What is the difference between AWA

and SWA Cable?

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Aluminium Wire Armour (AWA) is used in single core cable because it is non-magnetic. When an electric current
passes through a cable it produces a magnetic field (the higher the voltage the bigger the field). The magnetic field
will induce an electric current in steel armour (eddy currents), which can cause overheating in AC systems. The non-
magnetic aluminium armour prevents this from happening.

Steel Wire Armour (SWA) is particularly useful in external or underground projects. As well as providing effective
mechanical protection, the armour enables it to withstand higher pulling loads. SWA Cable is commonly used across
a whole range of industries including building and construction, and rail and transport. The armoured mains cable is
also supplied for transmission, distribution and power networks as well as automation and process control systems.

Cable Parts

Here, we will take a short overview of the main and the most typical cable construction parts:

Conductor

Usually stranded copper (Cu) or aluminium (Al). Copper is densier and heavier, but more
conductive than aluminium. Electrically equivalent aluminium conductors have a cross-sectional
area approximately 1.6 times larger than copper, but are half the weight (which may save on
material cost).

Annealing – is the process of gradually heating and cooling the conductor material to make it
more malleable and less brittle.

Coating – surface coating (eg. tin, nickel, silver, lead alloy) of copper conductors is common to
prevent the insulation from attacking or adhering to the copper conductor and prevents
deterioration of copper at high temperatures. Tin coatings were used in the past to protect against
corrosion from rubber insulation, which contained traces of the sulfur used in the vulcanising
process.

Conductor Screen

A semi-conducting tape to maintain a uniform electric field and minimise electrostatic stresses
(for MV/HV power cables).
Insulation

Commonly thermoplastic (eg. PVC) or thermosetting (eg. EPR, XLPE) type materials. Mineral
insulation is sometimes used, but the construction of MI cables are entirely different to normal
plastic / rubber insulated cables. Typically a thermosetting(eg. EPR, XLPE) or paper/lead
insulation for cables under 22kV. Paper-based insulation in combination with oil or gas-filled
cables are generally used for higher voltages.

Plastics are one of the more commonly used types of insulating materials for electrical
conductors. It has good insulating, flexibility, and moisture-resistant qualities. Although there are
many types of plastic insulating materials, thermoplastic is one of the most common. With the
use of thermoplastic, the conductor temperature can be higher than with some other types of
insulating materials without damage to the insulating quality of the material. Plastic insulation is
normally used for low- or medium-range voltage.

The designators used with thermoplastics are much like those used with rubber insulators. The
following letters are used when dealing with NEC type designators for thermoplastics:

T - Thermoplastic

H - Heat-resistant

W - Moisture-resistant

A - Asbestos

N - Outer nylon jacket

M - Oil-resistant

Paper has little insulation value alone. However, when impregnated with a high grade of mineral
oil, it serves as a satisfactory insulation for extremely high-voltage cables. The oil has a high
dielectric strength, and tends to prevent breakdown of the paper insulation. The paper must be
thoroughly saturated with the oil. The thin paper tape is wrapped in many layers around the
conductors, and then soaked with oil.

Enamel: the wire used on the coils of meters, relays, small transformers, motor windings, and so
forth, is called magnet wire. This wire is insulated with an enamel coating. The enamel is a
synthetic compound of cellulose acetate (wood pulp and magnesium). In the manufacturing
process, the bare wire is passed through a solution of hot enamel and then cooled. This process is
repeated until the wire acquires from 6 to 10 coatings. Thickness for thickness, enamel has
higher dielectric strength than rubber. It is not practical for large wires because of the expense
and because the insulation is readily fractured when large wires are bent.

Mineral-insulated (MI) cable was developed to meet the needs of a noncombustible, high heat-
resistant, and water-resistant cable. MI cable has from one to seven electrical conductors. These
conductors are insulated in a highly compressed mineral, normally magnesium oxide, and sealed
in a liquidtight, gastight metallic tube, normally made of seamless copper.

Silk and Cotton: in certain types of circuits (for example, communications circuits), a large
number of conductors are needed, perhaps as many as several hundred. Because the insulation in
this type of cable is not subjected to high voltage, the use of thin layers of silk and cotton is
satisfactory.

