Pakistan Cable

TABLE OF CONTENTS
Foreword 03
Trusted not to Compromise 05
Chapter 1: Introduction to Electricity 06
Chapter 2: Cable Construction and Cable Making Materials 14
Chapter 3: Performance of Cables under Fire 24
Chapter 4: Quality 38
Chapter 5: Handling, Storage and Safety of Cables 44
Chapter 6: Useful Information 54

02 Cables and Tables
ABOUT PAKISTAN
CABLES LIMITED
CHAPTER 1
Introduction to Electricity
Pakistan Cables 07
Introduction to Electricity
Electricity is indeed miraculous. It gives us light, starts our cars,
refrigerates our food. Its applications are innumerable. Truth is that we
cannot survive without electricity.
What is Electricity?
The entire universe is composed of matter. All matter consists of a combination of 118 elements.
Figure 1: The Modern Periodic Table

1 2
H He
3 4 hydrogen poor metals 5 6 7 8 9 10
alkali metals nonmetals
Li Be C Unq
B Unq N Unq
O Unq
F Ne
alkali earth metals noble metals
11 12 transition metals rare earth metals 13 14 15 16 17 18
Na Mg Si Unq
Al Unq P Unq
S Unq
Cl Ar
19 20 21 22 23 24 25 26 29 28 29 30 31 32 33 34 35 36
K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga Unq
Ge Unq
As Unq
Se Unq
Br Kr
37 38 39 40 41 42 43 44 45 46 47 48 49 60 51 52 53 54
Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Unq
Sn Unq
Sb Unq
Te Unq
I Unq
55 56 57 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86
Cs Ba La Hr Ta W Re Os Ir Pt Au Hg Ti Unq
Pb Unq
Bi Unq
Po Unq
At Rn
87 88 89 104 105 106 107 108 109 110
Fr Ra Ac Unq Unq Unh Unq Uns Uno Unn
58 59 60 61 62 63 64 65 66 67 68 69 70 71
Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu
90 91 92 93 94 95 96 97 98 99 100 101 102 103
Th Pa U Np Pu Am Cm Bk Cf Es Fm Md No Lr
The smallest unit of an element is called an atom. It is so small that it takes one million of them
to make up the diameter of human air.
Figure 2: Atomic Structure
High-speed
Nucleus electrons
(- charge)
Neutrons
(no charge) Protons
(+ charge)
Pakistan Cables 09
An atom has the nucleus in its center, comprising of positively charged protons and neutrally
charged neutrons .Neutrons and protons are identical in mass. Around the nucleus is a cloud
of electrons which are negatively charged. Electrons are 1837 times lighter than proton. The
attraction between negatively charged electron and positively charged nucleus keeps the
electrons near the nucleus.
For Example:
Copper atom which has 29 protons in its nucleus and therefore 29 electrons orbiting around
the nucleus.
Figure 3: Atomic Structure of Copper Atom
Valence electron One of 29

available for current electrons
flow
Nucleus with
29 protons and
Electron orbits
neutrons
or shells
The maximum number of electrons that can occupy a specific energy level (Shell) can be
found by the formula 2n2. Thus, copper has only one electron orbiting in its outermost shell
(2+8+18+1) which is also called the Valence shell.
The closer to the nucleus, the more tightly bound the electrons are to the atom. Electrons in
the outer shell can be forced out of the atom by applying external force such as magnetic field
or chemical reaction. Free electrons forced from atom leave a void which can be filled by an
electron forced out by another atom.
Figure 4: Copper Wire

Copper Wire
Electrical Force
Conductors and Insulators

An electric current flows when free electrons move from atom to atom in a material. Materials
that permit many electrons to move freely, are called conductors. Copper, silver, gold, aluminium
and iron are conductors. Copper and aluminium are mostly used as conductors in cables.
Figure 5: Conductor
Within an insulator, all outermost electrons in an atomic structure are bound together and
unable to move freely. That is each outermost electron is attracted to both its own nucleus and
simultaneously its nearest neighboring nucleus, it is thus unable to move freely.
In electric cables, electrons flow along copper or aluminium conductor to provide power to
electrical devices such as a lamp or a motor.
The insulation over the conductor is provided to keep electrons with in the conductor.
Figure 6:
Insulation Conductor
Current
The flow of free electrons in a material from one atom to the next atom in the same direction
is referred to as current (I). The amount of current flowing is determined by the number of
electrons that pass through the conductor in one second. The unit of current is ampere (A).
6.24x1018 electrons moving through a conductor per second is equal to one amp. Electron
flows from negative to positive.
Voltage
The force required to make electricity flow through a conductor is called electromotive force
(emf), a difference in potential. The unit of voltage is volt (V).
Resistance
Resistance opposes the current flow in a circuit. The larger the wire, lesser the resistance to
current flow & the unit of resistance is ohm (Ω).The amount of resistance (R) depends upon the
composition, length, cross section and temperature of the material. Resistance of a conductor
increases with an increase in length or decrease in cross sectional area.
Pakistan Cables 11
Ohm’s Law
A simple electric circuit consist of a voltage source, load and conductor to allow flow of electron
from voltage source to load and back to source.
Figure 7:
R
V
Ohm’s Law states that current varies directly with voltage and inversely with resistance.
I = V/R
Where,
Current (I) = ampere
Voltage (V) = volts
Resistance (R) = ohms
When the circuit is in operation, it transmits power (watts) from source (battery) to the load (fan
or light bulb). So the amps, volts, ohms and watts are related as follows:
1. amps = volts/ohms
2. volts = ohms x amp
3. ohms = volts/amps
4. watts = volts x amps
Direct Current (DC)

Batteries supply current in one direction only. There is one path of current that flows from the
negative terminal and returns to positive terminal.
Alternate Current (AC)

An AC generator makes electrons flow first in one direction then in another .The generator
works on the principle of electromagnetic induction.
Figure 8:
~ ~
+ -
- +
Alternating voltage and current vary continuously like a sine wave. The vertical axis represents
the direction and magnitude of current and voltage. The horizontal axis represents time. When
the wave is above the time axis, current is flowing in one direction i.e. +VE direction, when it is
below the time axis current is flowing in the opposite direction i.e. -VE direction. The sine wave
moves through a complete rotation of 360o which is called one cycle.
Figure 9:
+
Peak Value
0
Time
-
To the best of our knowledge, WAPDA /KESC generate and distribute electricity at a standard
rate of 50 cycles per second .The effective value of AC is defined in terms of equivalent heating
effect when compared to DC. The effective value or rms (root mean square) value of AC or
current is 0.707 x peak value.
Single phase and Three phase AC:

Single phase AC power is commonly used in homes and offices. Power companies generate,
transmit and distribute three phase AC power. Three phase power is used in commercial and
industrial applications. Three phase power is a continuous series of overlapping AC cycles.
Each wave represents a phase and is offset by 120 electrical degrees for each of the two other
phases.
Figure 10:
Phase A Phase B Phase C

+
o
120
- o
240
o
360
Pakistan Cables 13
The distribution transformers step down the voltage from 11kV to 3 phase 415 V and single
phase 240V for use at industrial, commercial and residential premises.
Figure 11:
L1
415V
L2
240V 240V
415V
415V
N
415V
240V
L3
Transmission and Distribution of Electrical Energy:

Most economical, technical and practical aspects are kept in mind in order to have optimum
solution. Therefore, overhead lines are made for transmission and distribution of electrical
energy in rural areas while insulated cables are buried underground in urban areas. In
Pakistan bulk power is transmitted through overhead transmission lines at 500 KV, 220 KV
and 132 KV from Power Generating Station to grid stations near the energy utilization centers.
Power transformers at grid stations step down the voltage to 11 KV for distribution of power
to Industrial and Commercial consumers through overhead lines or insulated cables. The
distribution transformer then steps down 11 KV to 3 phase 415 KV or single phase 240 KV for
domestic consumers
Alternating current has many advantages and three phase AC is used globally for transmission
and distribution of power. The voltage for electrical cables are expressed as Uo/U. Uo is the
voltage between conductor and earth while U is the voltage between phase conductors for
which the cable is designed.
As per BS and IEC standards general wiring cables are designated as 300/500V and 450/750V
while power cables as 600/1000V, 1900/3300V, 3800/6600V, 6350/11000V and 8700/15000V.
These grades of cables are manufactured by Pakistan Cables.
For electrical power transmission, only the value of U is quoted such as 66KV, 132 KV, 220KV
and 500 KV. Pakistan Cables manufactures Aluminium Conductor Steel Reinforced (ACSR), All
Aluminium Alloy Conductors (AAAC) and Aluminium Conductor with Composite Core (ACCC)
for overhead power transmission.
Power Grid Transmision Grid Distribution Distribution Residential,

station Station Lines Station Lines Substation / Commercial
Pole Mounted & Industrial
Transformer Users
CHAPTER 2
Cable Construction and

Cable making Materials
Pakistan Cables 15
Conductors
Conductors
Conductors are the paths along which a current flows. For most applications
the prime requirement of cable is that it should carry a specified electrical
current between two points in the most economical way. We look for a material
that offers minimum resistance to the flow of electricity to minimize energy loss
along the cable length. Silver is the best conductor but remains very expensive.
Copper and Aluminium

Copper and Aluminium are used as conductors in cables. Copper is the most widely used
conductor material. Aluminium conductors are mostly confined to applications in overhead
transmission lines and large sizes of cables for fixed installations. It is found unsuitable for
use in house wiring installations due to its lower resistance to fatigue and corrosion when
compared with Copper. Conductors are categorized by cross sectional areas in relation to their
electrical resistance.
The conductors are also classified according to their shape and formation. Such conductors
are listed below along with application:
(a) Solid conductors – general wiring cables up to 4mm2

(b) Circular Stranded conductors – for overhead use and underground cables
(c) Compacted circular – for Low Voltage and Medium Voltage cables
(d) Sector shaped with perspiral lay – for low voltage Power cables
(e) Flexible conductors – in areas demanding flexibility like cords, flexible cables, battery
leads for automobiles, etc.
Solid Circular Stranded Compacted Sector Flexible

Conductor Conductor Circular Shaped Conductors
Solid Conductors:
Solid conductors comprise of single wire and are used in domestic wiring cables up to 4.0mm2.
Use in higher sizes is restricted due to their inability to be pulled around sharp bends where
stranded conductors are used.
Stranded Conductors:
Stranded conductors comprise of suitable number of wires. These are circular, compacted
circular and sector shaped having concentric layers of wires with lays of opposite direction in
each layer.
• Circular conductors are compacted by pulling through a die resulting in smoother

surface and reduced overall diameter
• Sector shaped conductors are stranded in the same way but passed through shaping
rolls after application of wires in each layer. Rolls used for shaping and compacting
rotate around the conductor to produce pre-spiral lay. The spiral lay in the sectoral
shaped conductor is helpful while laying up the insulated core for multicore cables and
prevents the stress in insulation.
• Flexible conductors comprise of large number of small diameter wires. The smaller the
diameter of wires, the higher would be the flexibility for a particular cross sectional area.
Pakistan Cables 17
Electrical and Physical Properties

Taking cost into consideration copper and aluminium are mostly used as conductors.
Table 1: Electrical Properties

Electrical resistivity at
Relative conductivity
Metal 20oC
(Copper = 100)
x10-8 Ωm
Copper (HC, annealed) 100 1.724
Copper (HC, hard drawn) 97 1.777
Copper (HC, Oxygen free, annealed) 100 1.724
Alum (EC grade Semi Hard) 61.5 2.803
Alum (EC grade Hard) 61.4 2.808
Table 2: Physical Properties
Parameters Unit Copper Aluminium
Density at 20oC Kg/m3 8890 2703

Coefficient of thermal expansion per oC X10-6 17 23
o
Melting Point C 1083 659
Thermal conductivity W/cm oC 3.8 2.4
Ultimate Tensile Stress Soft MN/m2 225 70 - 90
Ultimate Tensile Stress Hard MN/m2 385 125 - 205
Elastic Modulus MN/m2 26 14
Copper wires in cables are normally used in annealed condition, but stranded Aluminum
conductor for cables and overhead conductors consists of wires in hard condition.
Copper vs. Aluminum

