
Total moisture barrier due to metal shield.
100% oil stop at the joint.
Usable with standard pressure of 10bar, higher pressure values for
special applications possible.
Available with different types of outer mechanical protection.
Excellent track record in different surroundings and climatic zones.
Types of Stop Joints:
Standard stop joint
Stop joint with back to back design
High Flexibility in earthing: All stop joints can either be chosen with cross bonding
or with screen interruption.
These specifications are specific to Brugg Cables
Figure 13
40. 40
Table 8
Advantage Standard stop joint:
Highest degree of
mechanical protection in
different environments.
Total sealing against
moisture penetration .
Stop joint with back –to
back design: Highest
degree of mechanical
protection in different
environments. Total
sealing against moisture
penetration.
Application In all types of laying ,
such as tunnels , concrete
or buried installations. In
installations with
permanent humidity or
temporary flooding.
In laying with concrete,
such as in tunnels or
concrete pits. In insulated
formations.
3.12Transition Joints:These joints are used to connect polymer with paper insulated
cables. They consist of conductor clamp , SiR stress cones with an insulator for the
polymer cable side and paper insulated cable ties. Transition joints are covered by a
moisture and a mechanical protection, and have an earthing link.
Conductor Clamps:-Conductor clamps connect both conductor ends of the cable
.Their main task is to ensure a low contact during lifetime. Although different
conductor clamps are possible, we recommend using pressed clamps for the conductor
connection of transition joints.
41. 41
Outstanding properties of SiR stress cone and insulator of the polymer cable side
:The stress cone and insulator of the polymer cable side are the same as those used
for conventional GIS or transformer terminations .Thus, the transition joint profits
from the well proven , prefabricated and pretested silicone slip on stress cones of
Brugg Cables .The hydraulic oil barrier is achieved with epoxy insulator of the
polymer cable side . All components within the insulator are completely separated and
connected to an external stainless steel expansion tank. Stress cones for the paper–
taped cable side are of the same reliable and qualitative design as those paper taped
joints or terminations. Thus the transitions joints profit from well proven, paper taped
coils of Brugg cables. The main advantage of transition joints is their excellent quality
and enduring reliability. They can be installed independently of any type of low
pressure oil filled (LPOF) or high – pressure pipe type (HPPT) cable.
Types of transition joints:There are 2 types of
single core transition joints: are used to connect single core polymer –
insulated cables to different types of single core paper –nsulated , or
paper/ polypropylene- insulated cables .
three core transition joints :Are used to connect a three core polymer –
insulated cable with three single core paper insulated or paer
/polypropylene insulated cables.
43. 43
Table 9
Advantage High degree of
mechanical protection
in different
environments.– Total
sealing against moisture
penetration.
Highest degree of
mechanical protection
in different
environments
– Total sealing against
moisture penetration
Application In laying with concrete,
such as in tunnels
or concrete pits
– In insulated
formations
In all types of laying,
such as in tunnels,
concrete or
buried installations
– In installations with
permanent humidity or
temporary
flooding
Earthing Straight through
connection, not
insulated
to ground
Screen interruption,
insulated to ground
4.HT Cables: KEI manufactures HT XLPE cables up to 220KV conforming to
National and International Standards at Bhiwadi plant. KEI has State of Art HT cable
plant with German technology. The manufacturing capability is upto 220KV.We have
CCV line with a Single point triple extrusion and computerized sophisticated control
and monitoring systems.
The CCV line was imported from Machinenbau Scholz GMBH & Co KG, a pioneer
in this technology and have supplied more than 250 lines world over.HT plant is
complete with heavy duty machines for wire drawing and conductor making, laying
up, armouring , sheathing and packing.The process commences with a compacted
circular conductor being fed from the pay off stands into the extruder on elevated
platform. The conductor passes through extruder’s crosshead, it is covered first with
semiconducting screen layer then the XLPE insulation, followed by the outer
semiconducting core screen.
44. 44
This crosshead is specially designed to feed three compounds from three extruders at
one point described as Singe point Triple extrusion.Thereafter, the extruded core
enters and passes through vulcanizing line known as CCV line (Continuous Catenary
Vulcanising) and the XLPE insulated core is cured in the process. In CV line inert
atmosphere is maintained by the Nitrogen gas which is at high pressure and high
temperature.This process is popularly known as Single point Triple extrusion
CDCC(Completely Dry Cured and Cooled Curing) Process.Over the cured core a
copper screening is provided by lapping of copper tape or for special requirements a
layer of copper wires is provided. Core is tested for Partial Discharge and then as per
requirement; the cores are laid up with fillers, provided with inner sheath, armoured
and sheathed. Sheath can be of PVC, HDPE, FRLS, ZHFR, PCP or CSP compound.
