P LY CABLES

TECHNICAL GUID
RANGE OF PRODUCTION

TYPE DESCRIPTION SIZE CORE VOLTAGE

2 2
NYY PVC Insulated PVC Sheathed 1.5mm -400mm Multi 600/1000
2 2
NYY PVC Insulated PVC Sheathed 1.5mm -1000mm Single 600/1000
2 2
XLPE Insulated Cable 1.5mm -1000mm Single 600/1000
2 2
NYA PVC Insulated Cable 0.5mm -16mm Single 600/1000
2 2
NYY-1 PVC Insulated PVC Sheathed Control Cable 1.5mm -120mm Multi 600/1000
2 2
NYAB PVC Insulated Flexible Cable 0.75mm -150mm Single 600/1000
NYYF Plain Annealed Flexible Stranded Copper Conductor 4mm2-35mm2 Multi 600/1000
2 2
BYA PVC Insulated Non-Sheathed Cable 1.0mm -1000mm Single 450/750
2 2
BYFY PVC Insulated PVC Sheathed Flat Cable 1.0mm -35mm Multi 300/500
2 2
BYFYE PVC Insulated PVC Sheathed Flat Cable with ECC 1.5mm -35mm Two 300/500
IYFY PVC Insulated PVC Sheathed Flat Cable 3/0.029-7/0.064 Two 250/440
2 2
BYM PVC Insulated PVC Sheathed Cable 1.0mm -35mm Single/ Multi 350/550
IYAL PVC Insulated Non-Sheathed Cable 3/0.029-7/0.064 Single 250/440
IYYL PVC Insulated PVC Sheathed Cable 3/0.029-7/0.064 Single 250/440
NYIFY PVC Insulated PVC Sheathed Flat Cable 1.5mm2-35mm2 Two/Three 220/380
2 2
NYFGbY PVC Insulated PVC Sheathed Flat/Round Steel Wire 1.5mm -400mm Multi 600/1000
Armour Cable
NYSEYFGbY H.T Cable 16mm2 -185mm2 Three 5800/104
AAC Conductor GNAT, ANT, WASP, etc. PVC & PE Insulated --- --- ---
ACSR Conductor Rabbit, Dog, Wolf, Merlin, Raven, Swallow, Penguin, --- --- ---
Gopher, Weasel, etc.
AAAC Conductor Ames, Azusa, Alliance, Darien, etc. --- --- ---
2 2
Service Drop Duplex & quadruplex Cable 2.5mm -25mm --- ---
Tele-Com Cable Jumper Wire, Telephone Cord --- --- ---
Tele Communication Cables (1pair to 100 pair) --- ---
Co-axial Cables with VHF & UHF 0.2mm2-1.23mm2 ---
Welding Cable PVC Sheathed with Tape 25mm2 -120mm2 Single 200

i
 P LY CABLES
Contents Page
1 Forward
2 Current Rating for insulated Cables 1
A. Close excess current Protection
B. Coarse excess current protection
3 “Defined/Normal Conditions” of installations 1
4 Regulation followed in Bangladesh for determining cable capacities 2
5 Current Ration and Associated Voltage drop/amp/meter for PVC insulated, non-armoured 2
cables with sheath, with copper conductor
Single core 600/1000V with coarse excess current protection
6 Current Rating and Associated Voltage drop/amp/meter for PVC insulated, non-armoured 3
cables with sheath with copper conductor
Single core 600/1000V with close excess current protection
7 Current Rating and Associated Voltage drop/amp/meter for PVC insulated, non-armoured 4
cables with sheath with copper conductor
Twin and multicore 600/1000V with coarse excess current protection
8 Current Rating and Associated Voltage drop/amp/meter for PVC insulated, non-armoured 4
cables with sheath with copper conductor
Twin and multicore 600/1000V with close excess current protection
9 Current Rating and Associated Voltage drop/amp/meter for Flexible cords, Insulated with PVC 5
10 Current Carrying Capacity of XLPE Cables 0.6/1.0kV, single core (IEC 60502) 5
11 Current Rating Factor 6
12 Selection of Low Tension Cables 8
13 Selection of High Tension Cables 11
14 Wiring Guideline 12
15 Recommended Capacity of PVC conduit for single core sheathed cable 13
16 Under Plaster Cable 13
17 Production of Quality Cables 14
A. LV Cable
B. 11kV Cable
18 Stranded plain annealed copper conductor for insulated cables 16
19 Guideline for selection of LV Cables for different type of insulation 16
20 Methods of installation of Cables and Conductors as per Bangladesh National Building Code (BNBC) 17
21 Allowance for Diversity (IEC Regulation) 19
22 Power Factor Correction Multipliers 20
23 Hard Drawn Bare Copper (HDBC) Conductor 20
24 Multiplying constants for resistance of copper wire of various temperature 21
25 Insulated Aluminum Stranded Conductors 21
26 All Aluminum Alloy Stranded Conductors (AAAC) 21
27 All Aluminum stranded Conductors (AAC) 22
28 Aluminum Conductors steel re-Inforced (ACSR) 22
29 Electrical Abbreviation & pre-fixes for units 23
30 Relation between Unit System 24
31 Conversion Factors 24
32 Physical constant for copper, Aluminum & Steel 25
33 Cable Laying and Installation Process for Single-Core Cables 25

ii
TECHNICAL GUID
FORWARD

This booklet is compiled to provide the electrical engineers with necessary data for selection of
electrical cables and conductors for various purposes. Our experience in selling cables for over
20 years and in cable manufacturing for over 6 years have tempted us to produce this booklet.
We have provided some basic guidelines for protection of cable and method of laying thereof as
per IEE/BNBC wiring regulation.
Our main catalogue gives details of all our products. In this booklet we have abridged
information on some frequently used cables and there may be some variation with the data given
in our main catalogue which will not affect practical application.
A few useful tables and useful formula have been incorporated to assist the Engineers to have
some technical information handy.
Any suggestion from any corner for improvement will be highly appreciated and will be taken
care of during revision.
We hope that this booklet will prove useful to the practicing electrical engineers and also to user
who are non-engineer entrepreneurs.
Our thanks to our Engr. Mohammad Ali and Engr. Anamul Kabir is acknowledge for proof
reading and checking of the calculation.

(Zakir Hossain)
Managing Director

iii
 P LY CABLES
2. Current Rating For Insulated Cables

The current rating quoted for various cables are generally as detailed in the relevant table of our main
catalogue but grouped to facilitate selection. The head of each table states whether the current ratings
relate to close or coarse excess-current protection. Where the class of excess-current protection differs
from that stated in the heading of the table, the appropriate rating factor must be applied.

A. CLOSE EXCESS-CURRENT PROTECTION

Excess-current protection which will operate within four hours at 1.5 times the designed load current of
the circuit which it protects. Devices affording close excess-current protection include:
i) Miniature and moulded-case circuit-breakers complying with BS 3871.
ii) Circuit-breakers set to operate at on over load not exceeding 1.5 times the designed load current
of the circuit.

B. COARSE EXCESS-CURRENT PROTECTION

Excess-current protection which will not operate within four hours at 1.5 times the designed load current
of the circuit which it protects. Devices affording coarse excess-current protection include:
i) BS 88 fuses fitted with fuse link marked to indicate a class Q2 or class R fusing factor.
ii) Semi-enclosed (rewirable) fuses complying with BS 3036.

3. “Defined/Normal Conditions” of Installations

The current rating in the columns of the tables headed “Defined/Normal Conditions” apply to cables run
under the conditions defined below.
For cables spaced by distances less than those described below, the current ratings in the columns headed
“Clipped direct to a surface” should be applied.

(a). SINGLE CORE CABLES

(1). Two or three single core cables are installed one above the other, fixed to the vertical
surface of a wall or open cable trench as follows, the distance between the wall and the surface of the
cable being at least 20mm in each instance. Cable in which the conductor cross-sectional area does not
exceed 185mm2 are installed at a distance between centres of twice the overall diameter of the cable.
Cable in which the conductor cross-sectional area exceed 185mm2 are installed at a distance between
centres of about 90mm.
The rating for two cables may be applied with safety in instances where such cable are installed in
horizontal formation on brackets fixed to wall, either spaced as indicated above or touching throughout.

(2). Three single core cables are installed in trefoil formation, fixed to the vertical surface of a
wall or open cable trench, the cables touching throughout the distance between the wall and the surface
of the nearest cable being at least 20mm or alternatively, three single core cables are installed in trefoil
formation and laid on a non-metallic floor, the cable touching each other and the floor throughout.
The cables are assumed to be remote from iron, steel or Ferro-concrete, other than the cable supports.

(b).MULTICORE CABLES
(1). Cables of all types other than single core cables when installed singly, fixed to the vertical
surface of a wall or open cable trench, the distance between the surface of the cable and the wall being at
least 20mm in every instance.

(2). If multicore cables are installed in groups, in open, duct or in earthen cable trench, the
rating given in the catalogue need to be multiplied by factors depending on the number of cables, heat
dissipation and the interspace gap between cables.

(3). There in no standard for laying of cables in covered concrete trenches, concrete ducts,
concrete pipes and the factor can be determined by use of experience and calculating the temperature rise.
1 The cable manufacturer can assist.
TECHNICAL GUID
4. Regulation Followed In Bangladesh For Determining Cable Capacities

The determination of the current carrying capacities of cables are determined by National Authorities In
Bangladesh, there being no such authority, prior to the establishment of M/S Eastern Cables the current
carrying capacity was based on BS (British Stranded) and the cable marketed by Cable manufacturers of
Pakistan was based on BS (British Stranded).
M/S Eastern Cables brought in the German technology and started manufacturing cable as per VDE
(German) specification. All other cable manufacturers in Bangladesh also started using VDE
specification in manufacturing cables, Side by side BS is also being used.
BSTI (Bangladesh Standard and Testing Institution) implemented. BDS regulation both for VDE
Standard and BS Standard.
The main purpose of all these regulations/standards of assigning current carrying capacities of cable is to
prevent fire and the ability of the insulations (of different types) around the conductor to resist heat as the
most important consideration.
Fox Example 10mm2 PVC/PVC in free air will carry about 60A while the some cable when installed in
an enclosure or raceway is limited to 40A.
Therefore current carrying capacity of cable (or bare copper) can not repeat con not be calculated as there
is no relationship between the area or resistance and the capacity.
For example 10mm2 PVC/PVC cable is a raceway will carry 40A but 120mm2 cable will carry 220A i.e.
can carry only 5 times the current, though have a cross section 12 times higher, because it con not
dissipate 12 times the heat generated in 120mm2 cable.
The various table showing current carrying capacities in this booklet are based on VDE/BS but the
protection and installation method follow the IEE/BNBC wiring regulation, as German (VDE) wiring
regulation is not practiced in this country.
From the current rating shown in section 5 to 8, it is clear that the rating depends on the type of laying
and whether the installation for single phase or three phase.
In IEE defined conditions current carrying capacity has not been indicated for underground installation.

