21 handling & installation of cables

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KL Office : No.9-1 & 9-2, Jalan Puteri 5/20, Bandar Puteri, 47100 Puchong, Selangor MALAYSIA Tel : +603-80601222, +603-8061112, +80601100 Fax : +603-80601212 Website : www.southerncable.cc Email : [email protected] Head Office & Factory : Lot 42, Jalan Merbau Pulas, Kawasan Perindustrian Kuala Ketil, 09300 Kuala Ketil, Baling, Kedah MALAYSIA Tel : +604-4161600 Fax : +604- 4161599 Website : www.southerncable.cc Email : [email protected] ISO9001 : 2000 Reg. No. : AR1757

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Page 1: 21   handling & installation of cables

KL Office :No.9-1 & 9-2, Jalan Puteri 5/20, Bandar Puteri,47100 Puchong, Selangor MALAYSIATel : +603-80601222, +603-8061112, +80601100 Fax : +603-80601212Website : www.southerncable.ccEmail : [email protected]

Head Office & Factory :Lot 42, Jalan Merbau Pulas,Kawasan Perindustrian Kuala Ketil,09300 Kuala Ketil, Baling, KedahMALAYSIATel : +604-4161600 Fax : +604-4161599Website : www.southerncable.ccEmail : [email protected]

ISO9001 : 2000Reg. No. : AR1757

Page 2: 21   handling & installation of cables

Sheathed cables clipped direct to or lying on a non-metallic surface

3 Reference to Table

Methods of Installation of Cables

Installation Method

Number Description

Installation Method Appropriate Reference for determining

Current-carrying Capacity

Open and Clipped Direct

Sheathed cables clipped direct to or lying on a non-metallic surface

1 Reference to Table

In Conduit

Single core non sheathed cables in metallic or non-metallic conduit on a wall or ceiling

2 Reference to Table

Page 3: 21   handling & installation of cables

Installation Method

Number Description

Installation Method Appropriate Reference for determining

Current-carrying Capacity

In Trunking

Cables in trunking on a wall or suspended in air

8 Reference to Table

Cables in flush floor trunking

9 Reference to Table

Single core cables in skirting trunking

10 Reference to Table

Methods of Installation of Cables

Page 4: 21   handling & installation of cables

Installation Method

Number Description

Installation Method Appropriate Reference for determining

Current-carrying Capacity

On Trays

Sheathed cables on a perforated cable tray, bunched and unenclosed. A perforated cable tray is considered as a tray in which the holes occupy at least 30% of the surface area.

11 Reference to Table

In Free Air

Sheathed single core cables in free air (any supporting metal work under the cables occupying less than 10% of the plan area) :2 or 3 cables vertically one above the other, distance between cables equal to the overall diameter (De); distance from the wall not less than 0.5 (De)

12 Reference to Table

Methods of Installation of Cables

Page 5: 21   handling & installation of cables

Installation Method

Number Description

Installation Method Appropriate Reference for determining

Current-carrying Capacity

In Free Air

Sheathed Multicores cables in free air distance between wall and cable surface not less than 0.3 De (any supporting metalwork occupying less than 10% of the plan area)

13 Reference to Table

Methods of Installation of Cables

Page 6: 21   handling & installation of cables

Nom. Cross Sectional Area

for Cu.

Cu. Conductor

Current Rating

Voltage Drop Cu. Conductor

Voltage Drop Al. Conductor

Equivalent Current Rating

of Al. Conductor

Nom. Cross Sectional

Area for Al.

mm2 (A) mV/A/m mV/A/m (A) mm2

1.5 18 25 11.82 28 62.5 25 15 11.82 28 64 33 9.5 7.91 39 106 43 6.4 4.2 57 16

10 59 3.8 4.2 57 1616 79 2.4 2.7 79 2525 104 1.5 1.35 123 3535 129 1.1 1.35 123 5050 167 0.84 0.94 159 7070 214 0.6 0.58 226 12095 261 0.47 0.48 261 150

120 303 0.4 0.41 299 185150 349 0.34 0.35 354 240185 400 0.31 0.31 410 300240 472 0.27 0.28 472 400300 545 0.25 0.26 546 500400 634 0.24 0.24 626 630500 723 0.23 0.23 709 800630 826 0.22 0.22 823 1000

The continuos current carrying capacities are based on the following condition :

a) Ambient temperature 30oC

b) Maximum continuos loading temperature of conductor 70oC

c) Clipped direct 3 or 4 cable, 3 phase a.c

Cu and Al Equivalent Size Comparison

Page 7: 21   handling & installation of cables

Nom. Cross Sectional Area

for Cu.

