Contents:
- What is Power and Control Cable ?
- Power and Control Cable Specification
- Power and Control Cable Price List
- Power and Control Cable Approval List
- Power and Control Cable Features
- Power and Control Cable Application
- Power and Control Cable Packaging & Shipping
- Types of Power and Control Cable
- Other Related Power and Control Cable
Manufacturers and Power and Control Cable suppliers for a wide range of high quality Power and Control Cable to suit all kinds of applications, from lawn mowers to buses and lorries. It is commonly the case that Power and Control Cable are required quickly and in small quantities. We use the latest technology available in our industry for the manufacturing of all Power and Control Cable which are now lighter, more durable and more flexible.
Bhuwal Insulation Cable Pvt. Ltd. is providing a wide range of control cables including Clutch Cables, Bowden Cables, Throttle Cables, Push Pull Cables, Motorcycle Control Cables, Marine Control Cables, Mechanical Control Cables, Gear Cables, Felsted Cables, Sensor and Control Cables, Morse Type Control Cables, Flexible Control Cables, Elevator Control Cables, Power and Control Cable, CY Control Cable, SY Control Cable, YY Control Cable, Teleflex Cables, Cablecraft Cables and Handbrake Cables for an even wider range of applications. These Power and Control Cable follow the DIN color codes required for EU-based technology.
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.
Bhuwal Insulation Cable is a specialist manufacturer of EHV cables in India. We can offer cables upto 400 kV range. High voltage power cables (HV): Up to 380 kV, ideal for transmission systems.
At Bhuwal Insulation Cable, all XLPE insulations of our High and Extra High Voltage Cables are done pursuant to standards outlined by IEC 60840 and IEC 62067, as applicable. The conductors used are Stranded Class 2 (round for 800 mm² and below and segmental for 1000 mm² and above); conductors are of plain annealed copper or aluminum up to 2500 mm² in accordance with IEC 60228.
Standard outer sheathing of our High Voltage Cables is extruded HDPE type ST7; other PE sheathing compounds such as LLDPE, LMDPE, and MDPE are available on request.
Insulating Compounds for Cable
| Insulating Compound | Maximum conductor temperature °C | |
|---|---|---|
| Normail Operation | Short Circuit (Max. duration 5s) |
|
| Low density thermoplastic polyethylene (PE) | 70 | 130 1) |
| High density thermoplastic polyethylene (HDPE) | 80 | 160 1) |
| Cross-linked polyethylene (XLPE) | 90 | 250 |
| Ethylene-propylene rubber (EPR) | 90 | 250 |
| High modulus or hard grade ethylene-propylene rubber (HEPR) | 90 | 250 |
| 1) For PE and HOPE, short circuit temperature up to 20° C in excess of those shown may be acceptable with suitable semi-conducting layers over the conductor and the insulation and by agreement between manufacturer and purchaser. | ||
Over Sheathing Compounds for Cables
| SB, XB | Both ends | SB, XB |
|---|---|---|
| Polyvinyl Chloride (PVC) | ST1 | 80 |
| ST2 | 90 | |
| Polyethylene | ST3 | 80 |
| ST4 | 90 |
Tan δ Requirements for Insulating Compounds for Cables
| Designation of Compound | PE | HDPE | EPR/HEPR | XLPE |
|---|---|---|---|---|
| Maximum tan 10-4 | 10 | 10 | 50 | 10 1) |
| 1) For cables produced with an XLPE compound containing special additives, the maximum tan δ is 50x10 -4 | ||||
