Medium-voltage KUSIL cable

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KUSIL cable according to TU 3500-024-76960731-2012

With cross-linked polyethylene insulation, for medium voltage 10, 20, 35 kV,
including flame-retardant "ng-LS", "ng-HF",
ultraviolet-resistant "UF", armored and non-armored

KUSIL medium-voltage cables are designed for the transmission and distribution of electrical energy in stationary installations, with a rated AC voltage of 10, 20, and 35 kV at a nominal frequency of 50 Hz for networks with a grounded or isolated neutral. The cables comply with the requirements of the international standard IEC 60502-2 for power cables.
Cables are intended for group or single installation in cable structures, ducts, industrial premises (including damp and frequently flooded areas), in the ground (including areas with high humidity), and in water (in non-navigable water bodies). Cables with the “UF” designation can be installed outdoors without protection from solar radiation. The cables are designed for routes without level difference restrictions. They can also be used in explosive zones in compliance with the requirements of GOST R IEC 60079-14-2008.

Design features, materials, and configurations

KUSIL cables according to TU 3500-024-76960731-2012 are manufactured as single-core and three-core (Table 1) with cross-linked polyethylene insulation. Armored cables are produced only in a three-core configuration.
The conductive cores of the cables are made of copper or aluminum, multi-wire, compacted, and comply with Class 2 according to GOST 22483-77.
The conductive cores of single-core cables for a rated voltage of 10 kV have a nominal cross-section of 35-1000 mm², and for a rated voltage of 20 and 35 kV — 50-1000 mm², as specified in Table 1.
The conductive cores of three-core cables for a rated voltage of 10 kV have a circular shape with a nominal cross-section of 35-300 mm² or a sector shape with a nominal cross-section of 120-300 mm², as specified in Table 1. The cores of three-core cables for a rated voltage of 20 and 35 kV have a circular shape with a nominal cross-section of 50-300 mm².
At the customer’s request, a numerical marking of the cores can be printed on the surface of the insulation screen of three-core cables.
All cables have a copper wire screen (Table 2), over which a copper tape is spirally applied.
Cables with longitudinal (“g”), longitudinal and transverse (“2g”) sheath sealing, as well as sealing of conductive cores (“zh”), can be used for installation in areas with high soil moisture, in damp and partially flooded premises, and in water (in non-navigable water bodies), provided that measures are taken to prevent mechanical damage to the cable.
Cables with a reinforced sheath (“u” — with longitudinal stiffening ribs) and armored cables (“B”) are used for installation on complex routes—those containing more than four bends at angles greater than 30° or straight sections with more than four transitions in pipes over 20 m in length, or with more than two pipe transitions exceeding 40 m in length. The armored cable (“B”) provides maximum protection for the conductive cores from external mechanical impacts due to the use of galvanized steel tapes and an additional sheath in its construction.
The outer sheath of cables marked with the sheath material designation “P” is made of polyethylene, allowing these cables to be installed in the ground regardless of soil corrosivity. The sheath of cables marked with the designation “V” is made of polyvinyl chloride (PVC) plastic compound—these cables are suitable for installation in dry soils (sandy-clay and normal soil with a moisture content of less than 14%).
Cables with fire safety ratings “ng(A)-LS” and “ng(B)-LS” have an outer sheath made of low-hazard PVC plastic compound (with reduced smoke and gas emissions). Cables with the “ng(A)-HF” rating have an outer sheath made of a halogen-free polymer composition—these cables do not emit corrosive gaseous byproducts when burning or smoldering. Cables with the “ng(A)-LS,” “ng(B)-LS,” or “ng(A)-HF” ratings can be used for group installations.

Cable designation when ordering

Number of cores: 1; 3

Nominal core cross-section (see Table 1)

“c” – sector-shaped core, only for 3-core cables with a voltage of 10 kV (see Table 1)¹

Cross-section of the copper screen (see Table 2)

Nominal voltage: 10; 20; 35kV

Core material¹
	copper
A	aluminum

Insulation of cores made of cross-linked polyethylene

“B” – armor made of galvanized steel tapes (only for 3-core cables)¹

Sheath material
V	PVC
P	polyethylene

“u” – reinforced polyethylene sheath with longitudinal stiffening ribs^1,2,3

Sheath sealing¹
g	longitudinal
2g	longitudinal and transverse

“zh” – longitudinal sealing of conductive cores, used together with longitudinal and transverse sheath sealing “2g”^1,2

Special cable characteristic¹
HL	frost-resistant design (only for cables with a PVC sheath)
UF	resistance to solar radiation (only for cables with a polyethylene sheath)

