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Electrical power cables used for transmission and distribution purposes consist of conductors stranded from plain high conductively annealed copper wires insulated with oil impregnated paper tapes. Underground construction is necessitated in the more density built up portions of cities by the heavy transformers and lines required and by the multiplication of service connections to buildings.
The cable may include uninsulated conductors used for the circuit neutral or for ground (earth) connection. Power cables are primarily used for overhead lines and underground cabling applications and can be broadly classified into three categories based on their operating voltage applications. The prospects for growth in this market will be impelled by the rising demand for high-temperature, superconducting cables from the power utility sector. A superconducting high-power transmission and distribution cable is capable of transmitting and distributing about 5-10 times the electrical current carried by a conventional copper or aluminum cable.
The overall assembly may be round or flat. Non-conducting filler strands may be added to the assembly to maintain its shape. Special purpose power cables for overhead or vertical use may have additional elements such as steel or Kevlar structural supports.
Some power cables for outdoor overhead use may have no overall sheath. Other cables may have a plastic or metal sheath enclosing all the conductors. The materials for the sheath will be selected for resistance to water, oil, sunlight, underground conditions, chemical vapors, impact, or high temperatures. In nuclear industry applications the cable may have special requirements for ionizing radiation resistance. Cable materials may be specified not to produce large amounts of smoke if burned. Cables intended for underground use or direct burial in earth will have heavy plastic or metal, most often lead sheaths, or may require special direct-buried construction.
Wires and cables sector basically consists of two areas: (i) power; and (ii) telecommunication. Power cables are PVC or PE clad, while the cables for telecommunication sector are based on PE (Polyethylene). Power cables are of 3 types depending on the intensity of power. Low-tension sector requires cables upto 1.1 KV and predominantly uses PVC insulation and jacketing. The medium tension power cables between 1.1 KV and 11 KV are based on PE as well as PVC. The high tension sector beyond 11 KV uses PE only. The low tension cables are used for tertiary distribution of power mainly from substations to buildings. Housing Sector requires many other products for myriad applications. The medium tension cables generally use crosslinkable PE compounds while the high-tension cables use continuous vulcanisation cables made from PE (LDPE).
The cable market is segmented by the combination of material used to form the conductor, the insulator, sheathing and armouring. Basically, the following types are produced and used:
- Paper insulated lead cables (PILC) upto 33 KV.
- Polyvinyl chloride (PVC) insulated power and control cables upto 11 KV.
- Cross-linked polyethylene (XLPE) power cables upto 33 KV.
- XLPE insulated extra high voltage (EHV) cables from 66 KV to 230 KV.
The Indian power cable industry has about a dozen producers in the organized sector, claiming more than two-thirds share of the market. The unorganized sector is constituted of a few small units. The divergence in the two segments goes beyond their unit sizes. The two sectors exhibit significant differences in quality and the capacities. While the organized sector has been manufacturing high voltage and specialty cables, the unorganized sector limits itself to the relatively low voltage market. The organized segment caters also to the industrial market. The State Electricity Boards remain the major buyers. Small buyers of power cables also include companies having their own power distribution within plant limits.
PVC coated cables and wires are extensively used in all electrical linings, domestic lightings and all other purposes. According to the present policy of the India Government, this time, PVC coating on electric cables and wire is exclusively reserved for development in small scale sector or in the cottage industries. The demand for PVC coating electrical wires is increasing at a rapid rate. There is a bright scope for starting new units in this field.
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