When crimping Aluminium ferrule, deep indent crimping is preferred in order to break the
Aluminium oxide layer on the surface of the Aluminium conductor. Corrosion of Aluminium
conductor is a major problem in damp outdoor installations. Exposed Aluminium conductors
have to be kept dry by sealing them with a heat shrink tubing.
Factors to be considered:
Most accessories (lugs, ferrule, connectors) and electrical equipment (circuit breakers,
switches) are designed for use with copper conductors. When using Aluminum conductor,
bimetallic accessories must be used to avoid the connection becoming loose, resulting in high
resistance connection (hot connection). This is due to different temperature coefficients of
expansion between copper and aluminum. On cooling, Aluminum conductor in copper ferrule
will contract more than copper thus becoming loose. This would result in short circuiting and
fire.
Insulation
Insulation
As mentioned in Chapter 1, electrical insulation is the material whose internal electrical charges
do not flow freely and therefore make it nearly impossible to conduct electric current under
the influence of electric field. Thus avoiding short circuit between conductors after application
around each.
Synthetic polymers are plastics and rubbers used as insulating materials such as PVC,
Polyethylene, thermoplastic rubber.
Many monomers when combined together form polymers. Monomer is a molecule (combination
of several atoms). Monomers of ethylene combined together form polyethylene and monomers
of vinyl chloride form Poly Vinyl Chloride
H CL H CL
Polymerization
C C C C
H H H H
n n
Vinyl Chloride Polyvinyl Chloride
H H H H
Polymerization
C C C C
H H H H
n n
Ethylene Polyethylene
Another category of polymers are elastomers like rubbers which are highly elastic. An elastomer
is a material which undergoes substantial deformation at room temperature by a weak stress. It
returns rapidly to its initial shape upon release of that stress. Rubber and elastomers are used
synonymously in the cable industry.
Pakistan Cables 19
Thermoplastics and Thermosets:
Plastics can be further divided into thermoplastics and thermosets. Thermoplastic flows when it
is above its melting point. The process is reversible and upon cooling the material hardens e.g.
polyvinyl chloride (PVC). Thermosetting polymers do not soften sufficiently on heating to be
reshaped e.g. cross linked polyethylene (XIPE). Thermoplastics are converted to thermosets
by adding chemical cross linking agent or by irradiation.
Polyvinyl Chloride(PVC):
PVC polymer cannot be extruded without the addition of processing aides e.g. plasticizers and
lubricants. Some grades of PVC are suitable for use as insulation up to 6.0 KV. Other ingredients
like fillers and stabilizers are also added to achieve desired electrical and physical properties.
PVC is suitable for use as insulation for conductors having continuous operating temperature
from 70oC to 85oC depending on the grade. It can sustain short circuit temperature of 160oC.
PVC is a fire retardant compound i.e. it is self-extinguishing and have low flame propagation.
Cross linked PE(XLPE):
Despite its excellent electrical properties, the use of polyethylene is restricted to a maximum
continuous operating temperature of 70oC being a thermoplastic. By cross linking, working
temperature is increased to 90oC and short circuit temperature to 250oC
Characteristics of PVC Insulation:
Parameters Unit Characteristics
Maximum conductor temperature in normal operation °C 70
Properties in the state as manufactured

2
Minimum tensile strength N/mm 12.5
Minimum elongation at break % 125
Properties after aging in air oven

Temperature °C 80±2
Duration h 7x24
2
Minimum tensile strength N/mm 12.5
Maximum Variation % ±20
Minimum elongation at break % 125
Maximum Variation % ±20
Bending at low temperature

Temperature °C -15±2
Requirement no cracks
Elongation at low temperature

Temperature °C -15±2
Minimum elongation without break % 30
Pressure at high temperature

Maximum indentation % 50
Resistance to cracking
Requirement no cracks
Loss of mass
Duration h 7x24
2
Maximum loss of mass mg/cm 2.0
Insulation resistance
Minimum K value Mohm-km 0.037
Pakistan Cables 21
Characteristics of XLPE Insulation:
Maximum conductor temperature in normal operation °C 90
Without Ageing
2
Tensile Strength (min) N/mm 12.5
Elongation at break (min) % 200
After aging in an air oven

after ageing without conductor treatment:
Temperature °C 135
Tolerance °C ±3
Duration h 168
Tensile Strength
Variation (max) % ±25
Elongation at break:
Variation (max) % ±25
Hot Set:
Treatment:
Air temperature (tolerance±3°C) °C 200
Time under load min 15
2
Mechanical stress N/cm 20
Maximum elongation underload % 175
Maximum permanent elongation after cooling % 15
Water Absorption:
Treatment:
Temperature (tolerance±2°C) °C 85
Duration hrs 336
2
Maximum increase of mass mg/cm 1
Shrinkage:
Distance between marks mm 200
Treatment:
Temperature (tolerance±3°C) °C 130
Duration hrs 1
Maximum Shrinkage % 4
Armour
Armour Wire
Armour comprises of a single layer of steel or aluminum wires applied over a layer of PVC
extruded over insulated conductors, which act as a bedding for the armour preventing damage
to the insulation. The armour provides mechanical strength to the cable against external
damage, and longitudinal reinforcement enabling cable to withstand high pulling loads during
installation. It also functions as a carrier for earth fault current.
Aluminium wires are used in single core cables instead of steel wire. A magnetic field exists
due to the current flowing within a single core cable. Steel wire being magnetic, this magnetic
field induces current, resulting in the cable’s overheating. This will not happen in case of non
magnetic aluminium wires.
Characteristics of Steel Armour Wire:

Torsion number of turns to fracture depends upon the diameter of wire
Tensile strength N/mm2 340-500
Elongation after fracture % 10
Electrical resistivity at 20oC Ohms-m 13.8 X 10-8
Mass of zinc coating gm/m2 depends upon the diameter of wire
Adherence of zinc coating - zinc coating should not flake off from wire surface
Pakistan Cables 23
Overall Sheath
Overall
Sheath
PVC sheath provides protective finish for cables and also prevents corrosion of the armour.
PVC provides toughness and resistance to deformation during and after installation. Medium
density PE is also used where more toughness is required. Protection against ants, termites
and vermins are also provided by including suitable additives during the extrusion process.
Characteristics of PVC Sheath:
Maximum conductor temperature on normal operation °C 70°C 90°C
Properties in the state as manufactured

Minimum tensile strength N/mm2 12.5 12.5
Minimum elongation at break % 125 150
Properties after aging in air oven

Temperature °C 80±2 100±2
Duration h 168 168
Minimum tensile strength N/mm2 12.5 12.5
Maximum Variation % ±20 ±25
Minimum elongation at break % 125 150
Maximum Variation % ±20 ±25
Bending at low temperature

Temperature °C -15±2 -15±2
Requirement no cracks no cracks
Elongation at low temperature

Temperature °C -15±2 -15±2
Minimum elongation without break % 30 20
Maximum conductor temperature on normal operation °C 70°C 90°C
Impact at low temperature

Temperature °C - -15±2
Requirement - - no cracks
Pressure at high temperature

Maximum indentation % 50 50
Resistance to cracking
Requirement no cracks no cracks
Loss of mass
Duration h 168 168
Maximum loss of mass mg/cm2 2 1.5
CHAPTER 3
Performance of Cables
Under Fire
Pakistan Cables 25
Performance of Cables Under Fire

Although cables seldom cause fire, they may be subjected to fire due to
other causes being an integral part of property and equipment. When PVC
burns, it produces poisonous gases, mainly hydrogen chloride (HCL).
When HCL combines with moisture, it forms hydrochloric acid, which is
a threat to life, electronic equipment, metal surface and even buildings.
It also gives off a thick black smoke preventing people to find their way
to exits and makes it difficult for others to evacuate them from the areas
affected by fire. It is therefore, recommended to use Low Smoke Halogen
Free cables for certain public places like airports, mass transit transport,
shopping malls etc. Cables manufactured with such materials have acid
gas evolution of less than 0.5 percent in comparison 25 to 30 percent for
PVC compounds.
This chapter mentions technical terms relating to performance of such cables under fire,
their characteristics and standards. There are different abbreviations used for such cables
having similar characteristics, such as LSF (Low Smoke and Fume), LSZH (Low Smoke Zero
Halogen), HFFR (Halogen Free and Fire Retardant).
Fire Retardant
Fire Retardant cables are designed for use in fire situations where the spread of flames along a
cable route needs to be retarded. Due to its relatively low cost, fire retardant cables are widely
used as fire survival cables. During a fire, the flame spread will be retarded and the fire is
confined to a small area, thus reducing the fire hazard due to fire propagation. The LV and MV
cables with PVC sheathing manufactured by Pakistan Cables, are fire retardant.
Low Smoke and Fume Fire Retardant Cables (LSF)

• All those cables releasing low smoke and fume during fire are called LSF cables.
Halogen Free cables fall under the category of LSF cables.
• PVC Compounds after inclusion of smoke suppressant and flame retardant additives,
reduce smoke generation. Thus, they have reduced flame propagating characteristics in
the event of fire, but these are not Halogen Free.
Low Smoke Zero Halogen Fire Retardant (LSZH)

LSZH cables are not only characterized by the fire retardant performance but also by the
halogen free properties. Thus, offering low corrosivity and toxicity. During a fire, such cables
will emit less smoke and acid gases which severely affect respiratory system of human
beings leading to death and at the same time damage expensive equipment. Compared with
PVC cables, LSZH cables outperform by their fire retardancy, low corrosivity and low smoke
emission properties.
Halogen Free Advantages
Low Smoke Low Corrosivity/Toxicity Safer Choice
• Improve visibility • Low acid gases from • Reduced chance of loss

• Increased time to exit halogens prevent of life due to less harmful
the fire area corrosion and damage to emissions.
equipment
• Less harmful emissions • Environmental friendly
• Increased time to exit the than PVC compound.
fire area
Pakistan Cables 27
Testing for Performance Under Fire

Pakistan Cables is the only manufacturer in Pakistan to have state of the art testing
equipment to verify performance of cables under fire as required by the International
standards for such types of cables.
Testing for Fire Retardance

IEC / BSEN 60332-1-2 - Single Cable IEC / BSEN 60332-3 - Bunched Cables
Testing for Smoke Density, Corrosivity/Toxicity

CORROSIVITY/TOXICITY
SMOKE DENSITY IEC / BSEN 60754-1 (HCL Emission)
IEC / BSEN 61034 IEC / BSEN 60754-2 (PH and Conductivity)
Pakistan Cables is the first wire and cable manufacturer in Pakistan to attain
KEMA Gold certification for its Low Smoke Zero Halogen (LSZH) power cables
by KEMA laboratories, Netherlands.
Pakistan Cables 29
Cable Construction and Standards

SINGLE CORE, LSZH INSULATED CABLES, WITHOUT SHEATH 450/750V
1 1. Copper Conductor
2. LSZH Insulation
2
Electric cables- low voltage energy cables of rated

BS EN 50525:
voltage upto and including 450 / 750 V (Uo / U)
Cables with special fire performance-single core non-

Part 3-31: sheathed cables with halogen-free thermoplastic
insulation, and low emission of smoke.
Conductor:
COPPER
Maximum Continuous
Conductor Operating 70oC
Temperature:
INSULATION: LSZH POLYMER (Red, Yellow, Blue,

Construction:
Black,Green)
HCL Emission : 0.5% (Max)
Corrosivity pH : 4.3(Min)
Performance: Conductivity: 10 µS/mm (Max)
Smoke Emission: Light Transmittance 60% (Min)
Fire Propagation: On single vertical cables
Note: Technical data mentioned in the Annexure
SINGLE CORE, XL-HFFR INSULATED CABLES, WITHOUT SHEATH 450/750V
1 1. Copper Conductor
2
2. Cross-linked XL-HFFR Insulation
Electric cables- low voltage energy cables of rated

BS EN 50525:
voltage upto and including 450 / 750 V (Uo / U)
Cables with special fire performance-single core

Part 3-41: non-sheathed cables with halogen-free Cross-linked
insulation, and low emission of smoke.
Conductor: COPPER
Maximum Continuous
Temperature:
INSULATION: XL-HFFR Hologen Free Cross-linked

Construction:
Insulation with low emission of smoke.
HCL Emission : 0.5% (Max)
Corrosivity pH : 4.3(Min)
Performance: Conductivity: 10 µS/mm (Max)
Smoke Emission: Light Transmittance 60% (Min)
Pakistan Cables 31
SINGLE CORE AND MULTICORE, XLPE INSULATED, UNARMOURED AND

ARMOURED, LSZH SHEATHED, 600/1000V:
1. Copper / Aluminium Conductor

1
2. XLPE Insulation
3. Polypropylene Filler
3 4. LSZH Bedding
2 5. Armour Wire
6. LSZH Oversheath
6
Power cables with extruded insulation and their

IEC 60502-1: accessories for rated voltages from 1 kV (Um = 1.2 kV)
upto 30 kV (Um = 36 kV)
Cables for rated voltages of 1 kV (Um = 1.2 kV) and 3 kV

Part 1:
(Um = 3.6 kV)
Conductor: COPPER and ALUMINIUM
Maximum Continuous
Temperature:
Insulation: XLPE (Red, Yellow, Blue, Black)

Construction: Bedding: LSZH POLYMER (Black)
Sheath: LSZH POLYMER (Black)
HCL Emission: 0.5% (Max)
Corrosivity : pH: 4.3(Min)
Conductivity: 10 µS/mm (Max)
Performance:
Smoke Emission: Light Transmittance 60%(Min)
On bunched cables
Precautions for Handling and Storing LSZH Cables