For underground installation refer to section 11, Page 6

5. Current Rating And Associated Voltage drop/amp/meter for

PVC insulated, non-armoured cables, with sheath, with copper conductor, Single core 600/1000volt
Condition of Installation:
Single circuit current ratings under conditions as listed below with coarse excess-current protection. For
other than single circuit and for close excess-current protection see rating factors bellow. Ambient
temperature 30˚C.
Conductor Bunched and enclosed non metallic conduit or truncking Clipped direct to a surface or on a cable tray, bunched and unenclosed
Nominal Number 2 cables, single phase a.c 3 or 4 cables, three phase a.c 2 cables, single phase a.c 3 or 4 cables, three phase a.c
Cross- and Volt Volt Volt Volt
Sectional Diameter Current Current Current Current
drop/amp/ drop/amp/ drop/amp/ drop/amp/
Area of Wires Rating Rating Rating Rating
meter meter meter meter
mm2 mm amp mV amp mV amp mV amp mV
1 2 3 4 5 6 7 8 9 10
1.5 1/1.38 13.44 27 11.37 23 16.54 27 15.50 23
2.5 1/1.78 17.65 10 15.69 14 22.55 16 19.61 14
4.0 7/0.85 23.45 10 21.50 8.8 29.32 10 26.20 8.8
6.0 7/1.04 30.66 6.8 27.70 5.9 37.59 6.8 33.63 6.9
10 7/1.35 42.72 4.0 39.67 3.5 51.88 4.0 46.79 3.3
16 7/1.70 58.20 2.6 55.08 2.2 70.67 2.0 63.39 2.2
25 7/2.14 77.08 1.6 74.96 1.4 93.98 1.6 84.47 1.4
35 19/1.53 99.32 1.2 97.11 1.0 120.30 1.2 108.15 1.0
2
 P LY CABLES
Total voltage drop between the consumer’s terminals and any other point in the installation must not
exceed 2.5 percent of the nominal voltage.
The ratings in column 3 and 5 relate to cables in non-metallic conduct and truncking. For cables in
underground pipes and ducts [see page 8].
Current rating factor [see page 6]

For class of excess-current protection the ratings tabulated may be multiplied by 1.33 where close excess-
current protection can be assured.

Non sheathed cable is to be used in heavy gauge metallic conduit only (IEE Regulation) and not in
PVC conduit. In Bangladesh heavy gauge metallic conduit is not being used now a day.
Groups and type of laying [see rating factors on section 11, page 6]
For higher than 35mm cable refer section 6

6. Current Rating And Associated Voltage drop/amp/meter for

PVC insulated, non-armoured cables, with sheath, with copper conductor, Single core 600/1000volt
Condition of Installation:
Single circuit current ratings under conditions as listed below with close excess-current protection. For
other than single circuit and for coarse excess-current protection see rating factors bellow. Ambient
temperature 30˚C.
Bunched and enclosed non metallic Clipped direct to a surface or on a Defined Conditions (See Page 3)
Conductor
conduit or truncking cable tray, bunched and unenclosed
Nominal 2 cables, single 3 or 4 cables, 2 cables, single 3 or 4 cables, Flat or vertical (2 cables, single phase Trefoil (3 cables,
Cross- phase a.c three phase a.c phase a.c three phase a.c a.c or 3 or 4 cables, three phase a.c) three phase a.c)
Sectional Current
Volt
Current
Volt
Current
Volt
Current
Volt
Current
Volt
Three Phase Current
Volt
Area drop/amp/ drop/amp/ drop/amp/ drop/amp/ drop/amp/ drop/amp/
Rating Rating Rating Rating Rating a.c Rating
meter meter meter meter meter meter

mm2 amp mV amp mV amp mV amp mV amp mV mV amp mV

1 2 3 4 5 6 7 8 9 10 11 12 13 14
50 162 0.97 139 0.84 195 0.93 178 0.82 217 0.95 0.85 189 0.80
70 203 0.71 178 0.62 245 0.65 223 0.59 267 0.68 0.62 234 0.59
95 256 0.59 217 0.48 300 0.48 266 0.45 333 0.52 0.49 289 0.42
120 294 0.48 248 0.42 350 0.40 316 0.38 395 0.44 0.43 339 0.34
150 --- --- --- --- 405 0.34 365 0.34 467 0.39 0.39 399 0.29
185 --- --- --- --- 460 0.29 414 0.30 534 0.36 0.36 454 0.25
240 --- --- --- --- 555 0.24 497 0.27 647 0.35 0.38 555 0.22
300 --- --- --- --- 640 0.22 572 0.25 754 0.33 0.35 652 0.19
400 --- --- --- --- 770 0.20 691 0.24 906 0.30 0.33 770 0.17
500 --- --- --- --- 900 0.18 799 0.23 1024 0.28 0.31 866 0.16
630 --- --- --- --- 1030 0.17 928 0.22 1333 0.26 0.30 996 0.15

Total voltage drop between the consumer’s terminals and any other point in the installation must not
exceed 2.5 percent of the nominal voltage.
The ratings in column 2 and 5 relate to cables in non-metallic conduct and truncking. For cables in
underground pipes and ducts [see page 8].
Current rating factor [see page 6]
For class of excess-current protection where coarse excess-current protection is afforded, the tabulated
ratings must be multiplied by 0.75.

Non sheathed cable is to be used in heavy gauge metallic conduit only (IEE Regulation) and not in
PVC conduit. In Bangladesh heavy gauge metallic conduit is not being used now a day.

Groups and type of laying [see Current Rating Factors on section 11, Page 6]

3
TECHNICAL GUID
7. Current Rating And Associated Voltage drop/amp/meter for
PVC insulated, non-armoured cables, with sheath, with copper conductor, Twin and Multicore
600/1000volt Condition of Installation:
Single circuit current ratings under conditions as listed below with coarse excess-current protection. For other than
single circuit and for close excess-current protection see rating factors bellow. Ambient temperature 30˚C.
Enclose in nonmetallic conduit or Clipped direct to a surface or on a cable Defined conditions (See Page 3)
Conductor
truncking tray, bunched and unenclosed
Nominal Number One three core cable One three core cable with or One three core cable
One twin core cable One twin core cable One twin core cable
with or without earth without earth continuity with or without earth
Cross- and with or without earth with or without earth with or without earth
continuity conductor conductor or one four continuity conductor
Sectional Diameter continuity conductor continuity conductor continuity conductor
or one four core core cable three phase or one four core
single phase a.c single phase a.c single phase a.c
Area of Wires cable three phase a.c a.c cable three phase a.c
Volt Volt Volt Volt Volt Volt
Current Current Current Current Current Current
drop/amp/ drop/amp/ drop/amp/ drop/amp/ drop/amp/ drop/amp/
Rating Rating Rating Rating Rating Rating
meter meter meter meter meter meter
mm2 mm amp mV amp mV amp mV amp mV amp mV amp mV
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1.5 1/1.38 12.38 28 11.43 24 14.28 28 12.38 24 --- --- --- ---
2.5 1/1.78 17.38 17 15.45 15 20.30 17 17.39 15 --- --- --- ---
4.0 7/0.85 23.39 11 21.44 9.1 26.31 11 23.39 9.1 --- --- --- ---
6.0 7/1.04 28.99 7.0 26.21 6.0 33.83 7.0 28.98 6.0 --- --- --- ---
10 7/1.35 38.84 4.1 36.51 3.6 46.61 4.1 39.81 3.6 --- --- --- ---
16 7/1.70 52.30 2.6 46.38 2.2 63.15 2.6 53.29 2.2 --- --- --- ---
25 7/2.14 69.88 1.7 61.73 1.5 82.71 1.7 72.22 1.5 100 1.7 83.86 1.5
35 19/1.53 89.53 1.2 78.64 1.0 105 1.2 87.11 1.0 127 1.2 111 1.0

Total voltage drop between the consumer’s terminals and any other point in the installation must not
exceed 2.5 percent of the nominal voltage.
The ratings in column 3 and 5 relate to cables in non-metallic conduct and truncking. For cables in
underground pipes and ducts [see page 8].
Current rating factor [see page 6]
For class of excess-current protection the rating tabulated may be multiplied by 1.33 where close excess-
current protection is assured.
Non sheathed cable is to be used in heavy gauge metallic conduit only (IEE Regulation) and not in
PVC conduit. In Bangladesh heavy gauge metallic conduit is not being used now a day.
Groups and type of laying [see rating factors on section 11, Page 6]
For higher than 35mm2 cable refer section 8

8. Current Rating And Associated Voltage drop/amp/meter for

PVC insulated, non-armoured cables, with sheath, with copper conductor, Twin and Multicore
600/1000volt Condition of Installation:
Single circuit current ratings under conditions as listed below with close excess-current protection. For
other than single circuit and for coarse excess-current protection see rating factors bellow. Ambient
temperature 30˚C.
Conductor Clipped direct to a surface or on a cable tray, bunched and unenclosed Defined conditions (See Page 3)
Nominal One twin core cable, single One three or four core cable, three One twin core cable, single One three or four core cable, three
Cross- phase a.c phase a.c phase a.c phase a.c
Sectional Volt drop/amp/ Volt drop/amp/ Volt drop/amp/ Volt drop/amp/
Area Current Rating Current Rating Current Rating Current Rating
meter meter meter meter
2
mm amp mV amp mV amp mV amp mV
1 2 3 4 5 6 7 8 9
50 150 0.94 134 0.81 182 0.94 155 0.81
70 190 0.66 168 0.57 233 0.66 206 0.57
95 230 0.49 203 0.42 278 0.49 246 0.42
120 270 0.40 232 0.34 324 0.40 286 0.34
150 305 0.33 268 0.29 366 0.33 323 0.29
185 350 0.28 301 0.24 414 0.28 366 0.24
240 410 0.24 362 0.20 486 0.24 432 0.20
300 470 0.21 412 0.18 549 0.21 485 0.18

Total voltage drop between the consumer’s terminals and any other point in the installation must not
exceed 2.5 percent of the nominal voltage. 4
 P LY CABLES
The ratings in column 3 and 5 relate to cables in non-metallic conduct and truncking. For cables in
underground pipes and ducts [see page 8].
Current rating factor [see page 6]
For class of excess-current protection where coarse excess-current protection is afforded the tabulated
ratings must be multiplied by 0.75.
Non sheathed cable is to be used in heavy gauge metallic conduit only (IEE Regulation) and not in PVC
conduit. In Bangladesh heavy gauge metallic conduit is not being used now a day.