KEI manufacturing plant and process ensures great XLPE cables for the new age
Power sector and industry. Our modern plant takes full advantage of the new
generation XLPE compounds which offer fast curing and superior electrical
parameters, dimensional control and higher productivity.Triple Extrusion and CDCC
process ensure contamination free cores. All three layers are bonded and core has
least eccentricity and ovality. Insulation itself is free of micro voids and with
negligible moisture content.To control the manufacturing process the line has been
provided with many sophisticated instruments and servo controls
all monitored by the computer. Important systems are:
X Ray Non touch sensors of SIKORA make for thickness and dimensional control.
This system continuously measures the dimensions of insulated cores. Unit has
capability to measure multilayer dimensions in all directions and record and analyse
the data on line.CCV tube has a Touch Less Sag control system. This ensures no
marks/lines on core unlike older lines.
Computerised control system ensures optimum efficiency, fast start up,
synchronized operations of compound feeds, three extruders, CCV line gas
temperature zones, pay off and takeup.Nevertheless KEI XLPE cables compare better
than those produced with older plants when checked for Microvoids, Moisture
content, PD levels, dielectric strength.
45. 45
We have strict Quality plan and fully equipped Testing laboratory to ensure cables of
best quality are produced as per the design and specifications prescribed. Cables have
been type tested as per International Standards.Inventory and production plans are
controlled by BANN ERP system. This ensures reliable and prompt delivery and
operational efficiency.KEI offers variety of designs to suit different installations viz.
Aerial Bunched cables, Water tight construction, Stainless steel armouring, for
Offshore and Ship installations etc.We have many satisfied customers from many
countries and diverse industry. We shall announce the expansion of our range beyond
220KV very soon.
5.LT CABLES: KEI INDUSTRIES LIMITED is manufacturing LT Power Cables
with PVC or XLPE insulation of voltage grade upto 3.3 KV conforming to various
Indian and International Standard Specifications. KEI also manufactures other types
of cables as listed at the end of this catalogue.
6.CROSS LINKED POLYETHYLENE (XLPE):-XLPE means cross-linked
polyethylene or vulcanized polyethylene. The basic material is low density
polyethylene. Polyethylene is a thermoplastic material consisting of long chain of
hydrocarbon molecules. At elevated temperatures these molecules tend to move
relative to one another so that the material becomes increasingly deformable and will
eventually melt at the temperature around 110oC.By means of process similar to the
vulcanization of rubber the polyethylene molecules can be cross-linked. The process
of cross-linking or vulcanization consists of producing chemical bonds at interval
between the long molecular chain to give a “ladder” effect which prevents slippage
between molecules. As a result of cross-linking the material becomes heat resistant
and does not soften at higher temperatures. Further it has better resistance to stress
cracking and good resistance to ageing in hot air. With the change of structure there is
no adverse effect on electrical properties.
46. 46
Advantages of “KEI” XLPE CABLES
Dielectric losses are very small.
Higher current carrying capacity.
Higher short circuit rating 250oC. as against 160oC for PVC.
KEI XLPE can retain flexibility down upto - 40oC.
Jointing and Termination is easy.
Light in weight.
They are not prone to fatigue damages due to vibrations or loading cycles.
Has better resistance to most chemicals, oils, acids, etc.
Can be installed along cable routes without elevation limitations.
47. 47
7.CONTROL CABLES :- A multi strand cable for transmission of info on the state ,
location or operating conditions of objects being controlled it is used where direct
access to such objects is difficult or impossible. Control cables occupy an
intermediate position between power cables and communication cables. They are
widely used to connect electric instruments and apparatus for secondary switching of
remote – control starters and regulators for protective relaying and in automation . In
contrast to communications cables , control cables are capable of carrying current
loads . Their strands consist of single copper or aluminum wires ( 4 to 61 strands with
a cross section of 1-10 sq mm for a cross section from 4- 10 sq mm the strands does
not exceed ten). The insulation of the cable is a made of rubber, polythene or PVC
and sheath is made of lead or plastic. Control cables have certain abbreviations
signifying the type of component used in making the cable.
