KEI manufactures HT XLPE cables up to 220KV conforming to National and International Standards at their Bhiwadi plant. KEI, as a leading high tension cable manufacturer in India has a state of art high voltage cable plant that uses German technology and features a manufacturing capability of upto 220KV.
We have CCV (Continuous Catenary Vulcanising) lines with a single point triple extrusion and sophisticated computerized control with monitoring systems. The CCV line was imported from Machinenbau Scholz GMBH & Co KG, a pioneer in this technology who have supplied more than 250 lines the world over.
The plant is designed to produce high tension power cables, high voltage cables as well as high tension cables for heavy duty machines. It is set up with heavy duty machines for wire drawing and conductor making, laying up, armouring, sheathing and packing.
The making of high tension cables
As a reputed high tension cable manufacturer in India the process of making the best high tension cables, be it medium voltage or high voltage cables is carefully monitored. It commences with a compacted circular conductor being fed from the pay off stands into the extruder, on an elevated platform. The conductor passes through the extruder’s crosshead; it is covered first with a semiconducting screen layer then the XLPE insulation, followed by the outer semiconducting core screen. This crosshead is specially designed to feed three compounds from three extruders at one point, described as Singe Point Triple Extrusion.
Thereafter, the extruded core enters and passes through the vulcanizing line known as the CCV line and the XLPE insulated core is cured in the process. In CCV line, inert atmosphere is maintained by the Nitrogen gas which is maintained at high pressures and a high temperature.
This process is popularly known as the Single point Triple extrusion CDCC (Completely Dry Cured and Cooled Curing) Process.
For our cured core, a copper screening is provided by the lapping of a copper tape or, for special requirements, a layer of copper wires is provided. The core is tested for Partial Discharge and then as per requirement, the cores are laid up with fillers, provided with an inner sheath, armoured and sheathed. The sheath can made of PVC, HDPE, FRLS, ZHFR, or CSP compounds.
The KEI high voltage cable manufacturing plant and its process ensure perfect XLPE cables for the new age power sector and industry. Our modern plant takes full advantage of the new generation XLPE compounds which offer fast curing and superior electrical parameters, dimensional control and higher productivity for our high voltage cables.
The Triple Extrusion and DCDC process ensures contamination free cores. All three layers are bonded and core has the least eccentricity and ovality as these are controlled by an X-ray unit online. The insulation itself is free of micro voids with a negligible amount of moisture content.
To control the manufacturing process, the line has been provided with many sophisticated instruments and servo controls all monitored by a computer. Important systems are:
X Ray Non touch sensors of SIKORA
These make for thickness and dimensional control. This system continuously measures the dimensions of insulated cores. Each unit has the capability to measure multilayer dimensions in all directions and record and analyse the data online.
CCV tube has a Touchless Sag control system.
This ensures no marks or lines form on the core, unlike older lines.
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