Design Standard

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Gulf Cables-Jordan Title : DESIGN OF STANDARD PRODUCTS Issue 1 CA/TE/P/01
1.0 PURPOSE :
To ensure all standard products and constructions are
carried out under controlled conditions and the required
specifications are met in all design stages.
2.0 SCOPE :
All standard products - Low voltage cables, Medium
voltage cables, and all products covered by Gulf Cables - Gulf Cables
Jordan Catalogues. Catalogues
3.0 REFERENCE:
ISO 9001(2000), section 4.4, Design control ISO 9001
4.0 RESPONSIBILITY :
Technical In charge, Technical Engineer
Production In charge, QC In charge
PROCEDURE :
5.0 Design of standard products for Low Voltage Cables,
Medium Voltage Cables and Wires as per appropriate
standard includes the following :
1) Dimensional Construction
2) Manufacturing Instruction (TE/F/03) TE/F/03
DESIGN AND DEVELOPMENT PLANNING :

5.1 This procedure deals with Standard products, which
have no special requirement. (Low Voltage cables and
Medium Voltage Cables as per IEC and BS).
Design includes mainly preparing manufacturing

instruction (TE/F/03) based on the above standards TE/F/03
Technical taking into consideration Gulf Cables production
Engineer capability and testing facilities.
As the above items are in regular production, follow

process control procedure CA/PR/01 for the required CA/PR/01
Production process.
Engineer
Follow procedures CA/QC/01, CA/QC/02 and CA/QC/03 CA/QC/01
for in-process inspection and final testing. CA/QC/02
QC Engineer CA/QC/03
Material shall be comply with procedure QMS-01 for QMS-01

Technical technical term of delivery which shall be prepared,
Engineer modified and approved by the technical department.
For Design Verification and Design Validation the

following steps shall be followed.
Compiled By: Mohamad Samih Approved By: Khalid Al-Turk Date Page
01 AUG., 07 1 of 47
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QC In charge Quality Control In charge shall be responsible for

performing at least one Type test per year for each type
of insulation. For Low Voltage cables the test shall be
performed as per IEC 60502-1, BS 6346, BS 5467 as IEC 60502-1,
applicable. BS 6346, BS 5467
For Medium voltage cables the type test shall be

performed as per IEC 60502-2 and BS 6622. Guide for IEC 60502-2
invoking type test shall be as per BS 6622 BS 6622
5.2 ORGANIZATIONAL AND TECHNICAL INTERFACE:

Interface and responsibility shall be as detailed out in
sub-clause 5.1.
5.3 DESIGN INPUT :

Low Voltage cables with PVC or XLPE insulation,
armoured (AWA, ATA, SWA, STA) and non-armoured
0.6/1 kV up to and including 1.8/3 kV
Medium Voltage cables (6, 10, 15, 20 and 30 kV cables)

with XLPE insulation armoured (AWA, ATA, SWA, STA)
and non-armoured cables with extruded insulation
screen - Bonded or Strippable, Copper wire or Copper
tape screen with or without Lead sheath.
Wiring cables 300/500 V, PVC insulated, PVC sheathed

with solid, stranded or flexible conductors round or flat
construction.
PVC insulated wires rated 450/750 V with solid, stranded

and flexible conductors.
DESIGN OUTPUT :
Prepare dimensional manufacturing instruction (TE/F/03)
Technical using formula as per form TE/F/17 based on the latest TE/F/03
Engineer 5.4 edition of the following standards either manually or TE/F/17
using the approved computer program.
IEC 227-3 for CU/PVC wires.

IEC 227-4 for CU/PVC/PVC cables rated 300/500 V IEC 227-3
IEC 227-5 for CU/PVC/PVC flexible cables rated 300/500 IEC 227-4
Volts (Table 9). IEC 227-5
IEC 60502-1 for cables up to and including 3 kV
IEC 60502-2 for cables up to and including 30 kV IEC 60502-1
IEC 60502-2
01 AUG., 07 2 of 47
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BS 6004 for CU/PVC wires rated 450/750 V and BS 6004

CU/PVC/PVC cables rated 300/500 Volts
BS 6500 for CU/PVC/PVC flexible cords rated 300/500 BS 6500

(Table 16).
For Flat cables, BS 6004 (Table 5,6) and BS 6500 BS 6004, BS 6500
(Table 15,16)
BS 6346 for PVC insulated cables rated 0.6/1 kV BS 6346
BS 5467 for XLPE insulated cables rated 0.6/1 kV and BS 5467

3 kV.
BS 6622 for XLPE insulated cables for rated voltages BS 6622

3.8/6.6 kV up to 19/33 kV
5.5 DESIGN REVIEW :

Technical If Manufacturing Instruction (TE/F/03) for standard TE/F/03
Engineer product is prepared manually, Technical engineer shall
cross-check for correctness of information.
If Manufacturing instruction (TE/F/03) is taken from TE/F/03
computer using the existing computer program, it shall
be considered as approved for correctness.
If minor manual changes are made on the computer
print-out by technical engineer such as, changing
armour wire diameter or changing of sheath thickness
in-line with BS Standards as per form TE/F/19, TE/F/19
approval shall be provided on form SA/F/02 by Technical SA/F/02
In charge/Senior Technical Engineer.
5.6 DESIGN VERIFICATION :

Production In Manufacture Cables as per Manufacturing Instruction
charge TE/F/03. Follow process control procedure CA/PR/01 and TE/F/03
provide sample when requested to Quality Control. CA/PR/01
QC Engineer Perform in-process tests and final testing as per test CA/QC/01
procedures CA/QC/01, CA/QC/02 and CA/QC/03 CA/QC/02
CA/QC/03
QC Engineer Perform type test when requested in the manufacturing
instruction or if instructed by Technical In charge.
01 AUG., 07 3 of 47
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For new material that has been used, material shall be

from an approved supplier and a part or complete type
test shall be performed.
In general for 0.6/1 kV cables, if type test was carried

out satisfactorily on one cable size, then type test should
not be repeated on other sizes of the same type of cable
which have the same composition of insulation and
sheathing material regardless of the nature of conductor
(Copper or Aluminium) or the type and material of
armour.
If the material of insulation has been changed then type

test for insulation and compatibility test shall be
performed. If the material of sheath has been changed
then type test for sheath material and compatibility test
shall be performed.
For medium voltage cables guide for type testing shall

be taken from BS 6622. BS 6622
5.7 DESIGN VALIDATION :

QC In charge Type test shall be carried out as per customer
request/internal policy as proof of validation. Completion
of order subsequent to type test results shall be
considered as customer approval for validation.
Third party inspection carried out as per customer

requirement shall also be proof of design validation.
Also, the long experience of Gulf Cables in Manufacture

of Medium Voltage and Low Voltage Cables for more
than 20 years without any major customer complaint
regarding cable performance and reliability confirms
design validity. More ever, the long experience of Gulf
Cables stuff shall be considered.
5.8
Technical DESIGN CHANGES :
Engineer Any amendments in the Standards, which shall affect
the cable construction, shall be brought to the notice of
Technical In charge.
Technical In
charge Implementing the changes of the computer program in
case any modification shall be done by the technical
department.
01 AUG., 07 4 of 47
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Technical Check the correctness of computer program output

Engineer manually or with the aid of computers and
keep/maintain records in a separate file.
Technical In Approve the computations from the computer program

charge and the approval shall be a go-ahead signal for
computer program implementation.
Any feedback regarding the applicability of

Production In manufacturing instruction or on cable construction,
charge/ which is thought as beneficial and might provide
QC In charge improvement shall be brought to the notice of Technical
In charge.
Study suggestions/advice of Production In charge and

Technical In QC In charge. If feasible and acceptable take necessary
charge steps for implementation as long as they comply with
the standard requirement.
For cables as per IEC, print out of the required size is

User directly taken from computer. Sample print outs for one
Low Voltage Cable and one Medium Voltage cable are
enclosed in form TE/F/03 TE/F/03
GUIDE FOR PREPARATION OF MANUFACTURING

6.0 INSTRUCTIONS :
For conductor construction and weight, refer to the

conductor construction tables in TE/F/18 TE/F/18
Unless specified by the customer, conductor for all Low

Voltage cables except 4 core cables shall be Round Non-
Compacted for sizes up to 16 mm2, while for sizes 16
mm2 and above, Conductor shall be Round Compacted
(GCIS *).
For 4 core cables, Conductor shall be sectoral stranded

for 4x25 mm2 cables and above, and shall be round
stranded Non-compacted for all other cables (GCIS *).
Conductor for medium voltage cables shall be round

stranded compacted (GCIS *).
Unless specified by the customer, the thickness of semi-

conductive conductor screen shall be as tabulated in TE/F/20
form TE/F/20
Unless specified by the customer, thickness of semi-

conductive insulation screen shall be as tabulated in TE/F/20
form TE/F/20
01 AUG., 07 5 of 47
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Thickness of copper tape for Medium Voltage cables

shall be 0.1 mm (Gulf Cables Internal Standard) unless a
different thickness is specified by the customer.
For copper wire screened cables the cross-section of

copper wire screen shall be as follows unless a different
cross-section is specified by the customer:
Conductor Size Screen Size

35 mm² to 120 mm² 16 mm²
150 mm² to 300 mm² 25 mm²
400 mm² to 630 mm² 35 mm²
Lay ratio for copper wire screen shall be 10 (Approx.)