Group and type laying [see rating factors on section 11, Page 6]

9. Current Rating And Associated Voltage drop/amp/meter for

Flexible cords, Insulated with PVC.
Nominal Cross- Number and Diameter of Current rating single phase Volt drop/amp/meter Maximum weight supportable
Sectional Area Wires forming conductor a.c or three phase a.c Single phase a.c Three phase a.c by twin flexible cord
mm2 mm amp mV Amp kg
1 2 3 4 5 6
0.5 16/0.20+ 3 83 72 2
0.75 24/0.20+ 6 56 48 3
1.0 32/0.20 10 43 37 5
1.5 30/0.25 15 31 26 5
2.5 50/0.25 20 18 16 5
4.0 56/0.30 25 11 9.6 5

Total voltage drop between the consumer’s terminals and any other point in the installation must not
exceed 2.5 percent of the nominal voltage (IEE regulation).
Note: The tabulated rating is not applicable to flexible cables wound on drums. The current rating of a
cable on a drum depends on the type of drum and may be less than one-half of the corresponding rating
stated in the table.
+28/0.15
For PVC parallel twin non-sheathed cords.
+42/0.15
Current rating factors for ambient temperature, PVC cords
Ambient Temperature 35˚C 40˚C 45˚C 50˚C 55˚C
Rating Factors 0.96 0.92 0.87 0.71 0.50
For Circular cable of conductor size up 16mm2.

10. Current Carrying Capacity of XLPE Cables 0.6/1.0kV, Single Core (IEC 60502)
Sustained current carrying are shown in the following table, of which calculated condition are given as follows.
Maximum conductor temperature 90˚C
In air 40˚C
Base temperature
Underground 25˚C
Thermal resistivity of soil 120˚C cm/W
Depth of laying underground 50cm
6D 6D
Flat
2D 2D
In Air
Trefoil 4.3D 4.3D

Cable
arrangement (D,
Cable overall 6D
50 cm
6D
Diameter) Flat
2D 2D
Underground
50 cm
Trefoil 4.3D 4.3D

5
TECHNICAL GUID
Un-armoured Cable
Conductor In Air Underground, Direct Burial
Nominal
Area mm2 1 cct 2 cct 3 cct 1 cct 2 cct 3 cct
Flat Trefoil Flat Trefoil Flat Trefoil Flat Trefoil Flat Trefoil Flat Trefoil
1.5 29 23 27 22 24 22 34 32 27 26 24 23
2.5 39 30 37 29 33 29 44 42 35 34 31 29
4 51 40 48 38 43 38 57 55 45 44 40 38
6 65 51 61 48 54 48 71 68 56 55 49 47
10 88 70 84 67 74 67 95 75 65 91 73 62
16 117 93 111 88 99 88 122 117 96 93 84 80
25 157 126 149 119 132 119 157 150 124 120 108 103
35 193 155 183 147 163 147 189 180 149 144 130 124
50 232 187 219 178 195 178 223 212 176 170 153 146
70 292 237 277 225 246 225 273 259 216 208 189 178
95 359 292 340 278 302 278 327 310 259 249 226 213
120 418 341 396 324 352 324 372 352 295 283 259 243
150 480 394 454 374 404 374 418 394 333 318 292 274
185 554 457 525 434 467 434 474 445 378 359 332 310
240 658 542 624 515 554 515 550 513 439 415 387 358
300 760 625 720 594 640 594 622 575 498 467 440 404
400 893 931 846 694 752 694 711 649 571 530 507 459
500 1034 839 979 797 870 797 807 726 651 594 578 515
630 1194 958 1131 911 1005 911 913 807 740 663 659 576

11. Current Rating Factor

TABLE-1, A. IN AIR
Rating Factors for Variation of Ambient Temperature for cables made as per VDE 0271/3.69
Ambient Temperature ˚C 25 30 35 40
Cable with E0 0.6 & 3.5kV 1.13 1.06 1.00 0.93
Cable with E0 5.8kV 1.15 1.08 1.00 0.91
Rating Factors for Variation of Ambient Temperature for cables made as per VDE 0250/3.69
Ambient Temperature ˚C 10 15 20 25 30 35 40 45 50 55 60
Rating Factors 1.31 1.25 1.19 1.14 1.07 1.00 0.93 0.85 0.76 0.66 0.53

Rating Factors for Variation of Ambient Temperature for cables made as per B.S 6004 & B.S 2004
Ambient Temperature ˚C 25 30 35 40 45 50 55 60
Rating factor for cables having
excess-current protection, which will
operate within four hours at 1.5 times 1.13 1.06 1.00 0.93 0.84 0.76 0.65 0.53
of the designed load current
Rating factor for cables having no
excess-current protection as above 1.05 1.03 1.00 0.97 0.94 0.91 0.79 0.65

TABLE-2, B. UNDERGROUND
Rating Factors for Variation of Ambient Temperature for cables made as per VDE 0271/3.69
Ambient Temperature ˚C 15 20 25 30 35 40
Cable with E/E0 6 & 3.5kV 1.18 1.12 1.07 1.00 0.95 0.87
Cable with E/E0 10/5.8kV 1.19 1.14 1.07 1.00 0.93 0.85
TABLE-3 GROUP RATING FACTOR
GROUPING IN GROUND
A. Group Rating Factors for Multicore Cable in the Ground: made as per VDE 0271/3.69 & 0250/3.69
Number of Cable in the trench 2 3 4 5 6 8 10
Cable laid direct in the ground in flat formation,
Clearance 7cm (thickness of a brick) between cables
0.85 0.75 0.68 0.64 0.60 0.56 0.53

B. Group Rating Factors for Single Core Cable in Three-Phase System in Ground
Number of Cable in the trench 2 3 4
Cable laid direct in the ground in flat formation, Clearance 7cm
between systems and also between individual cables in each system
0.82 0.72 0.68
Cables laid direct in the ground in trefoil formation, touching each 0.72
other, clearance 25cmm between systems
0.85 0.77
6
 P LY CABLES
TABLE-4, GROUPING IN AIR
GROUPING IN AIR
C. Group Rating Factors for Multicore Cable in Air
Arrangement Cable Clearance one diameter between Cable touching each other & in
adjacent cables and distance from the contact with the wall
wall not less that 2cm
Number of adjacently
1 2 3 6 9 1 2 3 6 9
laid cable
Cables laid on ground
0.95 0.90 0.88 0.85 0.84 0.90 0.84 0.80 0.75 0.73
in flat formation
Number of
Troughs
Cables Laid on 1 0.95 0.90 0.88 0.85 0.84 0.95 0.84 0.80 0.75 0.73
troughs (air 2 0.90 0.85 0.83 0.81 0.80 0.95 0.80 0.76 0.71 0.69
circulation restricted) 3 0.88 0.83 0.81 0.79 0.78 0.95 0.78 0.74 0.70 0.68
in flat formation 6 0.86 0.81 0.79 0.77 0.76 0.95 0.76 0.72 0.68 0.66
Number
of Racks
1 1.00 0.98 0.96 0.93 0.92 0.95 0.84 0.80 0.75 0.73
Cables Laid on racks 2 1.00 0.95 0.93 0.90 0.89 0.95 0.80 0.78 0.71 0.69
in flat formation 3 1.00 0.94 0.92 0.89 0.99 0.95 0.78 0.77 0.70 0.68
6 1.00 0.93 0.90 0.78 0.86 0.95 0.76 0.72 0.68 0.66
Cables arranged vertically
on structures or on wall
1 0.93 0.90 0.87 0.86 0.95 0.78 0.73 0.68 0.66

These factors are valid only when the ambient temperature is not increased appreciably by the heat
generated by the loaded cables. The vertical distance from one troughs or rack to another is 30cm.

TABLE-5
D. Group Rating Factors for Single-core in Three Phase System in Air
Arrangement Cable Clearance one diameter between Cables in trefoil formation clearance 2x
adjacent cables and distance from the diameter between systems and distance
wall not less that 2cm from the wall not less than 2cm
Number of
1 2 3 1 2 3
adjacently laid cable
Cables laid on ground
0.92 0.89 0.88 0.95 0.90 0.88
in flat formation
Number of
Troughs
Cables Laid on 1 0.92 0.89 0.88 0.95 0.90 0.88
troughs (air 2 0.87 0.84 0.83 0.90 0.85 0.83
circulation restricted) 3 0.84 0.82 0.81 0.88 0.83 0.81
in flat formation 6 0.82 0.80 0.79 0.86 0.81 0.79
Number
of Racks
1 1.00 0.97 0.96 1.00 0.98 0.96
Cables Laid on racks 2 0.97 0.94 0.93 1.00 0.95 0.93
in flat formation 3 0.96 0.93 0.92 1.00 0.94 0.92
6 0.94 0.91 0.90 1.00 0.93 0.90
Number of cables laid one above
1 2 3 --- --- ---
another
Cables arranged vertically on
0.94 0.91 0.89 --- --- ---
structures or on wall
Cables arranged vertically on
0.89 0.86 0.84 --- --- ---
structures or on wall touching them
These factors are valid only when the ambient temperature is not increased appreciably by the heat
generated by the loaded cables. The vertical distance from one troughs or rack to another is 30cm.

7
TECHNICAL GUID
GROUPING OF CABLES OR SYSTEMS MADE AS PER BS 6004 & BS 2004
TABLE-6
E. Group Rating Factors for Single-core in Three Phase System in Air
Number of System 2 3 4 5 6 8 10
Rating Factor 0.80 0.69 0.62 0.59 0.55 0.51 0.48

F. Group Rating Factors for Multicore cables in Air

Number of Cables 2 3 4 5 6 8 10
Rating Factor 0.80 0.70 0.65 0.60 0.57 0.52 0.48

TABLE-7
G. Rating Factors for Cables in Ground under Protective Cover
Condition of Laying Cables laid direct in the ground Cables laid direct in the ground covered with
and covered with protective protective cover and the space between cable and
covers of cables cover well filled with sand
Rating Factors 0.80 0.90

H. Cables in Trench, Pipes and Pipe Blocks

In this case the current rating factors may vary very widely, the permissible value of rating factors
for individual cases are to be determined separately by special arrangement with the
manufacturer.