A=Aluminium
Y=PVC
2X=XPLE
W= Galvanized Steel wire armour
Wa =Aluminium Round wire armoured
Fa= Aluminium Flat Strip Armourred
F=Galvanized Flat Strip armoured
3Cx 185sqmm= C stands for core
A2XWY= Aluminium –XPLE/wire/PVC
AYY= A-PVC-PVC
48. 48
8.INSTRUMENTATION CABLES:KEI Industries Limited manufactures a wide
variety of cables suitable for process instrumentation. In the projects related to power
generation & distribution, chemical & fertilizer industries and various other types of
engineering industries, the process instrumentation plays a vita role in measurement,
supervision and control of the process.
Introduction of microprocessor based/computerised instrumentation has demanded
stringent quality requirements along with special electrical parameters for
instrumentation cables. Very low level electrical signals pass between measuring end
and display units/controllers which are situated far off.
These low level signals are prone to external noise pickups and heavy silenuation
during transmission.All this means that the cables to be used for instrumentation
should be designed and manufactured very carefully, KEI with its meticulous efforts
in maintaining quality, stringent in process control during manufacture and the
knowledge of cable designing, is proud to say that it is capable of supplying
instrumentation cables meeting any Indian/International standard or a specific
requirement desired by project authority.
The efforts done by KEI are reqarded by acceptance of our quality by the country's
prime organisations such as NTPC, PDIL, EIL, BHEL, TATA's, IOCL, L&T, ABB,
KRUPP Ind, BPCL., HPCL, ESSAR, SIEMENS, Electricity Boards, Reliance, IOTL,
Mukand, Honeywell, etc.
49. 49
Range of Instrumentation Cables:-
Conductor:
0.4 mm dia (0.126 Sq.mm) to 2.5 sq.mm. or higher sizes of
electrolytic copper wire, Tinned/untinned, solid/stranded copper
conductors.
Insulation:
70/85/105oC. Grade PVC, Polyethylene, Halogen Free FRLS
Polymeric Compounds.
Elements:
Pairs/Triples/Quads, colour coded/number printed ring marked/dual
colour extruded.
Shields:
Aluminium Polyester tape screen with Copper drain wire or
alternately with with Copper wire braiding. Individual element or
overall shielding as specified.
Element
laying:
Concentric formation or unit & group formation as per applicable
specification.
Amounting: Galvanised steel wire/strip amount.
Sheathing: PVC 70/90oC. grade, PVC FRLS, ZHFR, CSP, PCP, EVA, etc.
Specification:
BS:5308 (1 & 2), iec-189 (1 & 2), VDE 0815, ENI 0181.00 and
customers specifications.
50. 50
Typical Instrumentation Cable Constructions
Figure 15
9.THERMOCOUPLE EXTENSION:- These cables can also be termed
as instrumentation cables, since they are used for process temperature measurement.
The construction is similar to paired instrumentation cable but the conductor material
is different. Thermocouples are used in processes to sense temperature and is
connected to the pyrometers for indication and control.The thermocouple and
pyrometers are electrically conducted by thermocouple extension/compensating
cables. The conductors used for these cables are required to have similar thermo-
electric (emf) properties as that of the thermocouple used for sensing the temperature.
The cables are manu-factured as per IS:8784, ANSI-MC 96. 1, B.S., ENI, DIN and
customers specification.
52. 52
Figure 18
10.RUBBER CABLES: In keeping with the company's commitment to technological
advancement, elastomer materials such as Polychloroprene (PCP), Chloro-
Sulphoneted Polyethelene (CSP), Nitrile Rubber / PVC blends, Ethylene Propelene
Rubber (EPR), Ethylene Vinyle Acetate (EVA) and Silicone have been specially
compounded to meet numerous heat oil and fire resisting requirements. In the recent
years KEI has also developed special Elastomeric Fire Survival Cables for power,
control and instrumentation wiring. Elastomeric compounds for insulating and
sheathing of cables are formulated to meet the requirement of IS 6380, BS 6899, IEC
60502 and other international specification.
53. 53
General Construction (Conforming to IS 9968 Part 1)
Conductor:
Annealed tinned Copper wires Solid (Class 1), Stranded (Class 2),
flexible (Class 5)complying with the requirement of IS 8130-1984
Seperator
Tape:
Suitable material seperator tape may be applied over the conductor
Insulation:
General service elastomer compound Type IE1 of IS 6380-1984
Heat Resisting elastomer compound Type IE2 of IS 6380-1984
Silicone Rubber Type IE 5 of IS 6380-1984
Core
Identification:
Coloured insulation, Nos.PE tape, Coloured proofed tape, Nos.
printing
Fillers:
Natural or synthetic fibres or elastomer suitable for the operating
temperature and compatible with the insulating material
Sheath:
General service sheath Type SE1/SE2 of IS 6380-1984
Heavy Duty Sheath Type SE3/SE4 of IS 6380-1984.
