Pilot Cables

technergy
INTEGRATED CABLING SOLUTIONS
TM

PILOT

Application
Pilot cables are used for control, protection, signalling, telecommunications and data transmission purposes associated with power distribution and transmission systems. Such systems are mainly operated by the electrical supply industry and similar applications occur in many industrial systems. Pilot cables are insulated with special materials which are designed to protect them from the danger of induced voltages coming from other cable circuits in close proximity (for example, faults in high voltage power cable circuits). An over voltage in the pilot cable cores may compromise alarm systems, prevent the proper operation of

Benefits
> High Transmission Performance
Ensures high transmission characteristics (low capacitance, attenuation and cross-talk) over a very wide range of frequencies. Allows future technological upgrade of auxiliary systems (e.g., higher working frequency or higher bit rate).

> Power System Integrity

Preserves the HV system from electrical fault chain effects and permanent damage. Reduces HV system maintenance and repair costs.

> Induced overvoltage control

Avoids permanent damage from short-circuits on electronic equipment such as instrumentation, control and telecommunication systems, both at head-end terminals and substations. Reduces risk of electric shocks and injuries to people working on current maintenance and repairs. Fail-safe performance customised for the customers specific electrical protection systems.

> Multifunctionality
Provides controlling, instrumentation and telecommunication services. Permits integration with interstitial fibre optic cables. Allows Utilities to grow their business to encompass further services.

> Customised Cable Engineering

Technical assistance and pilot cable specification based on the customers requirements. Customised lengths for specific installation requirements. Pilot cable testing based on proprietary facilities.

SAFE TRANSMISSION UNDER THE MOST SEVERE EMI CONDITIONS

protection equipment, resulting in severe damage to the power system. TechnergyTM Pilot cables protects the system from dangerous induced voltages and EMC problems through different shielding types designed for specific operating conditions. Screens provide a reduction factor that restricts the over voltage on the cable core up to 1/10th of the induced voltage (see the test plot, elsewhere in this brochure). TechnergyTM Pilot cables offer utilities, specifiers, contractors, system designers and installers the following benefits:

technergy
INTEGRATED CABLING SOLUTIONS

TM

> Typical Intrinsic Reduction Factor at 50 Hz

0.35 0.3 0.25 0.2 0.15 10 pairs 0.1 0.05 0 10 100 Induced voltage (V/km) 1000 2 pairs tipical limit

Reduction factor K (calculated values)

PILOT

About us
Prysmian Cables & Systems is a world-class multinational company. Founded in 1872 as Ditta Pirelli & C., it has achieved a leading position for more than a century of operations in its two key international markets - Energy Cables & Systems and Telecom Cables & Systems. Prysmian Cables and Systems is the worlds largest manufacturer of power and telecommunications cables, with 52 manufacturing facilities in 21 countries in five continents and a market share in excess of 10%. Prysmian Energy Cables and Systems is a global solutions provider, offering a wide range of integrated solutions, such as cable systems, system design and engineering, project management, installation and post-sale services. Prysmian Energy Cables and Systems concentrates on continuous product innovation and on achieving a competitive edge by focusing on research and development. This is done through Prysmians own R&D centres and by co-operating with universities, scientific institutions and above all, our customers. Prysmians world-wide organisation makes and delivers advanced technological solutions to customers anywhere in the world.

technergy
INTEGRATED CABLING SOLUTIONS

TM

Prysmians TECHNERGY integrated cabling solutionsTM is one of the worlds most comprehensive and technologically advanced answers to industry, infrastructure, contractors and OEMs specific requirements. TECHNERGY integrated cabling solutionsTM are designed and structured into twelve different product lines. Each of these offer tailored designs and added value solutions to the most diverse functional and environmental requirements in the following fields:

> Trains > Marine > Oil & Gas > Plant & Petrochem

> Cranes & Mobile Equipments > Electro-Mechanical > Data & Communication > Transportation Infrastuctures

> Mining & Tunnelling > Building & Civil Engineering > Defence > Power Plants

To find out more about the TECHNERGY integrated cabling solutionsTM, Prysmian Cables and Systems invites you to visit the web site: www.prysmian.com

Courtesy of Enel Distribuzione

Cable families at a glance

> PILOT CABLES 5 kV RATED: PE Insulated Al/PET or Copper Tape Collective Screen - Steel Wire Armoured or Double Steel Tape
Cable description Electrical characteristics at 20 C