| PROPERTIES | Low Density PE | MDPE | HDPE | Irradiated PE (XLPE) |
XLPEa |
|---|---|---|---|---|---|
| Volume resistivity, Ω - cm | > 1016 | > 1016 | > 1015 | > 1015 | > 1015 |
| Dielectric strength Short time, v/mil | 460-700 | 500-700 | 450-500 | 2500b | 550 |
| Step-by-step, V/mil | 420-700 | 500-700 | 440-600 | 1800b | 500 |
| Dielectric Constant | |||||
| 60 Hz | 2.3 | 2.3 | 2.35 | 2.3 | 2.30 |
| 103 Hz | 2.3 | 2.3 | 2.35 | 2.3 | - |
| 106 Hz | 2.3 | 2.3 | 2.35 | 2.3 | 2.28 |
| Dissipation factor | |||||
| 60 Hz | 0.0002 | 0.0002 | 0.0002 | 0.0005 | 0.0003 |
| 103 Hz | 0.0002 | 0.0002 | 0.0002 | 0.0005 | |
| 106 Hz | 0.0002 | 0.0002 | 0.0002 | 0.0005 | 0.0004 |
| Arc resistance, s (ASTM D495) | Melts | Melts | > 125 | - | - |
| Density, g/cm3 | 0.910-0.925 | 0.926-0.940 | 0.941-0.965 | 0.92 | 0.92 |
| Modulos of elasticity in tension, psi x 105 | 0.17-0.35 | 0.25-0.55 | 0.8-1.5 | - | - |
| Percent elongation, % (ult.) | 20-650 | 100-600 | 15-700 | > 200 | 550 |
| Tensile strength | 14-19 | 19-26 | 26-45 | - | 24 |
| Compressive strength, psi x 103 | - | - | 2.4 | - | - |
| Rockwell hardness | R10 | R15 | R30-R50 | - | (Shore D) |
| Impact strength, ft-lb/in. | - | - | 1-23 | - | 45 |
| Heat distortion temperature (at 66 psi), °F | 105-121 | 120-150 | 140-185 | - | - |
| Thermal conductivity, cal/cm.s. °C x 10-4 | 8 | - | 11-12 | - | - |
| Thermal expansion, in/in. per °C x 10-5 | 11-30 | 15-30 | 15-30 | 20 | - |
| Water absorption, % | < 0.02 | < 0.02 | < 0.01 | Nil | - |
| Burning Gate | Slow | Slow | Slow | - | - |
| aUnion Carbide HFDE-4201 NR EC crosslinkable compound. bA 5-mil film. | |||||
AND SEMI-CONDUCTIVE POLYETHYLENE JACKETS
| Physical Property | Test Method | PVC | LDPE | LLDPE | LPDPE | LHDPE | Semiconducting Thermoplastic PE |
|---|---|---|---|---|---|---|---|
| Melt index (190°, 2.1 kg), g/10 min | ASTM D1238 | - | 0.25 | 0.55 | 0.70 | 0.15 | |
| Density (23°C) g/cm3 | ASTM D1505 | - | 0.93 | 0.93 | 0.95 | 0.96 | 1.12 |
| Tensile strength Psi | ASTM | >1500 | 2100 | 2350 | 3500 | 4000 | 1600 |
| Mpa | D638 | 10.3 | 14.5 | 15.5 | 24.1 | 27.6 | 11.0 |
| Tensile elongation percent | ASTM D638 | > 100 | 650 | 650 | 900 | 800 | 250 |
| DSC melting point °C Flexural modulus | - | 110 | 119 | 125 | 130 | ||
| Psi | ASTM | - | 38,000 | 55,000 | 90,000 | 145,000 | |
| Mpa | D790 | 262 | 379 | 621 | 1000 | ||
| Dielectric Constant (1 MHz) | ASTM D1531 | - | 2.60 | 2.50 | 2.52 | 2.56 | |
| Dissipation factor (1 MHz) rad | ASTM D1531 | - | 0.005 | 0.0003 | 0.0003 | 0.0003 | |
| Dielectric strength, 0.030 in. Insulation thickness at 500V/s rate of rise V/mil kV/mm | ASTM D149 | - | - | 1230 46.6 |
|||
| Heat distortion at 115°C | - | 90 | 22 | 7 | 0 | ||
| 121°C | 20 | ||||||
| 135°C | - | Melted | Melted | Melted | Melted | ||
| Abrasion resistance, mg/100 revolutions | ASTM D3389 | - | 29 | 22 | 16 | 14 | |
| Shore D hardness | ASTM D2240 | - | 54 | 56 | 61 | 66 | |
| Cut-througth resistance lb | - | 2600 | 3000 | 3600 | 4000 | ||
| N x 104 | - | 1.20 | 1.3 | 1.6 | 1.8 | ||
| Water vapor transmission G/24 hr/m2 | ASTM E96 | 310.0 | 1.16 | 0.74 | 0.51 | 0.32 | < 1.5 |
| Brittleness temperature, °C | ASTM D3389 | - | - | -60 | - | - | -24 |
Note : LDPE, LLDPE, LMDPE, LHDPE, and semiconducting thermoplastic PE are Union carbide compounds.