Table 10: Working Temperature of Commonly used Elastomeric Insulating and
Sheathing Materials
Material
Max. Cond.
Temp.
for continuous
opertation
Deg C.
Max. Cond.
Temp. for
short
circuit
Deg C.
Min.
Working
Temp.
Deg C.
Natural Rubber (VIR & TRS) 60 200 -55
Ethylene PropyleneRubber (EPR) 90 250 -50
Polychloroprene(PCP) 70 200 -40
Chlorosupphonated Polyethylene(CSP) 90 200 -35
Silicone Rubber 150 / 180 350 -55
HR Natural Rubber (HR VIR) 75 200 -55
Styrene Butadience Rubber 60 200 -55
ButylRubber 85 220 50
54. 54
Table 11: Rubber Cables
ELASTOMERIC CABLES RANGE APPLICATION
CABLES UP TO 11KV Machine Trailing, Mining, Power
FLEXIBLE TRAILING CABLES
Reeling unreeling, Trailing, Festooning, Mobile
Machines, Cranes, Coal Handling and Conveyors
MINING CABLES
FT or Pliable Armoured or Landline type
As per IS 14494, NCB specs
for UG , Open cast, Coal or other mines and mining machines
THERMAL POWER PLANTS For coal handling plants, flexible power and control application
CABLES FOR STEEL PLANTS
Flexible and high temp withstanding cables for furnace, melting
shops, material handling
WIND ENERGY
Flexible cables for power and control for Wind Mill generator
connection
FIRE SURVIVAL CABLES Fire Survival for 3 Hrs or 20 Min
SHIP WIRING As per IEC specs and Naval specs DGS or DEFSTAN, NES
OFFSHORE and ONSHORE For Platforms and Rigs as per IEC and BS or NEK specs
SHORE SUPPLY AND GENERATOR
CABLES
For charging of ship batteries and supply frommobile generators
MOTOR COIL LEADS Elastomeric and Silicon as per IS, BS, or OEM specs
HIGH TEMP CABLES Silicon insulated, glass fiber braided or unbraided
PUMP CABLES For Water , submersible and sewerage pumps
CABLES FOR RAILWAYS Coach wiring, Metro railway
WIRES FIRE HFFR Low toxic emission under
PANEL WIRING
For flexible, high power high temp zone, polluted or moist
atmospheres
BATTERY CABLES For High current and long life
LOW TEMPERATURE
INSTALLATIONS
Suitable for subzero temp. installations and operations
MISC. APPLICATIONS
Outdoor High mast lighting, Site power supply, Whitegoods, Oil or
Chemical resistant
TYPES
Power and Control cables up to 61 Cores
Instrumentation Pairs 30 pairs, triads, quad
Wires, Flat cables
VOLTAGE GRADES 11KV, 6.6KV, 3.3KV, 1.1KV, 750V, 250V, 110V, 60V
CONDUCTORRANGE 0.5 to 630 Sq.mm
POLYMERS PROCESSED
EPR, EPDM, PCP, CSP, CPE, SILICON, EVA
HALOGENFREEAND FIRE RESISTANT COMPOUNDS
NON TOXIC COMPOUNDS
BRAIDING OFFERED ATC, GI wire braid, Syntheticor Textile yarn, Glass Fiber
ARMOURING Pliable armour or steel /copper wires/Stainless steel wires
55. 55
11.HOUSE WIRES :KEI industries has launched its new range of Flame retardant
PVC insulated wires for domestic household applications -homecab.Especially
designed for domestic house hold usage, Homecab a multi-strand flexible house wires
with fire resistant properties are equipped with specially formulated insulation, with a
high oxygen and temperature index, enables the cable to withstand overloads
preventing electric mishaps.
HOME CAB- FR.: KEI, is the name you have trusted for the past forty years, in the
wires and cables industry in India. It is a one-stop-shop for all your domestic cabling
needs. The KEI range of wires comes with a comprehensive Product Liability
Insurance Cover, ensuring safety for your home. KEI introduces Homecab wires,
multi-strand flexible house wires with fire resistant properties. Specially formulated
insulation, with a high oxygen and temperature index, enables the cable to withstand
overloads preventing electric mishaps.
Flame Retardant PVC lnsulated
Single Core Unsheathed Copper
Cables (Up to 1100Vdlts AC).
Conductor: The conductors, drawn from bright electrolytic grade copper are
annealed and bunched together.