Cu. Conductor Current Rating

Voltage Drop Cu. Conductor

Voltage Drop Al. Conductor

Equivalent Current Rating

of Al. Conductor

Nom. Cross Sectional

Area for Al.

mm2 (A) mV/A/m mV/A/m (A) mm2

10 73 4 4.2 76 16

16 94 2.5 2.7 90 25

25 124 1.65 1.45 136 50

35 154 1.15 0.97 174 70

50 187 0.87 0.72 211 95

70 238 0.6 0.58 245 120

95 289 0.45 0.47 283 150

120 335 0.37 0.39 323 185

150 386 0.3 0.31 382 240

185 441 0.26 0.26 440 300

240 520 0.21 0.22 517 400

300 599 0.185 0.19 605 500

400 673 0.165 0.175 691 630

Cu and Al Equivalent Size Comparison CU/XLPE/SWA/PVC/AL/XLPE/SCT/PE

The continuos current carrying capacities are based on the following condition :

a) Ambient temperature 30oC

b) Maximum continuos loading temperature of conductor 70oC

c) Clipped direct 3 or 4 cable, 3 phase a.c

Page 8: 21   handling & installation of cables

Cu and Al Equivalent Size Comparison XLPE/PVC

The continuos current carrying capacities are based on the following condition :

a) Ambient temperature 30 deg.C

b) Maximum continuos loading temperature of conductor 90 deg.C

c) Clipped direct 3 or 4 cable, 3 phase a.c

Nom. Cross Sectional Area

for Cu.

Cu. Conductor Current Rating

Voltage Drop Cu. Conductor

Voltage Drop Al. Conductor

Equivalent Current Rating

of Al. Conductor

Nom. Cross Sectional

Area for Al.

mm2 (A) mV/A/m mV/A/m (A) mm2

10 74 4 4.2 80 16

16 99 2.5 2.7 97 25

25 130 1.6 1.45 149 50

35 161 1.15 0.98 189 70

50 209 0.87 0.73 234 95

70 268 0.61 0.59 273 120

95 326 0.45 0.47 314 150

120 379 0.37 0.39 366 185

150 436 0.31 0.32 438 240

185 500 0.26 0.27 507 300

240 590 0.22 0.23 594 400

300 681 0.195 0.2 692 500

400 793 0.175 0.185 791 630

500 904 0.16 0.17 911 800

630 1033 0.15 0.16 1072 1000

800 1179 0.145 0.15 1217 1200

Page 9: 21   handling & installation of cables

Current-carrying Capacity for Single Core Copper Conductor, Non-armoured or without Sheath to BS6004 & BS6346

Conductor Cross

Sectional Area

Current Carrying Capacity

Method of Installation

Enclosed in Conduit in Thermally

Insulated Wall etc.

Enclosed in Conduit on

Wall or Trunking etc.

Clipped Direct

On a Perforated Cable Tray

Horizontal or Vertical

In Free Air

Horizontal Spaced

Vertical Flat

SpacedTrefoil

2 cables, single phase a.c or

d.c

3 or 4 cables, three phase

2 cables, single phase a.c or

d.c

3 or 4 cables, three phase

2 cables, single

phase a.c or d.c flat touching

3 or 4 cables, three

phase a.c flat &

touching @ trefoil

2 cables, single

phase a.c or d.c flat touching

3 or 4 cables, three

phase a.c flat &

touching @ trefoil

2 cables, single phase a.c or d.c or

3 cables three phase

a.c

2 cables, single

phase a.c or d.c or 3

cables three

phase a.c

3 cables, trefoil three phase

a.c

mm2 (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (A)

1.25 13 12 16 14 19 17 - - - - -

1.5 14.5 13.5 17.5 15.5 20 18 - - - - -

2.5 19.5 18 24 21 27 25 - - - - -

4 26 24 32 28 37 33 - - - - -

6 34 31 41 36 47 43 - - - - -

10 46 42 57 50 65 59 - - - - -

16 61 56 76 68 87 79 - - - - -

25 80 73 101 89 114 104 126 112 146 130 110

35 99 89 125 110 141 129 156 141 181 162 137

50 119 108 151 134 182 167 191 172 219 197 167

70 151 136 192 171 234 214 246 223 281 254 216

Page 10: 21   handling & installation of cables

Current-carrying Capacity for Single Core Copper Conductor, Non-armoured or without Sheath to BS6004 & BS6346

Conductor Cross

Sectional Area

Current Carrying Capacity

Method of Installation

Enclosed in Conduit in Thermally Insulated Wall etc.

Enclosed in Conduit on

Wall or Trunking etc.