CU/XLPE/CUW/LAT/PE - 69 KV (72.5 KV)
Dimensional Data
| Conductor Cross section | Conductor Cross section | Diameter of Conductor (approx) | Thickness of Insulation (nom) | Diameter over Insulation (approx) | Thickness of LAT (nom) | Thickness of Outer Sheath (nom) | Overall Diameter (approx) | Weight of Cable (approx) |
|---|---|---|---|---|---|---|---|---|
| [mm²] | [mm²]** | [mm] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] |
| 300 | 199 | 20.4 | 13.0 | 49.6 | 0.2 | 4.00 | 66 | 7700 |
| 400 | 199 | 23.2 | 13.0 | 52.4 | 0.2 | 4.00 | 69 | 8600 |
| 500 | 199 | 26.7 | 13.0 | 55.9 | 0.2 | 4.00 | 73 | 9800 |
| 630 | 199 | 30.4 | 13.0 | 59.6 | 0.2 | 4.00 | 76 | 11300 |
| 800 | 199 | 33.7 | 13.0 | 62.9 | 0.2 | 4.00 | 80 | 13100 |
| 1000 * | 199 | 41.0 | 13.0 | 70.2 | 0.2 | 4.00 | 87 | 15800 |
| 1200 * | 199 | 44.0 | 13.0 | 73.2 | 0.2 | 4.00 | 90 | 17600 |
| 1600 * | 199 | 50.0 | 13.0 | 79.2 | 0.2 | 4.00 | 96 | 21300 |
| 2000 * | 199 | 56.0 | 13.0 | 85.2 | 0.2 | 4.00 | 102 | 25500 |
* Round Segmental Conductor
** 199 mm² CUW screen shall withstand 31.5 kA for 1 second [non-adiabatic]
Electrical Data
| Conductor Cross Section | Parameters | Short Circuit Current kA for 1 second | Continuous Current Rating [Amperes] | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Rdc at 20°C | Rdc at 90°C | Inductance (Nominal) mH/km | Capacitance (Nominal) | Single Circuit in Ground | In Free Air & Shaded Area | ||||||||
| Close Trefoil | Flat** | Close Trefoil | Flat** | ||||||||||
| [mm²] | Ω/km | Ω/km | Trefoil | Flat | µF/Km |
Conductor | Screen* | Both Ends | Single/ cross | Single/ cross | Both Ends | Single/ cross | Single/ cross |
| 300 | 0.0601 | 0.0788 | 0.42 | 0.83 | 0.17 | 42.93 | 31.5 | 348 | 394 | 455 | 558 | 607 | 692 |
| 400 | 0.0470 | 0.0627 | 0.41 | 0.80 | 0.19 | 57.23 | 31.5 | 383 | 445 | 516 | 629 | 699 | 802 |
| 500 | 0.0366 | 0.0503 | 0.39 | 0.78 | 0.20 | 71.54 | 31.5 | 417 | 502 | 585 | 707 | 805 | 933 |
| 630 | 0.0283 | 0.0408 | 0.37 | 0.75 | 0.22 | 90.14 | 31.5 | 452 | 561 | 660 | 787 | 921 | 1080 |
| 800 | 0.0221 | 0.0340 | 0.36 | 0.73 | 0.24 | 114.47 | 31.5 | 481 | 619 | 735 | 860 | 1033 | 1229 |
| 1000 | 0.0176 | 0.0240 | 0.34 | 0.69 | 0.28 | 143.08 | 31.5 | 537 | 742 | 870 | 1008 | 1285 | 1518 |
| 1200 | 0.0151 | 0.0211 | 0.33 | 0.68 | 0.29 | 171.70 | 31.5 | 558 | 793 | 936 | 1066 | 1394 | 1661 |
| 1600 | 0.0113 | 0.0169 | 0.32 | 0.65 | 0.32 | 228.93 | 31.5 | 594 | 889 | 1068 | 1172 | 1605 | 1954 |
| 2000 | 0.0090 | 0.0144 | 0.31 | 0.63 | 0.35 | 286.17 | 31.5 | 619 | 961 | 1176 | 1256 | 1780 | 2213 |
* Maximum permissible non-adiabatic short circuit current as per IEC 949
** Flat formation with both ends bonded system is not recommended
Laying Conditions
| - Ground Temperature | 35 | °C |
|---|---|---|
| - Ground Thermal Resistivity | 2.0 | K.m/W |
| - Laying Depth | 1500 | mm |
| - Air Temperature | 50 | °C |
|---|---|---|
| - Number of Circuits | 1 | circuit |