KUSIL

185

–

ng(A)-HF

Cable fire safety indicator¹
ng(A)-LS	Category A for flame retardancy in group installations; with reduced smoke and gas emissions⁴
ng(B)-LS	Category B for flame retardancy in group installations; with reduced smoke and gas emissions⁴
ng(A)-HF	Category A for flame retardancy in group installations; does not emit corrosive gaseous products during combustion and smoldering²

¹ — this field is not mandatory and is filled in if necessary

² — only for cables with a polyethylene (P) sheath

³ — only for non-armored cables

⁴ — only for cables with a PVC (V) sheath

Example of a designation entry when ordering
KUSIL 3×150/25-35 PvPu2gzh TU 3500-024-76960731-2012	Power cable with longitudinal sealing of three round copper conductors, in a reinforced polyethylene sheath with longitudinal and transverse sealing, with a cross-section of 150 mm², with a copper screen of 25 mm², for a voltage of 35 kV

Table 1. Nominal cross-section of conductive cores

Conductor	Nominal cross-section of the conductor, mm²
Conductor	Single-core cables	Three-core cables
Round	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. Nominal cross-section of the copper screen: in single-core cables; in three-core cables with sector-shaped conductors; in three-core cables with round conductors – total cross-section of copper screens applied to each insulated conductor

Nominal conductor cross-section, mm²	Copper screen cross-section, mm² not less than
35-120	16
150-300	25
More than 400	35

Table 3. Technical specifications of the cable

Nominal voltage		AC voltage 10kV, 25kV, 35kV at 50 Hz frequency with grounded or isolated neutral
Operating temperature		— from -60°C to +50°C for cables with polyethylene (P) sheath — from -50°C to +50°C for cables with PVC (V) sheath — from -60°C to +50°C for frost-resistant cables (HL)
Minimum installation temperature (without preheating)		— not below -20°C for cables with polyethylene (P) sheath — not below -15°C for cables with PVC (V) sheath
Permissible continuous conductor heating temperature		90°C
Maximum permissible temperature	Conductor heating during short circuit		250°C
	Copper screen heating		350°C
	Conductor heating during short circuit under fire safety conditions		400°C (short-circuit current up to 5s)
Permissible conductor heating in overload mode		< 130°C, duration not more than 8 hours per day and not more than 1000 hours over the service life
Electrical resistance of conductors to DC		meets the requirements of GOST 22483-77
Climatic design		UHL and U, placement category 1 and 2 (according to GOST 15150-69), including installation in soil and water
Bending radius (D — outer cable diameter)		— at least 15D for single-core cables (7.5D allowed with a special template) — at least 10D for three-core cables
Warranty period		5 years
Service life		at least 30 years

Table 4. Estimated capacitance values of cables with round conductors (for reference)

Nominal conductor cross-section, mm²	Capacitance of 1 km of cable, µF
	Nominal cable 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

Table 5. Continuous allowable currents for single-core and three-core cables at a load factor of K=1.0 for an ambient temperature of +25°C when laid in air and +15°C when laid in the ground

Nominal conductor cross-section, mm²	Cable currents (A) at 10 kV / 20 and 35 kV voltage when laid in the ground / in the air
	Single-core cables				Three-core cables
	With copper conductor depending on arrangement		With aluminum conductor depending on arrangement		Cable with copper conductors	Cable with aluminum conductors
	In-plane	Triangular	In-plane	Triangular	Cable with copper conductors	Cable with aluminum conductors
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
Permissible overload currents are calculated as follows: when laid in the ground — by multiplying the currents specified in Table 5 by a factor of 1.17; when laid in the air — by a factor of 1.2 Permissible currents for cables laid in the ground in pipes longer than 10m: for single-core cables in separate pipes — the current values from Table 5 should be multiplied by a factor of 0.94; for three single-core cables in one pipe — by a factor of 0.9 Permissible currents for multiple cables laid in the ground, including those laid in pipes, should be reduced by multiplying the currents from Table 5 by the factors from Table 6 Permissible short-circuit currents for cables and in copper screens of cables should not exceed the values specified in Tables 7 and 8. For short-circuit durations different from 1s, the current value must be multiplied by factor K, calculated using the formula: K=1/√t , where t is the short-circuit duration in seconds.

Table 6. Coefficients

Clearance between cables, mm	Coefficients for the number of cables
Clearance between cables, mm	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. Permissible one-second short-circuit currents of cables (conductor temperature before SC: 90°C, maximum conductor temperature during SC: 250°C)

Nominal conductor cross-section, mm²	Permissible one-second short-circuit current of the cable, kA
Nominal conductor cross-section, mm²	with copper conductor	with aluminum 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. Permissible one-second short-circuit currents in copper cable screens

Nominal cross-section of the copper screen, mm²	One-second short-circuit current, kA, not exceeding
16	3,1
25	4,8
35	6,7
50	9,6
70	13,4

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Medium-voltage KUSIL cable