Silk and cotton insulation keeps the size of the cable small enough to be handled easily. The silk
and cotton threads are wrapped around the individual conductors in reverse directions. The
covering is then impregnated with a special wax compound.

Insulation Screen

A semi-conducting material that has a similar function as the conductor screen (ie. control of the
electric field for MV/HV power cables).

Conductor Sheath

A conductive sheath / shield, typically of copper tape or sometimes lead alloy, is used as a shield
to keep electromagnetic radiation in, and also provide a path for fault and leakage currents
(sheaths are earthed at one cable end). Lead sheaths are heavier and potentially more difficult to
terminate than copper tape, but generally provide better earth fault capacity.

Filler

The interstices of the insulated conductor bundle is sometimes filled, usually with a soft polymer
material.

Bedding / Inner Sheath

Typically a thermoplastic (eg. PVC) or thermosetting (eg. CSP) compound, the inner sheath is
there to keep the bundle together and to provide a bedding for the cable armour.

Individual Screen (Instrument Cables)

An individual screen is occasionally applied over each insulated conductor bundle for shielding
against noise / radiation and interference from other conductor bundles. Screens are usually a
metallic (copper, aluminium) or semi-metallic (PETP/Al) tape or braid. Typically used in
instrument cables, but not in power cables.

Drain Wire (Instrument Cables)

Each screen has an associated drain wire, which assists in the termination of the screen.
Typically used in instrument cables, but not in power cables.
Overall Screen (Instrument Cables)

An overall screen is applied over all the insulated conductor bundles for shielding against noise /
radiation, interference from other cables and surge / lightning protection. Screens are usually a
metallic (copper, aluminium) or semi-metallic (PETP/Al) tape or braid. Typically used in
instrument cables, but not in power cables.

Armour

For mechanical protection of the conductor bundle. Steel wire armour or braid is typically used.
Tinning or galvanising is used for rust prevention. Phosphor bronze or tinned copper braid is also
used when steel armour is not allowed.

 SWA - Steel wire armour, used in multi-core cables (magnetic),

 AWA - Aluminium wire armour, used in single-core cables (non-magnetic).

When an electric current passes through a cable it produces a magnetic field (the higher the
voltage the bigger the field). The magnetic field will induce an electric current in steel armour
(eddy currents), which can cause overheating in AC systems. The non-magnetic aluminium
armour prevents this from happening.

Outer Sheath

Applied over the armour for overall mechanical, weather, chemical and electrical protection.
Typically a thermoplastic (eg. PVC) or thermosetting(eg. CSP) compound, and often the same
material as the bedding. Outer sheath is normally colour coded to differentiate between LV, HV
and instrumentation cables. Manufacturer’s markings and length markings are also printed on the
outer sheath.

Termite Protection

For underground cables, a nylon jacket can be applied for termite protection, although sometimes
a phosphor bronze tape is used.

Conductor Protection (Appendix)

Wires and cables are generally subject to abuse. The type and amount of abuse depends on how
and where they are installed and the manner in which they are used. Cables buried directly in the
ground must resist moisture, chemical action, and abrasion. Wires installed in buildings must be
protected against mechanical injury and overloading. Wires strung on crossarms on poles must
be kept far enough apart so that the wires do not touch. Snow, ice, and strong winds make it
necessary to use conductors having high tensile strength and substantial frame structures.

Generally, except for overhead transmission lines, wires or cables are protected by some form of
covering. The covering may be some type of insulator like rubber or plastic. Over this, additional
layers of fibrous braid or tape may be used and then covered with a finish or saturated with a
protective coating. If the wire or cable is installed where it is likely to receive rough treatment, a
metallic coat should be added.

The materials used to make up the conductor protection for a wire or cable are grouped into one
of two categories: non-metallic or metallic.

Non-Metallic

The category of non-metallic protective coverings is divided into three areas. These areas are:

(1) according to the material used as the covering,

(2) according to the saturant in which the covering was impregnated, and

(3) according to the external finish on the wire or cable.

These three areas reflect three different methods of protecting the wire or cable. These methods
allow some wire or cable to be classified under more than one category. Most of the time,
however, the wire or cable will be classified based upon the material used as the covering
regardless of whether or not a saturant or finish is applied.