12. Selection of Low Tension (L.T) Cables

As an extremely reliable manufacturer of quality cable and wires, we feel it obligatory to tell users
specially the electrical design engineers something about the various aspects of proper methods of
selection the cables. While selecting the cables, the following points must be considered:
i. Purpose for which the cable would be used
ii. Location and its installation method
iii. The current ratings (Calculation)
iv. Voltage drop as per IEE regulation
v. The short circuit ratings based on the short time current
Once the purpose is known and the installation method is established, it would be necessary to determine
the cable size required for carrying the designed amount of current within the permissible voltage drop
and to meet the breaker rating.

Example:
i. Purpose for which the cable would be used:
Mixed, Power & lighting load. 300 meter away from the source.
ii. Location and its installation method:
Cables laid underground, directly in Kutchha cables trench, on sand bed covered by sand and protected
by bricks.
iii. The current rating (Calculation)
Maximum Demand 100kW
kW  1000 100  1000
Current , I    152 Amp
3  Voltage  p. f 3  400  0.95
iv. Selection of cable size:
Type of cable: Single core NYY
Red/Yellow/Blue/Green (Neutral)
Provisional selection: Cable Size 3x1C NYY
50mm2 for phase, 1x1C NYY 25mm2 for neutral
NYY 50mm2, current carrying capacity 8
 P LY CABLES
CCC from table [Section-6, Page 3]: = 189A (Trefoil)
Check:
a) Group rating factor [Section-11, Page 6]
i. Section-11, Table-3, Cable in Trench: laid flat formation 0.68
ii. Section-11, Table-7, Cable laid on sand bed 0.90
Total rating factor: 0.68x0.90 = 0.61
Actual CCC of 50mm2 cable: 189x0.61 = 115A [inadequette]

Check with 70mm2:

CCC from table [Section-6, Page 3]: 234A
Apply factor: 234x0.61 = 143A [inadequette]

Check with 95mm2:

CCC from table [Section-6, Page 3]: 289A
Apply factor: 289x0.61 = 176A [Acceptable]

v. Voltage drop as per IEE regulation:

Distance: 300 Meter
Voltage drop/meter for 95mm2 cable = 0.42mV [Section-6, Page 3]
mV  Length  Amp 0.42  300  152
 Voltage drop for 300 meter    19V (4.7%) [inadequet te]
1000 1000
Voltage drop/meter for 120mm2 cable = 0.34mV [Section-6, Page 3]
mV  Length  Amp 0.34  300  152
 Voltage drop for 300 meter    15.5V (3.8%) [inadequet te]
1000 1000
Voltage drop/meter for 150mm2 cable = 0.29mV [Section-6, Page 3]
mV  Length  Amp 0.29  300  152
 Voltage drop for 300 meter    13V (3.3%) [inadequet te]
1000 1000
Voltage drop/meter for 185mm2 cable = 0.25mV [Section-6, Page 3]

mV  Length  Amp 0.25  300  152

 Voltage drop for 300 meter    11V (2.75%) [inadequet te]
1000 1000
Voltage drop/meter for 240mm2 cable = 0.22mV [Section-6, Page 3]
mV  Length  Amp 0.22  300  152
 Voltage drop for 300 meter    10 V (2.5%) [Acceptable]
1000 1000
i.e. If sending end voltage is 400V, load end voltage shall be 390V. This is OK, for light, fan and 400V
motor.

vi. Short Circuit Current Calculation:

SHORT CIRCUIT CURRENT

An estimation of the prospective short circuit current (psc) in an installation is an important consideration
in the selection of the appropriate protective device.
The magnitude of the short circuit current (rms value of the ac component) at a point in the installation
will depend upon:
A). Prospective short circuit current at the origin of the installation.
B). The amount of resistance in the circuit between the origin of the installation and the point at which
the short circuit occurs.

9 C). The type of short circuit, phase to phase or phase to earth or phase to neutral.
TECHNICAL GUID
It is possible to arrive at a maximum prospective circuit value at the origin by taking the transformer
kVA rating and its reactance and calculating from the expression:
Transformer rating (kVA)  100
SC kA 
3  Transformer Voltage  %Reactance of Transformer
To calculate the resistance in the Low Voltage Circuit obtain details of length and sizes of cables between
the sources of supply and the point under calculation. Using the table, opposite, determine the sum of
cable resistance and then simply read off the estimate fault current from the relevant transformer curve on
the graph below.
The value assumes a symmetrical fault across the three phases. In a single circuit, for the line to neutral
faults, take the cable resistance value from the table and double it.

Estimating the Prospective Short Circuit Current

40
2000kVA

1500kVA
30
1250kVA
Fault Current (kA)

1000kVA

800kVA
20

500kVA

10
315kVA

200kVA
100kVA

0
0.1 1.0 10 100

Total Circuit Resistance (mΩ)

SHORT CIRCUIT CURRENT

Maximum Resistance of Conductors at 20˚C (mΩ)
Nominal Cable Length
Cross-
Sectional 5m 10m 15m 20m 30m 40m 50m 60m 70m 80m 90m 100m
Area
1 90.5 181.0 --- --- --- --- --- --- --- --- --- ---
1.5 60.5 121.0 182.0 --- --- --- --- --- --- --- --- ---
2.5 37.1 74.1 111.0 148.0 --- --- --- --- --- --- --- ---
4 23.1 46.1 69.2 92.2 138.0 --- --- --- --- --- --- ---
6 15.4 30.8 46.2 61.6 92.4 123.0 --- --- --- --- --- ---
10 9.15 18.3 27.5 36.6 54.9 73.2 91.5 110.0 --- --- --- ---
16 5.75 11.5 17.3 23.0 34.5 36.0 57.2 69.0 80.5 103.5 --- ---
25 3.64 7.27 10.9 14.5 21.8 29.1 36.4 43.6 50.9 58.2 65.4 72.7
35 2.62 5.24 7.86 10.48 15.7 21.0 26.2 31.4 36.7 41.9 47.2 52.4
50 1.94 3.87 5.81 7.74 11.6 15.5 19.4 23.2 27.1 31.0 31.8 38.7
70 1.34 2.68 4.02 5.36 8.04 10.7 13.4 16.1 18.8 21.4 24.1 26.8
95 0.96 1.93 2.30 3.86 5.79 7.72 9.65 11.6 13.5 15.4 17.4 19.3
120 0.77 1.53 2.10 3.06 4.59 6.12 7.65 9.18 10.7 12.2 13.8 15.3
150 0.62 1.24 1.86 2.48 3.72 4.96 6.20 7.44 8.68 9.92 11.2 12.4
185 0.49 1.00 1.49 1.98 2.97 3.96 4.96 5.96 6.94 7.93 8.92 9.91
240 0.34 0.75 1.13 1.51 2.26 3.02 3.77 4.52 5.28 6.03 6.79 7.54
300 0.30 0.60 0.90 1.20 1.80 2.40 3.00 3.61 4.21 4.81 5.41 6.01
400 0.23 0.47 0.70 0.94 1.41 1.88 2.35 2.85 3.29 3.76 4.23 4.70
500 0.18 0.37 0.55 0.73 1.10 1.83 1.83 2.20 2.56 2.93 3.29 3.66
630 0.14 0.28 0.42 0.57 0.85 1.46 1.42 1.78 2.15 2.51 2.88 3.25
10
 P LY CABLES
PSC at A approximately 27kA

PSC at B
Resistance A to B 0.30mΩ = 25kA
1000kVA
Transformer A PSC at C
Resistance A to B 0.30mΩ
10 meters 8c 300mm2
Resistance B to C 10.70mΩ
11.00mΩ = 12kA

B PSC at D
70 meters 4c 120mm2 Resistance A to B 0.30mΩ
Resistance B to C 10.70mΩ
Resistance C to D 17.00 mΩ
58.00mΩ = 3kA
C
20 meters 2c 16mm2 The above calculations have an inbuilt safety margin as they assume a no
D impedance fault condition which would not be the case in practice.

13. Selection of High Tension (HT, 11kV) Cables

For selecting 11kV cables, the procedure shall be:

(1). Check MVA rating of the 11kV breakers and tripping time (Normally in Bangladesh
350MVA Breakers are installed with tripping time 1 second).
(2). Check short circuit rating.
(3). Compare the cable size selected using short circuit rating with the cable size required on the
load current carrying capacity and use the longer size.
The size of 11kV (HT) cable does not depend on the size of the distribution transformer. The cable size
depends on the fault level of the 33/11kV substation which has its own fault level and the information on
the fault level at 11kV service point in available from BPDP/DESA. The larger the distance from the
33/11kV substation, the lesser is the fault level at the 11kV pole near the distribution transformer and that
depends on the conductor size 11kV overhead line.
The present fault level of a 33/11kV substation in Dhaka/Narayangonj/Tongi areas is 500MVA. Let us
assume that short circuit level at the 11kV service at the nearest 11kV pole is 350 MVA (This is to be
calculated).
350000000
The short circuit at 350MVA fault level will be :  18.3kA
3  11000
At 18.3kA for a tripping time of 1 second (Standard for BPDP/DESA), the cable size will be
between150-185mm2. For safety we should select 185mm2. (Refer short circuit curve at this
selection). Let us assume a maximum 11kV load of this customer is 3000kVA.
3000000
The current at 11kV for this load is :  157 A apx.
3  11000
For this load a cable size of 70mm2 should have been sufficient but for saving the 33/11kV S/S from any
11kV fault of the cable, the cable size must be 185mm2 .
In case it is found that the short circuit current at 11kV point of supply is say 4kA, for the short circuit
protection for 1second. The cable size should be 35mm2 (120A) short circuit curve refers. But since the
transformer size is 3000kVA, the cable size would be 70mm2 (180A). In this case transformer rating is
more important and selection cable shall be 70mm2.

Conclusion:
The 11kV cable size would be the larger size of the two calculations i.e. loads current and short circuit
withstands capacity of the cable.

Note:
In North Bengal, the certain areas fault level at same 11kV pole point is 150/200MVA. Therefore it is
11 necessary to check the fault level at service point in North Bengal and the kVA rating of the transformer
TECHNICAL GUID
and the cable size shall be determined accordingly. In North Bengal smaller size 11kV cable may be used
in many cases but definite calculation must be done.