• Cables should not be exposed to sun.
• Avoid any contact of cables with hot surface.
• It is preferable to lay cables in the morning hours.
• Rough terrain or sharp edges of the tray should be avoided while pulling the cables,
as it may damage LSZH sheath.
• Rollers and bends should be smooth.
• There should be a cushion between the clamp and cable surface. Clamps should not
be applied directly over the sheath.
Technical Data
Title of Tables. Page No.
Note:
For Current carrying capacity, Voltage drop and Short Circuit Ratings, please refer to the LSZH Catalogue.
URL: http://www.pakistancables.com/media/20678/pcl-lszh.pdf
Pakistan Cables 33
Conductor Data
Class 2 Stranded Conductors for Single-core and Multi-core cables
Diameters of stranded circular compacted copper and aluminium conductors

Dimensions and Weights

Single Core, 450/750V. LSZH Insulated Cables, Non Armoured Without Sheath
Single Core, 450/750V. XL-HFFR Insulated Cables, Non Armoured Without Sheath
1 2 3 4 5 6
Nominal Cross-sectional Minimum number of Radial thickness Mean overall diameter Approx Weight
area of *conductors wires in conductor on insulation Lower Limit Upper Limit of Cable
(BS EN 60228) specified value Copper
mm² mm mm mm Kg / Km
1.5 6 0.7 2.7 3.4 22
2.5 6 0.8 3.3 4.1 35
4 6 0.8 3.8 4.7 50
6 6 0.8 4.3 5.4 70
10 6 1.0 5.6 7.0 120
16 6 1.0 6.4 8.0 175
25 6 1.2 8.1 10.1 270
35 6 1.2 9.0 11.3 360
50 6 1.4 10.6 13.2 490
70 12 1.4 12.1 15.1 680
95 15 1.6 14.1 17.6 950
120 18 1.6 15.6 19.4 1170
150 18 1.8 17.3 21.6 1500
185 30 2.0 19.3 24.1 1820
240 34 2.2 22.0 27.5 2360
300 34 2.4 24.5 30.6 3000
400 53 2.6 27.5 34.3 3770
500 53 2.8 30.5 38.2 4840
630 53 2.8 34.0 42.5 6180
Pakistan Cables 35


Pakistan Cables 37

CHAPTER 4
Quality
Pakistan Cables 39
Quality Policy
At Pakistan Cables we are committed to achieve and enhance customer
satisfaction by providing quality Cables, Copper Rod, Aluminium
Extrusions and PVC Compounds. This is achieved by manufacturing
products according to the relevant national and international standards
and customer requirements.
Pakistan Cables shall continually review and improve the effectiveness of

Quality Management System in line with its objectives of achieving higher
productivity and quality.
In line with our quality policy, Pakistan Cables is committed to provide quality products,
excellent customer service, continuous innovation and enhanced process efficiencies. The
Company reiterates its commitment to consistently deliver enhanced value to its customers,
through continuous improvement of its products and processes. The quality management
system of the Company continues to conform to ISO 9001:2015 across all departments
of the Company as certified by BVQI, UK. Pakistan Cables, being an ISO 9001 certified
company, has trained personnel who are motivated and instructed to fulfill all requirements
laid down in the Quality Management System.
Pakistan Cables has adequate resources that are essential to implement the quality system
and to achieve its quality objectives as out lined in its Quality Policy. The maintenance of the
quality management system is achieved through internal and external Quality Audits. The
main purpose of Quality Audits is to take necessary corrective action to eliminate deviations
and bring further improvements to the system.
Quality Assurance
The Quality Control Programme for electrical cables at Pakistan Cables comprises of:
1. Receiving Inspection and Testing

2. In Process Inspection and Testing
3. Final Inspection and Testing
The Company has a highly advanced Quality Assurance laboratories, equipped with state
of the art equipment and manned by professional and skilled personnel, engaged to check
process variables at every step of the manufacturing process, ensuring that all products
comply with relevant international specifications.
• Raw Materials
- Grade A Copper purchased from LME approved suppliers
- Quality raw materials are procured from pre-qualified reputable sources
worldwide.
- Each raw material has passes through stringent approval process in which both
raw materials and suppliers capabilities are evaluated. A supplier not meeting
the Company’s standards is removed from the approved suppliers list.
• Interstage controls during manufacturing

- Experienced and fully trained workforce.
- Building quality during manufacture.
- Checks at every stage before moving further.
- Each meter of the insulation passes through high voltage test.
• Finished cables and wires

- All lengths of cables are subjected to testing as per standard.
A considerable portion of inspection man hours are spent on the production floor where
quality is built into the product. The finished cable is then subjected to tests as per standards.
Complaint Handling
Pakistan Cables also maintains a complaint handling procedure which is overseen by the
senior management of the Company. Each complaint is promptly investigated and corrective
and preventive action taken.
Pakistan Cables 41
Testing Equipments
LOM-510A MICRO-
Profile Projector Megger Mit 520.
OHMMETER
Partial Discharge High Voltage D.C. High

Detector Discharge System Voltage Test Set
Universal Testing Halogen Acid Gas Digital Low Resistance

Machine Analyser Ohmeter
Low Temperature 50 KN Universal

Cabinet Testing Machine
Pakistan Cables 43
CNC
Pakistan Cables is the only cable manufacturer in Pakistan with the CNC certification,
which certifies that Pakistan Cables product range meets European Health, Safety, and
Environmental protection legislation and can be legally sold and moved within the European
Union.
Other certifications
The Company’s products are also PSQCA certified, ERDA (Electrical Research and
Development Association), India, TUV SUD PSB Pte. Ltd., Singapore, and have also
been successfully type tested in Pakistan’s well reputed High Voltage and Short Circuit
Laboratory in Rawat. Moreover, it remains the only Pakistani manufacturer approved by
Oman’s regulatory authority to sell into the Oman market.
CHAPTER 5
Handling, Storage and
Safety of Cables
‫‪Pakistan Cables‬‬ ‫‪45‬‬
‫‪Handling, Storage and Safety‬‬ ‫اپور لبیک اک ااھٹان‪ ،‬ذریخہ رکان‬

‫‪of Cables‬‬
‫اور افحتظ‬
‫‪Handling‬‬ ‫اپور لبیک اک ااھٹان‬
‫ز‬
‫‪A cable can be damaged due to incorrect handling, which the‬‬
‫ک� ی�بل� ےک ڈرومں وک ااھٹےن ںیم ےب اایتحیط اور ویطلغں یک وہج ےس اصقنن چنہپ اتکس‬
‫ےہ۔ارثک ہی اصقنن ڈرم الف رجن ےک اناقلب اامعتسل وہ اجےن اور ضعب اواقت ڈ رم ریبول‬
‫‪drums and cables may be subjected to, causing breakdown‬‬
‫‪of the drum flanges and in exceptional cases. This may‬‬
‫‪occur during the movement of the drum barrels. Once the‬‬
‫یک وچںیل ڈیلیھ رٹپاجےن یک وصرت ںیم وہاتےہ ڈرم ےک اناقلب اامعتسل وہاجےن ےک‬
‫‪breakdown of the drum occurs the cable is immediately‬‬ ‫دعب لبیک وک یھب اصقنن ےنچنہپ ےک ااکمانت دیپاوہاجےت ںیہ‬
‫ز‬
‫وف رک ٹفل ڑ� ڑ�ک اامعتسل رکےن ںیم وکیئ رحج ںیہن رشب ہکیط وفرک وک ڈرم الف�ح ج‬
‫‪damaged.‬‬
‫� ےک‬
‫ز‬ ‫گ ڑ ت‬
‫‪Fork-lift trucks may be used in handling provided that care‬‬ ‫ےچینھس �ی��ے وتق ہی اایتحط رکیل اجےئ یک وہ ڈرم یک افحیتظ �پک� ی�گ وک اصقنن ہن اچنہپںیئ‬
‫‪is exercised not to damage or remove the protective lagging‬‬ ‫ارتواےت وتق یھب اس رطح اایتحط رکین اچےیئ وصتری ںیم اظرہ رکدہ رپمی اور و چن‬
‫‪when pushing the ‘fork’ under the drum flanges. Unloading‬‬ ‫ےک اامعتسل ےس اصقنن ےس اچب اج اتکس ےہ اور اسامن وک افحبتظ ااتر ااج اتکس ےہ‬
‫‪can also be safely accomplished by means of ramps and‬‬ ‫(دےئھکی وصترری ‪ 1‬اور ‪)2‬‬
‫)‪winches. (See Fig. 1 &2.‬‬
‫زڑ‬ ‫زڑ ز‬ ‫ز‬