Many types of non-metallic materials are used to protect wires and cables. Fibrous braid is by far
the most common and will be discussed first.

Fibrous Braid

Fibrous braid is used extensively as a protective covering for cables. This braid is woven over
the insulation to form a continuous covering without joints. The braid is generally saturated with
asphalt, paint, or varnish to give added protection against moisture, flame, weathering, oil, or
acid. Additionally, the outside braid is often given a finish of stearin pitch and mica flakes, paint,
wax, lacquer, or varnish depending on the environment where the cable is to be used.

Woven Covers

Woven covers, commonly called loom, are used when exceptional abrasion-resistant qualities are
required. These covers are composed of thick, heavy, long-fibered cotton yarns woven around
the cable in a circular loom, much like that used on a fire hose. They are not braids, although
braid covering are also woven; they are designated differently.

Rubber and Synthetic Coverings

Rubber and synthetic coverings are not standardized. Different manufactures have their own
special compounds designated by individual trade names. These compounds are different from
the rubber compounds used to insulate cable. These compounds have been perfected not for
insulation qualities but for resistance to abrasion, moisture, oil, gasoline, acids, earth solutions,
and alkalies. None of these coverings will provide protection against all types of exposure. Each
covering has its own particular limitations and qualifications.

Jute and Asphalt Coverings

Jute and asphalt coverings are commonly used as a cushion between cable insulation and
metallic armour. Frequently, they are also used as a corrosive-resistant covering over a lead
sheath or metallic armour. Jute and asphalt coverings consist of asphalt-impregnated jute yarn
heli-wrapped around the cable or of alternate layers of asphalt-impregnated jute yarn. These
coverings serve as a weatherproofing.

Unspun Felted Cotton

Unspun felted cotton is commonly used only in special classes of service. It is made as a solid
felted covering for a cable.

Metallic

Metallic protection is of two types: sheath or armour. As with all wires and cables, the type of
protection needed will depend on the environment where the wire or cable will be used.

Metallic Sheath

Cables or wires that are continually subjected to water must be protected by a watertight cover.
This watertight cover is either a continuous metal jacket or a rubber sheath molded around the
cable.

Lead-sheathed cable is one of three types currently being used: alloy lead, pure lead, and
reinforced lead. An alloy-lead sheath is much like a pure lead sheath but is manufactured with 2-
percent tin. This alloy is more resistant to gouging and abrasion during and after installation.
Reinforced lead sheath is used mainly for oil-filled cables where high internal pressures can be
expected. Reinforced lead sheath consists of a double lead sheath. A thin tape of hard-drawn
copper, bronze, or other elastic metal (preferably nonmagnetic) is wrapped around the inner
sheath. This tape gives considerable additional strength and elasticity to the sheath, but must be
protected from corrosion. For this reason, a second lead sheath is applied over the tape.

Metallic Armour

Metallic armour provides a tough protective covering for wires and cables. The type, thickness,
and kind of metal used to make the armour depend on three factors:

(1) the use of the conductors,

(2) the environment where the conductors are to be used, and

(3) the amount of rough treatment that is expected.

1. Wire-braid armour

Wire-braid armour, also known as basket-weave armour, is used when light and flexible
protection is needed. Wire braid is constructed much like fibrous braid. The metal is woven
directly over the cable as the outer covering. The metal used in this braid is galvanized steel,
bronze, copper, or aluminum. Wire-braid armour is mainly for shipboard use.

2. Steel tape

A second type of metallic armour is steel tape. Steel tape covering is wrapped around the cable
and then covered with a serving of jute. There are two types of steel tape armour. The first is
called interlocking armour. Interlocking armour is applied by wrapping the tape around the cable
so that each turn is overlapped by the next and is locked in place. The second type is flat- band
armour. Flat-band armour consists of two layers of steel tape. The first layer is wrapped around
the cable but is not overlapped. The second layer is then wrapped around the cable covering the
area that was not covered by the first layer.

3. Wire armour

Wire armour is a layer of wound metal wire wrapped around the cable. Wire armour is usually
made of galvanized steel and can be used over a lead sheath (see view C of the figure above). It
can be used with the sheath as a buried cable where moisture is a concern, or without the sheath
when used in buildings.