SHORT CIRCUIT CURVE FOR 11kV CABLE

CONDUCTOR IN mm2
200

CROSS –SECTIONAL
100
80

AREA OF
60
Current in kA

40

500
20 400

300
240
10 185
8 150
120
6
95
4
70

50
2
35

25
1
0.8 16
0.6
10

0.4
0.3
0.1 0.2 0.4 0.6 0.8 1 2 3 4 6

SWITCHING OFF TIME IN SECOND

14. Wiring Guideline

BNBC (Bangladesh National Building Code) specifies sheathed cable for use with locally available
electrical grade conduit. PWD schedule also has specified sheathed cable for use in PVC pipe.
NEC (National Electric Code) points out use of non-sheathed cable in such non-metallic pipe which can
be bent by a bending machine and not bending by heat. Bangladesh does not produce such grade of non-
metallic (PVC) conduit.
Use of non-sheathed cable, as per IEE wiring regulation is only for electrical grade steel conduit (16
SWG).
Cable rating shown in the current carrying capacity charts manufacturer’s catalogue is for defined
conditions at section 3 page 1.
The current ratings shown in manufacturer’s catalogue are to be multiplied by various factors depending
on the type of installation. A thumb rule of multiplying the tabulated rating with 0.6/0.7 would give a
near about current rating for industrial installations.
Motors will burn at a voltage 5% less than that of the motor rated voltage. So voltage drop calculation is
very important.
Motors will run better at 5-10% higher voltage. Prior to starting of any motor, a megger test of the motor
must be done using 1000V megger. A megger reading of over 5MΩ is acceptable. If the megger reading
is low, the motor is to be heated and cooled until the required insulation level is achieved. 12
 P LY CABLES
In Bangladesh, the declared voltage is 415V but we should work with a available voltage of 380/400V.
The country imports many motors rated 440V. All such motors must use a booster transformer to
increase the voltage from 380/400V to 440V.
Only black PVC cable shall be used as catenary cable as PVC of any other colour gets damaged by sun’s
ray.

15. Recommended Capacity of PVC Conduit for Single Core Sheathed Cable
A. Metric System
Conduit Cable Size
Size 1.5mm2 2.5mm2 4mm2 6mm2 10mm2 16mm2 25mm2 35mm2
1″ 8 6 4 3 2 --- --- ---
1 ½″ 20 15 12 10 8 6 4 ---
2″ 40 26 20 16 12 8 6 4
2 ½″ 60 40 30 20 18 12 8 6
3″ 80 50 40 30 25 16 12 10

B. Imperial System
Conduit Size
Cable Size
1″ 1 ½″ 2″ 2 ½″ 3″
3/0.029 10 20 40 60 80
3/0.036 8 20 40 50 70
7/0.029 6 20 35 45 60
7/0.036 5 15 25 40 50
7/0.044 4 12 20 30 40
7/0.052 3 10 16 20 35
7/0.64 3 8 14 16 25

16. Under Plaster Cable

Only PVC sheathed cable should be buried direct under plaster. This is because the PVC compound is
inert to any chemical present in the plaster, whereas rubber insulation could be affected.
The advantages of this method of installation are that it is cheap to install, no expense being involved in
conduit or exposed TW batten and there are no unsightly runs or exposed cables. A disadvantage is that
once buried in cement or plaster, the cable con not be easily withdrawn if an alteration is desired. So
system would need good designing.
It is recommended that twin or three core flat cables should be run by this method and not two or three
single core cables. In residences voltages of 250 volts and below can be supplied by cable buried direct
under plaster. If the voltage is above this value, the cable should be run in conduit. In factories 400V
sheathed cable can be laid under plaster.

Method of Burring PVC Sheathed Cable Direct in Under Plaster:

Where there is a possibility of mechanical damage, such as nails being driven into a wall etc. the cable
should be protected by some means such as strip of metal cemented into place over the cable run.
Alternatively, the cable can be run in as short length of conduit or a pipe, where damage in likely to be
incurred by screws, wall nails with consequent danger of shock.

First Step Second Step

Reinforcement
Place wooden batten ½” thick,
Width depending on number
of cables. (Maximum 10”)
After concreting, remove
batten by scrapping
Shuttering Shuttering removed

13
TECHNICAL GUID
Third Step Fourth Step

Place Cable and fix with

dab of plaster Plaster Finish

17. Production of Quality Cables

At the stages in the manufacture of insulated cables and conductors the policy at Poly Cable Industries
Limited is one of continuous inspection. Samples are taken from every order to check conductor size,
concentricity and thickness of protective coverings and overall size. The final test is continuity check for
each and every fool of cable that leaves the factory.
Manufacturing technique is constantly being improved under the guidance of the Company’s Technical
Group and with the Policy for continuous and through inspection, cables manufactured by Poly Cable
Industries Limited are products of the highest quality and has therefore been awarded with ISO 9001
certificate.

A) LV Cables
PVC insulated cables produced by Poly Cable Industries Limited are normally manufactured
and tested in accordance with VDE 271/3.69, VDE 0205/3.69, BS 6004 and BS 2004. They can also be
supplied when requested, to conform to other International Standard. All equipment and machinery used
in the production of each type of cable are carefully controlled, so that with the best quality raw materials
used, the finished product fully confirms to the specified physical and electrical standard required. No
raw materials accepted for inclusion in the processes unless it has been tested and approved by
internationally accepted testing organization.

The high standards required by the required standards are maintained at the factory of Poly Cable
Industries Limited by a series of tests carried out firstly on batch samples taken during the manufacturing
process and finally on the finished cable.

TEST ON COPPER CAONDUCTORS

Two types of copper wire are produced, hard drawn and annealed. Hard Drawn copper is used for
overhead line conductor and in HSOS cables which are required to be largely self supporting and
annealed copper is used in all general wiring cables.
Annealing increase the conductivity of copper wire by 3% to 4% as compared with the hard drawn state.
This result in increased current carrying capacity, which is always desirable so long as the cable is
adequately supported since annealing also softens the metal and reduces its tensile strength.
Testing for the correct degree of annealing achieved by stretching the wire on the tensile testing machine
and expressing its increase of length. The elongation should not be less than the appropriate value given
in the relevant standard.
The resistance of a copper conductor determines its current carrying capacity, the losses of energy which
occur (I2R loss) in the conductor during transmission and the voltage drop. It is, therefore, of great
importance that the resistance of a conductor comes within the specified values and tolerance given in the
standard. The resistance of copper conductor depends on the purity of copper used, the diameter of the
wire and the degree to which it is annealed. To ensure that resistance of the conductors produced at Poly
Cable Industries Limited is well within the limits specified by the standards, the copper cathode, the
basic raw material, is purchased against a stringent specification. During manufacture, the wire is quality
controlled, checked before stranding and finally the finished cables are batch sampled and the
conductors subjected to an accurate measurement of resistance by double Kalvin Bridge and also by
Digital Meter.
The main test on hard drawn copper is the tensile test which ensures that the copper wire is strong enough
to support its own weight plus loading induced by wind, rain, ice, birds etc. a sample of the copper wire
is placed between two clamps on a special tensile testing machine and a steadily increased pulling force
exerted until the wire breaks. The final breaking force is shown on a calibrated dial and no hard drawn
wire is passed it its breaking force is below the appropriated value specified in the relevant standard. 14
 P LY CABLES
An additional test, called the wrapping test, is performed on hard drawn copper wire which ensures that
the conductor remains reasonably flexible while still maintaining its tensile properties. A sample of wire
is wrapped 8 times around its own diameter, unwound 6 times. The wire should not crack or show any
signs of fracture.

TEST ON CABLE INSULATION

Following the insulating of the conductors with PVC the general wiring cable are subjected to another
series of test. Every inch of insulated core produced at the factory of Poly Cable Industries Limited is
run through a spark tester which subjects the insulation to a voltage far higher than it would normally
receive i.e. 300 volt grade cables are subjected to a voltage of 6000 volts and 600 volt grade cables to a
voltage of 10000 volts. In this way a very high factor of safety is obtained and the changes of the
insulation breaking down once the cable has been installed is negligible.
An additional voltage test is performed on samples taken from each batch of finished cables. Single core
cables are immersed in water for 12 hours and testing while still immersed. 300 volt grade cables are
subjected to a voltage of 1500 volts and 600 volt grade cables to 3000 volts for a period of 15 minutes.
The voltage is applied between the conductor and the water, which is earthed.
Finished twin and Multicore cables are subjected to the voltage test without immersion in water. The
voltage is maintained for five minutes and applied between conductors and between each conductor and
the earth continuity conductor, where provided, which is connected to earth during the test.
Immediately after the completion of this voltage test the same samples are tested for insulation resistance,
which should not be less than the specified values given in the appropriated standard.

B) 11 kV CABLE (COPPER)
Continuous permissible service voltage 7000/12000 volts
From 2001 Poly Cable Industries Limited has extended its range of manufacture to included XLPE
insulated 11kV armoured power cables. The cables are manufactured in accordance with VDE 0271/3.69
and BDS 901 and tested as per IEC 60502.
Cables can be manufactured to other international standards also when requested.

TEST ON CONDUCTORS
The conductors are tested for tensile strength, ductility either by an elongation test or by a wrapping test.
Relevant standard is ensured by batch testing during manufacture and by individual tests on each
completed drum of cables.

TEST ON CABLE INSULATION

Each completed drum of cable is further tested between conductors and earth at 17500 volts for 5 minutes
and between conductors at 19500 for 15 minutes.
Sample of XLPE insulation from completed drums of cable further subjected to the following tests:
• Tensile Strength • Elongation
• Cold Bend Test • Loss in weight on Ageing
• Hot Deformation • Heat Test
Samples taken from insulated cores during manufacture are also subjected to the above test.

TEST ON CABLE BEDDING AND SHEATH

Samples PVC bedding and sheath from completed drum of cable are also subjected to the tests listed
above.

