Construction of Cable

HIGH VOLTAGE CABLE
DESIGN
CONSTRUCTION OF CABLES
GRADING OF CABLES
The various part of cable are:
1. Core or conductor
A cable may have one or more than one
core (conductor) depending upon the type
of service for which it is intended.
The conductors are made of tinned copper

or aluminum an are usually stranded in
order to provide flexibility to the cable.
2. Insulation
Each core or conductor is provide with a
suitable thickness of insulator, the thickness
of layer depending upon the voltage to be
with stood by the cable.
3. Metallic sheath
In order to protect the cable from moisture,
gases or other damaging liquids (acids or
alkalis) in the soil and atmosphere, a
metallic sheath of lead or aluminum is
provided over the insulation.
4. Bedding
Over the metallic sheath is applied a layer of
bedding which consists of a fibrous material
like jute or hessian tape. The purpose of
bedding is to protect the metallic a against
corrosion and from mechanical in jury due
to armoring.
5. Armouring
Over the bedding armouring is provide
which consists of one or two layers of
galvanized steel wire or steel tape. Its
purpose is to protect the cable from
mechanical injury while laying it and during
the course of handling
6. Serving
In order to protect armouring from
atmospheric condition. Layer of fibrous
material (like jute) similar to bedding is
providing over the armouring. This is known
as serving.
INSULATION RESISTANCE OF SINGLE CORE
CABLE
The cable conductor is provided with
a suitable thickness of insulating
material in order to prevent leakage
current. The path of leakage current
is radial through the insulation. The
opposition offered by insulation to
leakage current is known as
insulation resistance of the cable.
For satisfactory operation, the
insulation resistance of the cable is
very high.
INSULATION RESISTANCE OF SINGLE CORE
CABLE
Insulation resistance of the whole cable:
𝜌 𝑟2
𝑅= 𝑙𝑛
2𝜋𝑙 𝑟1
This shows that insulation resistance of a
cable is inversely proportional to its
length. In other words, if the cable length
r1 – conductor radius
increases, its insulation resistance R2 – internal sheath radius
decreases and vice versa.
Sample Problem:
A single-core cable has a conductor diameter of 1 cm and insulation
thickness of 0.4 cm. If the specific resistance of insulation is 5 x 1014 Ω-cm,
calculate the insulation resistance for a 2 km length of the cable.
Solution:
1𝑐𝑚
Conductor radius r1: = 0.5 𝑐𝑚
2
length of cable: 𝑙 = 2km or 2,000 m
Resistivity of insulation: ρ = 5x1014 Ω − 𝑐𝑚 𝑜𝑟 5𝑥1012 Ω − 𝑚
Internal sheath radius: r2 = 0.5+0.4 = 0.9 cm
R=?
Sample Problem:
A single-core cable has a conductor diameter of 1 cm and insulation
thickness of 0.4 cm. If the specific resistance of insulation is 5 x 1014 Ω-cm,
calculate the insulation resistance for a 2 km length of the cable.
Solution:
𝜌 𝑟2
𝑅= 𝑙𝑛
2𝜋𝑙 𝑟1
5𝑥1012 Ω − 𝑚 0.9𝑐𝑚
𝑅= 𝑙𝑛
2𝜋(2,000𝑚) 0.5 𝑐𝑚
𝑅 = 0.234𝑥109 Ω 𝑜𝑟 234 𝑀Ω
Sample Problem:
The insulation resistance of a single-core cable is 495 MΩ per km. If the core
diameter is 2.5 cm and resistivity of insulation is 4.5 x 1014 Ω-cm, find the
insulation thickness.
Solution:
2.5𝑐𝑚
Conductor radius r1: = 1.25 𝑐𝑚
2
length of cable: 𝑙 = 1km or 1,000 m
Cable insulation resistance: R = 495 MΩ = 495x106 Ω
Resistivity of insulation: ρ = 4.5x1014 Ω − 𝑐𝑚 𝑜𝑟 4.5𝑥1012 Ω − 𝑚
Internal sheath radius: r2 = ?
Sample Problem:
The insulation resistance of a single-core cable is 495 MΩ per km. If the core
diameter is 2.5 cm and resistivity of insulation is 4.5 x 1014 Ω-cm, find the
insulation thickness.
Solution: 𝑟2
0.6911 = ln
𝜌 𝑟2 1.25
𝑅= 𝑙𝑛 0.6911 = ln 𝑟2 − 𝑙𝑛1.25
2𝜋𝑙 𝑟1 lnr2 = 0.6911 + ln(1.25)
r2 = e0.6911 + ln(1.25)
𝑅𝑥2𝜋𝑙 𝑟2
𝜌
= 𝑙𝑛
𝑟1
r2 = 2.5 cm
495𝑥106 Ω 𝑥2𝜋(1,000𝑚) 𝑟2 Insulation thickness = 2.5-1.25

= 𝑙𝑛
4.5𝑥1012 Ω − 𝑚 1.25 𝑐𝑚 Insulation thickness = 1.25 cm
MOST ECONOMICAL CONDUCTOR SIZE IN
A CABLE
It has already been shown that maximum stress in a cable occurs at the surface of the
conductor. For safe working of the cable, dielectric strength of the insulation should be more
than the maximum stress.
Maximum stress:
2𝑉
𝑔𝑚𝑎𝑥 = 𝑣𝑜𝑙𝑡𝑠/𝑚
𝐷
𝑑 ln
𝑑
The values of working voltage V and internal sheath diameter D have to be kept fixed at certain
values due to design considerations. This leaves conductor diameter d to be the only variable in
the above expression. For given values of V and D, the most economical conductor diameter will
𝐷
be one for which gmax has a minimum value. The value of gmax will be minimum when d ln is
𝑑
maximum.
MOST ECONOMICAL CONDUCTOR SIZE IN
A CABLE
Most economical conductor diameter is:
𝐷
𝑑= D – internal sheath diameter
2.718
And the value of gmax under this condition is:

2𝑉
𝑔𝑚𝑎𝑥 = 𝑣𝑜𝑙𝑡𝑠/𝑚 Where;
𝑑 V – peak value of voltage
gmax – dielectric stress
d – conductor diameter
Sample Problem
Find the most economical value of diameter of a single core cable to be used on 50
kV, single phase system. The maximum permissible stress in the dielectric is not to
exceed 40 kV/cm.
Solution:
Peak value of cable voltage: 𝑉 = 50 𝑥 2

𝑉 = 70.7 𝑘𝑉
Max. permissible stress: gmax = 40 kV/ cm
Most economical conductor diameter:
2𝑉
𝑑=
𝑔𝑚𝑎𝑥
2(70.7 𝑘𝑉)
𝑑=
40 𝑘𝑉/𝑐𝑚
𝑑 = 3.53 𝑐𝑚
CAPACITANCE GRADING
For three dielectrics of outer diameter d1 , d2 and D with relative
permittivity ε1 , ε2 and ε3 respectively, the potential across each layer
is:
𝑔𝑚𝑎𝑥 𝑑1
𝑉1 = 𝑑 𝑙𝑛 (inner layer)
2 𝑑
𝑔𝑚𝑎𝑥 𝑑
𝑉2 = 𝑑1 𝑙𝑛 2 (2nd layer)
2 𝑑1
𝑔𝑚𝑎𝑥 𝐷
𝑉3 = 𝑑2 𝑙𝑛 (3rd layer)
2 𝑑2
ε1 𝑑 = ε2 𝑑1 = ε3 𝑑2
The total potential difference bet. Core and sheath is:
𝑉 = 𝑉1 + 𝑉2 + 𝑉3
𝑔𝑚𝑎𝑥 𝑑1 𝑑2 𝐷
𝑉= [𝑑 𝑙𝑛 + 𝑑1 𝑙𝑛 +𝑑2 𝑙𝑛 ]
2 𝑑 𝑑1 𝑑2
CAPACITANCE GRADING
If the cable had homogeneous dielectric, then for the same values of
d, D and gmax, the permissible p.d between core and earthed
sheath:
𝑔𝑚𝑎𝑥 𝐷
𝑉′ = 𝑑𝑙𝑜𝑔
2 𝑑
If the maximum stress in the three dielectric is not the same, then,
𝑉 = 𝑉1 + 𝑉2 + 𝑉3
𝑔𝑚𝑎𝑥 𝑑1 𝑔𝑚𝑎𝑥 𝑑2 𝑔𝑚𝑎𝑥 𝐷
𝑉= 𝑑 𝑙𝑛 + 𝑑1 𝑙𝑛 + 𝑑2 𝑙𝑛
2 𝑑 2 𝑑1 2 𝑑2
Sample Problem
A single-core lead sheathed cable is graded by using three dielectrics of relative

permittivity 5, 4 and 3 respectively. The conductor diameter is 2 cm and overall
diameter is 8 cm. If the three dielectrics are worked at the same maximum
stress of 40 kV/cm, find the safe working voltage of the cable, assuming the
same conductor and overall diameter and the maximum dielectric stress.
Solution:
Hence;
d = 2cm d1 = ? d2 = ? D = 8cm
ε1 = 5 ε1 = 4 ε3 = 3 gmax = 40 kV/cm
As the maximum stress in the three dielectrics is the same;
ε1 d = ε2 d1 = ε3 d2
(5)(4) = 4 d1 = 3 d2
d1 = 2.5 cm
d2 = 3.34 cm
Sample Problem
A single-core lead sheathed cable is graded by using three dielectrics of relative permittivity
5, 4 and 3 respectively. The conductor diameter is 2 cm and overall diameter is 8 cm. If the
three dielectrics are worked at the same maximum stress of 40 kV/cm, find the safe working
voltage of the cable, assuming the same conductor and overall diameter and the maximum
dielectric stress. Solution:
Permissible Peak voltage for the cable:
𝑔𝑚𝑎𝑥 𝑑1 𝑑 𝐷
𝑉= [𝑑 𝑙𝑛 + 𝑑1 𝑙𝑛 2 𝑑2 𝑙𝑛 ]
2 𝑑 𝑑1 𝑑2
40 2.5 3.34 8
𝑉= [2 𝑙𝑛 + 2.5 𝑙𝑛 + 3.34 𝑙𝑛 ]
2 2 2.5 3.34
𝑉 = 81.808 𝑘𝑉
Safe working voltage (r.m.s) for cable:
81.808
𝑉=
2
𝑉 = 57.84 𝑘𝑉

Construction of Cable

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HIGH VOLTAGE CABLE

The conductors are made of tinned copper

495𝑥106 Ω 𝑥2𝜋(1,000𝑚) 𝑟2 Insulation thickness = 2.5-1.25

And the value of gmax under this condition is:

Peak value of cable voltage: 𝑉 = 50 𝑥 2

A single-core lead sheathed cable is graded by using three dielectrics of relative

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