4. Coaxial cable

Coaxial cable is defined as two concentric wires, cylindrical in shape, separated by a dielectric of
some type. One wire is the center conductor and the other is the outer conductor. These
conductors are covered by a protective jacket. The protective jacket is then covered by an outer
protective armour.

Coaxial cables are used as transmission lines and are constructed to provide protection against
outside signal interference.

Low Voltage Power and Control Cables

Low voltage power and control cables pertain to electrical cables that typically have a voltage
grade of 0.6/1 kV or below.
Armoured FAS Cable

An important item that is under the grouping known as 'Low Voltage Cables', is Type FAS (Fire
Alarm & Signal Cable). This 300-volt cable, is specifically designed for the interconnection of
security system elements, including fire protection signalling devices such as smoke and fire
detectors, fire alarms, and two-way emergency communications systems.

Fire alarm installations in non-combustible buildings require mechanical protection, consisting

of interlock armour, metallic conduit, non-metallic conduit embedded in concrete or installed
under-ground. Armoured FAS Cable provided with an interlocking aluminum armour, may be
expected to have an appreciable cost advantage, compared with cables installed in rigid conduit.

Other common cables are LVT (Low Voltage Thermoplastic) and ELC (Extra Low Voltage
Control), which are frequently used in residential installations for such items as door bells and
thermostats.

Low Voltage Instrumentation Cables

Instrumentation cables

Low voltage instrumentation cables pertain to cables for use in instrument applications and
typically have a voltage grade of 450/750 V or below.

Instrumentation Cables rated at 300 volts have copper conductors 0.33 mm2 (#22 AWG) to
2.08 mm2 (#14 AWG), while those rated at 600 volts have 0.82 mm2(#18 AWG) to 5.26
mm2(#10 AWG), and unarmoured and armoured types are available. The cables may be an
assembly of single conductors, pairs, triads or quads. The conductors are stranded seven-wire
tinned or bare copper. The insulation is usually a PVC compound chosen dependant on the
environment for which it is intended. Insulated conductors are paired with staggered lays to
prevent electromagnetic coupling and crosstalk. When individual shielding is specified, each pair
is aluminum/polyester shielded with drain wire to eliminate electrostatic interference.

Armoured cables have an interlocked aluminum or galvanized steel armour. The armouring is
applied over an inner PVC jacket, followed by a PVC outer jacket. Armoured cables are suitable
for installation on cable trays in dry, damp and wet locations, or direct earth burial.

Unarmoured Instrumentation Cables are intended for installation in raceways/conduit (except

cable trays) in dry, damp or wet locations, or direct earth buried. Unarmoured Cable with Type
TC (Tray Cable) designation, may be installed in cable trays.
Thermocouple Extension Cables

Thermocouple Extension Cables have a 300 volt rating, and are of similar construction to
Instrumentation Cables, but the metals/alloys used for the conductors are different.
Thermocouples measure temperature using the electric current created when heat is applied to
two dissimilar metals/alloys. The cable assembles may consist of as many as 50 pairs, depending
on the number of locations being temperature monitored.

Medium / High Voltage Power Cables

Medium or High Voltage power cables have voltage grade greater than 1 kV. Medium voltage
usually goes up to 46 kV and High voltage is considering all voltage levels above 46 kV.

Medium Voltage distribution systems begin at substations and supply electricity to a wide
spectrum of power consumers. When selecting a cable, the basic aim is to safely provide
adequate electrical power, with continuous, trouble-free operation, in a system that is able to
withstand unexpected demands and overload conditions. Each installation has particular
requirements that must be considered. There are distinct benefits from specifying a copper-
conductor cable that has been manufactured under rigid specification and quality control
procedures. It will provide maximum performance with minimum maintenance. There are seven
types different by construction for medium voltage copper power cables in the 1 kV to 46 kV
range. Most are available in single- and multi-core configurations. There are ranges of sizes and
design variations for each type.

The MV cable types are:

 Teck Cables,
 Shielded Cables,
 Concentric Neutral Cables,
 Paper-Insulated Lead-Covered Cables,
 Submarine Cables,
 Mining Cables,
 Aluminum-Sheathed Cables.

