State-of-the-art High Voltage Cables

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, PCP 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.

A computerised auto control system
This system ensures optimum efficiency, fast start up, synchronized operations of compound feeds, three extruders, CCV line gas temperature zones, pay off and take-up.

Nevertheless KEI XLPE high tension cables compare better than those produced with older plants and when checked for Micro voids, Moisture content, PD levels, and dielectric strength.

A strict quality plan and fully equipped test lab ensures these high voltage cables are of the best quality and are produced as per the design and specifications prescribed. These high voltage electrical cable and other medium voltage cables have been type tested as per International Standards at international labs.

Inventory and production plans are controlled by the BANN ERP system. This ensures reliable and prompt delivery with operational efficiency for all high voltage cables and other products produced.

KEI offers a variety of designs to suit different installations viz. Aerial Bunched cables, water tight construction and Stainless steel armouring for Offshore and Ship installations etc.

KEI has been manufacturing high tension cables for heavy duty machines and for power generators for many years now.

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“KEI” Single Core Compacted Aluminium & Copper Conductor, XLPE Insulated, Unarmoured & Armoured Cable AL & CU / XLPE / AL Wire / PVC Conforming to IS 7098 Part-2/1985
“KEI” Single Core Aluminium & Copper Conductor, XLPE Insulated, Unarmoured & Armoured Cable Conforming to IS 7098 Part-2/1985
“KEI” Three Core Aluminium & Copper Conductor, XLPE Insulated, Armoured Cable Conforming to IS 7098 Part-2/1985