‫‪When lifting drums of cable for loading or unloading, spindles‬‬ ‫لبیک ڈرزم وک ااتر ےت رٹچاھےت وتق رکنی سل�گ نیچ ای �� گ میب ےک اسھت س� پ� �ل‬
‫یھب الزام اامعتسل ایک اج ان اچےیئ ‪ ،‬یسک یھب احتل ںیم یسک یھب وہج ےس ڈرم وک یسک اور‬
‫‪must always be used in conjunction with crane slings, chain‬‬
‫ز‬
‫ادناز ںیم (الثم ہجنپَََ ایوارئ سل�گ) رہ زگ ںیہن ااتر انرٹچ اھان اچےیئ۔ (دےئھکی وصتری ربمن‪)۱‬‬
‫‪or lifting beams. On no account any drum be lifted by wire‬‬
‫)‪slings. (See Fig.1‬‬
‫زڑ ز‬
‫ڈرم ااھٹےت وتق نیچ یک وجڑی ےک ز زدرایمن ل�� گ میب رٹسرچی زرضور اامعتسل ےئک اجےن‬
‫اچںیئہ اس ےس لبیک وک اےنپ یہ الف ��ب�ر ےک وبھج ےلت دب رکرخاب وہےن ےس اچب ایاج‬
‫‪When lifting drums of cable, lifting beams or stretchers‬‬
‫‪between the sling of chain pairs must be used to prevent‬‬
‫)‪flanges crushing on to the cable.(See Fig.1‬‬ ‫اتکس اچےیئ۔ (دےئھکی وصتری ربمن ‪)۱‬‬
‫ز‬
‫‪NOTE: Normally the hooks or slings should be close to the drum‬‬ ‫ونٹ ‪� :‬ہک ای سل�گ وک ڈرم الف رجن ےک رقبی رانھک اچےیئ۔‬
‫‪flanges.‬‬
‫‪46‬‬ ‫‪Cables and Tables‬‬
‫‪Under no circumstances should a drum be rolled off a‬‬ ‫یسک یھب وہج ےس اور یسک یھب احتل ںیم ڈرومں وک ےچین ںیہن رٹلاکھایاج اناچےیئ‬
‫‪vehicle on to a ‘cushion’ of sand, tarpaulin, etc. This action‬‬ ‫۔رتی‪،‬یٹم ای رت اپل ےس ےنب وہےئ اڈے رپ یھب ڈرومں وک ںیہن رٹلاکھان اچےیئ ۔‬
‫‪could crumple the flanges and barrel of the drum, driving‬‬ ‫اس لمع ےس ڈرومں ےک الفجن اور ریبول رخاب وہےتکس ںیہ۔ اس ےس ضعب اواقت وخد‬
‫ک‬ ‫ڑ‬
‫)‪splinters and/or nails into the cable. (See Fig.3‬‬ ‫لبیک ںیم لیک ایلک�ری یک ھ�پ� پ�یاں وریغہ ھبچ یتکس ںیہ ۔(دےئھکی وصترری ‪)3‬‬
‫‪Rolling Drums:‬‬
‫ڈرومں وک ڑلاکھان‬
‫‪Drums of cable must always be rolled in the direction shown‬‬
‫‪by the arrow painted on the flanges, but such rolling should‬‬ ‫لبیک ےک ڈرومں وک دووصروتں ںیم رٹلاکھےن یک ااجزت ےہ۔ اول ہی ہک رصف الفجن‬
‫‪in any case be kept to a minimum.‬‬
‫رپےگل ریتےک اشنن رپیہ ڑلاکھےئ اجںیئ۔ دوم ہی لمع رصف رصتخم افہلص کت دحمود راھک‬
‫اجےئ۔‬
‫‪Turning Drums:‬‬
‫‪The best way to turn a cable drum is to roll it on to two‬‬ ‫ڈرومں وکومڑان‬
‫‪wellgreased thin plates or boards about 2 feet (square). The‬‬
‫لبیک ڈرم وک ومڑےن وک رتہبنی رطہقی تہی ےہ ہک اس وک رقتایب ‪ 2‬ٹف رمعب ےک دووتختں‬
‫ڑ‬ ‫ڑ‬
‫ای ایھچ رطح ےس رگسی یگل وہیئ دو � �ل پی �پل� �یوں رپراھک اجےئ۔رھپ ان وتختں ای �پل� �یوں وک‬
‫‪plates can then be used as a turntable and the drum rotated‬‬
‫‪to the desired direction.‬‬
‫رٹن لبیٹ ےک وطر رپ اامعتسل رکےت وہےئ ڑرم وک ولطمہب تمس ںیم ومڑایل اجےئ‬
‫‪Lowering and Lifting Drums:‬‬
‫ڈرومں وکااتران اور ڑچاھان‬
‫‪When drums are moved from one level to another, e.g.‬‬
‫ش‬
‫‪truck to ground, wharf ship, etc., lifting and lowering gear‬‬ ‫بج لبیک ڈرومں وک اکی ہگج ےس دورسی ہگج ااتران ڑچاھان وصقمد وہ(م�لا رٹک ےس‬
‫‪must always be used. When drums are lifted from the upper‬‬ ‫زںیم رپ ای دنبراگہ یک وگدی ےس اہجز رپ الد ےن ےک ےئل) وتہشیمہ حیحص اوزار ینعی ٹفل اور‬
‫‪layer of a tiered stack, care must be taken to ensure that‬‬ ‫وچن وریغہ اامعتسل رکان اچےیئ۔ ارگ ڈریھںیم رےھک وہں ڈرومں ںیم ےس اورپ ےچین ااتر‬
‫‪no movement of the bottom layer occurs so as to cause‬‬
‫ےن وصقمد وہں وت ہی اایتحط ہشیمہ رکین اچےیئ ہک اس لمع ےک دوران ڈریھںیم یلچن‬
‫سطحوں رپ رےھک وہےئ ڈرم لہ ہن اجنیئ ۔ اسی وصرت ںیم اسرے ڈریھ ےک رھکب ےن اک‬
‫‪collapse. Drums, whether loaded or empty, and too heavy to‬‬
‫‪be man-handled, should always be slung; they should never‬‬
‫واحض ادن ہیش وہات ےہ۔ اخیل وہں ای رھپ رھب ے وہےئ ڈرم اعم وطر رپ زوابزو ےس ااھٹان‬
‫�ہ ی ش ز‬
‫ٍہ سل�گ ےس ااھٹان او راھکان اچ ئ��ئے ڈرومں وک یسک یھب وصرت‬
‫)‪be dropped. (See Fig. 1 & 2‬‬
‫ںیہن۔ اںیہن م��‬ ‫ااسن‬
‫� پ زھ� ز ڑ پ �ز ز‬
‫�ے یک ااجزت ںیہن ۔(دےئھکی وصتری ربمن ‪1‬اور ‪)2‬‬ ‫ک��ے ی ای��‬
‫‪Pre Installation Inspection:‬‬
‫لبیک یک بیصنت رشوع رکےن ےس ےلہپ اک اعمہنیئ‬
‫‪To ensure reliability, it must be confirmed before laying that‬‬
‫‪the cable has not been damaged in transit or storage. Every‬‬ ‫لبیک یک بیصنت رشوعک�ےن ےس ےلہپ یلست رکنیل ہک لبیک رفس ےک دوران ای ذریخے ےک‬
‫‪drum to be inspected for any cable damage before accepting‬‬ ‫ڈوران ای ذریخے ےک دوران رخاب وت ںیہن وہیئگ۔‬
‫امتم آدمہ ڈرزموک ووصل رکےن ےس ےلہپ ایھچ رطح اعمہنئ رکںیل ہک لبیک وک وکیئ رضروت‬
‫‪the shipment.‬‬ ‫ز‬
‫ںیہن �پہ� پ�ا۔‬
‫‪Report if any of the following is observed:‬‬
‫‪1. Drum is kept flat on its flange.‬‬ ‫دنمرہج ذلی وعالم ارگ وموجدوہں وت اس ےس آاگہ رکںی‪:‬‬
‫‪2. Several drums are stacked on top of each other.‬‬ ‫‪۱‬۔ ارگ لبیک ڈرم‪ Flange‬یک حطس رپ رٹپ اوہ۔‬
‫‪3. Nails protruding on the inside of the flange.‬‬ ‫‪۲‬۔ یئک ڈرم اورپ ےلت رےھکےئگ وہں۔‬
‫‪4. Drum flange is damaged.‬‬ ‫‪۳‬۔ ڈرم ںیم یگل وہیئ ک�یل�یں ‪ Flange‬ےک ادنر یک اجبن وت ںیہن یلکن وہیئ۔‬
‫‪5. Lagging has been removed or broken which may have‬‬ ‫‪۴‬۔ ڈرم ز تےک ‪ Flange‬وک وکیئ رضر اچنہپ وہ۔‬
‫‪caused damage to sheath.‬‬ ‫‪۵‬۔ افح��ی ‪ Lagging‬دجا رکدی یئگ وہ ای وٹٹ یئگ وہ‬
‫‪6. Cable end cap has been removed or damaged.‬‬
‫‪۶‬۔ لبیک ےک ‪ End Caps‬ای وت سِرے ےس وہ یہ ںیہن ای ٹھپ اجےن یک وہج ےس‬
‫یمن ےک ااثر وہں۔‬
‫‪7. Cable drum has been dropped.‬‬
‫‪۷‬۔ لبیک ڈرم رگاای ایگ وہ۔‬

Pakistan Cables 47
Laying of Cables ‫لبیک اک اھچبان‬

‫ک یز ز‬
‫لبیک وک اھچبےن اور ھ�� پ��ے اک لمع رت یحیج وطررپادتبائ ےس ٓارخکت اکی لسلست‬
‫ںیم ایک اجان اچےیئ۔ وہفق رکےن یک وصرت ںیم لبیک رورل ںیم ھٹیب اجںیئ ےگ‬
The cable should preferebly be drawn to its final
‫اور لمع وکدوابرہز رشوع رکےن رپااسنونں اور ونیشمں وک ااضیف اطتق دراکر‬
position in a continuous manner. During stops,
‫ک ی ز‬
‫وہیگ۔ لبیک ھ�� پ��ے اک لمع ونیشمں ےک ذرہعی وہ ای ااسنونں ےک ذرہعی ہی‬
the cable will settle between rollers and may
‫لڑ‬
‫الزم ےہ ہک اکی رگناں صخش ک�ری ےک زمایتمح ےتخت ےک اسھت ڈرم ےک اپس‬
cause high strain on men and machines during
‫وموجدرےہ اتہک اچنیھکیئ رک اجےن یک وصرت ںیم ڈرم ےک البروک لھک‬
restarting. Whether the pulling is manual or with a
‫اجےن ےک لمع وکاگلم دی اج ےکس وصبرت درگییئک رکچ ڈےلیھ رٹپاجںیئ ےگ۔‬
winch, it is necessary for one man to be stationed
at the drum with a plank of wood wedged against
the flange of the drum so that over running of the
‫ز‬ ‫ز‬
drum is prevented if the pulling stops. Otherwise,
‫رہعی یک اجریہ وہ وت اہجں کت نکمم‬ ‫� ےک ذ ی ز‬‫بج لبیک یک کھ��ی�پایئ و �ی� چ‬
�‫� چ‬
‫کلسنم ایک اجےئ ااسی‬
‫وہ لبیک ےک رسے وک اہوھتں ےس و � یک ریس ےس ز‬
many loose turns can easily develop on the drum.
‫� ارپ ریٹ ےک ےئل‬‫رکےنےس لبیک رورل اور س ڑک� ٹیلپ اقوب ںیم رںیہ ےگ و �ی� چ‬
‫ڑ‬ ‫ز‬
‫الزم ےہ ہک وہ کھ��ی�پاو اظرہ رکےن وےل ڈا�ئ �ارٹیم رپاگنہ رےھک اور رقم رہ دح‬
When pulling by a winch it is advantageous for the
‫ےس اجتوز ہن وہےن دے اہجں اچنیھک یئ اک لمع وطلی افولصں کت الیھپ‬
cable end to be taken by hand as far as possible
‫وہ واہں رتیحیج وطر رپ رڈیوی وصبرت درگی اہنتی اقلب اابتعر راوطبں یک وموجد‬
before attaching the winch rope. This allows the
‫یگ الزم ےہ۔‬
leading cable rollers,skid plates, etc to take the
load and settle under well-controlled conditions.
The winch operator must, at all times, carefully
‫ز‬ ‫ز‬
observe the dynamometer to prevent overloading. ‫بج کھ��ی�پایئ وچین ےک ذرےعی یک اجےئ وتو �ی� چ‬
‫� رپ رٹپ ےن واےل دابو اور اس یک‬
‫وظنمر دشہ دح اکایخل رانھک الزم ےہ ایسی وصرت احل ںیم اچنیھکو ڈنکالبیک‬
On long pulls, good communication is essential,
‫ےہ اور‬6‫ا‬Kg/Sq mm‫ےک اسھت وجڑا اجان رضوری ےہ اچنیھکیئ یک دقمار‬
preferably by radio.
‫ ےہ۔‬2000kg ‫ٓارخی دح‬
When pulling a power winch, more attention has
to be given to the maximum pulling load which is
‫ز‬
permissible. For such installations a pulling eye �‫بج لبیک یسک وچوکر انیل ایوگل اپپئ ںیم کھ� ی‬
‫�پے اجرےہ وہں وت رگے‬
‫افٹئ پیل اک اامعتسل ایک اج ےئ۔‬
attached to the conductors is necessary and for
copper conductors a pulling tension of 6 kg force
per sq. mm of total conductor area can be applied
‫ب‬
‫یلھک انویلں ںیم لبیک �ح �پا ےن ای ریغب ومرٹمسق یک ابیصنتت ےک ےئل لبیک ااٹس‬
(with the provision of 2000 kg force maximum).
‫گنک اک اامعتسل ایک اج اتکس ےہ لبیک ےک درہے الغف وک وفحم ظ رےنھکےک ےئل‬
‫ڑ‬
‫ب�� یونم اک اامعتسل دنسپدیہ ےہ پیٹ یک دورسی ٹیپل یلہپ ٹیپل ےک مک ازمک‬
Graphite paste should be used for lubrication
‫ دصیف وک ڈاھپن ریہ وہ۔‬50
when cables are being pulled into ducts or pipes.
For open trench straight installations, a cable

‫ ںیم ںیہن ومرٹان اچےےئ‬Radius ‫لبیک ےک ریھگ وک وھچےٹ رداس‬
stocking can be used. It is advisable, however,
‫ڑ‬ ‫م‬
‫وموجدہگج ںیم ب�سں دحکت م کں وہ �ب�را ریھگ انبان اچےیئ۔ یسک یھب وبجمری وک‬
to protect the PVC oversheath with a layer of
‫اہبہن انب رک لبیک اک ریھگ رقم رہ دحود ےس مک ںیہن ایک اجاتکس ےہ۔ ز ہی اخص‬
bitumen tape applied with 50% overlap.
‫وطر رپ ان احالت ںیم الزم ےہ اہجں لبیک وک وچین ےک ذرہعی کھ��ی�پا اجےئ‬
‫اتہک رقمردشہ کھ �پا و ںیم ااضہف ہن وہ اور لبیک ومڑرپ اٹپچ وہ اجےن ےس وفحمظ‬
Cables should never be bent to a small radius.
‫ر ےہ۔‬
As large a radius as space permits should
be adopted. Under no circumstances should
the bending radius be less than the minimum
permissible limits. It is particularly important to
have a generous bending radius when cables are
to be pulled by a power winch, so as to keep within
the maximum permissible pulling tension and
prevent the cable being flattened around bends
or in ducts.
Final placing of Cable ‫لبیک اھچبےن ےک لمع ےک ٓارخی ادقاامت‬

