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Power Cables

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Power Cables

We are one of the leading Suppliers of Industrial Power Cables. In addition, we also provide Insulated Power Cables and High Voltage Power Cables of high efficiency. We can offer Power Cables as per the requirements of the customer. Power Cables are for use with heavy machines, feeders and branch circuits in industrial, commercial and electric utility applications.

  • High Efficiency
  • Good Thermal Resistivity of Soil
  • Long Lasting
  • Ductile

All our cables conform to IS : 1554 (Part -1) : 1988 for working voltages upto 1100 volts. Wherever required, KCP can offer cables as per other national or international standards or special requirements.
  • Low Tension Copper / Aluminium Conductor Un – Armoured PVC Insulated & Sheathed Power Cable
  • Low Tension Copper / Aluminium Conductor Armoured PVC Insulated & Sheathed Power Cable

Power cables are solid or stranded conductors surrounded by insulation, shielding, and a protective jacket.Generally the power cables are rated Low Voltage (<1kV), Medium Voltage (6-36 kV), and High Voltage (>40 kV).

Cable jacket includes polyvinyl chloride (PVC) or cross-linked polyethylene (XLPE). Cable shielding is a metallic layer placed around an insulated conductor or group of insulated conductors, to prevent electrostatic or electromagnetic interference between the enclosed wires and external fields.

Cable insulation material used is of a high resistance to the flow of electric current to prevent leakage of current from a conductor. Common materials include cross-linked polyethylene (XLP), polyethylene (PE), and polyvinyl chloride (PVC). A cable conductor is a wire or combination of wires not insulated from one another, suitable for carrying electric current.
  • Conductor
    • Copper or Aluminium
  • Applicable Standard
    • IS : 1554 (Part -1) : 1988
  • Range
    • 1C x 50 sq. mm to 1C x 400 sq. mm
    • 2C x 1.5 sq. mm to 2C x 250 sq. mm
    • 3C x 1.5 sq. mm to 3C x 250 sq. mm
    • 4C x 1.5 sq. mm to 4C x 250 sq. mm
    • 3.5 x 10 sq. mm to 3.5 x 250 sq. mm

Cable Construction
Conductor : Copper or Aluminium used for the Conductors obtained in the form of rods (8.0 mm Copper or 9.5 mm aluminium rods). After testing, rods are drawn into wires of required sizes. These wires are formed into final Conductor in the stranding machines under strict “Quality Assurance Program”.

Insulation : PVC is insulated over Conductor by Extrusion process. Extruded layer of PVC 70°C/85°C/105°C (conforming to IS: 5831: 1984) with colours as per specification or cores are identified by printing numbers under scheme as per IS: 1554(Part – 1): 1988.

Core Identification
For Power cables the cores are identified by different colours as per IS 1554 :
  • Single Core : Red, Black, Yellow or Blue
  • 2 Core : Red and Black
  • 3 Core : Red, Yellow and Blue
  • 3½ Core : Red, Yellow, Blue, and reduced neutral core in Black
  • 4 Core : Red, Yellow, Blue and Black

Laying : The insulated cores are laid up in right hand or alternating left & right hand direction of lay in the sequence of core numbers or colours. Wherever necessary; non-hygroscopic PP/PVC fillers & binder tape are used to form a compact and reasonably circular cable.

Bedding/Inner Sheath : All armoured cables have extruded PVC bedding. The PVC used for bedding is compatible with the temperature of Insulation material. An extruded layer of PVC is applied as bedding or PVC tape (conforming to IS: 5831: 1984)

Armouring (If requested) : When armouring is required, the armour consists of single layer of Galvanized steel wire conforming to IS: 3975. The armour is applied helically, with a left hand direction. We also provide other armours such as steel strip, tape or tinned copper. Single core cables are armoured with Aluminium or copper wires.

Outersheath : The standard cables are manufactured with Extruded black PVC Type-9 of B.S. 7655 or ST-2 of IEC 60502. Outer sheath is embossed or printed with the information required by the related standards. Special FR, FRLS compounds are used for outer sheathing of cables, to suit customer’s specification requirements.

Current Ratings

The current rating in table of Unarmoured Single Core Power Cables( Table1), Unarmoured Twin & Multicore Power Cables (Table2) & Armoured Twin & Multicore Power Cables (Table3 ) are as follows :
Maximum conductor temperature 70o
Ambient air temperature 40o
Ground temperature 30o
Depth of laying(for cable laid directly in ground 75 cm(1.1KV)
Thermal resistivity of soil 150o cm/watt
Thermal resistivity of cable 650o cm/watt
Max. short-circuit conductor temperature 160o
Max. Ambient Air Temperature 55o

Other construction can be supplied on request :
  • FR [Flame Retardant PVC]
  • FRLS [Flame Retardant Low Smoke PVC]
  • Zero halogen/ Low Halogen Low smoke Cables: with polymeric insulation and sheath
  • High Temperature Cables: With ETFE/FEP/PTFE tape (wrap) insulation/sheath

Power Cables are for use with heavy machines, feeders and branch circuits in industrial, commercial, and electric utility applications.

Technical Advisory Services
KCP’s staff includes specialist engineers with wide knowledge and decade long experience in the field of cables and their applications. This time tested technical expertise and experience is available to all the clients in the selection of appropriate cable design.

Recommendations for Storage & Installation of Cables
For easy and convenient installation conditions, and desired performance, following recommendations are made :
  • No drums should be stored one above the other
  • Drums should be stored on a plain ground without having any projected hard stones above the ground surface. The drums should be stored preferably in the shade.
  • Drums should be stored and kept in such a way that the bottom cable end does not get damaged.
  • Drums should be rotated only in the direction marked on the drum.
  • While laying the cable in a trench, the cable end should be pulled with a pulling eye only after mounting the drum on the jack.
  • 100% drums should be checked for continuity and cross continuity to ensure that there is no internal damage to the cable during transportation.
  • Insulation resistance should be measured with 500 V megger between the cores and all the cores to earth (Armour).
  • After the cable is installed, before commissioning, it should be tested for high DC voltage. The recommended volts and duration of the test between each core and metallic armour (earth) is 3 KVDC for 5 minutes. During High Voltage test, all the electrical equipment related to the cable installation must be earthed and adequate clearance should be maintained from the other equipments and from work, to prevent flash over.
  • Where the cable is to be joined with an existing cable, the sequence of cores at the two ends to be joined should be in the opposite direction i.e., if at one end it is in the clockwise direction, at the other end it should be in the 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.
  • The minimum bending radius for cable should not be less than the values shown in the table. Wherever possible 25% higher value should be adopted.
  • Avoid excessively high temperature when sealing joints of cable. Cool the sealant to about 1000C before pouring.

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