Conductor Annealed plain copper solid conductor. Insulation Solid Polyethylene, nominal thickness 0,5 mm. Cabling element Two insulated conductors uniformly twisted together to form a pair. Pair Identification According to BS 3573 tab. 3. Cable Assembly Pairs are assembled together in concentric layers. Core wrapping Non-hygroscopic tape applied over the cable assembly. Collective Screen Aluminium/polyester foil screen applied in continuous electrical contact with tinned copper drain wire (copper tape screen also available). Inner Sheath Black polyethylene. Armouring Galvanised steel wire or double steel tape. Outer Sheath Black flame retardant PVC sheath.

D.C. conductor resistance 1,5 mm2 conductor 2,5 mm conductor Minimum D.C. insulation resistance
Nominal mutual capacitance at 800 Hz
2

Max. Max. Min.

/km /km M x km

12,1 7,41 10000

nF/km

55

Maximum capacitance unbalanced pair to pair at 800 Hz D.C. voltage test for 1 minute conductor/conductor conductors/screen and armour

pF/500m

500

kV kV

7,5 7,5

Nominal attenuation at 1 kHz 1,5 mm2 conductor 2,5 mm conductor

2

Nominal impedance at 1 kHz 1,5 mm2 conductor 2,5 mm conductor

2

Conductor Size
Screening Armouring
ext. diam.

1.5 mm2
AI/PET tape Steel Wires
weight kg/km 760 1305 1605 1930 2780 lengths m 1000 1000 1000 1000 1000

Double Steel Tape

ext. diam. mm 19 25 28 30 37 weight kg/km 535 825 1110 1335 2070 lengths m 1000 1000 1000 1000 1000

n of pairs 5 10 15 20 30

mm 21 27 30 33 39

5 kV
dB/km dB/km 0,55 0,45 260 210
COPPER tape Steel Wires
weight kg/km 810

Double Steel Tape

weight kg/km 570 880

ext. diam. mm 21 27 30 33 39

lengths m

ext. diam. mm 19 25 28 30 37

lengths m

1000

1000 1000

1365 1680

1000 1000

1170 1410 2150

1000

2020 2880

1000 1000

1000 1000

Conductor Size
Screening Armouring
ext. diam.

2.5 mm2
AI/PET tape Steel Wires
weight kg/km 940 1640 2130 2760 3720 lengths m 1000 1000 1000 1000 500

COPPER tape Steel Wires

ext. diam. mm 23 31 35 38 45 weight kg/km 995 1715 2225 2835 3830 lengths
m

Double Steel Tape

ext. diam. mm 21 28 32 35 43 weight kg/km 660 1125 1485 1860 2875 lengths m 1000 1000 1000 1000 500

Double Steel Tape

ext. diam. mm 22 29 33 35 43 weight kg/km 710 1185 1595 1940 2995 lengths m 1000 1000 1000 1000 500

n of pairs 5 10 15 20 30

mm 23 31 35 38 45

1000 1000 1000 1000 500

> PILOT CABLES 15 kV RATED: PE Insulated - Copper Tape Collective Screen - Steel Wire or Double Steel Tape Armour
Cable description Electrical characteristics at 20 C

15 kV
Conductor Size
Screening Armouring Steel Wires
weight kg/km ext. diam. mm lengths m

Conductor Annealed plain copper solid conductor. Insulation Solid Polyethylene, nominal thickness 0,8 mm. Cabling element Two insulated conductors uniformly twisted together to form a pair. Pair Identification According to BS 3573 tab. 3. Cable Assembly Pairs are assembled together in concentric layers. Core wrapping Non-hygroscopic tape applied over the cable assembly. Collective Screen Copper tape screen. Inner Sheath Black polyethylene. Armouring Galvanised steel wire or double steel tape. Outer Sheath Black flame retardant PVC sheath.

D.C. conductor resistance 1,5 mm2 conductor 2,5 mm conductor Minimum D.C. insulation resistance Nominal mutual capacitance at 800 Hz Maximum capacitance unbalanced pair to pair at 800 Hz D.C. voltage test for 1 minute conductor/conductor conductors/screen and armour kV kV 15 22,5
2

Max. Max. Min.