(GCIS *)
For number of wires and diameter of copper wire

TE/F/21
screen refer to form TE/F/21 (GCIS *)
Binder tape over assembly for 3 core cables shall be

polypropylene tape of thickness 0.125 mm (GCIS *)
Bedding tape under lead sheath shall be of crepe paper

of thickness 0.5 mm (GCIS *)
Size of Polypropylene fillers for different constructions

are provided in form TE/F/24 for guidance. TE/F/24
Filler shall be of polypropylene string for multi core
cables of sizes 35 mm2 and above while for sizes
25 mm2 and below PVC bedding shall fill the interstices
of the multi core cables (GCIS*)
Width of Copper tape, Copper tape open helix,

Polypropylene tapes and Steel Tape are provided in form
TE/F/22 (GCIS *) TE/F/22
Lay ratio of Armour wire shall be 10 Approximately

(GCIS *).
Computation for taping angle, Lay length, Resistance

and Weight Ratio are enclosed in TE/F/23 (GCIS *).
TE/F/23
Densities of materials : Densities of sample materials
used in the construction of cables are provided in form
TE/A/F/25
TE/F/25
Note : The Values provided in forms TE/F/17 to TE/F/25
are based on standard material characteristics which can
be modified/improved based on revision of standards
and material improvement.
GCIS* = Gulf Cables Internal Standard
01 AUG., 07 6 of 47
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Forms:
TE/F/03 : Manufacturing Instruction from computer

For standard product
TE/F/17 : Formulae for weight computation
TE/F/18 : Conductor construction tables
TE/F/19 : Comparison tables between IEC & BS
TE/F/20 : Thickness of Semi-conducting screens
TE/F/21 : Calculation of wire diameter and
number of wires for copper wire screen
TE/F/22 : Width of Tapes
TE/F/23 : Computation of taping angle, Lay
Length, Weight and Resistance ratio
TE/F/24 : Size of Polypropylene fillers
TE/F/25 : Density of Materials
01 AUG., 07 7 of 47
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LEGENDS
Nc = number of cores
Wcr = weight of the conductor in tables
K = assembling factor
ti = Thickness of insulation
Dins = Diameter over insulation
Dnins = Diameter over insulation of neutral core
 = density of material
S = Total cross-section of all conductors
Dcore = diameter of core
Nc = number of cores
unb = Dia under bedding
tb = bedding thickness
assm = Diameter over assembly
tl = Thickness of lead sheath
Nr = Number of armour wires
dr = diameter of armour wire
tst = Thickness of steel tape armour
bed = Diameter over bedding
untp = Diameter under tape
tth = Thickness of tape
Or = % overlap ratio for tapes
tsh = Thickness of sheath
D = Diameter under outer sheath
Form # TE/F/17 01/08/07

01 AUG., 07 8 of 47
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1. Diameter of Conductor :
con = Diameter of conductor from table + 2*tsc
where
tsc = thickness of Semi-Conductive tape
2. Diameter over conductor screen:

Dcsc = Dins +2*tcsc
where :
tcsc = Thickness of semi-conductive conductor screen
3. Diameter over insulation:

Dins = con + (2tcsc +2*ti)
where :
con = Diameter of conductor
ti = Thickness of insulation
tcsc = Thickness of semi-conductive conductor screen
4. Diameter over insulation screen :

Dinsc = Dins+2*tinsc+2*tsc
where:
tinsc = Thickness of semi-conductive insulation screen
tsc = Thickness of semi-conductive tape
5. Diameter over metallic screen:

Dmsc = Dinsc + 4*tcu + 2*tsc for copper tape screen
= Dinsc + 2*dcuw + 2*tcu + 2*tsc for Cu wire screen+ binder
where:
tcu = Thickness of copper tape
dcuw = diameter of copper wires for metallic screen
6. Diameter over assembly :

assm = Dmsc * Fassm
where :
Fassm = Assembly factor from table for round conductor cable
S = Total cross section for all conductors
Form # TE/F/17 01/08/07
01 AUG., 07 9 of 47
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Assembly for sector shaped conductors :

For 2 core cables Assembly dia. = assm = (1.25 S + 4.04ti)*1.03
For 3 core cables Assembly dia. = assm = (1.25 S + 4.35ti)*1.03
1
For 3 cores and 4 core cables Assembly dia. = assm = (1.25 S + 4.88ti)*1.03
2
7. Diameter over bedding or inner covering :

bed = assm + 2*tb for single core cables
= assm + 4*tp + 2*tb for multi core cables
where:
tp = Thickness of polypropylene tape
tb = bedding thickness
8. Diameter over armour:

arm = bed + 2*dr ( with round wire armour)
= bed + 2*dr + 2*tst (with round wire + steel tape binder)
= bed + 4*tst (with steel tape armour)
where:
tst = Steel Tape thickness
dr = diameter of armour wire
9. Overall diameter of cable:

D = arm + 2*tsh
where:
tsh = thickness of outer sheath
Form # TE/F/17 01/08/07

01 AUG., 07 10 of 47
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Weight Computation
1. Conductor weight:
Wcond = Nc * Wcr * K
2. Weight of insulation:
For round conductors :

Please refer to the general formula attached
For sector shaped 3 core cables :

 

Wins =  A* π  3  ti π  3  * ti *  * 1.004

where:
1/2
 4
A =  1.20* S *   3 * ti
 π
S = Total cross section of all conductors
1
For sector shaped 4 & 3 core cables:
2
 
Wins = A* π  4   ti π  4  * ti *  * 1.004
 
Wins = 0.75 * A* π  4   ti π  4  * ti *  * 1.004
weight of insulation for neutral conductor shall be as given above.
where:
1/2
 4
A =  1.20 * S *   2 * ti
 π 
S = Total cross section of all conductors
3. Weight of metallic and non-metallic tapes
 100 
Wtp = (untp + 2* tth) * tth *  *  *  
 100 Or 
4. Filling of interstices : (for cables with round conductors)
π
2 core : Wf = [  assm 2  2  Dins 2 ]   
4
π
3 core : Wf = [  assm 2  3.0274 Dins 2 ]  γ
4
1
3 core :
2
Wf={ [  assm 2  4.102  Dins 2 ]  0.75    4.102  Dn ins 2  * 0.25 }   γ
2 π
 assm  4
4 core : Wf = [  assm 2  4.102 Dins 2 ] π  

4
Form # TE/F/17 01/08/07
01 AUG., 07 11 of 47
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π
5 core : Wf = [ assm2  5.20  Dins 2 ]  γ
4
π
6 cores : Wf = [ assm2  6.308  Dins 2 ]  γ
4
π
7 cores : Wf = [ assm2  7.308  Dins 2 ]  γ
4
Polypropylene fillers for multi core cables with sector shaped conductors :
Size of cable Center Each outer
mm2 Kg/km Interstice Kg/km
95 5 5
120 6 5
150 6 5
185 7 7
240 10 10
300 14 10
400 14 14
500 17 17
5. Weight of Inner covering or bedding for round conductor cables :
Single core
Wb =  (unb + tb) * tb * 
Multicore cables with penetrating sheath:

2 core cables : Wb = (bed2 - 2 * Dins2) *
π *γ
4
3 core cables : Wb = (bed2 - 3.0273966 * Dins2) *
π *γ
4
1 3 1
core cables Wb =(bed2 - 4.1016667 *( Dins2 + Dn 2 π *γ
3 ins ))*
2 4 4 4
π *γ
4
π *γ
4
multicore cables with non-penetrating sheath
Wb =  (unb + tb) * tb * 
6. Armour wires
Number of armour wires = Nr = (bed + dr) *  * 0.9/dr

Weight of armour wires = Nr * dr2 * *  * 1.05
4

Weight of steel tape armour =  * (bed + 2*tst) * tst *  * 
100 
 100  Or 
For steel tape armour Or = 25
γ
8. Weight of outer sheath = *(D + tsh)*tsh* + 0.1073*dr2*Nr*
0.9
Form # TE/F/17 01/08/07
01 AUG., 07 12 of 47
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9. If Lead sheath is applicable Weight of lead sheath = (Dul+tl) * tl *  * 
The General formula for the weight of insulation
Wins  cu  tins  tins  π α ins  Ainterstices α ins

ins = Diameter of the conductor(mm)
tins = Thickness of the insulation (mm)
ins = Density of the insulation (g/cm3)
Aint = Area of insulation filling the interstices of outermost layer
n
md x cos(360/2n)
md
Form # TE/F/17 01/08/07

01 AUG., 07 13 of 47
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General formula for the area of insulation filling the interstices of the conductors outermost
layer.
 nm  360  π  n 
Aint  π m  0.5 2  cos     1   d 2
 2  2n  4  2  
Where:
m = Number of layer over the central wire
n = Number of strands in the outermost layer
d = Diameter of strand (mm)
Number of Number of layer Number of Aint

strands per over the central strands in the
conductor wire (m) outermost layer
(n)
7 1 6 1.329d2
19 2 12 2.546d2
37 3 18 4.041d2
61 4 24 5.818d2
91 5 30 7.878d2
Form # TE/F/17 01/08/07
01 AUG., 07 14 of 47
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Non-Compacted Copper Conductors
Size No. of Conductor Wire Weight Prfm Lay L. L

Wire Diameter Diameter
0.5 1 0.80 0.80 5 0.00 0
1.0 1 1.13 1.13 9 0.00 0
1.5 1 1.38 1.38 13 0.00 0
1.5 7 1.55 0.52 13 0.00 25
2.5 1 1.98 1.78 22 0.00 0
2.5 7 1.98 0.67 22 0.00 32
4 1 2.25 2.25 35 0.00 0
4 7 2.52 0.85 35 0.00 38
6 1 2.76 2.76 51 0.00 0
6 7 3.12 1.04 51 0.00 52
10 1 3.57 3.57 86 0.00 0
10 7 4.01 1.335 86 0.00 68
16 1 4.51 4.51 137 0.00 0
16 7 5.03 1.675 137 0.00 84
25 7 6.30 2.10 216 0.00 100
35 7 7.44 2.48 301 0.00 110
50 19 8.90 1.78 408 0.00 150
70 19 10.62 2.124 588 0.00 190
95 19 12.40 2.48 819 0.00 195
120 37 14.07 2.01 1031 0.00 200
150 37 15.54 2.22 1274 0.00 210
185 37 17.50 2.50 1609 0.00 235
240 61 19.98 2.22 2110 0.00 260
300 61 22.50 2.50 2650 0.00 280
400 61 25.38 2.82 3410 0.00 290
500 61 28.53 3.17 4375 0.00 315
630 91 32.78 2.98 5690 0.00 360
800 91 36.96 3.36 7250 0.00 400
1000 91 41.00 3.73 8854 0.00 400
1200 91 44.30 4.03 10359 0.00 400
Tolerances on wire diameter : d< 2.85 ± 0.010 mm
d  2.85 ± 0.015 mm
Tolerance on Conductor diameter : Upto and including 150 mm² : ± 0.1 mm

Above 150 mm² : ± 0.2 mm
Note : Conductor Weight and Tolerance on Conductor diameter are for guidance only.
Maximum Conductor resistance should not be exceeded.
Form # TE/F/18 01/08/07

01 AUG., 07 15 of 47
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Compacted Copper Conductors
Size No. of Conductor Wire Weight Prfm Lay L.

Wire Diameter Diameter L
16 1 4.51 4.51 142 0.00 0.00
16 7 4.70 1.78 139 0.00 68
25 7 5.90 2.22 220 0.00 80
35 7 6.90 2.60 305 0.00 95
50 7 8.10 3.01 408 0.00 110
50 19 8.10 1.83 408 0.00 110
70 19 9.70 2.22 592 0.00 125
95 19 11.40 2.65 822 0.00 153
120 19 12.90 3.01 1035 0.00 173
120 37 12.90 2.13 1035 0.00 173
150 19 14.50 3.27 1277 0.00 188
150 37 14.30 2.35 1277 0.00 188
185 37 16.00 2.65 1602 0.00 211
240 37 18.30 2.97 2110 0.00 280
240 61 18.40 2.35 2110 0.00 240
300 37 20.40 3.34 2650 0.00 300
300 61 20.70 2.65 2650 0.00 271
400 61 23.20 2.96 3390 0.00 300
500 61 26.70 3.37 4348 0.00 0.00
630 61 30.40 3.73 5623 0.00 375
800 61 33.70 4.24 7210 0.00 400
1000 61 38.10 4.77 9053 0.00 431
1200 61 40.90 5.13 10572 0.00 431
Tolerances : d< 2.85 ± 0.010 mm

d  2.85 ± 0.015 mm
where d=diameter of wire

Above 95 mm² : ± 0.2 mm
Form # TE/F/18 01/08/07

01 AUG., 07 16 of 47
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Non-Compacted Aluminium Conductors
Size No. of Conductor Wire Weight Prfm Lay L. L

6 7 3.21 1.07 18 0.00 0.00
10 7 3.93 1.31 26 0.00 0.00
16 7 4.98 1.66 42 0.00 0.00
25 7 6.30 2.10 67 0.00 0.00
35 7 7.41 2.47 92 0.00 0.00
50 19 8.75 1.75 126 0.00 0.00
70 19 10.55 2.11 183 0.00 0.00
95 19 12.40 2.48 253 0.00 0.00
120 37 14.00 2.00 321 0.00 0.00
150 37 15.47 2.21 392 0.00 0.00
185 37 17.36 2.48 493 0.00 0.00
240 61 19.89 2.21 647 0.00 0.00
300 61 22.23 2.47 808 0.00 0.00
400 61 25.20 2.80 1039 0.00 0.00
500 61 28.62 3.18 1339 0.00 0.00
630 91 32.56 2.96 1735 0.00 0.00
800 91 36.74 3.34 2210 0.00 0.00
1000 91 41.25 3.75 2785 0.00 0.00

3.65 > d  2.56 ± 0.015 mm
d  3.65 ± 0.020 mm
Tolerance on Conductor diameter : Upto and including 120 mm² :± 0.1 mm

300>S>120 mm² : ± 0.15 mm
630>S300 mm² : ± 0.3 mm
S630 mm² : ± 0.4 mm
where S=cross-sectional area of conductor
Form # TE/F/18 01/08/07
01 AUG., 07 17 of 47
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Compacted Aluminium Conductors
Size No. of Conductor Wire Weight Prefm Lay L. L

10 1 3.47 3.47 26 0.00 0.00
16 7 4.70 1.71 42 0.00 57
25 7 6.00 2.14 66 0.00 71
35 7 7.10 2.51 92 0.00 85
50 7 8.30 2.88 124 0.00 97
70 14 9.70 2.54 176 0.00 118
95 19 11.55 2.54 249 0.00 138
120 19 12.95 2.85 309 0.00 155
150 19 14.30 3.19 380* 0.00 171
185 30 15.90 2.85 475 0.00 194
240 30 18.40 3.19 634 0.00 223
300 37 20.50 3.27 787 0.00 248
400 61 24.00 2.90 1018* 0.00 284
500 61 27.00 3.25 1310* 0.00 319
630 61 30.40 3.66 1689 0.00 362