‫کھ زی ز‬
Before disconnecting the pulling rope, the cable is
‫�پے وایل ریس وک دحیلعہ رکےن ےس ےلہپ امتم ولازامت وج اس‬�� ‫لبیک وک‬
laid off i.e. starting a one end, it is carefully lifted
from the rollers and deposited on the bottom of ‫لبیک وکرورلز ےس اٹہ رک انیل ےک‬، ‫لمع اک ہصح ےھت دور رک د ےیئ اجںیئ‬
the trench. About 10m of cable should be lifted ‫زینیم رفش رپ رھک دانی اچےیئ۔‬
at one time, any slack being carried forward. The
end position of a cable run may require double ‫ رٹیم لبیک دنلب رک ےک امتم انومہار ویں وک متخ رکدای اجےئ۔‬10 ََ‫رقتابی‬
handling because it is not possible to draw cables
‫لبیک ےک ٓارخی رسے وک بصن رکےن ےکےئل ااسنین تنحم اور اہمرت‬
straight into buildings. In this case the cable is
overpulled, then man-handled into the required ‫دراکر وہیگ۔ رہ وصرت ںیم اس ارم یک اپدنبی یک اجیگیئ ہک لبیک اک ریھگ‬
position. At all times the loops should be kept as ‫رقمرہ دح ےس مک ہن وہاجےئ۔‬
large as possible so that the bending radius is
always above the minimum permitted. ‫ یک لکش‬8’ ’‫دورسے رسے رپ ریغب لبیک وک ڈرم ےس ااترد ای ڑاجےئ اور‬
‫ڑ‬
‫ںیم ذریخہ رکدای اجےئ ۔ارگ ہگج مک وہ وت انمبس �ک�روں ںیم ابٹن‬
Similarly at the drum locations the necessary
‫دای اجےئ ۔ رسوں وک وفرا انمبس رط ےقی ےس لیس دنب رکدای اجےئ‬
‫اتہک یمن وریغہ ادنر دالخ ہن وہ ےکس’ اچنیھک ےک لمع ںیم اشلم ٓاالت‬
length of cable may be unwound from the drum
and laid out, in a figure of ‘8’ if space is limited,
prior to cutting to length and placing into position. ‫اک اعمہنئ یھب ایک اجےئ اتہک دصتقی وہاجےئ ہک ان ںیم وت وکیئ رخایب‬
Immediately after cutting the cable ends must be ‫ہن وہیگ وہ۔‬
suitably sealed to prevent ingress of moisture.
In this respect it is also important to carefully ‫لبیک وک اھچبےن ےک دعب اایتحط‬
examine the pulling end seal to ensure that it has
not been damaged during laying.(see figures 4 &
‫اھچبےن ےک دعب انیل وک دنب رکےن ےس ےلہپ لبیک یک امتم ابملیئ‬
‫لبیک ز‬
‫رپ رہگی ا� کھہ ےس اعمہنئ رکان ال زم ےہ ب�سں ںیم ان اومراک ایخل رانھک‬
5)
Backfilling and Reinstatement ‫الزم ےہ۔‬
Prior to backfilling, it is necessary to carry out ‫) ک�ی�بلوں ےک ارطاف ےس ینھچ وہ یئ رتی اییٹم وموجد ےہ‬1
‫ڑ ڑ‬
a visual inspection, and items which need to be
‫رھتپےک �ک�ر ے اور ون ےلیک مسج ارگ وموجد وہں وت ان وک‬
checked are:
‫اکنل دای اجےئ۔‬
1) The cables have a suitable bedding,
such as sieved sand or soil. Stone chips and ‫) ارگ اکی ےس زایدہ لبیک ڈاےل اجرےہ وہں وت ان ےک‬2
other sharp objects in the cable route should ‫درایمن افہلص درتس دقمار اک وہ۔‬
‫کھ زی ز‬
be removed.
‫�پے واےل االت اور اوزار لمکم وطر رپ اٹہ دےیئ اجںیئ ۔‬�� )3
2) The spacing is correct if there is more
than one cable in the trench.
‫) لبیک اھچبےن ےک لمع ےک دوران گل اجےن واےل‬4
3) Pulling equipment is carefully removed. ‫زومخں ےس اپک وہ ۔ لبیک ےک ےچین اہنیئ ےک ذرہعی‬
‫یلچن حطس یک وفحمظ وہےن یک دصتقی یھب الزم ۔‬
4) The cable is free from obvious damage caused
during installation. A very high proportion
‫) لبیک وک رگیم ےس ٹسیٹ ایک اج ےئ اتہک اوسن نشیل ےک‬5
of cable failures in service are due to such
damage. It may be necessary to inspect the ‫تحص دنموہےن یک دصتقی وہاجےئ۔‬
underside with a mirror. In such cases it is
advisable to make a first inspection whilst the :‫ونٹ‬
cable is still on rollers. ‫ےس مک راتھ ےہ واہں لبیک‬0oC ‫نج احالت ںیم درہج رحارت‬
‫اھچبےن ںیم اایتحط ےس اکم انیل اچےیہ۔‬
5) The cable to be MEGGER tested to ensure
health of insulation through out.
‫وہ وت ایسی لبیک وک اھچبےن‬PVC‫ارگ لبیک یک بس ےس اورپ وایل حطس‬
Note: ‫ ےٹنھگ ےک ےئل رانھک اچےیہ‬24 ‫ےس ےلہپڈرم وک یسک ایسی ہگج رپ مک از مک‬
Precautions must be taken in the event cables are 15oC‫وج رہ رطف ےس دنب وہ۔اےسی اموحل اک درہج رحارت مک از مک‬
to be installed below 0°C. ‫وہان اچےیہ۔‬
In case of PVC sheathed cables, the length on

‫لبیک وکڈرم رپ ےس آہتسہ ےس چنیھک رکاات رااجےئ اور اکم وک ایس دن‬
drum should be pre conditioned by keeping drums
in enclosed space for a minimum of 24-Hours at a ‫لمکم رکایل اجےئ۔‬
temperature of 15°C or higher.
‫ ہن یہ لب ڈاال اجےئ اور ہن یہ مک‬، ‫لبیک وک ہن یہ اورپ ےس رگاای اجےئ‬
Cable length should be pulled slowly and laid the ‫دارئے ںیم ومڑااجےئ۔‬
same day. It should not be dropped, kinked or bent
sharply.
‫‪Pakistan Cables‬‬ ‫‪49‬‬
‫‪Storage‬‬ ‫اپورلبیک وک اوٹسر رکان‬

‫‪If at any time the drums of cable are required to be stored for‬‬ ‫ارگ یھبک لبیک ڈرزم وک ھچک رعہص کت اوٹسر ںیم رےنھک یک رضوری رٹپاج ےئ (ےسیج روایگن‬
‫‪reasonably long periods, e.g. prior to shipment or installation,‬‬ ‫ایاامعتسل ےک ااظتنر ےک دروان) وت درج ذلی اومر اکدایھن راھکاجاناچےیئ۔‬
‫‪the following points should be noted.‬‬
‫ڑ‬
‫اوٹسر ےک رفش رپ اپین کھ�را وہےن اک وکیئ ادن ہشی ںیہن وہان اچےیئ۔ بس ےس ایھچ ابت‬
‫‪2.1 The site for storage of drums should be well drained,‬‬
‫نکمم ہن وہ وت رفش یک ایھچ رطح رھبایئ اور اٹکیئ‬
‫وت ہی وہیگ ہک رفش اکپوہ۔ ارگ ااسی ز‬
‫اچےیئ ۔رنم رفش ںیم ڈرم ےک دھ�س اجےن اک رطخہ رےہ اگ ۔ ارگ وکیئ ڈرم رفش‬ ‫وہین ز‬
‫‪hard packed soil, or preferably a concrete surface,‬‬
‫ںیم دھ�س ایگ وت ہن زرصف اس ےک اکنےنل ںیم الکشمت شیپ اںیئ یگ ہکلب اس دوران ڈرم‬
‫‪which will not allow the drums to sink and so give rise to‬‬
‫پ ز‬
‫اور لبیک وکاصقنن ��ہ پ��ے اک یھب رطخہ وہ اتکسےہ۔‬
‫‪damage due to the extreme difficulty in moving drums‬‬
‫‪when they are sunk into the ground.‬‬
‫ز‬ ‫تز‬
‫اوٹسر ںیم رےتھک و�� ت� رہ ڈرم یک ل�یک�گ اسمل وہین اچےیئ ۔ وہا یک رگدش ٓااسن انبےن ےک‬
‫‪2.2 All drums should be stored with the lagging intact, and‬‬
‫‪in such a manner as to leave sufficient space between‬‬
‫‪them for air circulation. Check and tighten barrel bolts‬‬ ‫ےئل رہ دو ڈرومں ےک درایمں ھچک اف ہلص وھچڑان رضوری ےہ ۔ وہفق وہفق ےس رہ ڈرم‬
‫‪on the drums at regular intervals.‬‬ ‫ریبل ےک وبٹل وک کیچ رکےت رانہ اچےیئ۔‬
‫‪2.3 Tier stacking of drums is not recommended. In no‬‬
‫ڑ‬
‫‪circumstances must the drums be stored on the flat i.e.,‬‬ ‫ڈرومں یک س �� یریھ انب رکںیہن ریھک اجین اچےیئ ۔ یسک یھب وصرت ںیم ڈرومں وک اھچبرک‬
‫)‪with flanges horizontal. (See Fig. 6‬‬ ‫ینعی الفجن وکایقف رخ رکھہ رک اوٹسر ںیہن رکان اچےیئ ۔(دےئھکی وصتری ربمن‪)6‬‬
‫اامعتسل ےک دوران (ینعی گنیل لھک اجےن ےک دعب) ڈرومں وک اس رطح رانھک اچےیئ‬
‫ہک ان الفجن ےک انکرے ٓاسپ نیم ےلم وہےئ وہں ۔ اس ےس یگنن اتروں ےک احداثیت‬
‫‪2.4 All drums during installation (i.e. when the lagging have‬‬
‫‪been removed) should be stored with the rims of flange‬‬
‫‪touching, so that there is no danger of the flanges of‬‬ ‫وطر رپ الف وجنں ےک اسھٹ لم اجےن اک ادن ہشی متخ وہاجاتےہ۔وےسیلبیک وک یھبک ریغ‬
‫‪drums coming into accidental contact with unprotected‬‬ ‫وفحمظ ادناز ںیم الھک ںیہن رےنہ دانی اچےیئ۔‬
‫‪cable on otherdrums.‬‬
‫امہ ابت‪:‬‬
‫‪IMPORTANT:‬‬ ‫اوٹسر ںیم رےنھک ای رفس ےک دوران لبیک ےک دوون ں رسے الزیم ط ررپاڈنی پیک ےس‬
‫‪Cable ends must be sealed with end cap during storage and‬‬ ‫لیس دنب رکدانی اچےیئ۔‬
‫‪transportation.‬‬
Fundamental requirements for Safety

‫افحتظ ےک اینب�دی اقتےض‬
The main factors to be considered while selecting ‫انمبس لبیک ےک انچو ےک ےئل دنمرہج ذلی وعالم وک دم رظنرںیھک‬
a cable are;
‫ربیق روزگرےن یک الصتیح وہ۔‬ ‫) لبیک ںیم لسلسم ڑ‬1
‫) لبیک یک ابملیئ ںیم وول��ی ج‬2
1. Continuous current carried by cable.
2. Permissible voltage drops. ‫� رقمرہ دحےس زایدہ رگےن ہن اپںیئ۔‬
3. Maximum fault current and time of its duration. ‫) لبیک ںیم اشرٹ رسٹک ےک دوران ربیق روزگرےن اور رقمرہ رک داوتق ےک‬۳
4. Ambient temperature conditions of the
‫اطمقب ےکٹھج وک ربداتش رکےن یک الصتیح وہ۔‬
installation.
‫) لبیک یک بیصنت ںیم واہں ےک اموحل ےک درہج رحارت اک ایخل رانھکاچےئ۔‬۴
In addition to the above factors it is necessary to
account for the possibility of load being increased
‫دنمرہج ابال وعالم ےک العوہ اس ابت اک یھب ایخل رںیھک ہک لبیک رپ لبقتسم ںیم ربیق‬
due to future developments.
‫رواکااضیف رکٹن ااھٹےن یک الصتیح وہ۔‬
The ratings are mentioned in our catalogues, which ‫)ںیم درج ںیہ وجہک‬Catalogues( ‫لبیک یک ربق وصخایصت امہرے اتکوچبں‬
are based on BS 7671 (Wiring Regulations). ‫(وارئگن ےک وقادئووضاطب)ےسیل یئگ ںیہ۔‬BS-7671
Workmanship and materials ‫اہمرت اوراسزاسامن‬

• Good workmanship and proper materials are
always used ‫رتہبنی اہمرت اور ایعمری اسزواسامن اکاامعتسل وہاگ۔‬
General : ‫وجمیع اقمدص‬

• All equipment shall be constructed, installed
and protected and shall be capable of being ‫بیصنت اور افحتظ اس ادناز‬،‫اہجں کت نکمم وہ امتم آالت یک ریمعت‬
maintained, inspected and tested so as to prevent ‫ےسیک اجےئ ہک ایکن ربخ ریگی اعمہنئ اور آالت یک اجچن رٹپ اتل ےب رطخ‬
‫یک اجےکس‬
danger so far as is reasonably practicable.
• All equipment shall be suitable for maximum

power demanded by thecurrent-using equipment ‫) ےک اطمقب انبےئ‬VA( ‫امتم ربیق آالت اس دقمار ےک ووٹل ا�یم ��پئر‬
‫اجںیئ ےگسج ےک ےئل ان وک اامعتسل وہان‬
when it is functioning in its intnded manner.
• All electrical conductor shall be of sufficient size

and current-carrying capacity for the purposes ‫امتم ربیق اتر اور لبیک ولطمہب رکٹن زگارےن یک الصتیح ےک اطمقب‬
for which they are intended.
‫وہےگن امتم ربیق اتر اس رطح وہےگن‬
• All conductors shall either ‫) ہک ربیق الغف رٹچےھ وہےگن اور اس ےک العوہ اہجں رضورت وہ‬i(
(i) be so insulated and where necessary further ‫زمدی ظفحت ےکاحلم وہےگن ای‬
‫) اس رطح اگلےئ اجںیئ ےگ ہک ااسنین چنہپ ےس دور رںیہ اتہک‬ii(
effectively protected, or
(ii) be so placed and safeguarded, to prevent
danger so far as is reasonably, practicable. ‫احداثت ہنکمم دحکت مک وہںیکس‬
،‫امتم ربیق وجڑ اور نشکنک اینپ استخ ےک اابتعرےس انمبس ااصیتیل‬
• Every electrical joint and connection shall be of
proper construction as regards conductance,
insulation, mechanical strength and protection. ‫ اکیمیکین اطتق اور ظفحت ےک احلم وہں‬،‫الغف‬
Pakistan Cables 51
Overcurrent protective devices :‫ارفاط رکٹن ےس ظفحت دےین واےل ٓاالت‬