TEST ON GAVANIZED STEEL WIRE ARMOUR

The galvanized steel wire armour used on cables manufactured to BS 3346 comples with BS 1442.
The wire is subjected to the following test before being used for manufacture:
• Tensile Tests • Elongation Test
• Torsion Test • Weight of Galvanized coating
15 • Uniformity of Galvanized coating
TECHNICAL GUID
18. Stranded Plain Annealed Copper Conductor For Insulated Cables
Bare Copper Conductor Stranded Multi Wires
Nominal Conductor No and Diameter of Nominal Diameter of Maximum Conductor Resistance at Nominal Weight per kM
Area wire Conductor 20˚C Single Core and Flat Cable of Conductor
mm2 No./mm mm Ohm/km kg
1.0 1/1.13 1.13 18.1 8.9
1.0 7/0.40 1.20 18.1 9.0
1.5 1/1.38 1.38 12.1 13.3
1.5 7/0.52 1.56 12.1 13.5
2.5 1/1.78 1.78 7.41 22.2
2.5 7/0.67 2.01 7.41 22.4
4.0 1/2.25 2.25 4.61 35.4
4.0 7/0.85 2.55 4.61 36.1
6.0 1/1.76 1.76 3.08 53.2
6.0 7/1.04 3.12 3.08 54.0
10 1/3.57 3.57 1.83 89.0
10 7/1.35 3.57 1.83 90.8
16 1/4.50 4.50 1.15 142
16 7/1.70 5.10 1.15 145
25 7/2.14 6.42 0.727 229
35 19/1.53 7.65 0.524 317
50 19/1.78 8.90 0.387 429
70 19/2.14 10.70 0.268 620
95 19/2.52 12.60 0.193 860
120 37/2.03 14.21 0.153 1086
150 37/2.25 15.75 0124 1334
185 37/2.52 17.64 0.0991 1673
240 61/2.25 20.25 0.0754 2199
300 61/2.52 22.68 0.0601 2759
400 61/2.85 25.65 0.0470 3528
500 61/3.20 28.80 0.0366 4448
630 127/2.52 32.76 0.0283 5744
800 127/2.85 37.05 0.0221 7346
1000 127/3.20 41.60 0.0176 9260

19. Guideline for Selection of LV Cables for Different Type of Installation

Type of Installation
In Steel Conduit Only
(Not PVC)
Local Electrical Grade
PVC Conduit and on
Tray or Underground
with Protective Cover
Type of Cable
Non Sheathed Cables:
BYA for Single Phase
NYA for Single Phase
IYAL for Three Phase
Sheathed Cables:
BYM
IYYL
NYY

Underground Without Sheathed Cables with

Protective Cover Armoured: NYFGbY
For Temporary Wiring Flexible Cables:
NYAB
NYYB
In Air/Underground &
at High Ambient
Temperature Area.
Conductor Temperature XLPE Cable
90˚C. Specially suitable
for Garments Industry
& Textile Industry
For Cranes, Overhead PVC/PVC Sheathed
Catenary Application Cables: NYYF
Service Drop Duplex & Quadruplex
16
 P LY CABLES
20. Methods of Installation of Cables and Conductors as per Bangladesh National Building
Code (BNBC)
Type Description and Example Type Description and Example
Sheathed Cables Enclosed in Non-Metallic Conduit Sheathed Cables in Free Air
Vertical Surface of a Wall or Open Cable Trench

20 mm min. 20 mm min.

Single-Core Multi-Core S
A Non-Sheathed Cables Enclosed in Metallic Conduit
S

Single-Core Multi-Core
Single-Core Multi-Core I
Cables Enclosed in Metallic Truncking For cable in which the conductor cross-
sectional area does not exceed 185mm2, S is
B equal to twice the overall diameter of the
cable. For cables in which the conductor
cross-sectional area exceeds 185mm2, S is
Single-Core Multi-Core about 90mm. For two cables in horizontal
Sheathed Cables Enclosed in Underground Non- formation on brackets fixed to a wall, may
Metallic Conduit, Ducts and Cable Ducting have any lesser value

C Single and multi-core cables in enclosed

Protecting Cover pucca trench 450mm wide by 600mm deep
(minimum dimensions) including 100mm
Single-Core Multi-Core cover. Single-core sheathed cables arranged in
Two or more Sheathed Single-Core Cables flat groups of two or three on the vertical
Contained in Separate Bores of a Multi-Core trench wall with surfaces separated by a
Conduit and Intended to be Solidly Embedded in distance equal to one diameter with a mini-
Concrete or Plaster or Generally Incorporated in the trench wall.
Building Structure
D
Ground Cover 100mm
Protecting Cover/Bricks

6 inch Sand Bed

Single Core Laid Flat
Sheathed Cables Clipped Direct to a Nom-
Metallic Surface 6 inch Sand Bed
Bottom of Trench
E
Ground Cover 100mm
Protecting Cover/Bricks
Single-Core Multi-Core
Sheathed Cables on a Cable Tray 6 inch Sand Bed

F Single Core Trefoil

Single-Core Multi-Core 6 inch Sand Bed
Sheathed Cable Embedded Direct in Plaster
J
G Ground Cover 100mm
Protecting Cover/Bricks
Single-Core Multi-Core
Sheathed Cables Suspended from or 6 inch Sand Bed
Incorporating a Catenary wire
Multi-Core Cable

H 6 inch Sand Bed

Single-Core Multi-Core

17
TECHNICAL GUID

Type Description and Example Type Description and Example

Single and Multi-Core cables in enclosed
pucca trench 450mmwide by 600mm deep
(minimum dimensions) including 100mm
cover. Single-Core sheathed cables arranged
in flat groups of two or three on the vertical
trench wall with surfaces separated by a
distance equal to one diameter with a minim
trench wall.
Single and Multi-Core cables in enclosed
pucca trench separation of 50mm between
groups. Multi-Core cables installed singly
separated by a minimum distance of 75mm.
All cables spaced at least 25mm from the
trench wall.
K M
100mm Cover
Ducts cast-in-situ in concrete, by mean of a
suitable former laid before the concreted is
poured, into which cables are to be drawn
(whether or not the former are retained in
position after the concrete has set) shall be so
formed that the radial thickness of concrete
surrounding the cross-section of the
completed duct is not less than 15mm at any
point.
100mm Cover with pull point at
convenient location on Routing

Steel Bracket
Steel Bracket

Concrete Duct
Brick/Concrete Wall
Single and Multi-Core cables in enclosed
pucca trench 600mm wide by 760mm deep
(minimum dimensions) including 100mm
cover. Single-Core sheathed cables arranged
in groups of two or three in flat formation
with the surfaces separated by a distance equal
to one diameter or in trefoil formation with
cables touching. Groups separated by a
minimum distance of 50mm either
horizontally or vertically. Multi-Core cables
installed singly separated by minimum
distance 75mm either horizontally or
vertically. All cables spaced at least 25mm
from the trench wall. Cables on overhead tray, truncking or any
Note

other method or installation, contact with

L 100mm Cover POLY CABLE INSDUSTRIES LIMITED.
Steel Bracket

Brick/Concrete Wall

18
 P LY CABLES
21. Allowance For Diversity (IEC Regulation)
Estimation of the maximum current which will normally flow in an installation (for use in calculation of
the sizes of cables and switchgear except for final sub-circuit)
Type of Installation
Purpose of final Individual houses. Block of residential Hotels, boarding Shops, store, offices
sub-circuit fed from Including individual flats (considered as houses, lodging & other business
wiring to which flats or block of flat a whole) house, etc premises not
diversity applies including factory
production building

Lighting 66% of total current 50% of total current 75% of total current 90% of total current
demand demand demand demand

Radial and Ring 100% of larges fuse 100% of largest fuse 100% of largest fuse 100% of largest fuse
final sub-circuits for rating of individual rating of individual rating of individual rating of individual
socket outlet and circuit plus 40% of circuit plus 40% of circuit plus 50% of circuit plus 50% of
stationary appliances sum of fuse rating sum of fuse rating sum of fuse rating sum of fuse rating
of other circuit of other circuit of other circuit of other circuit

Socket outlets and 100% of rating of 100% of rating of 100% of rating of 100% of rating of
stationary appliances largest point plus largest point plus largest point plus largest point plus
other than those list 40% of rating of 40% of rating of 75% of rating of 75% of rating of
above other points other points points in main other points
rooms plus 40% of
rating of remaining
points
Fixed heating and 100% of rating of 100% of rating of 100% of rating of 100% of rating of
power appliances load points of amp largest appliances largest appliances largest appliances
(not including plus 50% of any plus 50% of rating plus 80% of rating plus 75% of rating
motors, cookers or load over 10amp of 2nd largest of 2nd largest of remaining
water heaters) appliances plus 33% appliances plus 60% appliance
of rating of 3rd of rating of
appliances largest remaining appliance
appliances plus 25%
of rating of 4th
largest appliances
plus 20% of rating
of remaining
appliance
Fixed cooking 10 amperes plus 100% of rating of 100% of rating of 100% of rating of
appliances 30% f.l of largest appliances largest appliances largest appliances
connected cooking plus 50% of rating of plus 80% of 2nd plus 80% of rating of
appliances in excess 2nd plus 33% of largest appliances 2nd largest
10 amperes plus 5 rating of 3rd largest plus 60% of rating of appliances plus 60%
amperes if socket- plus 25% of 4th remaining appliances of rating of
outlet incorporated largest appliances remaining appliances
in unit plus 20% of
remaining appliances
Motors (other than 100% of rating of 100% of rating of
life motors) largest motor plus largest motor plus
50% of rating of 80% of rating of 2nd
remaining motors largest motor plus
60% of rating of
remaining motor
Water heaters, air- 100% of rating of 100% of rating of 100% of rating of 100% of rating of
cooler (constant each each each each
type)
Wiring in accordance with IEE regulation
Note: In Bangladesh these diversity factor are not generally applicable as these are applicable to
developed countries. Local engineers would need to apply his experience when using these factors
19 indicated by IEE.
TECHNICAL GUID
22. Power Factor Correction Multipliers

The vars or kvars (kilovars) of either static or synchronous condensers or capacitors can be determined
quickly and fairly accurately by use of a table given below. The existing power factor from 50 to 95
percent is shown in the left hand column.
Existing
Corrected Power Factor
Power Factor
% 100% 95% 90% 85% 80% 75%
50 1.732 1.403 1.247 1.112 0.982 0.850
52 1.643 1.314 1.158 1.023 0.893 0.761
54 1.558 1.229 1.073 0.938 0.808 0.676
55 1.518 1.189 1.033 0.898 0.768 0.636
56 1.479 1.150 0.994 0.859 0.729 0.597
58 1.404 1.075 0.919 0.784 0.654 0.522
60 1.333 1.004 0.848 0.713 0.583 0.415
62 1.265 0.936 0.780 0.645 0.515 0.383
64 1.201 0.872 0.716 0.581 0.451 0.319
65 1.168 0.839 0.683 0.548 0.418 0.286
66 1.139 0.810 0.654 0.519 0.389 0.257
68 1.078 0.749 0.593 0.458 0.328 0.196
70 1.020 0.691 0.535 0.400 0.270 0.138
72 0.964 0.635 0.479 0.344 0.214 0.082
74 0.909 0.580 0.424 0.289 0.159 0.027
75 0.882 0.553 0.397 0.262 0.132 ---
76 0.855 0.526 0.370 0.235 0.105 ---
78 0.802 0.473 0.317 0.182 0.052 ---
80 0.750 0.421 0.265 0.130 --- ---
82 0.698 0.369 0.213 0.078 --- ---
84 0.646 0.317 0.161 --- --- ---
85 0.620 0.291 0.135 --- --- ---
86 0.594 0.265 0.109 --- --- ---
88 0.540 0.211 0.055 --- --- ---
90 0.485 0.156 --- --- --- ---
92 0.426 0.097 --- --- --- ---
94 0.363 0.034 --- --- --- ---
95 0.329 --- --- --- --- ---
When the power factor of a load is to be improved, the known power factor is found in the left column, as
example, 60 percent. If this power factor is to be improved to 90 percent, the decimal 0.848 is found in
the same row and under the proper column. The decimal from the table is multiplied by the power in
watts or kilowatts of the existing load to obtain the vars or kvars of the capacitors to be installed.