Insulation: The bunched conductors are insulated with specially formulated FR PVC
compound with a high insulation resistance value. The insulation process is carried
out on modern high speed extrusion lines, which ensures high accuracy and
consistency in performance. Flame retardant properties enable the cable to withstand
overloads. The insulation is resistant to boiling water, steam and vapours. This
prevents ageing and cracking in kitchens, bathrooms, damp walls and chemical
industries.
Marking: The cables are printed with generic marking 'HOMECAB'. Colours: Red,
Yellow, Blue, Black, Green and Grey.
Packing: 90 Meters (approx. 100 yards) pack in protective cartons.
56. 56
Table 12
CON FLAME FRLS: KEI, is a name trusted for the past forty years. in the wires and
cables industry. in India. It is a one-stopshop for all your domestic cabling needs. The
KEI range of wires comes with a comprehensive Product Liability Insurance Cover.
ensuring safety for your home.KEI Conflame is ideal for wiring solutions in multi-
storied buildings, hotels, hospitals, commercial establishments and residential
complexes. It is shielded by a specially formulated flame retardant PVC compound.
During fire, ordinary PVC emits black smoke and toxic fumes which are acidic in
nature. This impairs visibility and hampers rescue operations. Conflame insulation
retards spread of fire and emits minimum smoke and toxic gases, thereby reducing the
risk of injury.
Flame Retardant Low Smoke PVC
Insulated Single Core Unsheathed
Copper Cable (Up to 1100 Volts AC)
57. 57
Conductor: The condtictors, drawn from bright electrolytic grade copper, are
annealed and bunched together.
Insulation: Bunched conductors are insulated with specially formulate" Flame
Retardant Low Smoke Compound. During a fire situation, the FRLS compound
restricts the spread offlame. The smoke emission is also minimal.
Marking: The cables are printed with generic marking 'CON FLAME'
Colours: Red, Yellow, Blue, Black, Green and Grey
Packing: 90 Meters (approx. 100 yards) pack in protective cartons
Table 13
58. 58
Table 14
BAN FIRE-ZHFR: KEI, is the name you have trusted for the past forty years, in the
wires and cables industry in India. It is a one-stop-shop for all your domestic cabling
needs. The KEI range of wires comes with a comprehensive Product Liability
Insurance Cover, ensuring safety for your home.KEI Banfire is processed using a
Zero Halogen Flame Retardant compound (ZHFR). The insulation is of superior
quality, 100% PYC free and eco friendly. In case of a fire situation Banfire does not
emit toxic or poisonous fumes, which enables safe evacuation. These wires are best
suited for wiring in hospitals, hotels, business establishments and high rise buildings
where fire can be detrimental.
Zero Halogen FIame Retardant
Insulated Single Core Unsheathed
Copper Cables (Up to 1100 Volts AC)
59. 59
Conductor: The conductors, drawn from bright electrolytic grade copper, are
annealed and bunched together.
Insulation: Bunched, specially formulated grade of Halogen Free Flame Retardant
(HFFR) compound is used. The insulation does not melt or drip in case of fire. The
smoke emission is transparent, non-toxic and minimal. The victims trapped in the fire
do not suffer suffocation and evacuation is convenient.
Marking: The cables are printed wit4 generic marking 'BANFIRE'.
Colours: Red, Yellow, Blue, Black, Green a.l1d Grey
Packing: 90 Meters (approx. 100 yards) pack in protective cartons.
Table 15
61. 61
12.SINGLE/ MULTI CORE FLEXIBLE WIRES: Single core flexible wires:
single core insulated copper conductor (unsheathed )flexible cable , 1100 voltage
grade for industrial application
i. High safety factors
ii. Compact construction
iii. Choice of superior insulation system for meeting IEC classification ,
temperature rise , protection etc.
MULTI CORE FLEXIBLE WIRES: Multicore flexible for appliances and
machine tools
i. Compact construction reduces weight per metre
ii. Rugged yet flexible for industrial use.
iii. High temp insulation
62. 62
Table 17
Type of
insulation
Type of
sheathing
Applicable standards Type of
applications
Standard
PVC
Standard
PVC ,
HRPC
IS694, BS-6500, IEC-60227,
DIN VDE 0281
power cords for
appliance ,
temporary power
supplies , 3 core
flat cables are
suitable for
submersible
pump
applications.
Heat
resistant
PVC upto
103°C
Standard
PVC,
HRPVC
IS694, BS-6500, IEC 60227
DIN VDE 0281
High power
appliances ,
ovens, temporary
power in higher
temp areas.