Where necessary to prevent danger, every
installation and every circuit thereof shall be ‫اہجں رطخے ےس اچبو الزم ےہ رہبیصنت اور رہرصٹک اک ارفاط رکٹن‬
protected against over-current by ‫اک ظفحت اےسی آالت ےس دای اجےئ وج‬
‫) ارفاط رکٹن یک وصرت ںیم وخداکر رطےقی ےس عطقنم وہ ںیکس۔‬i(
devices which:
(i) will operate automatically at values of current
‫) اس اطتق ےک احلم وہں ےگ ہک رکٹن وکعطق رکےن اور رواں‬ii( ٍ
‫ز‬
which are suitably related to the safe current
rating of the circuit, ‫رکےن یک ارطضاری ک�ی� ت� وک رپداتش رکسک� ی زں اور‬
‫) انمبس ہگج رپ بصن وہں اور ان ےک استخ اس ونتیع یک وہیگ‬iii(
(ii) are of adequate breaking capacity and where
appropriate
(iii) are suitably located and are constructed as ‫ہک زایدہ رگیم ہلعش دیپا وہےئ ایاگنچری ےنلکن یک وصرت ںیم وفحمظ‬
to prevent danger from overheating, arcing or the ‫رہ ںیکس اور ربیق رکٹن وک ےب رطخ رواں رھک ںیکس اور احبل رکںیکس۔‬
scattering of hot particles when they come into
operation and to permit ready restoration of the
supply without danger.
‫ارض ل�کی�ی ج‬
: ‫� اور ارض افٹل رکٹن یک وصرت ںیم اایتحط‬
Precautions against earth leakage and earth
fault curents
‫اہجں ربیق ایالت ےک اےسی داھیت ےصح وج رکٹن زگارے ےس قلعتم‬
• Where metalwork of electrical equipment, other ‫ہن وہں ارگ احداثیت وطر رپربق اچرج یک اکشر وہاجٰٰںیئ اور اس رطح‬
than current-carrying conductors, may become : ‫رطخے اکببس نب ےتکس وہں وت‬
‫) اےسی داھیت مسج وک ارض ےس الم دای اجےئ اتہک ربیق اچرج ارض‬i(
charged with electricity in such a manner as to
cause danger:
(i) the metalwork shall be connected with earth ‫ںیم دنف وہاجںیئ۔‬
in such a manner as will cause discharge of ‫) رطخے ےس ےنچب ےک ےئل درگیدتاریب یھب لمع ںیم الیئ اجںیئ۔‬ii(
electrical energy without danger, or
(ii) other equally effective precautions shall be ‫رہ رصٹک ےک ےل ااسی ااظتنم ایک اجےئ ہک رطخانک دقمار ےک ارض ل�کی�ی ج‬
�
taken to prevent danger.
‫رکٹن لقتسم وطر رپ رواں رےنہ ےس وفحمظ رںیہ۔‬
• Every circuit shall be arranged so as to prevent
the persistence of dangerous earth leakage
‫زم وکرہ ابال اضہطب ےک تحت ٖارض ےس وجڑے ےئگ داھیت وصحں وک‬
‫لقتسم ارض ل�کی�ی ج‬
currents.
:‫� ےک ربرقاررےنہ ےس اچب ؤےک ےیل‬
• Where metalwork is connected with Earth ‫) ارفاط رکٹن ظفحت ےک ٓاالت اضوطبےکں اطمقب اگل ےئ اجںیئ ےگ‬i(
in accordance with relevent regulations. The
‫� رصٹک ربرکی ای اس اک مہ ہلپ وکیئ دورسا آہل اگلای اجےئ‬ ‫) ارض ل�کی�ی ج‬ii(
circuit concerned shall be protected against the
persistence of an Earth fault current by: ‫اگ۔‬
(i) the over-current protective devices as required ‫� رصٹک ربرکی اس وصرت ںیم اگل اجےئ اگ ہک بج ارض افٹل‬ ‫ارض ل�کی�ی ج‬
‫رکٹن اس دقر فیفخ وہ ہک ارفاط رکٹن ےس ظفحت ےک آالت اکم ہن‬
by regulation or
(ii) a residual current device or equally effective
device. ‫رکںیکس۔‬
The method described in item (ii) above shall
‫ایسی وصراحتل ںیم ہکبج ربق آالت ےک داھیت ےصح اضوطبں ےک اطمقب‬
be used whenever the prospective Earth fault
current is insufficient to cause prompt operation ‫ش‬
of the over-current protective devices. ‫ارض ےس وجڑدےیئ ےئگ وہں اور ان ےک رقبی درگی دخامت م�لا سیگ‬
‫ای اپین وریغہ ےک ےئل اخرط وخاہ اسجتم ےک داھیت مسج یھب چنہپ ےک‬
• Where any metalwork of electrical equipment ‫ادنروہں وت ان داھیت ومسجں وک وبضمیط ےس ارض ےک اسھت وجڑان‬
is connected with earth in accordance with
regulation and is accessible simultaneously ‫وہاگ۔‬
with substantial exposed metal parts of other
services, the latter shall be effectively connected
to the main earthing terminal of the installation.
‫ز‬
‫چ‬ ‫�ہ‬
Protective devices and switches : ‫ظفحت رفامہ رکےن واےل آالت اور وس� وریغہ‬
‫ز‬ ‫ز‬
‫س�گ ل وپل �� ی�یوزوس ئ�ہ چ‬
• A single-pole fuse switch or circuit-breaker shall
be inserted in the phase conductor only. ‫ایرصٹک ربرکی وک رصف زیف ےک اتر ںیم اگلای اجےئ‬، �
‫اگ ۔‬
• No switch or circuit-breaker, excepting where
linked, or fuse shall be inserted in an earthed
‫رصٹک ربرکی ایویفز ںیہن‬، �‫یسک یھب ارض دشہ وینرٹل اتر ںیم وکیئ وس ہ� ئ� چ‬
neutral conductor and any linked switch or linked
circuit-breaker inserted in an earthed neutral ‫اگلای اجےئ اگ اچر وپل ےک آالت ز ںیم وینرٹل دحیلعہ رکےن یک وصرت‬
conductor shall be arranged to break all the ‫ںیم رضوری وہاگ ہک اس ےس ےلہپ م��لکہ ونیتں ریف یھب دحیلعہ وہاجںیئ ۔‬
‫اس ےک دعب وینرٹل دحیلع ہ وہ۔‬
‫تت‬
related phase conductor
‫ط‬��‫م‬
Isolation and switching
: ‫ربیق رواک ع رکان اور اس اک وھکانل اور دنب رکان‬
• Effective means, suitably placed for ready
،‫ےک ےئل رضوری وہاگ ہک رہ بیصنت‬ ‫رطخے وک رو ےنک ای اس ےس اچب�ئو ڑ‬
‫اس ےک رصٹک اورآےل ےس امتم وول ��ی� ی ج‬
operation, shall be provided so that all voltage
may be cut from every installation, from every ‫� وک وفری وطر رپ عطقنم رکےن‬
circuit thereof and from all equipment, as may be ‫ےک ےئل ومرث ذراعئ ومعق رپ اقلب لمع وہں اور‬
necessary to prevent or remove danger.
‫ڑ‬
‫رطخے ےس اچب�ئو ےک ےئل رضوری وہاگ ہک رہاجدم ربیق ومرٹےس امتم وول��ی ج‬
�
• Every fixed electric motor shall be provided
with an efficient means of switching off, readily ‫وفری وطر رپ عطقنم رکےن ےک ےئل ومرث ذراعئ انمبس اقمم رپاقلب لمع‬
accessible, easily operated and so placed as to ‫وہں‬
prevent danger.
Accessibility of equipment :‫ربق آالت کت چنہپ‬

• Every piece of equipment which requires ‫رہ ااسی آہل ےسج الچ ےن ای سج یک رگناین ےک ےئل یسک ااسنن یک رضورت‬
operation or attention by a person shall be so ‫اےس اس رطح بصن ایک اجےئ ہک اس کت راسیئ ےک ےئل انمبس‬، ‫وہ‬
installed that adequate space are afforded for
‫اور وفحم ظ ذراعئ وموجد رںیہ اور اےس الچےن اور اس یک رگناین ےکےئل‬
such operation or attention.
‫انمبس ہگج ایہم یک یئگ وہ۔‬
Precaution in adverse conditions
:‫ارتب اموحل ںیم اایتحیط رطہقی اکر‬
• All equipment likely to be exposed to
weather,corrosive atmosphere or other adverse ‫زگن ٓازیم اموحل ای درگی ارتب احالت‬، ‫امتم اےسی ربیق ٓاالت ںیہنج ےلھک وممس‬
conditions, shall be so constructed or protected
as may be necessary to prevent danger arising ‫ںیم بصن وہان وہ ان ےک ےل رضوری وہاگ وہ ایسی وصخمص اور وفحم ظ‬
from such exposure. ‫استخ ےک وہں ہک رہہنکمم رطخے ےس وفحمظ رہ ںیکس۔‬
‫ب ز‬
All equipment in surroundings susceptible to ‫امتم ا اےسی االت ربق االت �ہ ��یں اےسی اموحل ںیم بصن وہان وہ اہجں‬
‫ٓاگ ای دامھ ےک اک ک رطخہ وموجد وہان ےک ےئل رضوری وہاگ رک وہ‬
risk of fire or explosion shall be so constructed
or protected and such other special precautions
shall be taken, as may be necessary to prevent ‫ایسی وفحمص ور وفحمظ استخ ےکوہں اور ان یک بیصنت ںیم امتم‬
danger. ‫اایتحیط دتاریب اامعتسل یک اجںیئ وج اےسی یسک رطخے ےس اچبؤ ےک ےئل‬
‫الزیم وہں۔‬
Additions and alterations to an installation
• No addition or alteration, temporary or permanent,

:‫وموجد بیصنت ںیم ااضےف اور دبتایلیں‬
shall be made to an existing installation, unless
it has been ascertained that the rating and the ‫�ئ ااضہف اعریض ای لقتسم دبتیلی‬‫یسک یھب وموجدبیصنت ت تںیم رہ زگ وک ی‬
condition of any existing equipment,including ‫ںیہن یک اجےئ یگ ات و�� یکہ ہی دصتقی ہن رکیل اجےئ ہک واہں وموجد‬
that of the supplier, which will have to carry ‫ربق ٓاالت ومشبل ان ٓاالت ےک وجیلجب الپسئ ینپمک یک تیکلم وہےت ںیہ اور‬
‫نج وک ولطمہب ااضیف ربیق رفامہ رکان وہیگ یک ادعتساد درتحص رضورت‬
any additional loads is adequate for the altered
circumstances and the earthing arrangments is
also adequate. ‫ےک اطمقب ےہ اور ہی ہک ارض رکےن ےک انمبس ااظتنامت یھب وموجد‬
‫ںیہ۔‬
Pakistan Cables 53
Inspection and testing :‫اعمہنئ اور ٓاالت ےس دصتقی‬

• On completion of an installation or an extension
or alteration of an installation,appropriate ‫یسک یھب بیصنت ںیم ااضےف ایرت میم یک وصرت ںیم رضوری وہاگ ہک‬
inspection and tests shall be made,to verify so far ‫اس بیصنت اک اعمہنئ اور ٓاالت ےس دصتقی یک اجےئ ہک اہجں کت نکمم‬
as is reasonably practicable that the requirement ‫وہاکس ےہ ہقلعتم اضوطبں ںیم ذرکرکدہ امتم اقتےض وپرے رکےئل ےئگ‬
of regulations have been met. The person ‫ںیہ۔ اعمہنئ اور دصتقی رکےن واےل صخش ای اس ےک امندنئے ےک ےئل‬
‫رضوری ےہ ہک وہ ٓادنئہ اعمےنئ ےک ےئل اینپ افسراشت اس صخش کت‬
carrying out the inspection and tests or a person
acting on their behalf, shall inform the person ‫ت ز‬
ordering the work of the recommendations for ‫اچنہپےئ وج اس �ص�� ی ب� ےک اعمےنئ اک مکح دےنی اک اجمز وہ۔‬
periodic inspection and testing in future.
CHAPTER 6
Useful Information
Pakistan Cables 55
Useful Information
1. Conductor Data
a. Conductor sizes, D.C resistance of rigid and flexible conductors
b. Diameter of stranded compacted circular conductors
2. Color of Insulation
3. Electrical Formulas
4. Cable capacities of Conduit and Trunking
5. Minimum internal radius of Bend
6. Pulling Tensions
7. Conversion table
8. First Aid instructions for Accident caused by Electrocution
9. Product Range.
Section 1: Conductor Data