3.65 > d  2.56 ± 0.015 mm
d  3.65 ± 0.020 mm

300>S>120 mm² : ± 0.15 mm
630>S300 mm² : ± 0.3 mm
S630 mm² : ± 0.4 mm
where S=cross-sectional area of conductor
* weigth by extrapolation
Form # TE/F/18 01/08/07
01 AUG., 07 18 of 47
Doc. Nr.
Sector Shaped Copper Conductors: SCUB (90oC)
Size No. of Height Wire Weight Prfm Lay L. L

Wire Diameter
16 7 4.40 1.75 139 0.00 68
25 7 5.80 2.22 220 0.00 84
35 7 6.60 2.65 303 0.00 135
50 19 7.50 1.86 411 1270 150
70 19 9.10 2.25 595 1360 190
95 19 11.00 2.65 825 1665 210
120 19 12.20 3.01 1035 1665 225
120 37 12.20 2.16 1035 1665 225
150 19 13.80 3.27 1282 1665 235
150 37 13.80 2.35 1282 1665 235
185 37 15.10 2.65 1605 2055 240
240 37 17.60 3.01 2110 2055 260
240 61 17.60 2.35 2110 2055 260
300 37 19.80 3.40 2650 2055 280
300 61 19.80 2.65 2650 2055 280
400 61 23.20 3.01 3390 2512 320
500 61 26.30 3.38 4352 2512 340

d  2.85 ± 0.015 mm
Note : Conductor Height and Weights are for guidance only. Maximum Conductor resistance
should not be exceeded.
Form # TE/F/18 01/08/07
01 AUG., 07 19 of 47
Doc. Nr.
Sector Shaped Aluminium Conductors: SALB (90oC)
Size No. of Height Wire Weight Prfm Lay L. L

Wire Diameter
25 7 5.50 2.18 66 0.00 90
35 7 6.50 2.56 92 0.00 105
50 7 7.50 2.98 124 1270 125
70 14 9.10 2.53 179 1360 150
95 19 10.80 2.56 249* 1665 170
120 19 12.20 2.88 309 1665 190
120 37 12.20 2.07 309 1665 190
150 19 13.50 3.19 380* 1665 215
150 37 13.50 2.29 380* 1665 215
185 30 15.20 2.85 473 2055 230
185 37 15.20 2.57 473 2055 230
240 30 17.50 3.26 632 2055 240
240 37 17.50 2.94 632 2055 240
240 61 17.50 2.29 632 2055 240
300 30 19.60 3.65 789 2055 260
300 37 19.60 3.29 789 2055 260
300 61 19.60 2.55 789 2055 260
400 61 22.50 2.92 1018* 2512 290
500 61 25.60 3.31 1311 2512 290
630 61 29.20 3.76 1722 2512 290

3.65 > d  2.56 ± 0.015 mm
d  3.65 ± 0.020 mm
Where d=diameter of wire
Note : Conductor Height and Weights are for guidance only. Maximum Conductor resistance
should not be exceeded.
* weight by extrapolation
Form # TE/F/18 01/08/07
01 AUG., 07 20 of 47
Doc. Nr.
ARMOURING REQUIREMENT AS PER

BS 5467 & IEC 60502-1
FOR XLPE INSULATED CONTROL CABLES
SIZE 1.5 mm² 2.5 mm² 4 mm²

mm²
NUMBER GALVANISED STEEL WIRE ARMOUR DIAMETER
OF BS IEC BS IEC BS IEC
C 5467 60502-1 5467 60502-1 5467 60502-1
ORES
2 0.9 0.8 0.9 0.8 0.9 0.8
3 0.9 0.8 0.9 0.8 0.9 0.8
4 0.9 0.8 0.9 0.8 0.9 0.8
5 0.9 0.8 0.9 0.8 1.25 1.25
7 0.9 0.8 0.9 1.25 1.25 1.25
10 1.25 1.25 1.25 1.25 1.6 1.6
12 1.25 1.25 1.25 1.25 1.6 1.6
14 1.25 1.25 1.25 1.25 1.6 1.6
16 1.25 1.25 1.25 1.6 1.6 1.6
19 1.25 1.25 1.6 1.6 1.6 1.6
24 1.6 1.6 1.6 1.6 1.6 1.6
27 1.6 1.6 1.6 1.6 1.6 1.6
30 1.6 1.6 1.6 1.6 2.0 1.6
37 1.6 1.6 1.6 1.6 2.0 2.0
44 1.6 1.6 1.6 2.0 2.0 2.0
48 1.6 1.6 2.0 2.0 2.0 2.0
52 - 1.6 - 2.0 - 2.0
61 - 2.0 - 2.0 - 2.0
Form # TE/F/19 01/08/07

01 AUG., 07 21 of 47
Doc. Nr.
INSULATION, SHEATHING & ARMOUR REQUIREMENTS

AS PER BS 5467 & IEC 60502-1
FOR XLPE INSULATED SINGLE CORE LV POWER CABLES
SIZE XLPE ALUMINIUM UNARMOURED ARMOURED

INSULATION BEDDING WIRE DIA. CABLES CABLE
(mm2) (mm) (mm) (mm) (mm) (mm)
BS IEC BS IEC BS IEC BS IEC BS IEC
5467 60502-1 5467 60502-1 5467 60502-1 5467 60502-1 546 60502-1
7
1.5 0.6 0.7 - 1.0 - - - 1.4 - -
2.5 0.7 0.7 - 1.0 - - - 1.4 - -
4.0 0.7 0.7 - 1.0 - - - 1.4 - -
6.0 0.7 0.7 - 1.0 - - - 1.4 - -
10 0.7 0.7 - 1.0 - - - 1.4 - -
16 0.7 0.7 - 1.0 - - - 1.4 - -
25 0.9 0.9 - 1.0 - 0.8 - 1.4 - 1.8
35 0.9 0.9 - 1.0 - 0.8 - 1.4 - 1.8
50 1.0 1.0 0.8 1.0 0.9 1.25 - 1.4 1.5 1.8
70 1.1 1.1 0.8 1.0 1.25 1.25 - 1.4 1.5 1.8
95 1.1 1.1 0.8 1.0 1.25 1.25 - 1.5 1.6 1.8
120 1.2 1.2 0.8 1.0 1.25 1.6 - 1.5 1.6 1.8
150 1.4 1.4 1.0 1.0 1.6 1.6 - 1.6 1.7 1.8
185 1.6 1.6 1.0 1.0 1.6 1.6 - 1.6 1.8 1.8
240 1.7 1.7 1.0 1.0 1.6 1.6 - 1.7 1.8 1.9
300 1.8 1.8 1.0 1.0 1.6 1.6 - 1.8 1.9 1.9
400 2.0 2.0 1.2 1.2 2.0 2.0 - 1.9 2.0 2.1
500 2.2 2.2 1.2 1.2 2.0 2.0 - 2.0 2.1 2.2
630 2.4 2.4 1.2 1.2 2.0 2.0 - 2.2 2.2 2.3
800 2.6 2.6 1.4 1.4 2.5 2.5 - 2.3 2.4 2.5
1000 2.8 2.8 1.4 1.4 2.5 2.5 - 2.4 2.5 2.7
Form # TE/F/19 01/08/07
01 AUG., 07 22 of 47
Doc. Nr.

AS PER BS 5467 & IEC 60502-1
FOR XLPE INSULATED TWO CORES LV POWER CABLES
SIZE XLPE BEDDING GALV. STEEL UNARMOURED ARMOURED

INSULATION WIRE CABLES CABLE
5467 60502-1 5467 60502-1 5467 60502-1 5467 60502-1 546 60502-1
7
1.5 0.6 0.7 0.8 1.0 0.9 0.8 - 1.8 1.3 1.8
2.5 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
4.0 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
6.0 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
10 0.7 0.7 0.8 1.0 0.9 1.25 - 1.8 1.5 1.8
16 0.7 0.7 0.8 1.0 1.25 1.25 - 1.8 1.5 1.8
25 0.9 0.9 0.8 1.0 1.25 1.6 - 1.8 1.6 1.8
35 0.9 0.9 1.0 1.0 1.6 1.6 - 1.8 1.7 1.8
50 1.0 1.0 1.0 1.0 1.6 1.6 - 1.8 1.8 1.8
70 1.1 1.1 1.0 1.0 1.6 1.6 - 1.8 1.9 2.0
95 1.1 1.1 1.2 1.2 2.0 2.0 - 2.0 2.0 2.1
120 1.2 1.2 1.2 1.2 2.0 2.0 - 2.1 2.1 2.2
150 1.4 1.4 1.2 1.2 2.0 2.0 - 2.2 2.2 2.3
185 1.6 1.6 1.4 1.4 2.5 2.5 - 2.3 2.4 2.5
240 1.7 1.7 1.4 1.4 2.5 2.5 - 2.5 2.5 2.7
300 1.8 1.8 1.6 1.6 2.5 2.5 - 2.7 2.6 2.8
400 2.0 2.0 1.6 1.6 2.5 2.5 - 2.9 2.8 3.1
500 - 2.2 - 1.6 - - - 3.1 - 3.3
630 - - - - - - - - - -
Form # TE/F/19 01/08/07
01 AUG., 07 23 of 47
Doc. Nr.