Standard
FRLS
PVC
FRLS(flame
retardant
IS 694, BS- 6500, IEC-60227,
DIN- VDE- 0281,
IEC – 60754-1,
IEC 603-32-1, BS- 4066-1
ASTMD 2843, ASTMD 2863
Power cords for
application used
in fire prone
areas, flame
proof equipments
machine tools
used in critical
locations and
heat zones .
63. 63
13.WINDING WIRES/ 3 CORE FLAT CABLES FOR SUBMERSIBLE
PUMPS:(HR/ PVC insulated winding as per IS: 8783(Part 4/ Sec 1)1995)
Kei’s PVC insulated winding wires for submersible pump motors serve more than 350
submersible pump manufacturers and thousands of rewinders across India with the
fine quality products . Kei’s winding wire is insulated with a superior grade of pvc
compound as per IS 5831 to give it the needed electrical strength and resistance to
abrasion the copper conductors used by KEI are of the highest level of purity and
conductivity these conductors are also annealed to stringent specifications. Although
proper care is taken while handling of the winding wire from manufacturing to
packaging stage , this product being delicate requires utmost care during storage and
insertion into stator slot for proper product performance .
Poly Wrapped Wires: Commonly known as submersible copper winding wire. the
copper conductor is wrapped with thin polyester film and biaxial oriented modern
plant with sophisticated wrapping heads and in line continuous heat shrinkage furnace
is installed to get uniform covering. A complete quality assurance testing by
instruments covering all governing stds is available. These are used in submersible
motors of all sizes for domestic and industrial applications. Available in coil form
with sustainable length as per size , in polythene bag and packed in inner and outer
corrugated boxes.
64. 64
Salient Features :
Saves energy – ETP grade high conductivity annealed copper used. Less
Current leakage – no air gap between the films .
Tear resistant – high mechanical strength – high tensile strength.
Each coil tested at 3500V.
Heat shock test at 150C.
Easy winding – resistance annealed copper and controlled OD.
Manufactured by ultra modern automatic plant.
The quality assurance having all testing facilities with ultra modern, high
precision instruments and rigorous testing plans.
Submersible Flat Cables (3 Core) for 1100V AC: Fits perfect required
Grommet. It is as per IS dimension. Perfect sheathing for under water
application.
Technical specifications: Nicely bunched high purity bright, electrolytic
grade , plain annealed copper with superb flexibility according to harmonized
grades H05V-K, H07V-K, BS , 6360 class 5 available in various sizes.
Insulation and sheathing: Generally available with general purpose insulation
and normal PVC sheathing choice of insulation sheathing is available on
special order.
65. 65
Figure 19
14.Stainless Steel Wires: KEI industries limited is an established player in
the Stainless Steel Wires segment and among the largest Stainless Steel Wires
manufacturing companies in India. KEI industries limited manufactures stainless
steel wires in various range for wide range of applications. KEI is one of the few
companies in country to manufacture speciality Wires fro very critical application.
KEI is perhaps one of the few companies in India to offer customers a unique
range of specialty SS Wires such as wide range with the best quality. An ability to
utilize more than 90% of its resources makes KEI one of the most efficient players
in the industry. The various types of stainless steel wires manufactured under the
stainless steel category are:
66. 66
Welding Wire: KEI’s stainless steel wire for welding electrodes wire are
manufactured having excellent mechanical properties , under strict guidance of
technical people , diameter from 1.60 mm to 5.00mm in Matte and Bright
finish and can supply in coil as well as in cut length .the commonly
manufactured grades are AWS ER 308, ER308L, ER309L, ER310, ER312,
ER316, ER316L.
Hard stainless steel wire : It manufactures stainless steel wire for springs
with excellent mechanical properties ( surface , cast and helix ) manufactured
under strict guidance of technical people , diameter from 0.19mm to 1.20mm
in bright finish and 0.50 mm to 6.0 mm in matte finish (coated )in grade of
AISI 302, 304 and 316, 321, Std ASTM A313 and others. It has following
characteristics :
Excellent surface finish
High corrosion resistance
Superior coiling efficiency
High fatigue strength.
In particular to provide optimum spring efficiency , this type of wire is
painstakingly finished to eliminate flaws.
Cold Heading wires: These are made by special heat treatment , copper –
bearing austenitic steel 302CHQ , 304HQ, normal 304 and 430 are also used
for cold heading fasteners.
Special Characteristics :-
Excellent corrosion resistance and mechanical strength and is most suitable
material for bolts , screws and other fasteners and has a marked work
hardening characteristics .All kei wires are coated to ensure smooth heading
operations condition. Cold drawn and annealed, cold drawn, annealed and skin
pass or as per customer requirement with very fine tolerance.
