Aberdare Cables
Aberdare Cables
Aberdare Cables, a member of the Powertech Group, is a leading African manufacturer of cables and
distributor of electrical accessories. With manufacturing sites in three provinces of South Africa, and
offshore operations in Mozambique, Portugal and Spain, Aberdare Cables manufactures an extensive
range of electrical cables for application in power transmission, power distribution, rail, petrochemical,
mining, ports, airports, wholesale, construction and domestic building environments. Aberdare Cables
prides its self on its ability to identify and satisfy customer needs through development of innovative
products; unique, cost effective cable solutions for a wide range of industries. This and their extensive
project experience make them the supplier of choice for cable, electrical accessories (switches, sockets,
circuit breakers and reticulation) and special cable projects.
Technology focus
Aberdare Cables pursues on-going technology development programmes, and through active association
with its local and overseas affiliates, continues to remain at the forefront of technology.The company has
been recognised internationally as a pioneer in cable advancements. Aberdare serves on a number of
SABS and International Electro Technical Commission (IEC) cable working groups. As much as ten years
ago, in a move towards facilitating the provision of electricity for all countrywide, Aberdare Cables
designed products with an emphasis on cost efficiency of electrification.To this end, Aberdare created its
Electrodac range, which is aimed specifically at facilitating rural electrification by lowering the cost of
electricity delivery. More recently, in accordance with Siemens specifications, Aberdare produced an
unarmoured cable, with stringent fire characteristics, that was designed to reduce the propagation of fire
by cables.This cable is used at Eskom's open-cycle gas turbine generators at Mossel Bay and Atlantis.To
cater for international markets, Aberdare introduced fire survival cable with stringent properties that allow
continuous operation and circuit integrity for extended periods during a fire.
Quality focus
Aberdare Cables is a forerunner in the industry with regard to quality. The manufacturing, quality
assurance, testing and research resources of Aberdare are of a world-class standard. In fact, the company
was one of the first companies in South Africa to be awarded the South African Bureau of Standards
(SABS) Quality Assurance Certification, and has been ISO 9001 compliant for many years. Aberdare
Cables is UL listed and has Basec QA accreditation.
Transformation focus
Aberdare has embraced the empowerment concept. Today, Izingwe Consortium owns 30% of the
company and the company has assisted in the development of a number of black enterprises, such as
DRUMCO, the company that makes Aberdare Cable Drums. At Aberdare, education, training and
development are seen as a foundation for economic productivity and as crucial tools to build empowered
and dedicated employees. In this regard, the company actively promotes and follows a number of
education programmes, including adult education, apprentices, trainees, learnerships and formal
education assistance.
Aberdare Cables has always been an active supporter and pillar of strength for the communities in which it
operates. The company is championing a number of social investment initiatives across our country. The
biggest of these investments has been the continuous sponsorship of Sinethemba home for street
children in Port Elizabeth.
As a proudly South African company, Aberdare participated actively in the development of the ICT charter
and the draft DTI BBBEE codes. Aberdare will continue to adopt a proactive approach to effect the
transformation that the codes specify and to lead the cable industry in this regard. We enjoy a BBBEE
status of Level 3.
Contents
Medium voltage Electric Cable - 6,6 kV to 33 kV
Testing 3
General Characteristics 4
Manufacturing Range 5
Types of Cable 6
Construction 7
Product Range 21
The Aberdare Group’s product range and services are wide but specialised. Tried and tested
and carrying South African National Standards (SANS) marks and complying with
International Standards.
XLPE insulated cables up to 33 kV. Conductor size up to 630 mm² (single core).
What is Vultex XLPE
Medium voltage Electric Cable - 6,6 kV to 33 kV
Vultex is Aberdare’s registered brand name for MV power cable insulated with XLPE
Thermoplastic polyethylene:
Polyethylene consists of long chain molecules, with some chain branching. These chains are
not interconnected and when subjected to rising temperatures, softening and eventual
melting of the polyethylene occurs.
However, by introducing suitable activators and catalysts in accurately measured ratios, three-
dimensional links between adjacent chains are created to form “cross-linked” polyethylene
(XLPE). This is thermally stable, with a much increased melting point and without adverse
effects on the electrical properties which remain outstanding.
1
Manufacturing of Vultex XLPE cable
Medium voltage Electric Cable - 6,6 kV to 33 kV
The manufacturing techniques of this type of cable, such as the stranding of the conductor,
the application of the semi-conductive layers, the insulation, the earth screen and the sheath
are, in principle, not different from other plastic insulated cables. The laying-up of three core
assemblies is also similar to that of other plastic cables of comparable dimensions.
Therefore good use can be made of the more than 40 years’ experience Aberdare have had in
this field in the manufacture of PVC and PE insulated cables.
Particular in the manufacture is the composition of the insulation material. Polyethylene plus
additives, including the cross-linking agent, are fed to extruders where the extruded conductor
screen and the integrally bonded dielectric and the core screen are vulcanised. A chemical
reaction occurs causing the cross-linking described earlier.
CCV Process
In the continuous catenary vulcanisation process, clean polyethylene and the semiconducting
screening formulations, fully compounded with their necessary additives including the cross-
linking agent, are fed into extruders which form the three layers over the conductor
concentrically, with the necessary close adhesion between conductors, screen and
insulation. The composite application then passes into a catenary shaped vulcanising tube
sealed to the main extruder head. The temperature in the tube is graded over 10 zones
typically from 520°C to 20°C using nitrogen gas at ±10 atmospheres pressure as the heat
transfer medium (dry curing principle). This pressure prevents voiding in the insulation and at
its screening interfaces, so that cavities are not developed, if the cable is exposed to bending
or other deformations. On leaving the vulcanising zone the cable is passed through a cooling
zone and wound on a take up drum.
MONOSIL Process
The Monosil process relies on slightly different chemistry and mechanical arrangements. All
three extruders feed into a common triple head, and the cross-linking agents and catalysts are
metered in as fluids at the extruder throats. The insulation extruder disperses the cross-linking
agents before extruding the mix conventionally. The significant chemical in the cross-linking
formula is a functional vinyl silane which couples onto the polyethylene molecules to prepare
cross-linking sites for later activation.
From the triple head, the core is extruded in a thermoplastic operation into an annealing and
cooling trough of water graded from ± 90°C to ambient temperature, and is then taken on to a
drum for curing.
The curing process consists of exposing the drum of core to hot water (80-90°C) or saturated
steam for a pre-determined period. During this time the functional silane “bags” on the
polyethylene molecules are hydrolysed and condensed into Siloxane (-Si-O-Si) bridges
between adjacent carbon atoms.
2
Testing
Medium voltage Electric Cable - 6,6 kV to 33 kV
On the basis of the many years experience in the field of electrical and physical tests on both
PVC and PE and later for XLPE insulated cables, internal testing standards have been
established, warranting a reliable product. Amongst other things, a great deal of research
has been carried out on detecting and preventing partial discharges in the insulation.
The test equipment is sufficiently sensitive to detect and to plot energy discharges down to a
value of 1 pC.
TypeTests
Among others the following tests were performed on cable and accessories, including those
undertaken by the SABS:
International Specifications
Vultex XLPE cables can be designed and tested to comply with all relevant foreign
specifications.
RoutineTests
Each length of completed cable is subjected to the following check and tests before despatch.
• conductor resistance
• dimensions and physical tests
• voltage test of completed cable
• partial discharge test of completed cable
• sheath integrity test (if applicable)
SpecialTests
3
General Characteristics
Medium voltage Electric Cable - 6,6 kV to 33 kV
The performance of the cable at low temperatures is determined by the properties of the
sheath material, the cold flexibility of which is adequate down to -15°C. This does not apply to
temperatures during installation of the cables.
Working temperatures
• Conductor temperature for continuous operation 90°C.
• Conductor temperature during emergency loads of 130 °C (up to 33 kV).
Maximum duration of 8 hours continuously, with a maximum total of 125 hours/annum.
• Conductor temperature after short-circuit 250°C.
• Screen and armouring temperature after short-circuit 200°C (PVC sheath assumed).
Current rating
Explanation of the tables:
Conditions, under which the values mentioned in the tables apply, are:
• One three-phase circuit, continuously fully loaded.
• Single-core cables in trefoil formation touching and in flat formation respectively with
axial separation of 150 mm and regular transposition.
• Conductor temperature 90°C • Ground temperature 25°C.
• Depth of laying 800 mm • Soil thermal resistivity 1.2 K.m/W.
• Ambient temperature 30°C in free air (shaded) • Solidly bonded at both ends.
• Absence of other heat sources.
Remarks
In certain types of soil, a conductor operating temperature of 90°C for cables laid direct or in
pipes may result in drying of the soil where a critical temperature of 55°C is exceeded. Various
alternatives have been recommended, eg:
Aberdare Power Cables Technical Division will be pleased to advise on ratings and backfills
necessary for your requirements.
Note:
The nominal data supplied in this publication has been compiled with every attempt at
accuracy with the sole purpose of providing for the reader a convenient and practical directive
without commitment.
All dimensions are in line with SANS 1339, unless otherwise stated.
4
Manufacturing Range
Medium voltage Electric Cable - 6,6 kV to 33 kV
* Note: The maximum and minimum conductor sizes given above are our standard.
Cables and dimensions are in accordance with SANS 1339, except for the
87/15 kV cables.
5
Type of Cables
Medium voltage Electric Cable - 6,6 kV to 33 kV
VULTEX TYPE A
fault currents.
2 2
2
VULTEX TYPE B
6
Construction
Medium voltage Electric Cable - 6,6 kV to 33 kV
1
2 1
3 2
4
2 2 2 2 2
2 2
2 2 2
2 2 2 2
5 3
2
4
6
5
6
7
8 9
9
10
10
11 11
7
Properties and applications
Medium voltage Electric Cable - 6,6 kV to 33 kV
Due to the fact that Vultex XLPE insulation is resistant to high temperatures, it is also obvious
that higher temperatures are permissible in the cable.
For XLPE, continuous conductor temperatures up to 90°C are permissible, whilst for some
hours a temperature of 130°C is permissible. In case of short-circuit the conductor can
withstand considerably higher temperature (up to 250°C).
• suitable for a sustained conductor temperature of 90°C as a result of which a high current-
carrying capacity is obtained
• suitable up to 125 hours/annum, (no event being longer than 8 hours continuously) at a
conductor temperature of 130°C so that emergency loads can be tolerated
• no drainage problems
• clean handling
The high current-carrying capacity can profitably be used in those cases where higher
temperatures do not occur for too long or too often, viz. as a result of daily or yearly winter
peaks. Normally improved thermal dissipation during the night or colder weather improves
the thermal stability of the installation.
Notwithstanding these claims for higher sustained current ratings, where higher than normal
ambient temperatures are obtained, (as in enclosed cable ducts or in ground which may dry
out progressively under a sustained buried cable load) care should be taken when selecting
the conductor material and area. Refer to remarks (a) and (b) under General Characteristics.
In the current rating tables, the values in brackets next to the continuous current values,
indicates the outer sheath temperature in °C, expected when the cable is fully loaded under
the stated conditions of installation.
8
9
2 2
VULTEX Type A - Three Core 2 2
VULTEX 2 2 2 2
2 2 2 2 2
2 2
2
XLPE insulated, copper tape screened, PVC bedded, galvanised steel
wire armoured and PVC sheathed.
Constructional Data
Copper and Aluminium Conductors Electrical Properties Current Ratings
(nominal values)
Capaci-
Gross Mass D.C. A.C. Ground Ducts Air
Con- Diameter XLPE Diameter Cable Mass Reactance tance
SWA** Diameter per 300m Drum Resistance at 20°C Resistance at 90°C 25°C 25°C 30°C
Ductor Over Insulation Over per per
Diameter Overall at 50 Hz
Size Conductor Thickness Bedding phase phase
at 50 Hz
* Not to SANS 1339 ** SWA = Steel Wire Armour NB. Figures in brackets are sheath temperature in Degrees Celsius Technical data on larger conductor sizes available on request.
10
11
VULTEX VULTEX Type A - Single Core
XLPE insulated, copper tape screened, PVC bedded, aluminium
wire armoured and PVC sheathed.
Constructional Data
Copper and Aluminium Conductors Electrical Properties Current Ratings
(nominal values)
* Not to SANS 1339 ** AWA = Aluminium Wire Armour # Horizontal Plane Spaced 150 mm (double Bonded) NB: Figures in brackets are sheath temperature in Degrees Celsius Technical data on larger conductor
sizes available on request.
12
13
2 2
2 2
VULTEX VULTEX Type B - Three Core 2 2 2 2
2 2 2 2 2
2 2
2
XLPE insulated, copper tape screened, and PVC sheathed.
Constructional Data
Copper and Aluminium Conductors Electrical Properties Current Ratings
(nominal values)
A.C. Capaci-
Gross Mass D.C. Ground Ducts Air
Con- Diameter XLPE Cable Mass Resistance at 90°C Reactance tance
Diameter per 300m Drum Resistance at 20°C 25°C 25°C 30°C
Ductor Over Insulation at 50 Hz per per
Overall
Size Conductor Thickness phase phase
at 50 Hz
* Not to SANS 1339 NB. Figures in brackets are sheath temperature in Degrees Celsius
14
15
VULTEX VULTEX Type B - Single Core
XLPE insulated, copper tape screened, PVC sheathed.
Constructional Data
Copper and Aluminium Conductors Electrical Properties Current Ratings
(nominal values)
* Not to SANS 1339 # Horizontal plane spaced 150 mm (double point bonded) NB. Figures in brackets are sheath temperature in DEGREES CELSIUS Technical data on larger conductor sizes available on request.
16
Fault rating - kA for 1 sec (Copper)
Medium voltage Electric Cable - 6,6 kV to 33 kV
Earth Fault
Symmetrical Faults
Maximum permissible short-circuit current rating for Vultex XLPE cables up to 33 kV Copper
conductors
200
Copper
100
90
80
70
60
50
40
500
30
400
20 300
240
185
10 150
9
8 120
7
6 95
5
70
4
3 50
35
2
25
1
0.1 0.2 0.3 0.4 0.5 1 2 3 4 5
SHORT-CIRCUITTIME IN SEC
Max. conductor temperature at the beginning of K = copper constant of 143 for conductor
short-circuit is 90°C. temperature rising from 90°C to 250°C
Max. conductor temperature at the end of short-
circuit is 250°C.
The graphs are calculated with the formula: Note: In case the cable does not carry full load,
consequently the conductor temperature is below
q 90°C, this K-factor can be adjusted as follows:
I = K, where:
k t
90 - tc
I = max. permissible short-circuit K = 143 + x 11
k current (A) 20
17
Fault rating - kA for 1 sec (Aluminium)
Medium voltage Electric Cable - 6,6 kV to 33 kV
Earth Fault
TYPE A 3-CORE
Conductor Size Rated Voltage kV
(mm²) 3,8/6,6 kV 6,35/11 kV 12,7/22 kV 19/33 kV
25 7,4 10,4 16,5
35 11,1 12,2 17,2
50 12,0 13,1 19,7 21,3
70 12,9 17,6 20,8 28,1
95 17,3 18,7 25,0 29,4
120 18,3 19,7 25,9 30,3
150 19,4 20,8 27,2 31,6
185 20,8 25,0 28,6 33,0
240 25,5 26,8 30,3 34,7
300 27,2 28,6 32,1
Symmetrical Faults
Maximum permissible short-circuit current rating for XLPE cables up to 33 kV aluminium
conductors
200
Aluminium
100
90
80
70
60
50
40
30
20 500
400
300
10
240
9
8
185
7
6 150
5 120
4
95
3
70
50
2
35
1 25
SHORT-CIRCUITTIME IN SEC
90 - tc
I = max. permissible short-circuit K = 92 + x7
k current (A) 20
18
Rating Factors
Medium voltage Electric Cable - 6,6 kV to 33 kV
19
Rating Factors
Medium voltage Electric Cable - 6,6 kV to 33 kV
30 mm
touching 0.94 0.80 0.66
On
floor
30 mm d max 30 mm
with spacing 0.94 0.90 0.87
30 mm
On
floor
30 mm
d max 30 mm
20
Product Range
Our Services are Wide but Specialised
The Aberdare Group's product range and services are wide but specialised. Tried and tested and carrying South African
Bureau of Standards (SABS) marks and complying with International Standards, we stand by our products.
Technical / Product Application queries email: [email protected] call: +27 (0)11 396 8107
21
Notes
Medium voltage Electric Cable - 6,6 kV to 33 kV
Notes
Medium voltage Electric Cable - 6,6 kV to 33 kV