Example: Improve Power Factor from 70% to 95% for a load of 500kW

Solution: The multiplier to determining the capacity of the P.F.I plant for improving Power Factor from
70% to 95% is 0.691. Therefore, the kvar rating of the capacitors is found to be, 500x0.691 = 345.50kva.
Say 350kvar.

23. Hard Drawn Bare Copper (HDBC) Conductor

Gauge System Diameter Cross-Sectional Area Resistance at 20˚C Weight of Copper
SWG mm inch mm2 inch2 Ohm/m Kg/m
4/0 10.16 0.400 81.70 0.1257 0.0648 0.7207
3/0 9.449 0.372 70.12 0.1087 0.0749 0.6234
2/0 8.839 0.348 61.36 0.09512 0.0856 0.5455
0 8.230 0.324 53.19 0.08245 0.0987 0.4729
1 7.620 0.300 45.60 0.07068 0.1152 0.4054
2 7.010 0.276 38.60 0.06983 0.1361 0.3431
3 6.401 0.252 32.18 0.04988 0.1633 0.2861
4 5.893 0.232 27.27 0.04227 0.1926 0.2425
5 5.385 0.212 22.77 0.03530 0.2307 0.2025
20
 P LY CABLES
Gauge System Diameter Cross-Sectional Area Resistance at 20˚C Weight of Copper
SWG mm Inch mm2 inch2 Ohm/m Kg/m
6 4.877 0.192 18.68 0.02895 0.2813 0.1661
7 4.470 0.176 15.69 0.02432 0.3349 0.1395
8 4.064 0.160 12.97 0.02010 0.4051 0.1153
9 3.658 0.144 10.507 0.01629 0.5002 0.0934
10 3.251 0.128 8.302 0.01287 0.6330 0.0738
11 2.984 0.116 6.818 0.01057 0.7705 0.0606
12 2.642 0.104 5.480 0.008495 0.9586 0.0487
13 2.337 0.092 4.284 0.006648 1.225 0.0380
14 2.032 0.080 3.243 0.005072 1.6202 0.0288
15 1.828 0.072 2.627 0.004072 2.0006 0.0233
16 1.626 0.064 2.075 0.003217 2.5317 0.0184

The current carrying capacity has not been shown because for HDBC, current carrying capacity given in
any book in misnomer. Most important criteria are voltage drop: for 3 phase line and
for single phase line (I = Current, R = Line Resistance) to be used for Voltage Drop Calculation.
Resistance to be corrected at ambient temperature Section 24 refers.

24. Multiplying Constants for Resistance of Copper Wire at Various Temperature

Temperature (˚C) Multiplying Factor for Temperatures above 20˚C Temperature (˚F)
20 1.000 68
25 1.019 77
30 1.039 86
35 1.059 95
40 1.079 104
45 1.098 113
50 1.118 122
55 1.137 131
60 1.157 140
65 1.176 149
70 1.196 158
75 1.216 167
80 1.236 176
85 1.225 185
90 1.275 194
95 1.294 203
100 1.314 212

25. Insulated Aluminum Stranded Conductor. (Type-8) As per BS 6485 & BDS 1036
Code Stranding Cross- Weight of Diameter Minimum Nominal Calculated Weight of Current
Name Number Sectional Bare of Bare Thickness Overall Breaking Insulated Rating
Diameter Area of Conductor Conductor of Diameter of Load Conductor
Insulated
Wire Conductor Insulation Conductor
(Minimum)

mm mm2 kg/km mm mm mm kg kg/km amp

MIDGE 7/2.06 23.32 65 6.18 0.80 7.78 407 95 106
GNAT 7/2.21 26.84 75 6.63 0.80 8.23 468 110 115
ANT 7/3.10 52.84 145 9.30 0.80 11.30 845 215 172
EARWIG 7/3.78 78.58 215 11.34 0.80 13.74 1218 315 218
WASP 7/4.39 106.00 290 13.17 0.80 15.57 1632 380 260

26. All Aluminum Alloy Stranded Conductors (AAAC); As Per ASTM-B 399-86
Code Size Number Strand Diameter Conductor Overall D.C Resistance at 20˚C Ultimate Conductor
Name of Strand Diameter Strength
kmil inches cm inches cm ohm/mile ohm/km pounds kilogram
AMES 77.47 7 0.1052 0.267208 0.316 0.80264 1.373 0.8570 2800 1276
AZUSA 123.3 7 0.1327 0.337058 0.398 1.01092 0.861 0.5350 4460 2023
ALLIANCE 246.9 7 0.1878 0.477012 0.563 1.43002 0.431 0.2678 8560 3883
DARIEN 559 19 0.1716 0.435864 0.858 2.12970 0.190 0.1180 18800 8528

21
TECHNICAL GUID
27. All Aluminum Stranded Conductors (AAC); As Per BS 215 Part-1 and BDS 1036
Code Cross- Equivalent Stranding Minimum Total Approximate Nominal Maximum D.C
Name Sectional Area Copper Wire Thickness of Area Weight Breaking Resistance at
of Conductor Area Diameter Insulation Load 20˚C
mm2 mm2 mm mm mm2 kg/km kgf Ohm/km
MIDGE 22 14.2 7/2.06 6.2 23.32 64 408 1.227
GNAT 25 16.1 7/2.21 6.6 26.48 73 468 1.068
MOSQUITO 35 22.6 7/2.59 7.8 37.00 101 617 0.7731
LADYBIRD 40 25.8 7/2.79 8.3 42.77 118 698 0.6313
ANT 50 32.3 7/3.10 9.3 52.80 145 846 0.5419
FLY 60 38.7 7/3.40 10.2 63.52 174 1010 0.4505
BLUE BOTTLE 70 45.2 7/3.66 11.0 73.60 202 1156 0.3884
EARWIG 75 48.4 7/3.78 11.4 78.51 215 1218 0.3645
GRASSOPPER 80 51.6 7/3.91 11.7 84.00 230 1303 0.3405
CLEGG 95 58.6 7/4.17 12.5 95.60 262 1482 0.2994
WASP 100 64.5 7/4.39 13.2 106.00 290 1632 0.2702
BEETLE 105 64.5 19/2.67 13.4 106.33 293 1776 0.2699
BEE 130 80.6 7/4.90 14.7 132.00 361 2033 0.2169
CRICKET 150 96.8 7/5.36 16.1 157.60 432 2432 0.1814
HORNET 150 96.8 19/3.25 16.3 157.90 434 2519 0.1825
CATERPILLAR 185 113.0 19/3.53 17.7 186.00 512 2920 0.1547
CHAFER 200 129.0 19/3.78 18.9 213.20 587 3304 0.1349
COCKROACH 230 145.0 19/3.99 20.0 236.90 652 3672 0.1214
SPIDER 250 161.3 19/4.22 21.1 265.61 725 4121 0.1082
BUTTERFLY 300 193.6 19/4.65 23.2 322.50 880 4973 0.0892

28. Aluminum Conductors Steel Re-Inforced (ACSR); As Per BS 215 Part-2 and BDS 1037&
ASTM-B 232-74
Code Cross-Sectional Area Number and Diameter of Wires Overall Calculated D.C Total
Name Diameter of Breaking Resistance Weight
Conductor Aluminum Aluminum Steel Conductor Load at 20˚C
mm2 mm2 No. mm No. mm mm kg ohm/km kg/km
SOUIRREL 24.46 20.97 6 2.11 1 2.11 6.33 806 1.3680 85
GOPHER 30.60 26.23 6 2.36 1 2.36 7.08 070 1.0930 106
WEASEL 36.86 31.60 6 2.59 1 2.59 7.77 1168 0.9076 128
FERRET 49.46 42.39 6 3.00 1 3.00 9.00 1550 0.6776 171
RABBIT 61.67 52.85 6 3.35 1 3.35 10.05 1871 0.5426 215
SKUNK 100.10 63.19 12 2.59 7 2.59 12.95 5399 0.4566 462
RACCOON 91.92 78.79 6 4.09 1 4.09 12.27 2759 0.3639 318
CAT 110.78 94.96 6 4.49 1 4.49 13.47 3472 0.3007 381
DOG 118.47 104.93 6 4.72 1 4.72 14.15 3335 0.2733 394
HARE 122.42 104.93 6 4.72 1 4.72 14.16 3836 0.2730 423
WOLF 194.84 157.98 30 2.59 7 2.59 18.13 7056 0.1828 726
LYNX 226.20 183.40 30 2.79 7 2.79 19.53 8192 0.1576 842
DINGO 176.38 158.57 18 3.35 1 3.35 16.75 3640 0.1815 505
BEAR 325.98 264.29 30 3.35 7 3.35 23.45 11362 0.1093 1214
SPARROW 39.17 33.58 6 2.67 1 2.67 8.01 1265 0.8527 137
PENGUIN 125.03 107.17 6 4.77 1 4.77 14.31 3818 0.2676 434
WAXWING 142.41 134.91 18 3.09 1 3.09 15.45 3097 0.2134 432
ORIOLE 210.17 170.41 30 2.69 7 2.69 18.83 7727 0.1704 786
MERLIN 179.60 170.14 18 3.47 1 3.47 17.35 3940 0.1692 543
GROS BEAK 374.70 321.68 26 3.97 7 3.97 25.15 11400 0.0900 1304
SWALLOW 31.10 26.65 6 2.38 1 2.38 7.14 1040 1.0760 108
FOX 42.77 36.66 6 2.75 1 2.75 8.37 1346 0.7827 149
RAVEN 62.38 53.48 6 3.37 1 3.37 10.11 1990 0.5364 216