67. 67
Fine stainless steel wires: These wires are used in weaving, hoses and
braiding filters, fencing, knitting. The grades suitable for these applications are
304, 304L, 316; 316L.The surface finish of wires can be bright or matte
finished and high resistance to corrosion. Having regular winding pitch and
tension they are manufactured under strict process control. For knitting the
wire is equipped with mechanical properties (elongation, tensile strength ,
yield strength ) and good lubrication for high productivity.
Wires for general purpose: The stainless steel wires are used in engineering,
chemical, construction and many other industries besides various type of
application in manufacturing of Kitchens wares, ornaments, utensils. These
wires are manufactured as per International Standards as well as in accordance
with customers specifications.
Special Characteristics:-Produced from wire rods meeting International Stds.
Supplied in annealed, 1/8 hard, 1/4 hard and 1/2 hard, 3/4 hard, full hard
conditions. Drawn to very close tolerance limit. Excellent surface finish.
Quality checked at each process stage.
Wire for Kitchenware and Baskets: The Kei allows to manufacture Stainless
steel wires in bright as well as in matte finish, suitable for kitchenware and
basket , grade AISI 304 , in various sizes .Kei is a major market player for
wires in Electro polish quality. Balls, pins, nails and other general application.
Wire for Scrubber: For this purpose Kei offers a stainless wire with bright
smooth finish and its extra softness enables further cold working by
customers.
Stainless steel wire for wall Tie/Tying Wires Reinforcement bars: Kei’s
stainless steel wire find application in construction industry. Kei manufactures
stainless steel wires in grades of 302. 304. 316. 316Ti. In bright as well as
annealed condition. Suitable to manufacture wall tie. Tying wire as well as re
–inforcement bars for building and construction. The sizes offered are 0.9mm
to 8.0mm.
68. 68
15.Marine and Offshore Cables :Kei industries offers extensive wide range of
cables for industrial , power , control instrumentation , fire resistant and mud
resistant and infrastructure projects as per International specifications. Our marine
and off shore cables complement our offering of high performance cables for this
fast growing industry. Kei supply Marine and Offshore cables to important
projects of Indian defense shipyards and private shipyards around the world
.Cables have been supplied to renowned shipyards like Mazagon Docks , Garden
Reach Shipyard , Naval Dockyards, Goa Shipyard , Cochin Shipyard, Hindustan
Shipyard , Larsen and Toubro, Gunasua, ONGC in India and also exported to
Sime –Darby Malysia, ZADCO UAE, NPCC UAE, etc.
Construction:
Conductor: Tinned or untinned copper with stranding class 2 or class 5 from
0.5 to 1000 sq mm or 22-19 AWG to 2000Kcmil.
Solid single strand for communication cables as required.
Standards IEC 60228, BS 6360 or UL.
For Thermocouple Cables:-
KX, JX, EX,TX,KX/VX, SX/RX.
Insulations :
EPDM, XPLE, Halogen free EVA based, silicon rubber glass braided and
vanished, PE, PVC.
Dual layer EPDM+HF or PVC + Polyamide (Nylon).
Fiberglass tape insulation as per NES standard.
69. 69
Fire Resistant Cable: Heat barrier of glass mica tape lapped in double layer
shall be provided over the conductor , before the insulation.
Sheath:
Thermoplastic Halogen free Type SHF1, Cross Linked thermo set Type SHF2
or EVA, silicon ,FR PVC, HDPE, Mud Resistant SHF2.
PCP. CPE or CSP sheaths for EPDM or Silicon insulated cables.
TPR sheath
Oil resistant sheath also available in SHF2 or SW4 grade.
Braiding/Armour :
ATC wire ,plain copper , bronze , stainless steel Aluminium alloy wire
Copper braid of desired conductivity can be designed as required to meet
installation specific requirement or to serve as Earth continuity conductor.
Instrumentation Cables: Cores twisted in pairs , triads or Quadd to form an
element .
Screen Provision :
Each element can have individual screen or shielding of Aluminium Mylar
backed tape or copper Mylar backed tape .
Each unit has ATC drain wire
Multi element cable can have overall screen or shielding of Aluminium Mylar
backed tape or copper Mylar backed tape , with a ATC drain wire.
ATC wire braiding can be offered as alternative to tape type screen for an
individual element or overall screen .
70. 70
Special Protection:
Cables can be supplied with special sheath like Lead alloy or Polyamide
(Nylon) as a proven moisture barrier in highly contaminated areas. Cables not
having a lead sheath are ROHS compliant.
Core Identification and Sheath Color:
Standard color coding as per CENELEC for cores and Black or Grey for the
sheath.