AS PER BS 5467 & IEC 60502-1
FOR XLPE INSULATED THREE CORES LV POWER CABLES
SIZE XLPE BEDDING GALV. STEEL UNARMOURED ARMOURED

INSULATION WIRE CABLES CABLE
5467 60502-1 5467 60502-1 5467 60502-1 5467 60502- 5467 60502-1
1
1.5 0.6 0.7 0.8 1.0 0.9 0.8 - 1.8 1.3 1.8
2.5 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
4.0 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
6.0 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
10 0.7 0.7 0.8 1.0 1.25 1.25 - 1.8 1.5 1.8
16 0.7 0.7 0.8 1.0 1.25 1.25 - 1.8 1.6 1.8
25 0.9 0.9 1.0 1.0 1.6 1.6 - 1.8 1.7 1.8
35 0.9 0.9 1.0 1.0 1.6 1.6 - 1.8 1.8 1.8
50 1.0 1.0 1.0 1.0 1.6 1.6 - 1.8 1.8 1.9
70 1.1 1.1 1.0 1.2 1.6 2.0 - 1.9 1.9 2.0
95 1.1 1.1 1.2 1.2 2.0 2.0 - 2.0 2.1 2.2
120 1.2 1.2 1.2 1.2 2.0 2.0 - 2.1 2.2 2.3
150 1.4 1.4 1.4 1.4 2.5 2.5 - 2.3 2.3 2.5
185 1.6 1.6 1.4 1.4 2.5 2.5 - 2.4 2.4 2.6
240 1.7 1.7 1.4 1.6 2.5 2.5 - 2.6 2.6 2.8
300 1.8 1.8 1.6 1.6 2.5 2.5 - 2.8 2.7 3.0
400 2.0 2.0 1.6 1.6 2.5 2.5 - 3.1 2.9 3.2
500 - 2.2 - 1.8 - 3.15 - 3.3 - 3.5
630 - 2.4 - 1.8 - - - - - -
Form # TE/F/19 01/08/07
01 AUG., 07 24 of 47
Doc. Nr.

AS PER BS 5467 & IEC 60502-1
FOR XLPE INSULATED FOUR CORE LV POWER CABLES
SIZE XLPE GALV. STEEL UNARMOURED ARMOURED

INSULATION BEDDING WIRE CABLES CABLE
5467 60502-1 5467 60502-1 5467 60502-1 5467 60502-1 5467 60502-1
1.5 0.6 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
2.5 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
4.0 0.7 0.7 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
6.0 0.7 0.7 0.8 1.0 1.25 1.25 - 1.8 1.5 1.8
10 0.7 0.7 0.8 1.0 1.25 1.25 - 1.8 1.5 1.8
16 0.7 0.7 0.8 1.0 1.25 1.6 - 1.8 1.6 1.8
25 0.9 0.9 1.0 1.0 1.6 1.6 - 1.8 1.7 1.8
35 0.9 0.9 1.0 1.0 1.6 1.6 - 1.8 1.8 1.9
50 1.0 1.0 1.0 1.0 1.6 1.6 - 1.9 1.9 2.0
70 1.1 1.1 1.2 1.2 2.0 2.0 - 2.0 2.1 2.2
95 1.1 1.1 1.2 1.2 2.0 2.0 - 2.1 2.2 2.3
120 1.2 1.2 1.4 1.4 2.5 2.5 - 2.3 2.3 2.5
150 1.4 1.4 1.4 1.4 2.5 2.5 - 2.4 2.4 2.6
185 1.6 1.6 1.4 1.4 2.5 2.5 - 2.6 2.6 2.8
240 1.7 1.7 1.6 1.6 2.5 2.5 - 2.8 2.7 3.0
300 1.8 1.8 1.6 1.6 2.5 2.5 - 3.0 2.9 3.2
400 2.0 2.0 1.8 1.8 3.15 3.15 - 3.3 3.2 3.5
500 - 2.2 - 1.8 - 3.15 - 3.5 - 3.8
630 - - - - - - - - - -
Form # TE/F/19 01/08/07

01 AUG., 07 25 of 47
Doc. Nr.
ARMOURING REQUIREMENT AS PER

BS 6346 & IEC 60502-1
FOR PVC INSULATED CONTROL CABLES
SIZE 1.5 mm² 2.5 mm² 4 mm²

mm²
NUMBER GALVANISED STEEL WIRE ARMOUR DIAMETER
OF BS 6346 IEC BS 6346 IEC BS 6346 IEC
C 60502-1 60502-1 60502-1
ORES
2 0.9 0.8 0.9 0.8 0.9 0.8
3 0.9 0.8 0.9 0.8 0.9 1.25
4 0.9 0.8 0.9 0.8 1.25 1.25
5 0.9 0.8 0.9 0.8 1.25 1.25
7 0.9 0.8 1.25 1.25 1.25 1.25
10 1.25 1.25 1.25 1.25 1.6 1.6
12 1.25 1.25 1.25 1.25 1.6 1.6
14 1.25 1.25 1.6 1.6 1.6 1.6
16 1.25 1.25 1.6 1.6 1.6 1.6
19 1.25 1.6 1.6 1.6 1.6 1.6
24 1.6 1.6 1.6 1.6 1.6 2.0
27 1.6 1.6 1.6 1.6 2.0 2.0
30 1.6 1.6 1.6 1.6 2.0 2.0
37 1.6 1.6 1.6 1.6 2.0 2.0
44 1.6 1.6 2.0 2.0 2.0 2.5
48 1.6 2.0 2.0 2.0 2.0 2.5
52 - 2.0 - 2.0 - 2.5
61 - 2.0 - 2.0 - 2.5
Form # TE/F/19 01/08/07
01 AUG., 07 26 of 47
Doc. Nr.

AS PER BS 6346 & IEC 60502-1
FOR PVC INSULATED SINGLE CORE LV POWER CABLES
SIZE PVC ALUMINIUM UNARMOURED ARMOURED

INSULATION BEDDING WIRE CABLES CABLE
6346 60502-1 6346 60502-1 6346 60502-1 634 60502-1 6346 60502-1
6
1.5 0.6 0.8 - - - - - 1.4 -
2.5 0.7 0.8 - - - - - 1.4 -
4.0 0.8 1.0 - - - - - 1.4 -
6.0 0.8 1.0 - - - - - 1.4 -
10 1.0 1.0 - - - - - 1.4 -
16 1.0 1.0 - - - - - 1.4 -
25 1.2 1.2 - 1.0 - 0.8 - 1.4 - 1.8
35 1.2 1.2 - 1.0 - 0.8 - 1.4 - 1.8
50 1.4 1.4 0.8 1.0 1.25 1.25 - 1.4 1.5 1.8
70 1.4 1.4 0.8 1.0 1.25 1.25 - 1.4 1.6 1.8
95 1.6 1.6 0.8 1.0 1.25 1.25 - 1.5 1.6 1.8
120 1.6 1.6 1.0 1.0 1.6 1.6 - 1.5 1.7 1.8
150 1.8 1.8 1.0 1.0 1.6 1.6 - 1.6 1.7 1.8
185 2.0 2.0 1.0 1.0 1.6 1.6 - 1.7 1.8 1.8
240 2.2 2.2 1.0 1.0 1.6 1.6 - 1.8 1.9 1.9
300 2.4 2.4 1.0 1.0 1.6 2.0 - 1.9 1.9 2.0
400 2.6 2.6 1.2 1.2 2.0 2.0 - 2.0 2.1 2.1
500 2.8 2.8 1.2 1.2 2.0 2.0 - 2.1 2.1 2.2
630 2.8 2.8 1.2 1.2 2.0 2.0 - 2.2 2.2 2.4
800 2.8 2.8 1.4 1.4 2.5 2.5 - 2.3 2.4 2.5
1000 3.0 3.0 1.4 1.4 2.5 2.5 - 2.5 2.5 2.7
Form # TE/F/19 01/08/07
01 AUG., 07 27 of 47
Doc. Nr.