Class 2 Stranded Conductors for Single-core and Multi-core cables
Pakistan Cables 57
Class 5 Flexible copper conductors for single core and multi core cables
1 2 3 4
Maximum Maximum Resistance of Conductor
diameters of wires in
Nominal Cross Plain Wires Metal Coated Wires
conductor
Sectional Area mm Ω/km Ω/km
mm
0.5 0.21 39.0 40.1
0.75 0.21 26.0 26.7
1 0.21 19.5 20.0
1.5 0.26 13.3 13.7
2.5 0.26 7.98 8.21
4 0.31 4.95 5.09
6 0.31 3.30 3.39
10 0.41 1.91 1.95
16 0.41 1.21 1.24
25 0.41 0.780 0.795
35 0.41 0.554 0.565
50 0.41 0.386 0.393
70 0.51 0.272 0.277
95 0.51 0.206 0.210
120 0.51 0.161 0.164
150 0.51 0.129 0.132
185 0.51 0.106 0.108
240 0.51 0.0801 0.0817
300 0.51 0.0641 0.0654
400 0.51 0.0486 0.0495
500 0.61 0.0384 0.0391
630 0.61 0.0287 0.0292

Diameters of stranded circular compacted copper and aluminium conductors
1 2 3
Stranded compacted circular Conductors (Class 2)
Minimum diameter Maximum diameter
Cross sectional Area mm²
(mm) (mm)
10 3.6 4.0
16 4.6 5.2
25 5.6 6.5
35 6.6 7.5
50 7.7 8.6
70 9.3 10.2
95 11.0 12.0
120 12.3 13.5
150 13.7 15.0
185 15.3 16.8
240 17.6 19.2
300 19.7 21.6
400 22.3 24.6
500 25.3 27.6
630 28.7 32.5
Section 2: Colour of Insulation

XLPE / PVC cables have coloured cores
Number of cores Colours
Single Black or Red
Two Red, Black
Three Red, Yellow, Blue
Four Red, Yellow, Blue, Black
Black denotes the neutral and other colours for phase conductos in two, three or four core
cables.
Following colour identification is also offered provided the quantity is economical:

Number of cores Colours
Single Blue or Brown
Two Blue, Brown
Three Brown, Black, Grey
Four Brown, Black, Grey, Blue
Blue denotes the neutral and other colours for phase conductors in two, three and four core
cables.
Pakistan Cables 59
Section 3: Electrical Formulas

ALTERNATING CURRENT
DESIRED DATA
Single Phase Three Phase
Amperes when kva is known kva x1000 / E kva x1000 / 1.73 x E
Amperes when kilowatts are known kw x1000 / E x pf kw x1000 / 1.73 x E xpf
Amperes when horsepower is known hp x 746 / E x %Eff xpf hp x 746 /1.73 x E x %Eff xpf
Kilovolt-Amperes I x E /1000 I x E x 1.73/1000
Kilowatts I x E x pf /1000 I x E x 1.73 x pf /1000
Horsepower I x E x %Eff x pf / 746 I x E x 1.73 x %Eff x pf /746
E = volts (conductor to conductor)

I = Amps
%Eff = percent efficiency in decimals
pf = power factor in decimals
kva = kilovolt ampere
kw = kilowatts
hp = horsepower
Section 4: Cable capacities of conduit and trunking

A number of variable factors affect any attempt to arrive at a standard method of assessing the
capacity of conduit and trunking.
Some of these are

• reasonable care (of drawing-in)
• acceptable use of the space available
• tolerance in cable sizes
• tolerance in conduit and trunking
The following tables can only give guidance on the maximum number of cables which should
be drawn in. The sizes should ensure an easy pull with low risk of damage to the cables.
Only the ease of drawing-in is taken into account. The electrical effects of grouping are not. As
the number of circuit increases the installed current carrying capacity of the cable decreases.
Cable sizes have to be increased with consequent increase in cost of cable and conduit.
It may sometimes be more attractive economically to divide the circuits concerned between
two or more enclosures.
The following three cases are dealt with single core thermoplastic (PVC) insulated cables in:
i. Straight runs of conduit not exceeding 3 m in length (Tables 1 & 2).
ii. Straight runs of conduit exceeding 3 m in length or in runs of any length incorporating
bends or sets (table 3 & 4)
iii. Trunking (Table 5 & 6)
A) Single –core thermoplastic (PVC) insulated cables in straight runs of conduit

not exceeding 3 m in length.
For each cable it is intended to use, obtain the appropriate factor from Table 1.
Add the cable factors together and compare the total with the conduit factors
given in Table 2.
The minimum conduit cable size is that having a factor equal to or greater than
the sum of cable factors.
Table 1: Cable factors for use in conduit in short straight runs.
Conductor cross sectional

Type Of Conductor Cable Factor
area (mm2)
1 22
Solid 1.5 27
2.5 39
1.5 31
2.5 43
4 58
Stranded 6 88
10 146
16 202
25 385
Table 2: Conduit factors for use in short straight runs.
Conduit diameter (mm) Conduit Factor

16 290
20 460
25 800
32 1400
38 1900
50 3500
63 5600
B) Single –core thermoplastic (PVC) insulated cables in straight runs of conduit

exceeding 3 m in length or in runs of any length incorporating bends or sets.
For each cable it is intended to use, obtain the appropriate factor from Table 3
Add the cable factors together and compare the total with the conduit factors
given in Table 4 taking into account the length of run it is intended to use and the
number of bends and sets in that run.
Pakistan Cables 61
The minimum conduit size is the size having a factor equal to or greater than
the sum of the cable factors .For the larger sizes of conduit, multiplication
factors are given relating them to 32 mm diameter conduit.
Table 3: Cable factors for use in conduit in long straight runs over 3 m or runs of any length
incorporating bends.
Conductor cross sectional

Type Of Conductor 2 Cable Factor
area (mm )
1 16
1.5 22
2.5 30
4 43
Solid or Stranded
6 58
10 105
16 145
25 217
The inner radius of a conduit bend should be not less than 2.5 times the outside diameter of
conduit.
Table 4: Conduit factors for runs incorporating bends and long straight runs.
Length Conduit diameter (mm)
of run 16 20 25 32 16 20 25 32 16 20 25 32 16 20 25 32 16 20 25 32
(m) Straight One Bend Two Bends Three Bends Four Bends
1 188 303 543 947 177 286 514 900 158 256 463 818 130 213 388 692
1.5 Covered by 182 294 528 923 167 270 487 857 143 233 422 750 111 182 333 600
2 Tables 177 286 514 900 158 256 463 818 130 213 388 692 97 159 292 529
2.5 1 and 2 171 378 500 878 150 244 442 783 120 196 358 643 86 141 260 474
3 167 270 487 857 143 233 422 750 111 182 333 600
3.5 179 290 521 911 162 263 475 837 136 222 404 720 103 169 311 563
4 177 286 514 900 158 256 463 818 130 213 388 692 97 159 292 529
4.5 174 282 507 889 154 250 482 800 125 204 373 667 91 149 275 500
5 171 278 500 878 150 244 442 783 120 196 258 643 86 141 260 474
6 167 270 487 857 143 233 422 750 111 182 333 600
7 162 263 475 837 136 222 404 720 103 169 311 563
8 158 256 463 818 130 213 388 692 97 159 292 529
9 154 250 452 800 125 204 373 667 91 149 275 500
10 150 244 442 783 120 196 358 643 86 141 260 474
Additional factors:
For 38 mm diameter use 1.4 x (32 mm factor)
C) Single –core thermoplastic (PVC) insulated cables in trunking.

For each cable it is intended to use, obtain the appropriate factor from Table 5.
Add the cable factors together and compare the total with the factors for
trunking given in Table 6.
The minimum size of trunking is that size having a factor equal to or greater
than the sum of cable factors.
Table 5: Cable factors for trunking
Conductor cross sectional PVC BS 6004

Type of Conductor 2
area (mm ) Cable factor
1.5 8.0
Solid
2.5 11.9
1.5 8.6
2.5 12.6
4 16.6
6 21.2
10 35.3
Stranded
16 47.8
25 73.9
Notes:
1) These factors are for metal trunking and may be optimistic for plastic trunking, where
the cross sectional area available may be significantly reduced from the nominal by
the thickness of wall material.
2) The provision of spare space is advisable, however any circuits added at a later date
must take into account grouping, Regulation 523.5.
Table 6: Factors for trunking.
Dimensions of trunking
Factor
(mm x mm)
50 x 38 767
50 x 50 1037
75 x 25 738
75 x 38 1146
75 x 50 1555
75 x 75 2371
100 x 25 993
100 x 38 1542
100 x 50 2091
100 x 75 3189
100 x 100 4252
150 x 38 2999
150 x 50 3091
Pakistan Cables 63
Dimensions of trunking
Factor
(mm x mm)
150 x 75 4743
150 x 100 6394
150 x 150 9697
200 x 38 3082
200 x 50 4145
200 x 75 6359
200 x 100 8572
200 x 150 13001
200 x 200 17429
225 x 38 3474
225 x 50 4671
225 x 75 7167
225 x 100 9662
225 x 150 14652
225 x 200 19643
225 x 225 22138
300 x 38 4648
300 x 50 6251
300 x 75 9590
300 x100 12929
300 x 150 19607
300 x 200 26285
300 x 225 29624
300 x 300 39428
Note: Space factor is 45 % with trunking thickness taken into account
Other sizes and types of cable or trunking:

For sizes and types of cable or trunking other than those given in Tables 5 and 6 the number
of cables installed should be such that the resulting space factor does not exceed 45% of the
net internal cross sectional area.
Space factor is the ratio (expressed as a percentage) of the sum of overall cross sectional
area of cables (including insulation and any sheath) to the internal cross sectional area of
the trunking or other cable enclosure in which they are installed. The effective overall cross
sectional area of a noncircular cable is taken as that of circle of diameter equal to the major
axis of cable.
Care should be taken to use trunking bends etc. which do not impose radii on cable less than
those mentioned in Section 5.
Section 5: Minimum Internal Radius of Bend

Bending or twisting cables sharply may permanently damage the insulation or other components
of cables which ultimately result in premature failure. It is therefore recommended that as large
a radius of bend as possible should be adopted during installation but not in any case less than
those mentioned below:
General Wiring Cables:
Overall Cable diameter Minimum Bending Radius

S. No
(D) mm
1 D ≤ 10 3xD
2 10 < D ≤ 25 4xD
3 D > 25 6xD
LV Power Cables:
Minimum Bending Radius

S. No Cable Type
mm
Single Core Cables
1 8xD
(Unarmoured & Armoured)
Multi Core Cables
2 12 x D
(Unarmoured & Armoured)
D = Overall Diameter of CableSection
Section 6: Pulling Tensions
1. While pulling with conductors using pulling eyes following pulling tensions to be adopted.
Copper stranded conductor --- 5 times the conductor cross sectional area (kg)
Aluminum stranded conductor --- 3 times the conductor cross sectional area (kg)
For multicore cables, the maximum tension can be increased by number of core in the
cable, provided pulling eye is attached to each conductor.
2. The above values are also adopted in case of pulling with stocking .The stocking should
be of the correct diameter and length so that tension is transferred to the conductor.
There should not be any relative movement between extruded layers and conductor at
the pulling end.
3. When cable is pulled using the armour pulling eye following tension to be adopted.
Galvanized Steel Wire Armour --- 10 times the conductor cross sectional area (kg)
Aluminum wire Armour --- 3 times the conductor cross sectional area (kg)
Pulling tension not to exceed 2000 kg.