In the cable descriptions a number of insulation and sheath (jacket) materials have been
abbreviated as follows:

 Cross-Linked Polyethylene - XLPE,

 Ethylene-Propylene Rubber - EPR,
 Polyvinyl Chloride - PVC,
 Polyethylene - PE,
 Tree-Retardant Cross-Linked Polyethylene - TR-XLPE.

Teck Cables

Teck Cables were originally developed for use in mines, but they are now widely used in
primary and secondary industries, chemical plants, refineries and general factory environments.
They are also used in multi-storey and commercial buildings. They are flexible, resistant to
mechanical abuse, corrosion resistant, compact and reliable. A modified Teck Cable construction
may be used for vertical installations, such as in mine shafts and multi-storey buildings, where
the armour is locked-in-place to prevent slippage of the inner core. There are many different
combinations of conductor size, voltage rating, armour type and so forth, available in Teck
Cables to meet the requirements of particular installations. Annealed, bare, copper is used for the
conductor (s), and they are usually compact stranded to reduce diameter. In multi-conductor
cables, the insulated conductors are cabled together, including the bare copper bonding
(grounding) conductor. In shielded multi-conductor cables, the bonding (grounding) conductor is
positioned to contact the copper shields. A PVC outer jacket which may be colour-coded
depending on the rating of the cable is applied.

Shielded Cables

Shielded Power Cable may be single-or three-conductor. The basic construction begins with a
conductor of annealed, bare, solid or concentric-stranded copper, which may be compact or
compressed. This is followed by a semi-conducting conductor shield, insulation, and then a semi-
conducting insulation shield. Metallic shielding follows, which is usually either gapped or lapped
copper tape. Other types of metallic shielding are available, including concentric wires and
longitudinally corrugated copper tape. The outer jacket is either PVC or PE.

Concentric Neutral Cables

These power cables may be used in dry or wet locations, for a wide variety of types of
installations, and may be single- or three-conductor. The two standard constructions are
Unjacketed and Jacketed, the latter being most frequently used. The conductor is typically
annealed, bare, stranded copper, but tin-coated wire and solid conductors are also available. The
concentric neutral conductor, from which the cable derives its name, is bare or tin-coated copper
wire, applied helically over the insulation shield. These wires act as the metallic component of
the shield and the neutral, at the same time.

Paper-Insulated Lead-Covered Cables (PILC)

PILC cables are used in power distribution and industrial applications, and they may be installed
exposed, in underground ducts or directly buried. Their design begins with annealed, bare copper
conductor(s) which may be round, concentric, compressed or compact stranded, compact sector,
and in larger sizes … Type M segmental stranded. An example of compact sector conductors is
shown in the illustration. The insulated cable core is impregnated with a medium viscosity
polybutene-based compound. The combination of the excellent electrical and mechanical
characteristics of the liquid and the paper has resulted in a reliable and economic insulation,
which now claims a history of almost 100 years. It is little wonder why so many utilities and
power-consuming industries, still continue to specify PILC. To prevent the ingress of moisture, a
seamless lead-alloy sheath is applied. The outer jacket may be PVC or PE, and if required by the
application, armour is available.

Submarine Cables

For submarine installations, usually Self-Contained Liquid-Filled Cables (SCLF), or Solid

Dielectric Cables are selected, depending on voltage and power load. SCLF Cables are capable
of handling very high voltages. However, for medium-voltage installations, a Solid Dielectric
Cable can easily fulfil the electrical demands of the system. A submarine Solid Dielectric Cable
is shown in the illustration. Its construction begins with a compact stranded, annealed, bare
copper conductor, followed by a semi-conducting conductor shield. A copper tape shield is
helically applied, followed by a lead-alloy sheath. Due to the severe environmental demands
placed on submarine cables, a lead-alloy sheath is often specified because of its compressibility,
flexibility and resistance to moisture and corrosion. The sheath is usually covered by a number of
outer layers, comprising a PE or PVC jacket and metal wire armouring.