AS PER BS 6346 & IEC 60502-1
FOR PVC INSULATED TWO CORES LV POWER CABLES
SIZE PVC BEDDING GALVANIZED UNARMOURED ARMOURED

INSULATION STEEL WIRE CABLES CABLES
6346 60502-1 6346 60502-1 6346 60502-1 634 60502-1 634 60502-1
6 6
1.5 0.6 0.8 0.8 1.0 0.9 0.8 - 1.8 1.3 1.8
2.5 0.7 0.8 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
4.0 0.8 1.0 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
6.0 0.8 1.0 0.8 1.0 0.9 1.25 - 1.8 1.5 1.8
10 1.0 1.0 0.8 1.0 1.25 1.25 - 1.8 1.6 1.8
16 1.0 1.0 0.8 1.0 1.25 1.25 - 1.8 1.6 1.8
25 1.2 1.2 1.0 1.0 1.6 1.6 - 1.8 1.7 1.8
35 1.2 1.2 1.0 1.0 1.6 1.6 - 1.8 1.8 1.8
50 1.4 1.4 1.0 1.0 1.6 1.6 - 1.8 1.9 1.9
70 1.4 1.4 1.0 1.0 1.6 1.6 - 1.9 1.9 2.0
95 1.6 1.6 1.2 1.2 2.0 2.0 - 2.0 2.1 2.2
120 1.6 1.6 1.2 1.2 2.0 2.0 - 2.1 2.2 2.3
150 1.8 1.8 1.2 1.2 2.0 2.0 - 2.2 2.3 2.4
185 2.0 2.0 1.4 1.4 2.5 2.5 - 2.4 2.4 2.6
240 2.2 2.2 1.4 1.4 2.5 2.5 - 2.6 2.5 2.8
300 2.4 2.4 1.6 1.6 2.5 2.5 - 2.7 2.7 2.9
400 2.6 2.6 1.6 1.6 2.5 2.5 - 3.0 2.9 3.2
500 2.8 2.8 - 1.8 - 3.15 - 3.2 - 3.4
630 - - - - - - - - - -
Form # TE/F/19 01/08/07
01 AUG., 07 28 of 47
Doc. Nr.

AS PER BS 6346 & IEC 60502-1
FOR PVC INSULATED THREE CORES LV POWER CABLES
SIZE PVC BEDDING GALVANIZED UNARMOURED ARMOURED

INSULATION STEEL WIRE CABLES CABLE
634 60502-1 6346 60502-1 6346 60502-1 6346 60502-1 634 60502-1
6 6
1.5 0.6 0.8 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
2.5 0.7 0.8 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
4.0 0.8 1.0 0.8 1.0 0.9 1.25 - 1.8 1.4 1.8
6.0 0.8 1.0 0.8 1.0 1.25 1.25 - 1.8 1.5 1.8
10 1.0 1.0 0.8 1.0 1.25 1.25 - 1.8 1.6 1.8
16 1.0 1.0 0.8 1.0 1.25 1.25 - 1.8 1.6 1.8
25 1.2 1.2 1.0 1.0 1.6 1.6 - 1.8 1.7 1.8
35 1.2 1.2 1.0 1.0 1.6 1.6 - 1.8 1.8 1.8
50 1.4 1.4 1.0 1.0 1.6 1.6 - 1.8 1.9 2.0
70 1.4 1.4 1.2 1.2 2.0 2.0 - 2.0 2.0 2.1
95 1.6 1.6 1.2 1.2 2.0 2.0 - 2.1 2.1 2.2
120 1.6 1.6 1.2 1.2 2.0 2.0 - 2.2 2.2 2.3
150 1.8 1.8 1.4 1.4 2.5 2.5 - 2.3 2.4 2.5
185 2.0 2.0 1.4 1.4 2.5 2.5 - 2.5 2.5 2.7
240 2.2 2.2 1.6 1.6 2.5 2.5 - 2.7 2.6 2.9
300 2.4 2.4 1.6 1.6 2.5 2.5 - 2.9 2.8 3.1
400 2.6 2.6 1.6 1.8 2.5 3.15 - 3.1 3.0 3.4
500 2.8 2.8 - 1.8 - 3.15 - 3.4 - 3.6
630 - - - - - - - - - -
Form # TE/F/19 01/08/07
01 AUG., 07 29 of 47
Doc. Nr.

AS PER BS 6346 & IEC 60502-1
FOR PVC INSULATED FOUR CORE LV POWER CABLES
SIZE PVC GALVANIZED UNARMOURED ARMOURED

INSULATION BEDDING STEEL WIRE CABLES CABLE
6346 60502-1 6346 60502-1 6346 60502-1 6346 60502-1 6346 60502-1
1.5 0.6 0.8 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
2.5 0.7 0.8 0.8 1.0 0.9 0.8 - 1.8 1.4 1.8
4.0 0.8 1.0 0.8 1.0 1.25 1.25 - 1.8 1.5 1.8
6.0 0.8 1.0 0.8 1.0 1.25 1.25 - 1.8 1.5 1.8
10 1.0 1.0 0.8 1.0 1.25 1.25 - 1.8 1.6 1.8
16 1.0 1.0 1.0 1.0 1.6 1.6 - 1.8 1.7 1.8
25 1.2 1.2 1.0 1.0 1.6 1.6 - 1.8 1.8 1.8
35 1.2 1.2 1.0 1.0 1.6 1.6 - 1.8 1.9 1.9
50 1.4 1.4 1.2 1.2 2.0 2.0 - 1.9 2.0 2.1
70 1.4 1.4 1.2 1.2 2.0 2.0 - 2.1 2.1 2.2
95 1.6 1.6 1.2 1.2 2.0 2.5 - 2.2 2.2 2.4
120 1.6 1.6 1.4 1.4 2.5 2.5 - 2.4 2.4 2.5
150 1.8 1.8 1.4 1.4 2.5 2.5 - 2.5 2.5 2.7
185 2.0 2.0 1.6 1.6 2.5 2.5 - 2.7 2.6 2.9
240 2.2 2.2 1.6 1.6 2.5 2.5 - 2.9 2.8 3.1
300 2.4 2.4 1.6 1.6 2.5 2.5 - 3.1 3.0 3.3
400 2.6 2.6 1.8 1.8 3.15 3.15 - 3.4 3.3 3.6
500 2.8 2.8 - 1.8 - 3.15 - 3.6 - 3.9
630 - - - - - - - - - -
Form # TE/F/19 01/08/07
01 AUG., 07 30 of 47
Doc. Nr.
I. Conductor Screen
Conductor size Nominal Minimum Thickness to be

(mm²) Thickness Thickness Specified in
(mm) (mm) customer
Technical Data
0 – 120 mm² 0.6 0.305 0.6
150 – 240 mm² 0.6 0.305 0.6
300 – 500 mm² 0.7 0.508 0.6
II. Insulation Screen
Diameter over Nominal Minimum Thickness to be

Insulation Thickness Thickness Specified in
(mm) (mm) (mm) customer
Technical Data
0 – 25.4 0.8 0.6 0.8
25.4 – 38.1 1.0 0.8 0.8
38.1 – 50.8 1.3 1.0 1.0
Above 50.8 1.3 1.0 1.0
Form # TE/F/20 01/08/07
01 AUG., 07 31 of 47
Doc. Nr.
Calculation of diameter and number of wires for copper wire screening:

ST
Area of screen per core (Score)   S (mm2)
P CUT
Where: ST = Total screen area

SCUT = Area of copper tape binder
P = Number of cores
1/ 2
S 4
Find do from the equation do   core   (mm)
 no 
no = 60 for Score < 15 and no = 78 for Score > 15
If 0.5 >do use d = 0.5 mm

