CABLES

The main requirements of insulating materials used for cables are:-

1- High insulation materials to avoid leakage current.
2- High dielectric strength to avoid the break-down of the cable.
3- Good mechanical properties (i.e .tensity & elasticity).
4- Immune to attacks by acids and alkalis over range of temperature of
about: 18- 940 0C.
5- Non-hygroscopic.
6- Non-inflammable.
7- Low coefficient of thermal expansion.
8- Low permittivity.
9- Capability of withstanding high rupturing voltages.

The main points which may be taken into consideration while

selecting cable type and size:-
1- Load. 5- Short circuit current.
2- Voltage Drop. 6- Running cost against
3- Installation Condition. Initial cost.
4- Cable Length. 7- Mechanical hazard.
Types of insulating materials:-
1- Rubber. 6- Vulcanized India rubber.
2- Poly ethylene. 7- Impregnated Paper.
3- Poly Vinyl Chloride (PVC).
4- Cross-Linked Poly Ethylene (XLPE).
5- Silk and Cotton.
The sources of heat generation of the cables:-
1- I2R losses in the conductor.
2- Mechanical losses in the cable insulation.
3- Losses in the metallic sheath and armouring.
Classification of cables according to operating voltage:-
1- Low voltage cables for operating voltage up to 1 KV.
2- High voltage cables for operating voltage up to 11 KV.
3- Super-tension cables for operating voltage up to 33 KV.
4- Extra high tension cables for operating voltage up to 66 KV.
5- Extra super- voltage cable for operating voltage up to 132 KV.
General Construction of LV Cable as the Following:-

a. Conductors :

Aluminum conductor Copper conductor

It requires larger sizes to carry
the same current as copper.
It is light in weight and large in
diameter.
It is cheaper.
It has high losses.
1mm2 = 1 ampere.
It requires lower sizes to carry
the same current as aluminum.
It is large in weight but light in
diameter.
It is expensive.
It has less losses.
1mm2 = 2 or 3 ampere.
 b. Insulating materials (insulation):-
PVC Material
Under normal condition, PVC
0
operate at 70 C.
Under short circuit condition, this
cable can withstand;
PVC =160 0C for C.S.A ≤ 300 mm2
PVC =1400C for C.S.A ≥ 300 mm2
Mechanical properties of PVC are
not good.
PVC cannot withstand this effects
It is cheap.
PVC cables are used for low and
medium domestic lights and power.
XLPE Material
Under normal condition, XLPE operate at
90 0C.
Under short circuit condition, this cable
can withstand up to 250 0C.
XLPE can withstand vibration and hot
impacts.
It also has 100 times more moisture
resistance capacity compared to PVC.
It is expensive.
For medium voltage applications XLPE
cable acts well.

c. Metallic Sheath :-
 A metallic sheath is a layer in order to protect the cable from moisture,
gasses, acids or alkalis in the soil and atmosphere.
 The metallic sheath must be electrically continuous (Not only water
proof protection, but also provides an electrical earth shield the
potential of the conductor).

d. Bedding :-
 Bedding is a layer over the metallic sheath to protect the metallic sheath
against corrosion and from mechanical injury due to armouring.

e. Armouring :-
 It is a layer that is used to protect the cable from the mechanical damage
and it is divided into two categories:
 Steel-Tape Armouring (STA) Wire Armouring (SWA)
It is provided over the bedding but they It has been found that a single layer of
are not flexible, and their used is limited wire armouring provides better
where bedding of the cable cannot be mechanical protection as against two
avoided. layers of steel tape.

Specifications of Cables:-
Number of Cores, Type of conductor & construction, Type of Insulation, Type
of Armouring, PVC sheathed.

Ex;
 Multicore cable, copper stranded, PVC insulated, STA armoured, PVC
sheathed.
 Multicore cable, Al. stranded, XLPE insulated, SWA armoured, PVC
sheathed.
Or
 CU/PVC/PVC - CU/XLPE/PVC - AL/PVC/PVC - AL/XLPE/PVC

Reading of Cables (According to E.C):-

1. If C.S.A ≤ 16 mm2 Use (4 x ph.) [3-Փ & N ]
2. If C.S.A ≥ 16 mm2 Use (3 x ph. + 1 x 0.5ph.)
For Neutral Cable:-
 C.S.A for neutral = C.S.A for any phase
 C.S.A (R) = C.S.A (Y) = C.S.A (B) = C.S.A (N)

Because:
1) Third harmonic.
2) Unbalanced system.
Calculation of Cables
1. Calculate Designed Current (Ib)

Ib = 1.5 x KVA for 3 - 𝝓

Or

Ib = 4.5 x KVA for 1- 𝝓

2. Calculate Cable Current (Iz)

𝐼𝑏
Iz =
𝐷.𝐹
 Types of Derating Factor:-
a) Soil thermal resistivity.
b) Ambient temperature Derating factor.
c) Ground temperature Derating factor.
d) Burial depth Derating factor.
e) Grouping factor.