Clipped Direct

On a Perforated Cable Tray

Horizontal or Vertical

In Free Air

Horizontal Spaced

Vertical Flat

SpacedTrefoil

2 cables

, single phase a.c or

d.c

3 or 4 cables, three phase

2 cables, single

phase a.c or d.c

3 or 4 cables, three phase

2 cables, single

phase a.c or d.c flat touching

3 or 4 cables, three

phase a.c flat &

touching @ trefoil

2 cables, single

phase a.c or d.c flat touching

3 or 4 cables, three

phase a.c flat &

touching @ trefoil

2 cables, single phase a.c or d.c or

3 cables three phase

a.c

2 cables, single

phase a.c or d.c or 3

cables three

phase a.c

3 cables, trefoil three

phase a.c

mm2 (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (A)

95 182 164 232 207 284 261 300 273 341 311 264

120 210 188 269 239 330 303 349 318 396 362 308

150 240 216 300 262 381 349 404 369 456 419 356

185 273 245 341 296 436 400 463 424 521 480 409

240 320 286 400 346 515 472 549 504 615 569 485

300 367 328 458 394 594 545 635 584 709 659 561

400 - - 546 467 694 634 732 679 852 795 656

500 - - 626 533 792 723 835 778 982 920 749

630 - - 720 611 904 826 953 892 1138 1070 855

800 - - - - 1030 943 1086 1020 1265 1188 971

1000 - - - - 1154 1058 1216 1149 1420 1337 1079

Page 11: 21   handling & installation of cables

Current-carrying Capacity for Multicore Copper Conductor, Non-armoured to BS6004 & BS6346

Conductor Cross

Sectional Area

Current Carrying CapacityMethod of Installation

Enclosed in Conduit in Thermally

Insulated Wall etc.

Enclosed in Conduit on Wall or Trunking etc. Clipped Direct

On a Perforated Cable Tray

Horizontal or Vertical

1 two-cores cable, single phase a.c or

d.c

1 three-core cable

or four-core cable, three

phase a.c

1 two-cores cable, single

phase a.c or d.c

1 three-core cable

or four-core cable, three

phase a.c

1 two-cores cable, single

phase a.c or d.c

1 three-core cable

or four-core cable, three

phase a.c

1 two-cores cable, single phase

a.c or d.c

1 three-core cable

or four-core cable, three

phase a.c

mm2 (A) (A) (A) (A) (A) (A) (A) (A)1.5 14 13 16.5 15 19.5 17.5 22 18.52.5 18.5 17.5 23 20 27 24 30 254 25 23 30 27 36 32 40 346 32 29 38 34 46 41 51 43

10 43 39 52 46 63 57 70 6016 57 52 69 62 85 76 94 8025 75 68 90 80 112 96 119 10135 92 83 111 99 138 119 148 12650 110 99 133 118 168 144 180 15370 139 125 168 149 213 184 232 19695 167 150 201 179 258 223 282 238

120 192 172 232 206 299 259 328 276150 219 196 258 225 344 299 378 319185 248 223 294 255 392 341 434 364240 291 261 344 297 461 403 514 430300 334 298 394 339 530 464 593 497400 - - 470 402 634 557 715 597

Page 12: 21   handling & installation of cables

Current-carrying Capacity for Single Core Copper Conductor, Armoured to BS6346

Conductor Cross

Sectional Area

Current-Carrying Capacity

Method of Installation (in free air)

Clipped DirectOn a Perforated Cable

Tray Horizontal or Vertical

2 cables, single phase a.c

2 cables, single phase d.c

3 or 4 cables, three phase a.c

2 cables, single phase

a.c or d.c flat &

touching

3 or 4 cables,

three phase a.c, flat & touching

2 cables, single phase

a.c or d.c flat &

touching

3 or 4 cables,

three phase a.c, flat & touching

Horizontal Spaced

Vertical Flat

Spaced

Horizontal

Spaced

Vertical Flat

Spaced

Horizontal

Spaced

Vertical Flat

Spaced

3 cables Trefoil

mm2 (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (A)

50 193 179 205 189 229 217 229 216 230 212 181

70 245 225 259 238 287 272 294 279 286 263 231

95 296 269 313 285 349 332 357 340 338 313 280

120 342 309 360 327 401 383 415 396 385 357 324

150 395 354 413 373 456 436 479 461 438 407 373

185 447 399 469 422 511 489 548 525 490 456 425

240 525 465 550 492 593 568 648 622 566 528 501

300 594 515 624 547 668 640 748 719 616 578 567

400 687 575 723 618 737 707 885 851 674 632 657

500 763 622 805 673 810 777 1035 997 721 676 731

630 843 669 891 728 893 856 1218 1174 771 723 809

800 919 710 976 777 943 905 1441 1390 824 772 866

1000 975 737 1041 808 1008 967 1685 1627 872 816 945

Page 13: 21   handling & installation of cables

Current-carrying Capacity for Multicore Copper Conductor, Armoured to BS6346

Conductor Cross Sectional Area

Current-Carrying Capacity

Method of Installation (in free air)