Pakistan Cables 65
Section 7: Conversion Tables

SI Prefixes Expressing Decimal Factors
Factor Prefix Symbol Factor Prefix Symbol

1018 exa E 10-1 deci D
1015 peta P 10-2 centi C
1012 tera T 10-3 milli M
109 giga G 10-6 micro µ
106 mega M 10-9 nano N
103 kilo k 10-12 pico P
102 hecto h 10-15 femto f
101 deka da 10-18 atto a
SI Base Units
Quantity Unit Symbol

length meter m
Mass Kilogram kg
Time Second s
Electric current Ampere A
Thermodynamic temperature* Kelvin K
Amount of substance Mole mol
Luminous intensity Candela cd
*Celsius temperature is, in general, expressed in degrees Celsius (symbol °C)
Multiply By To Obtain
Weight-Imperial
Ounces 28.3495 grams
Pounds (Av) 453.59 grams
Pounds (Av) 0.45359 kilograms
Tons (short) 907.19 kilograms
Tons (long) 1016.05 kilograms
Weight-Metric
Grams 0.03527 Ounces
Grams 0.002205 Pounds
Kilograms 35.274 Ounces
Kilograms 2.2046 Pounds
Kilograms 0.001102 tons (short)
Kilograms 0.0009842 tons (long)
Miscellaneous-Imperial
Pounds per 1000 feet 1.48816 Kg/Km
Pounds per mile 0.28185 Kg/Km
Pounds per square inch 0.0007031 Kg.per square mm.
Pounds per square inch 0.07031 Kg.per square cm.
Pounds per cubic 27.68 grams per cubic cm.
Feet per second 18.288 meters per minute.
Feet per second 1.09728 kilometers per hour.
Miles per hour 1.60935 kilometer per hour.
Ohms per 1000 feet 3.28083 ohms per kilometer.
Ohms per mile 0.62137 ohms per kilometer.
Decibels Per 1000 feet 3.28083 decibles per kilometer.
Decibels per miles 0.62137 decibles per kilometer.
Decibels 0.1153 nepers.
Miscellaneous-Metric
Kg/Km 0.67197 pounds per 1000 feet.
Kg/Km 3.54795 pounds per mile.
Kg.Per square mm 1422.34 pounds per square inch.
Kg.Per square cm 14.2234 pounds per square inch.
Grams per cubic cm 0.03613 pounds pre cubic inch.
Meters per minute 0.05468 feet per second.
Kilometers per hour 0.91134 feet per second.
Kilometer per hour 0.62137 miles per hour.
Ohms per kilometer 0.3048 ohms per 1000 feet.
Ohms per kilometer 1.6093 ohms per mile.
Decibles per kilometer 0.3048 decibels per 1000 feet.
Decibles per kilometer 1.6093 decibles per mile
Nepers 0.1153 decibels
Length-Imperial
Mils 0.001 inches.
Mils 0.0254 mm.
Inches 1000 mils.
inches 25.4 mm.
inches 2.54 cm.
Feet 30.48 cm.
Feet 0.3048 meters.
Feet (thousands of) 0.3048 kilometers.
Yards 0.9144 meters.
Miles 1.6093 kilometers.
Temperature
°Fahrenheit 5/9(°F)-32 °Celsius
°Celsius 9/5(°C)+32 °Fahrenheit
Pakistan Cables 67
Length-Metric
Millimeters 39.37 mils.
Millimeters 0.03937 inches.
Centimeters 0.3937 inches.
Centimeters 0.032808 feet.
Meters 39.37 inches.
Meters 3.2808 feet.
Meters 1.0936 yards.
Kilometers 3280.83 feet.
Kilometers 0.62137 miles.
Area-Imperial
Square mils 1.2732 circular mils
Square mils 0.000001 square inches
Circular mils 0.7854 square mils
Circular mils 0.0000007854 square inches
Square mils 0.0005067 square mm.
Square inches 1000000 square mils
Square inches 1273240 square mils
Square inches 645.16 square mm.
Square inches 6.4516 square cm.
Square feet 0.0929 square meters
Square yards 0.8361 square meters
Area-Metric
Square millimeters 1973.52 circular mils
Square millimeters 0.00155 square inches
Square centimeters 0.155 square inches
Square meters 10.7638 square feet
Square meters 1.19599 square yards
Volume-Imperial
Cubic inches 16.38716 cubic cm.
Cubic feet 0.028317 cubic meters.
Volume-U.S.
Quarts (liquid) 0.9463 liters.
Gallons 3.7854 liters.
Volume-Metric
Cubic centimeters 0.06102 cubic inches.
Cubic meters 35.3145 cubic feet.
Liters 1.05668 quarts (liquid U.S.)
Liters 0.26417 gallons (U.S.)
Section 8: First Aid Instruction for Accident Caused by

Electrocution
Preliminary Precautions
1. Switch off the line. Then only remove the victim from contact with the electric conductor.
If the line is alive and the victim is being removed inspite of this fact, the rescuer is
exposed to danger.
In such a case, adopt any of following procedures:
In the case of low-Voltage installation:

a) Insulate yourself from the ground by several layers of dry boards, beams or wooden
boxes.
b) Remove the line from the victim by means of long, dry wooden sticks, dry ladder
etc.
If this does not work:

c) Pull or push the victim away from the line while standing on insulating board etc.Wrap
several layers of dry clothing around your hands, do not touch the victim except by
clothing.
In the case of high voltage installation:

1. Only experts should be permitted to remove the victim.
2. If the victim is hanging on the wires, spread straw hay or bedding undemeath .
3. Notify the Power Company and call the doctor.
4. Post a guard at the site of accident.
Treatment in Case of Unconsciousness

After the victim has been removed from contact with the power line, start first of all with
immediate attempts to restore the breathing.
• Place the unconscious person on his back, head to one side with a pillow under
his shoulders.
• Open his collar, scarf, belt and tight clothing etc.
• Carefully open the mouth of patient and place some hard object, preferably a
piece of wood between his teeth, (remove any denture).
• Slowly but with sufficient strength pull out his tongue. Using a handkerchief let
somebody hold or tie to the chin of victim.
• Try to get him to breathe spontaneously, by tickling his nose and throat.
• If no immediate success is achieved, start at once with artificial breathing,
Kneel down behind the head of the victim, grasp his arms under the elbows,
press them firmly against his chest and then draw them slowly a part in a circle
over his head. After two seconds bring the arms back to their initial position. Repeat
the exercise at the rate of 16 – 20 times a minute. If necessary, for several hours, until the
arrival of a doctor. More rapid movements are harmful and needlessly tiring.
Stop the artificial respiration as soon as the victim starts breathing; activate the
blood circulation by sprinkling his head and chest with cold water and rubbing
heart. If the victim recovers, cover him up and let him sip warm drinks from a
teaspoon as soon as he is able to swallow.
• Leave any further aid for the doctor.
Pakistan Cables 69
Section 9: Product Range

PRODUCT SPECIFICATION RANGE USAGE
GENERAL WIRING 450/750V & 300/500V a) SINGLE CORE (PVC Insulated) Homes, offices, recreational areas,
BS-6004, BS-50525, BS-6500 1 mm² to 630 mm² multistoried complexes, buildings and plazas
such as hospitals, hotels, apartments, and
other commercial spaces.
b) SHEATHED CABLES
Single Core 1 mm² to 10 mm²
Multi Core 1 mm² to 10 mm²
L.V. CABLES 600/1000V & 1900/3300V a) SINGLE CORE Multiple sectors e.g. Cement, Chemical,
16 mm² to 1000 mm² Textile, Oil & Gas, Process Automation,
Airports, Railways, Metros, Sugar Industry,
COPPER OR ALUMINIUM BS-6346 Armoured / Unarmoured / Screened
and similar other projects
CONDUCTOR XLPE OR BS-5467
PVC INSULATED IEC-60502-1 b) MULTI CORE
16 mm² to 400 mm²
Armoured / Unarmoured / Screened
M.V. CABLES 11000 -15000 V a) SINGLE CORE Primary Cable of Utility Companies for
COPPER OR ALUMINIUM 16 mm² to 630 mm² distribution to Sub-Station.
Industrial Projects
CONDUCTOR, XLPE INSULATED IEC-502, IEC-60502-2 Armoured/Unarmoured
b) MULTI CORE
16 mm² to 400 mm²
Armoured/Unarmoured
LOW SMOKE ZERO HALOGEN Hotels, Commercial Buildings, Hospitals,
(LSZH) CABLES Shopping Malls, Cinemas, Airports, Mass
Transit, Ships, Data Centers and Similar
General Wiring
Public Places.
a) LSZH INSULATED 70°C BS EN-50525-3-31 450 / 750 V 1.5 mm² to 630 mm²
b) XL-HFFR INSULATED 90°C BS EN-50525-3-41 450 / 750 V 1.5 mm² to 630 mm²
LV CABLE
COPPER OR ALUMINIUM IEC-60502-1, 600/1000V a) SINGLE CORE
CONDUCTOR XLPE INSULATED 1.5 mm² to 1000 mm²
LSZH SHEATHED Armoured / Unarmoured
b) MULTI CORE
1.5 mm² to 400 mm²
Armoured / Unarmoured
ENHANCED FIRE RETARDENT CABLES Multiple sectors e.g. Cement, Chemical,
COPPER OR ALUMINIUM IEC-60502-1, 600/1000V Single & Multi Core Cable Textile, Oil & Gas, FMCG, Process
Automation, Airports, Railways, Metros,
CONDUCTOR XLPE INSULATED IEC-60332-3-22, CAT-A 1.5 mm² to 400 mm²
Sugar Industry, and similar other projects
LSZH SHEATHED IEC-60332-3-24, CAT-C Armoured/Unarmoured
CONTROL CABLES 600/1000 V MULTI CORE Industrial Control Wiring
COPPER CONDUCTOR BS-6346, IEC-60502-1 1.5 mm² to 4.0 mm²
XLPE OR PVC INSULATED, PVC
SHEATHED
TELEPHONE /INTERCOM CABLES PCL Design 1 pair to 5 pairs Telecommunications
PE INSULATED Unarmored
AUTO MOBILE CABLES JIS-D611, C-3406 Different types & sizes as per customer's Automotive Industry
requirements
SPECIAL CABLES
a. AIR FIELD LIGHTING CABLE Civil Aviation Authority As per customer requirements Airport lighting
b. COAXIAL CABLES 5C - 2V 75ohm, RG-6, RG-11 As per customer specifications Dish Antenna CC TV and cable wiring
c. SUBMERSIBLE CABLES BS-6004, Customer Specification All sizes as per customer requirements Water submersible pumps
d. MISCELLANEOUS As per Customer Specifications As per customer requirements As per customer requirements and usage
OTHER CABLES
CONDUCTORS
PACC: Plain Annealed Copper Conductor BS-6360, BS EN-60228 Upto 1000mm² Earthing Conductor
Upto 400mm² and above sizes as per customer
HDBC: Hard Drawn Bare Conductor BS-7884
requirement
ACSR: Alum Conductor Steel Reinforced BS-215, ASTM B-232, IEC-61089 Upto 1250mm²
BS-215, ASTM B-231, BS-50182, Upto 865mm² and above sizes as per customer Overhead Transmission Lines
AAC: All Alum Conductor
IEC-61089 requirement
Upto ACCC drake and above size as per
ACCC: Alum Conductor Composite Core ASTM B-857
customer requirement
HIGH CONDUCTIVITY OXYGEN FREE ASTM B-49 8mm Dia Electrical & Enamel wire manufacturing
COPPER ROD Distribution/Installation & communication
wires
ALUMINIUM SECTION BS-1474, ASTM-B221, a) Sections for sliding doors and windows Architectural, Industrial & Commercial
(Profiles) BS-3987 & AAMA CLASS-1 b) Sections for hinged doors and windows Applications
Alum-Ex c) Sections for fixed glazing/shop fronts

Brand d) Sections for double glazed sliding Doors
and Windows
Anodized as Well as e) Sections for double glazed openable Doors
Powder Coated and Windows
f) Glass door sections
g) Curtain wall sections/Structural glazed
sections
h) Centrally pivoted window sections
i) Swing door sections
j) Sections for casement/awning windows
k) False ceiling sections
l) Special sections to suit customer's
specifications
PVC Compound Different types as per customer's requirements Insulation and Sheath of electrical cables
BS-7655, BS-60363

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TABLE OF CONTENTS

Trusted not to Compromise 05

Chapter 1: Introduction to Electricity 06

Chapter 2: Cable Construction and Cable Making Materials 14

Chapter 3: Performance of Cables under Fire 24

Chapter 5: Handling, Storage and Safety of Cables 44

Chapter 6: Useful Information 54

Figure 1: The Modern Periodic Table

Figure 2: Atomic Structure

Figure 3: Atomic Structure of Copper Atom

Valence electron One of 29

Figure 4: Copper Wire

Conductors and Insulators

Direct Current (DC)

Alternate Current (AC)

Single phase and Three phase AC:

Phase A Phase B Phase C

Transmission and Distribution of Electrical Energy:

Power Grid Transmision Grid Distribution Distribution Residential,

Cable Construction and

Copper and Aluminium

(a) Solid conductors – general wiring cables up to 4mm2

Solid Circular Stranded Compacted Sector Flexible

• Circular conductors are compacted by pulling through a die resulting in smoother

Electrical and Physical Properties

Table 1: Electrical Properties

Table 2: Physical Properties

Parameters Unit Copper Aluminium

Density at 20oC Kg/m3 8890 2703

Copper vs. Aluminum

Thermoplastics and Thermosets:

Cross linked PE(XLPE):

Characteristics of PVC Insulation:

Parameters Unit Characteristics

Maximum conductor temperature in normal operation °C 70

Properties in the state as manufactured

Properties after aging in air oven

Bending at low temperature

Elongation at low temperature

Pressure at high temperature

Characteristics of XLPE Insulation:

Parameters Unit Characteristics

Maximum conductor temperature in normal operation °C 90

After aging in an air oven

Characteristics of Steel Armour Wire:

Parameters Unit Characteristics

Characteristics of PVC Sheath:

Parameters Unit Characteristics

Maximum conductor temperature on normal operation °C 70°C 90°C

Properties in the state as manufactured

Properties after aging in air oven

Bending at low temperature

Elongation at low temperature

Maximum conductor temperature on normal operation °C 70°C 90°C

Impact at low temperature

Pressure at high temperature

Performance of Cables Under Fire

Low Smoke and Fume Fire Retardant Cables (LSF)

Low Smoke Zero Halogen Fire Retardant (LSZH)