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KUSIL is a xPLE insulated power cable optimized for 10, 20, 35 kV voltages
manufactured acc. to ТУ 3500-024-76960731-2012

KUSIL cables are designed for transmission and distribution of electric power in stationary equipment with rated AC voltages of 10, 20, 35 kV and nominal frequency of 50 Hz for networks with grounded or insulated neutral. Cables meet all the requirements of international standard IEC 60502-2.

The cables are designed both for group and single cable laying in cable structures, sewers, industrial premises (including wet and often flooded locations), as well as for laying in the ground (including excessively wet soils), and water (non-navigable water). "УФ" marked cables are UV-resistant cables that can be installed outdoors without solar radiation protection. The cables can also be laid in cable raceways with no restrictions to level difference. The cables can be used in explosive hazardous zones regarding the requirements of IEC 60079-14-2008.

Cable design features, materials and types

  • Cables meet all the requirements of inter-national standard IEC 60502-2
  • Cables withstand high-frequency and short-circuit currents due to cross-linked polyethylene insulation
  • Conductor cross-section varying from 35 mm² to 1000mm²
  • Number of conductors: 1 or 3
  • New materials are applied to provide the best fire safety characteristics ("нг(A)-LS" and "нг(A)-HF")
  • Cable marked with "УФ" index is resistant to solar radiation
  • Longitudinal, lateral, and conductor sealing technologies are applied to protect the cable against moisture ingress
  • Wide range of applications in all explosive hazardous areas

TU 3500-024-76960731-2012 KUSIL cable product series include xLPE insulated single core and three core (Table 1) cables. Armor can be applied to three core cables only.

All conductors comply with Class 2 of GOST 22483-77 standard and may be compacted or stranded, of aluminum or copper.

Single core cables with nominal conductor cross-section of 35-1000 mm² are optimized for rated voltage of 10 kV, and those with nominal conductor cross-section of 50-1000 mm² are optimized for rated voltage of 20 kV and 35 kV, according to Table 1.

Three core cables that feature round-shaped conductors with nominal conductor cross-section of 35-300 mm², and those with sector-shaped conductors and nominal cross-section of 120-300 mm² are optimized for rated voltages of 10 kV, according to Table 1. Three core cables, which are optimized for rated voltages of 20 kV and 35 kV, feature round-shaped conductors with nominal conductor cross-section of 50-300 mm².

At the customer’s request a digit core marking can be printed on the three core cable conductor insulation shield surface.

All cables have a copper wire shield (Table 2) with a copper tape spirally applied over it.

Cables with longitudinal sealing ("г"), longitudinal and lateral sealing ("2г"), as well as those with conductor sealing ("ж"), can be applied for laying in the ground (excessively wet soils), and water (non-navigable water), as well as installed in wet and often flooded locations in case all the measures to prevent mechanical cable damage are followed. Reinforced cables ("у" - with longitudinal stiffeners) and armoured cables ("Б") are designed for laying in complex cable raceways that contain more than 4 turns at an angle of more than 30° or straight sections with more than four pipe transitions longer than 20m or more than two pipe transitions longer than 40m. Armoured cable ("Б") provides maximum conductor protection against external mechanical impacts due to galvanized steel tapes and additional sheath used in cable design.

The outer sheath of cables marked with "П" material index is made of polyethylene. These cables can be laid in the ground regardless of soil aggressiveness. The sheath of those cables marked with "B" material index is made of PVC plastic, which allows laying them in dry soils (sandy-clay soil and normal soil with moisture level of no more than 14%).

Cables with "нг(A)-LS" or "нг(A)(В)-LS" fire safety index have the outer sheath made of flame retardant and low smoke PVC. Cables marked with "нг(A)-HF" index have the outer sheath made of a halogen-free polymer composition, which means the cables do not emit corrosive gases when burning or smouldering. Cables with "нг(A)-LS", "нг(A)(В)-LS", and "нг(A)-HF" indexes can be used for group laying.