22
 P LY CABLES
29. Electrical Abbreviation and Prefixes for Units
Alternating Current ac Ampere A
Ampere-Turn At Amplitude Modulation AM
Automatic Frequency Control AFC Micro-Ampere µA
Automatic Gain Control AGC Bandwidth BW
Centimeter cm Cubic Meter m3
Decibel dB Degree Celsius ˚C
Degree Fahrenheit ˚F Degree Kelvin ˚K
Degree (Plane Angle) …˚ Direct Current dc
Electromotive Force EMF Farad F
Field Effect Transistor FET Foot ft
Frequency Modulation FM Henry H
Hertz Hz Horsepower hp
Hour h Inch in
Inductance Capacitance LC Intermediate Frequency IF
Joule j Junction Field Effect Transistor J-FET
Kilogram kg Kilohertz kHz
Kilometer km Kilovar kvar
Kilovolt kV Kilovolt ampere kVA
Kilowatt kW Kilowatt hour kWh
Kirchhoff’s Current Law KCL Kirchhoff’s Voltage Law KVL
Logarithm log Logarithm, Natural ln
Magnetomotive Force MMF Megahertz MHz
Megavolt MV Megawatt MW
Metal-Oxide MOS Semi-Conductor Meter m
Micro-Farad µF Micro-Henry µH
Mile per Hour mi/h Millihenry mh
Millimeter mm Millisecond ms
Millivolt mV Milliwatt mW
Minute (Time) min Nanoampere nA
Nanosecond ns Newton N
Newton Meter N-m Operational Amplifier op-AMP
Picofarad pF Pound lb
Pulse-Amplitude Modulation PAM Pulse-Wide Modulation PWM
Pulse-Code Modulation PCM Radian rad
Radio-Frequency RF Resistance Capacitance RC
Resistance Inductance RL Resistance Inductance Capacitance RLC
Revolution per Minute r/mim Revolution per Second r/s
Root-Mean-Square rms Second (Time) s
Silicon-controlled Rectifier SCR Square Foot ft2
Square Inch in2 Square Meter m2
var var Volt V
Voltage Controlled Oscillator VCO Volt-ampere VA
Watt W Watt-Hour Wh
Weber Wb Mile mi

PREFIXES FOR UNITS

Prefix Multiple Abbreviation Prefix Multiple Abbreviation

Tera 1012 T Giga 109 G

Mega 106 M Kilo 103 k
Hecto 102 h Deca 10 da
Deci 10-1 d Centi 10-2 c
Milli 10-3 m Micro 10-6 µ
Nano 10-9 n Pico 10-12 p
Femto 10-16 f Atto 10-18 a

23
TECHNICAL GUID
30. Relation Between Unit System
Physical Quantity Symbol M.K.S. Unit & Abbreviation C.G.S. or Other Equivalent
Length L, l Meter, m 102cm
Mass M, m Kilogram, kg 103gm
Time T, t Second, s or sec Second
Force F Newton, Nw 105dynes
Energy W Joule, J; Nw-m 107ergs
Power P Watt, W; Nw-m/s 107ergs/s
Current I Ampere, A 10-1e.m.u; 10c e.s.u
Potential E Volt, V 108e.m.u; 106/c e.s.u
Potential Difference V Volt, V 108e.m.u; 106/c e.s.u
Electrical Field Strength ε Volt per meter, V/m 104/c e.s.u
Resistance R Ohm, Ω 109e.m.u
Conductance G Mho, 10-9e.m.u
Resistivity Ρ Ohm-meter, Ω-m 102Ω-cm; 1011 e.m.u
Inductivity Σ Mho per meter, /m 10-2Ω-cm; 10-11 e.m.u
Capacitance C Farad, F 10-5 c2 e.s.u
Permittivity k Farad per meter, F/m 4π. c2. 107 e.s.u
Magnetomotive Force F Ampere (-turn.), A(T) 4π. 10-1 e.m.u (Gilbert)
Inductance L Henry, H 109 e.m.u
c = free space velocity of e.m. wave propagation ≡ 3x108m/s

Miscellaneous constants and conversions

1J = 1Nw-m 1lb-ft = 0.138kg-m
7
= 10 ergs = 1.35Nw-m
= 0.24cal 1Nw = 105dynes
1Cal = 4.18J = 0.102kg force
1B.Th.U = 778ft-lb = 0.225lb force
= 1058J 1h.p. = 746W
= 253cal 1lb = 0.454kg
1ft-lb = 1.36J 1in = 2.54cm
1m = 39.4in

31. Conversion Factors

1inch = 25.4 mm (1meter = 39.3701 in)
(1kg/m2 = 29.4935 oz/yd2)

(1kg/m2 = 0.204816 lb/ft2)

(1kg/m2 = 3.27706 oz/ft2)

(1kpa = 0.145038 lbf/in2)

1foot = 0.3084 m (1meter = 3.28084 ft)
(1kpa = 20.8854 lb/ft2)
(1t/m2 = 1.4223 lb/in2)

(1N/m = 0.06852 lb/f)

1yard = 0.9144 m (1meter = 1.09361 yd)

(1N = 0.224809 lbf)

1chain = 20.1168 m (1km = 49.7097 chain)

1furlong = 0.201168 km (1km = 4.97097 furlong)
1mile = 1.609344 km (1km = 0.62137 mile)
1in2 = 645.16 mm2 (1m2 = 1550.00 in2)
1ft2 = 0.092903 m2 (1m2 = 10.7639 ft2)
1yd2 = 0.836127 m2 (1m2 = 1.19599 yd2)
1acre = 0.404666 ha (1ha = 2.47105 acre)
1mile2 = 2.5899 km2 (1km2 = 0.386102 mile2)
1in3 = 16.3871 cm3 (1cm3 = 0.0610237 in3)
1ft3 = 28.3168 m3 (1m3 = 35.3147 ft3)
= 703.070kg/m2
= 4.88243kg/m2
= 305.152g/m2
= 33.9057g/m2

= 14.5939N/m

1yd3 = 0.764555 m3 (1m3 = 1.30795 yd3)

= 47.8803pa
= 6.8947kpa
= 4.44822N

1gal = 4.54609 litre (1dm3 = 0.29969 gal)

1qt = 1.13652 litre (1dm3 = 0.879877 qt)
1pt = 0.56826 litre (1dm3 = 1.75975 pt)
1US gal = 3.78541 litre (1dm3 = 0.264172 US gal)
1oz = 28.3495 g (1kg = 35.2704 oz)
1lb = 0.4359237 kg (1kg = 2.20462 lb)
1oz/yd2

1lbf/in2

1stone = 6.35029 kg (1kg = 0.157473 stone)

1lbf/ft2
1lb/in2
1oz/ft2

1lb/ft2

1cwt = 50.8023 kg (1t = 19.6841 cwt)

1lbf
1lbf

1ton = 1016.05 kg (1t = 0.984207 ton) 24

 P LY CABLES
To Convert Into Multiply by

tonf/in2 N/mm2 15.4443

lbf/in2 N/mm2 0.006894777
N/mm2 tonf/in2 0.064749
N/mm2 lbf/in2 145.03776
ft.lbf J (joules) 1.35582
kgf.m J (joules) 9.806650
kgf.m ft.lbf 7.23301
ft.lbf kgf.m 0.138255
J (joules) ft.lbf 0.737562
in/min m/hr 1.5240
m/hr in/min 0.656168
cu.ft/hr l/min 0.47195
l/min cu.ft/hr 2.118936
lb/cu.ft g/cm3 0.01602
g/cm3 lb/cu.ft 62.43

32. Physical Constants For Copper, Aluminum and Steel

COPPER:
Resistance of a standard annealed copper wire at 20˚C is 1/58 Ω for 1m length and 1mm2 cross-
section 0.0173µΩ-m (1.73 µΩ-cm) or 0.68 µΩ-inch.

Resistance of hard-drawn copper is taken as 102% of that of standard annealed copper.

Resistance temperature co-efficient: The resistance Rt of a wire at temperature t˚C is given by

Rt = R0 (1 + αt + βt2)
Where, R0 is the resistance at 0˚C and α = 0.00426 =1/234.5 per ˚C at 0˚C; β = 0.00000112 and is
neglected expect where stated otherwise
Specific Gravity: 8.89
Specific Heat: 0.095
Electrochemical Equivalent: 0.000328

ALUMINUM:
Resistance of a standard aluminum wire, 1m long and 1mm2 cross-section is 0.0286Ω at 20˚C.

Resistance temperature co-efficient: α = 0.00380 per ˚C at 0˚C.

Specific Gravity: 2.70

STEEL:
Specific Gravity of armature steel plates: 7.80; of transformer steel plates: 7.5
Specific Heat L = 0.16

To allow for insulation of stampings, assume: net iron length = 0.9 x gross iron length.

33. CABLE LAYING AND INSTALLATION PROCESS FOR SINGLE-CORE CABLES

A. The spacing between three cables laid in one plane should be not less than the cable diameter.
Where the cables are arranged in a duct or a rack in this way, each one should be secured either
to be base or to the others by non-magnetic, non-corrosive clamp every 0.5 to 0.8 inches.
B. When the cable run is several kilometers long, the cables should be transposed at one-third and at
two-third of the total lengths.
C. Cables can also be laid in trefoil arrangement in ducts or on racks which improve current
distribution and reduce sheath losses. Non-magnetic clamps may not be essential in this case and
it suffices to bind the cable with steel, copper, aluminum or plastics tapes every 0.5 to 0.6 inches.
25
TECHNICAL GUID
D. The cables do not have to be bound clamped when laid in ground. Single-core cables should not
be installed individually in protective steel ducts; instead, all three should be laid together in one
single duct.
E. If several single-core cables are laid per phase, these should be arranged as follows to ensure
balanced current distribution:

R Y B B Y R R Y B B Y R
and so on
1 2 3 3 2 1 1 2 3 3 2 1
OR
R Y B B Y R

1 2 3 3 2 1
b

R Y B B Y R

1 2 3 3 2 1

OR WITH TREFOIL ARANGEMENT

Y Y Y Y

R 2 B B 2 R R 2 B B 2 R

1 3 3 1 1 3 3 1
OR
Y Y

R 2 B B 2 R

1 3 3 1
b

Y Y
Where,
R 2 B R 2 B a≈6D
b≈2D
1 3 3 1 D= Cable Diameter
26
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