/km /km M x km

12,1 7,41 10000

nF/km

50

pF/500m

500

Nominal attenuation at 1 kHz 1,5 mm2 conductor 2,5 mm conductor

2

dB/km dB/km

0,50 0,40

Nominal impedance at 1 kHz 1,5 mm2 conductor 2,5 mm conductor

2

290 230

1.5 mm2

COPPER tape Double Steel Tape

ext. diam. mm weight kg/km lengths m

n of pairs 5

26 33 34

1180

1000 1000 1000 1000 500

23 30 31 35 41

745 1155 1385 1710 1535

1000 1000 1000 1000 500

10 15

1730

1975 2570 3345

20 30

38 44

Conductor Size
Screening Armouring
ext. diam.

2.5 mm2
COPPER tape Steel Wires
weight kg/km lengths m ext. diam. mm

Double Steel Tape

weight kg/km lengths m

n of pairs 5 10 15 20 30

mm

28 37 38 43 50

1405 2320 2710 3265 4650

500 500 500 500 500

26 34 35 40 47

940 1490 1825 2490 3390

500 500 500 500 500

SAFE TRANSMISSION UNDER THE MOST SEVERE EMI CONDITIONS

Cable design
Main cable design elements Main cable main features

Customised
solutions
Prysmian Technergy is aware of the wide variety of customer demands; we manufacture a broad range of auxiliary cables covering both 5kV and 15kV levels of induced voltages, and providing each customer with numerous and easily customised alternatives. The following options are available: > INSULATION Polyethylene or PVC; PE is recommended for long distance (>1km) and for High Frequency systems. > CABLING Multipair or multicore; multipair for instrumentation purposes and multicore for control purposes. > SCREENS Al/PET or copper tape screens; copper tape screens for a higher level of screening attenuation. > ARMOURING Galvanised steel wire or double steel tape; Wire for mechanical shocks and for pulling; Tape for crush and rodent resistance. > OUTER SHEATH Polyethylene (LDPE or HDPE) or PVC; PE for underground moisture resistance and PVC for flame retardance. Termite-proof additives also available.

Insulation PE PVC Cabling Pairs Water blocking Water swellable tape Jelly Screens Aluminium tape Copper tape Armouring Steel Wires Steel Tapes Outer sheath PE PVC Moisture Resistance Strongly recommended Rodent Resistance Impact Resistance Pulling Strength High Frequency Not recommended Recommended Not relevant Suitable Long distance connections

References
Customer Siemens (Germany) Total Engineering (Brunei) Conspel (Abu Dhabi) GEC (Brunei) Heliopolis Electric (Abu Dhabi) Total Engineering (Brunei) HSE Engineering (Brunei) Prolux (Singapore) Prolux (Singapore) Prolux (Singapore) Mahkota Techn./GIS Group (Brunei) Heliopolis Electric (Abu Dhabi) End User Department of Electrical Services (Brunei) Department of Electrical Services (Brunei) Water and Electricity Department (Brunei) Department of Electrical Services (Brunei) Water and Electricity Department (Abu Dhabi) Department of Electrical Services (Brunei) Department of Electrical Services (Brunei) Civil Aviation Authority (Singapore) Port of Singapore Authority (Singapore) Ministry of Defense (Singapore) Department of Electrical Services (Brunei) ADWEA (Abu Dhabi)

Flame Retardancy

EMC

ARGENTINA Prysmian Energa Cables y Sistemas de Argentina S. A. Fbrica La Rosa, Av. da Argentina 6784 1439 Capital Federal tel. +54 11 46302000 fax +54 11 46302100 AUSTRALIA Prysmian Power Cables & Systems Australia PTY LTD 1 Heathcote Road Locked Bag 7042, Liverpool Business Centre 1871 NSW tel. +61 2 96000 777 fax +61 2 96000 747 AUSTRIA Prysmian OEKW GmbH Lembockgasse 47A, 1230 Wien tel. +43 1 866770 fax +43 1 86677109 BRAZIL Prysmian Energia Cabos e Sistemas do Brasil S. A. Av. Alexandre de Gusmao 145 09110-900 Santo Andr - SP tel. +55 11 49984000 fax +55 11 49984811 CHINA Prysmian Tianjin Cables Co. Ltd. 513, Huang He Road, Nankai District Tianjin, 300112 tel. +86 22 2753 9679 fax +86 22 2753 3485 EGYPT Prysmian Cables & Systems 8 Abd El Azim Aoudallah st. Hegaz sq. Heliopolis - Cairo tel. +20 2 2418557 fax +20 2 6381327 FINLAND Prysmian Cables & Systems Oy P.O. Box 13 FIN-02401 Kirkkonummi tel. +358 10 77551 fax +358 9 2982204 FRANCE Prysmian Energie Cables et Systmes France s.a. 19, Avenue de la Paix - BP 712 Paron - 89100, Sens Cedex tel. +33 3 86957769 fax +33 3 86957781 GERMANY Prysmian Kabel und Systeme GmbH Austrasse 99 96465 Neustadt bei Coburg tel. +49 9568 93 2697 fax +49 9568 93 2527