If 0.5 <do<0.7 use d = 0.7 mm
If 0.7 <do<0.8 use d = 0.8 mm
If 0.8 <do<1.05 use d = 1.05 mm
If 1.05 <do<1.35 use d = 1.35 mm
If 1.35 <do<1.68 use d = 1.68 mm
If 1.68 <do<2.11 use d = 2.11 mm
If 2.11 <do<2.51 use d = 2.51 mm
If 2.51 <do<2.85 use d = 2.85 mm
If 2.85 <do<3.16 use d = 3.16 mm
For the value of d, calculate the number of wires from the below equation :
S core
n
 d 2 
 
 4 
The gap between wires shall not exceed 4 mm as per RC internal standard. From the diameter of wire
and number of wires obtained, calculate gap between wires using the formula :
D  d  
Gap   1.048  d
n
If the gap exceeds 4 mm then the number of wires shall be adjusted to keep the minimum gap
regardless of the cross-section. This can occur only for smaller screen cross-sections where “d” shall be
= 0.5 mm (RC internal standard). In such cases the value of “n” shall be

 D  0 .5 
n
4 .5
Form # TE/F/21 01/08/07
01 AUG., 07 32 of 47
Doc. Nr.
Calculation of diameter and number of wires for copper wire screening:
 ( Area of copper wire screen  Area of binder tape)

n
4  no. of cores
 d2
Area of copper wire screen  A  n
4
4A
i.e. n  ………
 d2
The gap between wires shall not be less than 4 mm
 (D  d )
i.e. n  ……….
4d
4A  (D  d )
equating equation 
d 2
4d
2 (4  d )
or d A
 (D  d )
For a given Area, substitute the value of “d” inside the square root starting from 0.5 mm. Substitute the
value of d obtained again inside the square root. Continue the iteration till the difference in the
substituted value and the obtained value of “d” is 0.001.
If 0.5 >d use d = 0.5

If 0.8 >d> 0.5 use d = 0.7
If 1.05 >d> 0.8 use d = 0.7
If 1.35 >d>1.05 use d = 0.7
If 1.68 >d>1.35 use d = 0.7
If 2.11 >d>1.68 use d = 0.7
If 2.51 >d>2.11 use d = 0.7
If 2.85 >d>2.51 use d = 0.7
If 3.16 >d>2.85 use d = 0.7
Suppose the value of d obtained is less than 1.35 but is greater than 1.05. select d=1.05. Calculate
 (D  d )
spacing from gap   d and no. of wires from equation
n
If the spacing (gap) is found to be less than 0.5 mm or the number of wires is greater than 60, select
d=1.35 and compute gap and no. of wires again so that gap is higher than 0.5 mm and number of wires
is less than 60.
Form # TE/F/21 01/08/07
01 AUG., 07 33 of 47
Doc. Nr.
WIDTH OF COPPER TAPE (SCREENING)
DIAMETER UNDER TAPE (mm) WIDTH

(mm)
7.5 mm upto 10.5 mm (One tape) 20*
10.5 mm upto 19 mm (One tape) 25*
19 mm upto 29.6 mm (2 tapes) 25*
29.6 mm upto 45.5 mm (2 tapes) 30
45.5 mm upto 60 mm (2 tapes) 40
Above 60 mm (2 tapes) 50*
WIDTH OF COPPER TAPE (OPEN HELIX)

(mm)
Upto 25 mm 10
25 mm and Above 15
WIDTH OF POLYPROPYLENE TAPES (20% Overlap)

(mm)
Upto 20 mm (One tape) 20*
Above 20 mm and upto 30 mm (2 Tapes) 30*
Above 30 mm and upto 50 mm (2 Tapes) 40
Above 50 mm (2 Tapes) 60
WIDTH OF STEEL TAPES (2 Tapes, 25% Overlap)

(mm)
Upto 15 mm 10*
Above 15 mm and upto 25 mm 20*
Above 25 mm and upto 35 mm 30*
Above 35 mm and upto 50 mm 40
Above 50 mm and upto 60 mm 50
Above 60 mm 60
*Tape with other widths may be used, but the overlap ratio shall be maintained.
Form # TE/F/22 01/08/07
01 AUG., 07 34 of 47
Doc. Nr.
LAY LENGTH :
L
L
 
 a/cos b/cos
 
a
 ab ab ab

  
Cos Cos. Sin   Cos )
(Cos = Sin = and
2
a  b
Sin  Cos  1   
   ( For 2 Tapes)
2
a  c
Sin  Cos  1   
   (For 1 Tape)
ab ab

Cos 2
a  b
1   
L=    (For 2 Tapes)
ac ac

Cos 2
a c
1   
L=    (For 1 Tape)
Form # TE/F/23 01/08/07
01 AUG., 07 35 of 47
Doc. Nr.
WEIGHT AND RESISTANCE RATIO:

L
L
 
 a/cos b/cos
 
b
2
A B ab
Cos  1   
L= Cos ,   
 ab 
2
2    
  Cos  
L² =
L2   
2
 2  a  b2
  Cos 2   1  1
L2 = a b = a  b
2
  
   1  1
= a b
L   
 
L = a b For 2 Tapes
L   
 
L = a c For 1 Tape
Form # TE/F/23 01/08/07
01 AUG., 07 36 of 47
Doc. Nr.
Weight and Resistance ratio for Copper wire screen, Armour and Concentric conductor
shall be 1.048 from the following calculation :
L
D
L² = L²+(D)²
2
L  D 
R   1 
L  L 
2
  
 1 L 
 
 D  
L
when  10
D
2
 
R  1  
 10 
= 1.048
Form # TE/F/23 01/08/07
01 AUG., 07 37 of 47
Doc. Nr.
Computation of Extra weight for Copper Tapes applied with Overlap :
a b
b
ab ab
c= 2 c= 2
a= Width of the tape

b= Gap
c= overlap
ab ab
Extra Area (Volume)  c or b = a-2c
ab 2
c
a  ( a  2c ) 2c c
Covering     a
a  a  2c 2a  2c ac c
1
a
c
(where  overlap ratio)
a
c
Weight = 1 + Covering = 1 + a  c
a 1
 
ac c
1
a
Form # TE/F/23 01/08/07

01 AUG., 07 38 of 47
Doc. Nr.
P. P. FILLERS FOR
LOW VOLTAGE (0.6/1 kV) THREE CORE CABLES
(ROUND CONDUCTORS)
Size of cable Centre Each Interstices

(mm2) (Deniers) (Deniers)
3x16 7,000 70,000
3x25 10,000 120,000
3x35 15,000 160,000
3x50 15,000 220,000
3x70 20,000 300,000
3x95 30,000 400,000
3x120 40,000 500,000
3x150 60,000 630,000
3x185 70,000 800,000
3x240 90,000 1,020,000
3x300 110,000 1,250,000
3x400 150,000 1,640,000
3x500 190,000 2,030,000
Form # TE/F/24 01/08/07

01 AUG., 07 39 of 47
Doc. Nr.
P. P. FILLERS FOR
LOW VOLTAGE (0.6/1 kV) FOUR CORE CABLES
(ROUND CONDUCTORS)
Size of cable PVC Centre Filler Each Interstices

(mm2) ‘d’ (mm) (Deniers)
4x16 2.70 50,000
4x25 3.41 90,000
4x35 3.91 110,000
4x50 4.58 160,000
4x70 5.40 220,000
4x95 6.17 290,000
4x120 6.95 370,000
4x150 7.7 460,000
4x185 8.69 580,000
4x240 9.82 750,000
4x300 10.96 930,000
4x400 12.45 1,200,000
4x500 13.83 1,400,000
Form # TE/F/24 01/08/07

01 AUG., 07 40 of 47
Doc. Nr.
P. P. FILLERS FOR
LOW VOLTAGE (0.6/1 kV) FIVE CORE CABLES
(ROUND CONDUCTORS)
Size of cable PVC Centre Filler Each Interstices

(mm2) ‘d’ (mm) (Deniers)
5x16 4.51 40,000
5x25 5.69 70,000
5x35 6.51 90,000
5x50 7.63 125,000
5x70 9.00 185,000
5x95 10.29 240,000
5x120 11.58 300,000
5x150 12.84 380,000
5x185 14.49 480,000
5x240 16.37 610,000
Form # TE/F/24 01/08/07

01 AUG., 07 41 of 47
Doc. Nr.
P. P. FILLERS FOR
LOW VOLTAGE (0.6/1 kV) THREE AND HALF CORE CABLES
Size of cable Centre Each side between Each Side