Cable marking when ordering:

КУСИЛ x / -
1 2 3 4 5 6 7 8 9 10 11 12 13 14
  1. Number of conductors: 1; 3
  2. Nominal conductor cross-section (see Table 1)
  3. "с" - sector-shaped conductor, for 10kV three core cables only (see Table 1) (1)
  4. Copper shield cross-section (see Table 2)
  5. Rated voltage: 10; 20; 35 kV
  6. "А" - aluminium conductors (leave empty for copper conductors) (1)
  7. xLPE conductor insulation
  8. "Б" - galvanized steel tapes armour (for three core cables only) (1)
  9. Sheath material:
    • "В" - PVC
    • "П" - polyethylene
  10. "у" - reinforced polyethylene sheath with longitudinal stiffeners (1),(2),(3)
  11. 11. Sheath sealing: (1)
    • "г" - longitudinal
    • "2г" - longitudinal and lateral
  12. "ж" - longitudinal conductors sealing combined together with lateral sheath sealing "2г" (1),(2)
  13. Fire safety index: (1)
    • "нг(A)-LS" - flame retardant (A category) and low smoke if group cable laying is applied (4)
    • "нг(A)(В)-LS" - flame retardant (B category) and low smoke if group cable laying is applied (4)
    • "нг(A)-HF" - flame retardant (A category) if group cable laying is applied; no corrosive gases emitted when burning or smouldering (2)
  14. Special cable indexes: (1)
    • "ХЛ" - cold-resistant (for PVC coated cables only)
    • "УФ" - resistant to solar radiation (for polyethylene coated cables only)

(1) - optional field
(2) - for polyethylene (П) coated cables only
(3) - for unarmoured cables only
(4) - for PVC (В) coated cables only

An example of cable marking when ordering

Сable КУСИЛ 3х150/25-35 ПвПу2гж ТУ 3500-024-76960731-2012
- 35 kV power cable featuring longitudinal sealing of three round-shaped copper conductors with cross-section of 150 mm², including reinforced polyethylene sheath with lon-gitudinal and later sealing and copper shield with cross-section of 25 mm².

Table 1. Nominal conductor cross-section

Conductor

Nominal conductor cross-section, mm²

Single core cable

Three core cable

Round- shaped

35; 50; 70; 95; 120; 150; 185; 240; 300; 400; 500; 630; 800; 1000

35; 50; 70; 95; 120; 150; 185; 240; 300

Sector- shaped

-

120; 150; 185; 240; 300

Table 2. Copper shield nominal cross-section: for single core cables; for three core cables with sector-shaped conductors; for three core cables with round-shaped conductors - total cross-section of copper shields applied to each insulated conductor

Nominal conductor cross-section, mm²

Copper shield cross-section, mm²
at least

35-120

16

150-300

25

> 400

35

Cable characteristics

Table 3. Cable technical data

Rated voltage

AC voltage of 10 kV, 25 kV, 35 kV, 50 Hz with grounded or insulated neutral

Operating temperature

- from -60° to +50°C for polyethylene ("П" material index) coated cables

- from -50° to +50°C for PVC ("В" material index) coated cables

- from -60° to +50°C for cold-resistant "ХЛ" cables

Minimum cable installation

temperature (without preheating)

- -20°С or higher for polyethylene ("П") coated cables

- -15°С or higher for PVC ("В ") coated cables

Cable conductor continuous
heating temperature

90°C

Limiting
temperature of

short-circuit conductor heating

250°C

copper shield heating

350°C

noncombustible short-circuit conductor heating

400°C (short-circuit current duration up to 5s)

Conductor continuous heating temperature for emergency overload conditions

< 130°С, can be exposed to overload conditions for no more than 8 hours a day and no more than 1000 hours during the entire service life

DC conductor resistance

Meets the requirements of GOST 22483-77 standard

Climatic category

"УХЛ" and "У" indexes, with the categories of placement 1 and 2 (according to GOST 15150-69 standard), including laying in the ground and water

Cable bending radius
(D -outside cable diameter)

- 15 D or more for single core cables (7,5 D is allowed if a specific
template is applied)

- 10 D or more for three core cables

Warranty service life

5 years

Cable service life

At least 30 years

Table 4. Calculated capacitance values for cables with round-shaped conductors (for reference use)

Nominal conductor cross-section, mm²

Cable capacitance for 1 km of cable, mF

Cable rated voltage, kV

10

20

35

35

0,22

-

-

50

0,25

0,17

0,14

70

0,29

0,19

0,16

95

0,32

0,21

0,18

120

0,35

0,23

0,19

150

0,38

0,26

0,20

185

0,42

0,27

0,22

240

0,46

0,29

0,24

300

0,51

0,32

0,26

400

0,57

0,35

0,29

500

0,63

0,39

0,32

630

0,70

0,43

0,35

800

0,77

0,49

0,40

1000

0,87

0,57

0,39

Cable admissible current

Table 5. Continuous admissible current for single core and three core cables with load factor of К=1.0 and ambient temperature of +25°C when laid in the air, and +15°C when laid in the ground

Nominal conductor cross-section, мм²

Current (А) values for 10 kV / 20kV and 35 kV cables when laid
in the ground / in the air

Single core cables

Three core cables

with copper conductor

with aluminium conductor

with copper conductors

with aluminium conductors

flat formation

trefoil formation

flat formation

trefoil formation

35

175 / -
217 / -

181 / -
192 / -

153 / -
189 / -

145 / -
150 / -

175 / -
173 / -

136 / -
134 / -

50

250 / 230
290 / 290

225 / 225
240 / 250

195 / 185
225 / 225

170 / 175
185 / 190

207 / 207
206 / 215

156 / 161
159 / 163

70

310 / 290
360 / 365

275 / 270
300 / 310

240 / 225
280 / 280

210 / 215
230 / 240

253 / 248
255 / 264

193 / 199
196 / 204

95

336 / 336
448 / 446

326 / 326
387 / 389

263 / 263
349 / 348

253 / 253
300 / 301

300 / 300
329 / 331

233 / 233
255 / 256

120

380 / 380
515 / 513

370 / 371
445 / 448

298 / 298
403 / 402

288 / 288
346 / 348

340 / 341
374 / 376

265 / 265
291 / 292

150

416 / 417
574 / 573

413 / 413
503 / 507

329 / 330
452 / 451

322 / 322
392 / 394

384 / 384
423 / 426

300 / 300
329 / 331

185

466 / 466
654 / 652

466 / 466
577 / 580

371 / 371
518 / 516

364 / 365
450 / 452

433 / 433
479 / 481

338 / 339
374 / 375

240

531 / 532
762 / 760

537 / 538
677 / 680

426 / 426
607 / 605

422 / 422
531 / 533

500 / 500
562 / 564

392 / 392
441 / 442

300

590 / 582
865 / 863

604 / 605
776 / 779

477 / 477
693 / 690

476 / 476
609 / 611

563 / 563
630 / 630

456 / 456
490 / 490

400

633 / 635
959 / 957

677 / 678
891 / 895

525 / 526
787 / 783

541 / 541
710 / 712

500

697 / 700
1081 / 1081

759 / 762
1025 / 1027

287 / 588
900 / 897

614 / 615
822 / 824

630

762 / 766
1213 / 1213

848 / 851
1166 / 1172

653 / 655
1026 / 1023

695 / 699
954 / 953

800

825 / 830
1349 / 1351

933 / 942
1319 / 1325

719 / 722
1161 / 1159

780 / 782
1094 / 1096

1000

900 / 906
1423 / 1430

1003 / 1007
1411 / 1415

800 / 805
1220 / 1230

845 / 850
1180 / 1186

  • Admissible overload currents are calculated as follows: when laid in the ground - multiply current values, represented in
  • Table 5, by 1.17; when laid in the air multiply the values by 1.2
  • Admissible currents for cables laid in pipes of more than 10m: for single core cables laid in separate pipes - multiply current values, represented in Table 5, by 0.94; for three single core cables laid in one pipe multiply the values by 0.9
  • Admissible currents for several cables laid in the ground, including those laid in pipes, should be decreased through multiplying current values, represented in Table 5, by coefficients from Table 6
  • Admissible one-second short-circuit currents in cable copper screens should not exceed the values represented in Table 7 and Table 8.
    For short-circuit current duration that differs from 1 second, please, multiply the value from the table by K coefficient that is to be calculated as follows: K = 1 / √t , where t is short-circuit current duration.
Table 6. Coefficients

Distance between cables, mm

Coefficients depending on cables quantity

1

2

3

4

5

6

100

1,0

0,90

0,85

0,80

0,78

0,75

200

1,0

0,92

0,87

0,84

0,82

0,81

300

1,0

0,93

0,90

0,87

0,86

0,85

Table 7. Admissible one-second short-circuit currents (conductor temperature before short-circuiting: 90°С, max short-circuit conductor temperature: 250°С)

Nominal conductor cross-section, mm²

Admissible one-second short-circuit current, kA

with copper conductor

with aluminium conductor

35

5,0

3,3

50

7,15

4,7

70

10,0

6,6

95

13,6

8,9

120

17,2

11,2

150

21,5

14,2

185

26,5

17,5

240

34,3

22,7

300

42,9

28,2

400

57,2

37,6

500

71,5

47,0

630

90,1

59,2

800

114,4

75,2

1000

142,9

94,5

Table 8. Admissible one-second short-circuit currents in cable copper shield

Copper shield nominal cross-section, mm²

One-second short-circuit current, kA, max

16

3,1

25

4,8

35

6,7

50

9,6

70

13,4