However, we can provide any customized color coding as per project
requirement.
71. 71
Table 18: Specification Compliance
Specification Types Offered
IEC 60092-350,353 Power and control cables 0.6/0.1kV
EPDM, HEPR, or XPLE or Silicon
rubber or PVC insulated.
NEK 606 Power and control cables 0.6/01Kv
EPDM insulated RFOU, RFCU,
BFOU, BFCU.
NEK 606 Instrumentation cables 250 V EPDM
insulated RFOU(o), RFOU(i),
RFCU(o), RFCU(i), BFOU(o),
BFOU(i), BFCU(o), BFCU(i)
NAVAL STDS
NES 525 Small wires.
NES 526 & DEFSTAN 512 P3 Dual Extruded Insulation EPR +lFH,
LFH Sheathed Power and Control
cables.
ONGC OFFSHORE
FS 4011 Power, Control and Instrumentation
cables for offshore installations.
FS 3508 Instrumentation cables for Offshore
installations.
FIRE TESTS REFRENCE
IEC 60332-1-2- test Flame retardant test for single
insulated wire and cable.
IEC 60332-3-22-test Flame retardant (FR)-test for bunched
wires and cables , category A
IEC 60754-1,2 Halogen –evolution from insulation or
sheath material.
72. 72
Key Clients: (In Power and transmission)
Ahmadabad Electricity Corporation
BSES Ltd
CEB, Mauritius
Essar Group
NTPC
Jindal Power
Power Grid Corporation Of India
Tata Power
16.SOLAR CABLES: KEI has been at the forefront of India’s wire and cable
industry for the last forty years. Solar photovoltaic’s is now, after hydro and wind
power, the third most important renewable energy source in items of globally installed
capacity. This results in the great demand for 'SOLAR CABLE'. Solar cable is the
interconnection cable used in photovoltaic power generation. A solar cable
interconnects solar panels and other electrical components in the photovoltaic system.
Matching step with the environment friendly shift the Solar Cable has been made
which performs highest standards of application in its diverse usage.
73. 73
Properties
A lifetime 'Partner' lasts up to 30 years even under tough conditions.
Used in extreme weather conditions.
Equipped with UV Resistance.
Halogen-free: low smoke emission and low toxicity during fire.
Flame & Fire retardant.
Flexibility & strip ability: for fast and easy installation.
Easily Recyclable: in accordance with new government norms.
Easy installation: with color identification.
Suitable to common connector types.
TUV, UTE and IMQ-certified.
One common factor for most of the photovoltaic power system is outdoor use,
characterized by high temperatures and high UV radiation.
Features
Chemical Features:
Weather resistant.
Resistant to mineral oils.
Resistant to acids & alkaline.
Thermal Features:
Ambient Temperature : -40oC ~ +90oC.
Maximum Temperature at Conductor: 120oC (20000h).
Short Circuit Temperature: 200oC at conductor (max. 5 sec).
74. 74
Electrical Features:
Rated Voltage: 0.6/1 kV AC .
Rated DC Voltage: 1.5 kV.
Maximum Permitted DC Voltage: 1.8 kV (conductor / conductor, non earthed
system, circuit not under load).
Maximum Permitted AC Voltage: 0.7/1.2 kV .
Working Voltage: DC 1000 V.
Insulation Resistance: 1000 MW-km.
Spark Test: 6000 Vac (8400 Vdc).
Voltage Withstand: 6500 V as per EN50395 for 5 min.
75. 75
17.CONCLUSION: The industry is progressing and caters to the commercial and
industrial demands efficiently by offering different types of cables based on the
customer specifications. The insulated cabling systems offers aerial (overhead) as
well as underground cabling systems but the drawback of aerial overhead cables is
that if they burst due to technical faults in the system it will cause much adverse
effects in terms of damage and expense. On the contrary the underground cables
although offer 500KV and are costly but adverse effects are minimum and durability
is more .The meggar meter reading is cumbersome job to manage for the underground
systems. The near future offers bright prospects for EHV, Solar , HV DC cables as
they are being used in the converters and inverters .
76. 76
18.REFERENCES:-
www.Kei-Ind.Com
Catalogue- The Power.
Pdf File Of Indian Standard Cross Linked Poly Ethylene Insulated Thermoplastic
Sheathed Cables.
High Voltage Xlpe Cabling Systems- Technical User Guide.
Submersible_Winding_ Wire_ Flat_Cable.Pdf
Fact Book High Voltage Accessories Of Brugg Cables__En.Pdf
Ehv Power Cable Systems.Pdf.