HONG KONG Prysmian Cable Systems Pte. Ltd. Unit A, 18/F, China Overseas Building 139 Hennessy Road Wanchai, Hong Kong tel. +85 2 2827 8308 fax +85 2 2827 7212 HUNGARY Prysmian MKM Magyar Hungarian Cable Works Co. Ltd. Barzda u. 38 H-1116 Budapest tel. +36 1 3822222 fax +36 1 3822202 INDONESIA PT. Prysmian Cables Indonesia Gedung BRI II, Suite 1502 Jln. Jend Sudirman No 44-46 Jakarta 10210 tel. +62 264 351222 fax +62 264 351780 ITALY Prysmian Cavi e Sistemi Energia Italia Srl Viale Sarca 222, 20126 Milano tel. +39 02 6449 1 fax +39 02 6449 2931 MALAYSIA Prysmian Cable Systems Pte. Ltd. Lot 2 Jalan Kawat 15/18, 40702 Shah Alam Selangor Darul Ehsan tel. +60 3 5518 4575 fax +60 3 5511 9590 NETHERLANDS Prysmian Cables and Systems B.V. Schieweg 9, 2627 AN Delft P.O. Box 495, 2600 AL Delft The Netherlands tel. +31 15 260 5260 fax +31 15 261 3808 NEW ZEALAND Prysmian Cables & Systems 71 Hugi Johnson Drice, P.O. Box 12162 Penrose, Auckland tel. +64 9 5251260 fax +64 9 5251262 NORTH AMERICA Prysmian Cables & Systems North America 700 Industrial Drive Lexington, SC 29072 - USA tel. +1 803 9511130 fax +1 803 9511092 NORWAY Prysmian Kabler og Systmer AS P.O.Box 1384, N - 1401 Ski tel. +47 64 915713 fax +47 64 915714

ROMANIA Prysmian Cabluri si Sisteme SA Soseaua Draganesti, Km. 4 0500 Slatina tel. +40 49 435699 fax +40 49 433484 RUSSIA Prysmian Cables and Systems 20/12, Str.1, Podsosenskiy Per. Moscow 105062, Russia tel. +7 095 933 7036 fax +7 095 933 7035 SINGAPORE Prysmian Cable Systems Pte. Ltd. No 4 Tuas Avenue 12. 3rd Storey 639047 Singapore tel. +65 6862 9866 fax +65 6862 9877 SLOVAKIA Prysmian Kablo s.r.o Tovarenska 11 812 61 Bratislava tel. +421 7 50211111 fax +421 7 52961773 SPAIN Prysmian Cables y Sistemas S.L. Carretera C-15, Km. 2 08800 Vilanova i la Geltr (Barcelona) tel. +34 93 811 6181 fax +34 93 811 6011 SWEDEN Prysmian Kablar och System Ab Gustavslundsvgen 141 P.O.Box 14147 SE-16714 Bromma tel. +46 8 260416 fax +46 8 260413 TURKEY Turk Prysmian Kablo ve Sistemleri A.S. Buyukdere Caddesi No 117 34394 Gayrettepe, Istanbul tel. +90 212 3551500 fax +90 212 2175810 U.A.E. (Dubai) Prysmian Cabels and Systems Middle East P.O. Box 72125, Dubai tel. +971 4 345 7870 fax +971 4 345 7101 UK Prysmian Cables & Systems Limited P. O. Box 6 Leigh Road Eastleigh Hampshire, SO50 9YE tel. +44 2380 295555 fax +44 2380 295111

World Wide Excellence Center

tel. +39 02 6449 8108, fax +39 02 6440 8108

Head Office
Prysmian Cavi e Sistemi Energia Srl - Viale Sarca 222, 20126 Milano, Italy - tel. +39 02 6449 1, fax +39 02 6449 2931 - www.prysmian.com

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