| - Distance between Conductors (flat) | 400 | mm |
CU/XLPE/CUW/LEAD/PE - 69 KV (72.5 KV)
Dimensional Data
| Conductor Cross section | Conductor Cross section | Diameter of Conductor (approx) | Thickness of Insulation (nom) | Diameter over Insulation (approx) | Thickness of LAT (nom) | Thickness of Outer Sheath (nom) | Overall Diameter (approx) | Weight of Cable (approx) |
|---|---|---|---|---|---|---|---|---|
| [mm²] | [mm²]** | [mm] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] |
| 300 | 156 | 20.4 | 13.0 | 49.6 | 2.5 | 4.00 | 71 | 12800 |
| 400 | 152 | 23.2 | 13.0 | 52.4 | 2.5 | 4.00 | 74 | 13900 |
| 500 | 149 | 26.7 | 13.0 | 55.9 | 2.5 | 4.00 | 78 | 15400 |
| 630 | 147 | 30.4 | 13.0 | 59.6 | 2.5 | 4.00 | 81 | 17300 |
| 800 | 145 | 33.7 | 13.0 | 62.9 | 2.5 | 4.00 | 85 | 19300 |
| 1000 | 140 | 41.0 | 13.0 | 70.2 | 2.5 | 4.00 | 92 | 22700 |
| 1200 | 138 | 44.0 | 13.0 | 73.2 | 2.5 | 4.00 | 95 | 24700 |
| 1600 | 134 | 50.0 | 13.0 | 79.2 | 2.5 | 4.00 | 101 | 28900 |
| 2000 | 129 | 56.0 | 13.0 | 85.2 | 2.5 | 4.00 | 107 | 33600 |
* Round Segmental Conductor
** Specified size of CUW screen along with the LEAD sheat shall withstand 31.5 kA for 1sec [non-adiabatic], [for special constructions, screen area may vary slightly]
Electrical Data
| Conductor Cross Section | Parameters | Short Circuit Current kA for 1 second | Continuous Current Rating [Amperes] | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Rdc at 20°C | Rdc at 90°C | Inductance (Nominal) mH/km | Capacitance (Nominal) | Single Circuit in Ground | In Free Air & Shaded Area | ||||||||
| Close Trefoil | Flat** | Close Trefoil | Flat** | ||||||||||
| [mm²] | Ω/km | Ω/km | Trefoil | Flat | µF/Km |
Conductor | Screen* | Both Ends | Single/ cross | Single/ cross | Both Ends | Single/ cross | Single/ cross |
| 300 | 0.0601 | 0.0787 | 0.44 | 0.83 | 0.17 | 42.93 | 31.5 | 351 | 397 | 457 | 569 | 618 | 703 |
| 400 | 0.0470 | 0.0626 | 0.42 | 0.80 | 0.19 | 57.23 | 31.5 | 386 | 448 | 518 | 642 | 711 | 814 |
| 500 | 0.0366 | 0.0502 | 0.40 | 0.78 | 0.20 | 71.54 | 31.5 | 421 | 504 | 587 | 722 | 818 | 946 |
| 630 | 0.0283 | 0.0406 | 0.38 | 0.75 | 0.22 | 90.14 | 31.5 | 456 | 564 | 662 | 805 | 935 | 1095 |
| 800 | 0.0221 | 0.0337 | 0.37 | 0.73 | 0.24 | 114.47 | 31.5 | 487 | 621 | 737 | 880 | 1049 | 1246 |
| 1000 | 0.0176 | 0.0240 | 0.35 | 0.69 | 0.28 | 143.08 | 31.5 | 545 | 739 | 872 | 1033 | 1297 | 1537 |
| 1200 | 0.0151 | 0.0210 | 0.34 | 0.68 | 0.29 | 171.70 | 31.5 | 566 | 788 | 938 | 1093 | 1404 | 1680 |
| 1600 | 0.0113 | 0.0168 | 0.33 | 0.65 | 0.32 | 228.93 | 31.5 | 605 | 880 | 1068 | 1206 | 1612 | 1975 |
| 2000 | 0.0090 | 0.0143 | 0.32 | 0.63 | 0.35 | 286.17 | 31.5 | 633 | 949 | 1174 | 1296 | 1782 | 2234 |
* Maximum permissible non-adiabatic short circuit current as per IEC 949 for both CUW & LEAD sheath
** Flat formation with both ends bonded system is not recommended
Laying Conditions
| - Ground Temperature | 35 | °C |
|---|---|---|
| - Ground Thermal Resistivity | 2.0 | K.m/W |