Mining Cables

A number of different types of cables are used in mines. There are fixed mining cables and
portable mining cables, the latter being described here. The key requirements of portable cables
are flexibility, and resistance to mechanical abrasion and damage. Due to the additional demands
put on portable mining cables used for reeling and dereeling applications, special design may be
required. There are many types of portable mining cables. They are available in ratings up to 25
kV, and may have as many as five conductors. An example of SHD-GC Cable, is shown in the
illustration. It has three insulated, shielded conductors, two bare ground wires, a ground check
wire, and an overall jacket. The conductors for this cable are annealed, bare or tinned copper
wires. The braided shield may be tin-coated wires, or a tin-coated copper wire/textile composite.
The grounding conductor(s) annealed, bare or tinned, stranded copper wires, and the ground
check conductor is annealed, bare, stranded copper wires with EPR insulation and nylon braid,
elastomeric jacket holds the conductor assembly firmly in place, to minimize snaking and cork-
screwing during reeling and dereeling.

Aluminum-Sheathed Cables

These power cables are used for exposed and concealed wiring, in wet and dry locations, and
where exposed to the weather. They may be installed in ventilated, unventilated and ladder-type
cable-troughs, and ventilated flexible cableways. Aluminum-Sheathed Power Cables may be
single-,two-,three- or four-conductor, the conductor(s) being annealed, bare, compressed-round
stranded copper. The insulated core is enclosed in a liquid- and vapour-tight solid corrugated
aluminum sheath, covered by a PVC jacket.

Paper- Submarine
Shielded Insulated Cable Mining Cable Aluminum-
Cable Lead-Covered overview overview Sheathed
Teck Cable overview Cable
Concentric Cable
overview overview
Neutral Cable overview
overview
How to Calculate/Find the Rating of Transformer in kVA (Single Phase and Three
Phase)?
We know that, Transformer always rated in kVA. Below are the two simple formulas to find the rating of
Single phase and Three phase Transformers.

Find Rating of Single Phase Transformer

Rating of Single Phase Transformer:

P = V x I.

Rating of a single phase transformer in kVA

kVA= (V x I) / 1000

Rating of a Three Phase Transformer

Rating of a Three Phase Transformer:

P = √3. V x I

Rating of a Three phase transformer in kVA

kVA = (√3. V x I) /1000

But Wait, A question is raised here… Look at the General nameplate rating of a 100kVAtransformer.

Did you notice something????Anyway, I don’t care what is your answer but lets me try to explain.

Here is the rating of Transformer is 100kVA.

But Primary Voltages or High Voltages (H.V) is 11000 V = 11kV.

And Primary Current on High Voltage side is 5.25 Amperes.

Also Secondary voltages or Low Voltages (L.V) is 415 Volts

And Secondary Current (Current on Low voltages side) is 139.1 Amperes.

In simple words,

Transformer rating in kVA = 100 kVA

Primary Voltages = 11000 = 11kV

Primary Current = 5.25 A

Secondary Voltages = 415V

Secondary Current = 139.1 Amperes.

Now calculate for the rating of transformer according to

P=V x I (Primary voltage x primary current)

P = 11000V x 5.25A = 57,750 VA = 57.75kVA

Or P = V x I (Secondary voltages x Secondary Current)

P= 415V x 139.1A = 57,726 VA = 57.72kVA

Once again, we noticed that the rating of Transformer (on Nameplate) is 100kVA but according to
calculation…it comes about 57kVA…

The difference comes due to ignorance of that we used single phase formula instead of three phase
formula.

Now try with this formula

P = √3 x V x I

P=√3 Vx I (Primary voltage x primary current)

P =√3 x 11000V x 5.25A = 1.732 x 11000V x 5.25A = 100,025 VA = 100kVA

Or P = √3 x V x I (Secondary voltages x Secondary Current)

P= √3 x 415V x 139.1A = 1.732 x 415V x 139.1A= 99,985 VA = 99.98kVA

Consider the (next) following example.

Voltage (Line to line) = 208 V.

Current (Line Current) = 139 A

Now rating of the three phase transformer

P = √3 x V x I

P = √3 x 208 x 139A = 1.732 x 208 x 139

P = 50077 VA = 50kVA

Note: This post has been made on the request of our Page fan Anil Vijay.