D.F = K1 x K2 x K3 x K4 x k5

Where D.F is the Derating Factor or Correction Factor that depends on

1. Soil Thermal Resistivity (K1)

The current-carrying capacities of cables in the ground are based on a ground resistivity
equal to 120 oC.cm/W. For other values, the correction factor is given in the table below
(According to Elsewedy Catalogue).
Soil Thermal
Resistivity oC.cm/W
80 90 100 120 150 200 250 300

K1 1.17 1.12 1.07 1.0 0.91 0.80 0.73 0.67

Based on experience (According to IEC), a relationship exist between the soil nature

and resistivity. Then, empiric values of correction factors K1 are proposed in table

below, depending on the nature of soil.

Nature of soil K1
Very wet soil (saturated) 1.21
Wet soil 1.13
Damp soil 1.05
Dry soil 1.00
Very dry soil (sunbaked) 0.86
 2. Ambient or Air Temperature Factor (K2)
The current-carrying capacities of cables in the air are based on an average air
temperature equal to 40 °C. For other temperatures, the correction factor is given in
table below for PVC, and XLPE insulation material (According to Elsewedy
Catalogue).

Air Temperature oC 20 25 30 35 40 45 50 55
PVC cables rated 70 oC 1.29 1.22 1.15 1.08 1.00 0.95 0.82 0.71
XLPE cables rated 90 oC 1.18 1.14 1.10 1.05 1.00 0.90 0.89 0.84

3. Ground Temperature Factor (K3)

The current-carrying capacities of cables in the ground are based on an average ground
temperature equal to 35 °C. For other temperatures, the correction factor is given in
table below for PVC, and XLPE insulation material (According to Elsewedy
Catalogue).

Ground Temperature oC 15 20 25 30 35 40 45 50 55

PVC cables rated 70 oC 1.25 1.19 1.13 1.07 1.00 0.93 0.85 0.76 0.65

XLPE cables rated 90 oC 1.16 1.13 1.09 1.04 1.00 0.95 0.90 0.85 0.80

4. Depth of Burial Factor (K4)

Cable Cross Section
Depth of
Up to 70 95 up to 240 300 mm2 &
Laying (m)
mm2 mm 2 above
0.50 1.00 1.00 1.00
0.60 0.99 0.98 0.97
0.80 0.97 0.96 0.94
1.00 0.95 0.93 0.92
1.25 0.94 0.92 0.89
1.50 0.93 0.90 0.87
1.75 0.92 0.89 0.86
2.00 0.91 0.88 0.85
 5. Grouping Factor (K5)
The current-carrying capacities of cables in the ground are based on the grouping
factor that is depend on type of laying:-
a. Laid Direct in Ground.

No. of
Circuits
Trefoil Formation Flat Formation
Touching Spacing = 15 cm Spacing = 30 cm
N0. Trefoil Flat Trefoil Flat Trefoil Flat
2 0.81 0.81 0.87 0.87 0.91 0.91
3 0.69 0.70 0.76 0.78 0.82 0.84
4 062 0.63 0.72 0.74 0.77 0.81
5 0.58 0.60 0.66 0.70 0.73 0.78
6 0.54 0.56 0.63 0.67 0.70 0.76

b. Laid in Free Air

B1. For Three Single Core Cables
Clearance = 2d Number of Circuits
Laying Form
Clearance from the wall > 2cm 1 2 3

Laid on the Ground 0.95 0.90 0.88

Laid cables in troughs

(Circulation of air is restricted)
No. of troughs
1 0.95 0.90 0.88
2 0.90 0.85 0.83
3 0.88 0.83 0.81
6 0.86 0.81 0.79
Laid on cables racks
No. of racks
1 1.00 0.98 0.96
2 1.00 0.95 0.93
3 1.00 0.94 0.92
6 1.00 0.93 0.90
 ‫‪B2. For Multi Core Cables‬‬
‫‪Clearance = d‬‬ ‫‪Number of Circuits‬‬
‫‪Laying Form‬‬
‫‪Clearance from the wall > 2cm‬‬ ‫‪1‬‬ ‫‪2‬‬ ‫‪3‬‬ ‫‪6‬‬ ‫‪9‬‬

‫‪Laid on the Ground‬‬ ‫‪0.95‬‬ ‫‪0.90‬‬ ‫‪0.88‬‬ ‫‪0.85‬‬ ‫‪0.84‬‬

‫‪Laid cables in troughs‬‬

‫)‪(Circulation of air is restricted‬‬
‫‪No. of troughs‬‬
‫‪1‬‬ ‫‪0.95‬‬ ‫‪0.90‬‬ ‫‪0.88‬‬ ‫‪0.85‬‬ ‫‪0.84‬‬
‫‪2‬‬ ‫‪0.90‬‬ ‫‪0.85‬‬ ‫‪0.83‬‬ ‫‪0.81‬‬ ‫‪0.80‬‬
‫‪3‬‬ ‫‪0.88‬‬ ‫‪0.83‬‬ ‫‪0.81‬‬ ‫‪0.79‬‬ ‫‪0.78‬‬
‫‪6‬‬ ‫‪0.86‬‬ ‫‪0.81‬‬ ‫‪0.79‬‬ ‫‪0.77‬‬ ‫‪0.76‬‬
‫‪Laid on cables racks‬‬
‫‪No. of racks‬‬
‫‪1‬‬ ‫‪1.00‬‬ ‫‪0.98‬‬ ‫‪0.96‬‬ ‫‪0.93‬‬ ‫‪0.92‬‬
‫‪2‬‬ ‫‪1.00‬‬ ‫‪0.95‬‬ ‫‪0.93‬‬ ‫‪0.90‬‬ ‫‪0.89‬‬
‫‪3‬‬ ‫‪1.00‬‬ ‫‪0.94‬‬ ‫‪0.92‬‬ ‫‪0.89‬‬ ‫‪0.88‬‬
‫‪6‬‬ ‫‪1.00‬‬ ‫‪0.93‬‬ ‫‪0.90‬‬ ‫‪0.87‬‬ ‫‪0.86‬‬

‫طرق دفن الكابالت‬

‫كابالت الجهد المتوسط‪-:‬‬ ‫كابالت الجهد المنخفض‪-:‬‬

‫فى حالة كابل واحد (دائرة واحدة)‬ ‫فى حالة كابل واحد (دائرة واحدة)‬
‫‪40cm width x 80cm Depth‬‬ ‫‪40cm width x 50cm Depth‬‬
‫فى حالة كابلين (دائرتين)‬ ‫فى حالة كابلين (دائرتين)‬
‫‪60cm width x 80cm Depth‬‬ ‫‪60cm width x 50cm Depth‬‬
‫فى حالة ثالث كابالت (ثالث دوائر)‬ ‫فى حالة ثالث كابالت (ثالث دوائر)‬
‫‪80cm width x 80cm Depth‬‬ ‫‪80cm width x 50cm Depth‬‬

‫‪ ‬اما اذا كان الكابل ‪ Single Core‬ولكن ‪( three phase‬كل فازة لها كابل خاص بها)‬
‫يتم وضعهم على شكل دلتا ‪ Δ‬وربط الثالث كابالت كل ‪ 1‬متر مع بعضهم برباط دوبارة (رباط‬
‫غير موصل للتيار)‬
 ‫لدفن الكابالت يتم االتى‪-:‬‬
‫فى حالة كابل واحد‪-:‬‬
‫نضع حوالى ‪ 10‬سم رمل ناعم ثم نضغط عليه ليكون ‪Compact‬‬ ‫‪.1‬‬

‫الحفرة‪.‬‬ ‫ثم نضع الكابل فى منتصف‬ ‫‪.2‬‬

‫الحفرة‪.‬‬ ‫ثم نضع عليه الرمل حتى ‪ 20‬سم من قاع‬ ‫‪.3‬‬

‫فوقه‪.‬‬ ‫ثم نضع طوب طفلى‬ ‫‪.4‬‬

‫الحفرة‪.‬‬ ‫نضع رمل ناعم من النوع الجيد فى باقى‬ ‫‪.5‬‬

‫‪ .6‬قبل النهاية بحوالى ‪ 15‬سم نضع شريط تحذيرى ذو اللون البرتقالى‪.‬‬

‫فى حالة كابلين‪-:‬‬

‫‪ .1‬نحفر فى االرض حفرة عمقها ‪ 80‬سم بعرض ‪ 60‬سم–‬
‫‪ .2‬ثم نضع حوالى ‪ 10‬سم رمل ناعم ثم نضغط عليه ليكون‪-‬‬
‫‪ .3‬نضع الكابل االول و الكابل الثانى بحيث تكون المسافة بينهما ‪ 40‬سم‪-‬‬
‫‪ .4‬نضع طوب رأسى بين الكابالت‪-‬‬
‫‪ .5‬ثم نكرر مثل باقى الخطوات السابقة فى حالة كابل واحد‬