Clipped Direct On a Perforated Cable Tray Horizontal or Vertical or in free air

1 two-cores cable, single

phase a.c or d.c

1 three-core cable or four-core

cable, three phase a.c

1 two-cores cable, single

phase a.c or d.c

1 three-core cable or four-core

cable, three phase a.c

mm2 (A) (A) (A) (A)1.5 21 18 22 19

2.5 28 25 31 26

4 38 33 41 35

6 49 42 53 45

10 67 58 72 62

16 89 77 97 83

25 118 102 128 110

35 145 125 157 135

50 175 151 190 163

70 222 192 241 207

95 269 231 291 251

120 310 267 336 290

150 356 306 386 332

185 405 348 439 378

240 476 409 516 445

300 547 469 592 410

400 621 540 683 590

Page 14: 21   handling & installation of cables

Current-carrying Capacity for Aluminum Conductor

Nominal Sectional

Area (mm2)

Continuous Current Rating (Unit Amperes)Short Circuit

Current Rating for 1 sec.

In Air at 40oC On Ground at 25oC

Single Conductor

3 cables S=2d

Twin Conductor

Three or Four

Conductors

Single Conductor

3 cables S=2d

Twin Conductor

Three or Four

Conductors

4 - 29 24 - 38 32 305A6 - 36 31 - 47 41 405

10 - 49 41 - 63 53 760

16 - 66 55 - 82 69 1.22 kA25 - 86 72 - 105 89 1.935 - 105 90 - 130 105 2.6650 150 125 105 150 150 125 3.870 185 170 140 185 190 155 5.3295 220 205 165 215 225 185 7.22

120 265 230 195 250 260 215 9.12150 285 270 235 280 285 240 11.4185 350 305 255 320 325 270 14.1240 405 360 295 365 380 320 18.2300 460 420 355 420 430 355 22.8400 570 - - 495 - - 25.8500 650 - - 550 - - 32.6630 750 - - 640 - - 40.8800 890 - - 725 - - 50.3

1000 1015 - - 815 - - 65.3Single conductor : Single point bonded

Page 15: 21   handling & installation of cables

Short Circuit Ratings

Short Circuit Rating (A) Copper Conductor Aluminum Conductor

Up to and including 300mm2 115 X (S/√t) 76 X (S/√t)

Greater than 300mm2 103 X (S/√t) 68 X (S/√t)

t : Short circuit duration time in second

S : Cross sectional area in mm2

Conditions : Max. permissable continuous operating temperature 70 deg.C Max. permissable temperature at short-circuit 160 deg.C

Air Temperature (oC) 25 30 35 40 45

Rating factor (max. conductor

temperature 70oC)1.22 1.15 1.08 1.00 0.91

Rating Factor for Variation in Ambient Temperature

Ground Temperature (oC) 10 15 20 25 30

Rating factor (max. conductor

temperature 70oC)1.15 1.11 1.05 1.00 0.94

Rating Factor for Variation in Ground Temperature (Direct Laid on the Ground)

Page 16: 21   handling & installation of cables

Rating Factors for Depth Laying for Cables Laid Direct on the Ground

Depth of Laying (meter)

600/1000V Cables

Up to 50 mm2 70 mm2 to 300 mm2 Above 300 mm2

0.5 1.03 1.04 1.060.6 1.02 1.02 1.030.8 1.00 1.00 1.001 0.98 0.97 0.98

1.25 0.97 0.96 0.951.5 0.96 0.94 0.93

1.75 0.95 0.93 0.912 0.94 0.92 0.90

2.5 0.93 0.91 0.893.0 and above 0.92 0.89 0.87

Page 17: 21   handling & installation of cables

HANDLING AND INSTALLATION OF CABLE

1.Minimum bending radius and permissable pulling tension - to prevent damage on electrical and physical properties of the cable

Page 18: 21   handling & installation of cables

Lifting by crane Drum rolling direction Do not lay on flanges

Lifting drum by forklift correctly

Drums secure adequately during transportation

HANDLING AND INSTALLATION OF CABLE

Page 19: 21   handling & installation of cables

DO NOT attempt “coiling” on the ground

On the ground cable can be FLAKED in a figure of eight formation

HANDLING AND INSTALLATION OF CABLE