| - Laying Depth | 1500 | mm |
| - Air Temperature | 50 | °C |
|---|---|---|
| - Number of Circuits | 1 | circuit |
| - Distance between Conductors (flat) | 400 | mm |
| Power and Control Cable Specification | |
|---|---|
| Extreme temperature range: |
(-40oC to 105oC) can withstand the extremes of automotive environments |
| Power and Control Cable range: | 0GA, 2GA, 4GA, 6GA, 8GA, 10GA, 12GA, 14GA, 15GA, 16GA, 18GA, 20GA and ultra classic strands |
| High strand counts | High strand counts |
| Conductor Type | Stranded 99.99% OFC (oxygen free copper), and tin plated copper,copper coated al |
| Material | Environmentally friendly, quality, glossy material Tinned, Silver or Nickel plated copper etc. |
| Power and Control Cable Colour: | Customized |
| Packing | carton packing, pallet packing , wooden / plastic reels |
| We can manufacture Power and Control Cable as per customers' requirement. | |
Power and Control Cable Approved by |
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Bhuwal Insulation Cable offer huge quantities of Medium Voltage Cables while in the High Voltage cable the cumulative quantity is more than 1000 kms of 132 kV and more than 1000 kms of 69 kV cables.
High Voltage cables from 66 kV to 230 kV with different constructions and material manufactured by Bhuwal Insulation Cable India has been successfully type tested. 16 type tests have been performed on 132 kV cables, 6 of these type tests are with accessories. 4 type tests have been performed on 110-115 kV cables, 6 type tests have been performed on 69 kV cables and 1 type test was performed on 230 kV Cable totaling 27 type tests which prove suitability of design stress up to 9 kV /mm and lower.
Power and Control Cable Type:
PVC insulated, PVC out sheath control cable: From 2x0.75 to 2x40. Till 61x0.75mm2 to 61x2.5mm2
PE insulated, PE out sheath control cable
PE insulated, PVC out sheath control cable
PE insulated, PVC out sheath, copper wire braided shield control cable
69 kV Cables generally to IEC 60840
69 kV Cables generally as per IEC 60840 and SEC-EOA specification
110 kV Cables generally as per IEC 60840 and SEC-WOA specification
115 kV Cables generally as per IEC 60840 and SEC-EOA specification
132 kV Cables generally to IEC 60840
132 kV Cables generally to IEC 60840 (CUW 40 kA for 1 second)
132 kV Cables generally as per IEC 60840 and SEC-COA specification
132 kV Cables generally to IEC 60840 (CUW+LEAD 40 kA for 1 second)
132 kV Cables generally to IEC 60840 and SEC-SOA specification (CUW 40 kA for 3 second)
132 kV Cables generally to IEC 60840 and SEC-SOA specification (CUW+LEAD 40 kA for 3 second)
220 kV Cables generally to IEC 62067
Such Power and Control Cable are suitable for laying indoors and in the electrical cabinets, however, the cables can’t bear larger external mechanical forces. Power and Control Cable is used for the signal transmission, controlling and measuring system of the electric apparatus.