(mm2) (Deniers) Round and Sector between sectors
(Deniers) (Deniers)
3x35+16 20,000 80,000 20,000
(50,000 + 30,000)
3x50+25 20,000 90,000 20,000
(50,000+2x20,000)
3x70+35 20,000 130,000 20,000
(2x50,000+30,000)
3x95+50 40,000 150,000 40,000

(2x20,000) (3x50,000) (2x20,000)
3x120+70 50,000 160,000 40,000

(2x50,000+2x30,000) (2x20,000)
3x150+70 50,000 280,000 40,000

(2x125,000+30,000) (2x20,000)
3x185+95 60,000 335,000 60,000
(2x30,000) (250,000+85,000) (2x30,000)
3x240+120 85,000 420,000 85,000
(250,000+2x85,000)
3x300+150 125,000 500,000 85.000

(2x250,000)
3x400+185 125,000 670,000 125,000

(2x250,000+2x85,000)
3x500+240 150,000 800,000 150,000

(2x250,000+2x150,000)
Note: Sizes mentioned in brackets are possible combinations.
Form # TE/F/24 01/08/07

01 AUG., 07 42 of 47
Doc. Nr.
P. P. FILLERS FOR LOW VOLTAGE

(0.6/1 kV) FOUR CORE CABLES (SECTORAL)
Size of cable Centre Each Side

(mm2) (Deniers) (Deniers)
4x16 (rm) 40,000 50,000
(2x20,000)
4x25 (rm) 60,000 90,000 (50,000+2x20,000)

(2x30,000)
4x35 (sm) 20,000 20,000

4x50 (sm) 20,000 20,000
4x70 (sm) 20,000 20,000
4x95 (sm) 40,000 40,000
(2x20,000) (2x20,000)
4x120 (sm) 50,000 40,000

(2x20,000)
4x150 (sm) 50,000 40,000

(2x20,000)
4x185 (sm) 60,000 60,000

(2x30,000) (2x30,000)
4x240 (sm) 85,000 85,000

4x300 (sm) 125,000 85,000
4x400 (sm) 125,000 125,000
4x500 (sm) 150,000 150,000
Note: Sizes mentioned in brackets are possible combinations.
Form # TE/F/24 01/08/07
01 AUG., 07 43 of 47
Doc. Nr.
POLYPROPYLENE FILLERS FOR THREE CORE MEDIUM VOLTAGE CABLES
Form # TE/F/24 01/08/07

01 AUG., 07 44 of 47
Doc. Nr.
METALS
Metal Density (g/cc)

Copper 8.89
Aluminium 2.703
Lead 11.38
Steel 7.78
Insulating and Sheathing Materials
Material Density (g/cc)

XLPE 0.92
Semi-conductive compound 1.15
PVC (Insulation) 1.48
PVC (Sheathing) 1.56
LLDPE 0.95
MDPE 0.95
HDPE 0.96
LSF 1.52
Rubber 1.90
Semi-conductive PE 1.98
XLPE (LSF) 1.4
Metallic Tapes
Metallic No. of Density Thickness of tape

Tapes laminted sides (g/cc)
Copper 1 6.905 0.15+0.05
Copper 2 5.714 0.05+0.15+0.05
PE Lamination Aluminium 1 2.353 0.2+0.05
Aluminium 2 2.120 0.05+0.15+0.05
Copper 1 7.048 0.15+0.05
Copper 2 5.942 0.05+0.15+0.05
PVC Lamination Aluminium 1 2.467 0.2+0.05
Aluminium 2 2.309 0.05+0.15+0.05
Form # TE/F/25 01/08/07
01 AUG., 07 45 of 47
Doc. Nr.
Tapes and Fillers
Material Density (g/cc)

Swellable Powder (GTP 100) 0.5
Nylon Tape (C2002/202) 0.679
Graphite 0.5
Mylar 0.572
Crepe paper Tape 0.624 for 0.4 mm (with overlap)
0.624 for 0.5 mm (with overlap)
0.706 for 0.7 mm (with overlap)
PP Filler 0.5
PP Tape 0.75 (with 20% overlap)
Hessian Tape 0.725
Bitumen 1.25
Non-Conductive Water Swellable tapes
N.C.W.S.T Thickness (mm) Density (g/cc)

GFS 1120 0.19 0.290
GFS 1130 0.21 0.333
GFS 1140 0.24 0.375
3E1141 0.33 0.258
3E1151 0.35 0.28
Semi-Conductive Water Swellable tapes
S.C.W.S.T Thickness (mm) Density (g/cc)

GFS 2120 0.50 0.19
GFS 2130 0.51 0.206
GFS 2140 0.52 0.231
GFS 2340 0.65 0.246
3C1151 0.32 0.375
3C1161 0.33 0.394
Semi-Conductive Separating Water Swellable tapes
GTS 605 0.32 0.366

GTS 608 0.35 0.417
GTS 611 0.38 0.461
3C4311 0.20 0.71
Form # TE/F/25 01/08/07

01 AUG., 07 46 of 47
Doc. Nr.
Semi-Conductive Separating Tapes
GT 601 0.13 0.462

GT 603 0.19 0.526
GT 605 0.08 0.750
GT 607 0.53 0.189
GT 608 0.19 0.495
GT 611 0.15 0.780
3C3091 0.50 0.190
3C4201 0.14 0.429
Form # TE/F/25 01/08/07
01 AUG., 07 47 of 47

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Gulf Cables-Jordan Title : DESIGN OF STANDARD PRODUCTS Issue 1 CA/TE/P/01

DESIGN AND DEVELOPMENT PLANNING :

Design includes mainly preparing manufacturing

As the above items are in regular production, follow

Material shall be comply with procedure QMS-01 for QMS-01

For Design Verification and Design Validation the

QC In charge Quality Control In charge shall be responsible for

For Medium voltage cables the type test shall be

5.2 ORGANIZATIONAL AND TECHNICAL INTERFACE:

5.3 DESIGN INPUT :

Medium Voltage cables (6, 10, 15, 20 and 30 kV cables)

Wiring cables 300/500 V, PVC insulated, PVC sheathed

PVC insulated wires rated 450/750 V with solid, stranded

IEC 227-3 for CU/PVC wires.

BS 6004 for CU/PVC wires rated 450/750 V and BS 6004

BS 6500 for CU/PVC/PVC flexible cords rated 300/500 BS 6500

BS 6346 for PVC insulated cables rated 0.6/1 kV BS 6346

BS 5467 for XLPE insulated cables rated 0.6/1 kV and BS 5467

BS 6622 for XLPE insulated cables for rated voltages BS 6622

5.5 DESIGN REVIEW :

5.6 DESIGN VERIFICATION :

For new material that has been used, material shall be

In general for 0.6/1 kV cables, if type test was carried

If the material of insulation has been changed then type

For medium voltage cables guide for type testing shall

5.7 DESIGN VALIDATION :

Third party inspection carried out as per customer

Also, the long experience of Gulf Cables in Manufacture

Technical Check the correctness of computer program output

Technical In Approve the computations from the computer program

Any feedback regarding the applicability of

Study suggestions/advice of Production In charge and

For cables as per IEC, print out of the required size is

GUIDE FOR PREPARATION OF MANUFACTURING

For conductor construction and weight, refer to the

Unless specified by the customer, conductor for all Low

For 4 core cables, Conductor shall be sectoral stranded

Conductor for medium voltage cables shall be round

Unless specified by the customer, the thickness of semi-

Unless specified by the customer, thickness of semi-

Thickness of copper tape for Medium Voltage cables

For copper wire screened cables the cross-section of

Conductor Size Screen Size

Lay ratio for copper wire screen shall be 10 (Approx.)

For number of wires and diameter of copper wire

Binder tape over assembly for 3 core cables shall be

Bedding tape under lead sheath shall be of crepe paper

Size of Polypropylene fillers for different constructions

Width of Copper tape, Copper tape open helix,

Lay ratio of Armour wire shall be 10 Approximately

Computation for taping angle, Lay length, Resistance

GCIS* = Gulf Cables Internal Standard

TE/F/03 : Manufacturing Instruction from computer

Form # TE/F/17 01/08/07

2. Diameter over conductor screen:

3. Diameter over insulation:

4. Diameter over insulation screen :

5. Diameter over metallic screen: