Instrumentation Cables—XLPE Insulated, Overall Screened, Lead Sheathed, Wire Armoured,PVC Sheathed Cables(CU/XLPE/OSCR/LEAD/SWA/PVC)
Instrumentation Cables with XLPE Insulated, Overall Screened, Lead Sheathed, Wire Armoured and PVC Sheathed construction (CU/XLPE/OSCR/LEAD/SWA/PVC) are designed for reliable signal and control transmission in harsh and corrosive environments. The copper conductor combined with XLPE insulation provides excellent electrical performance, thermal stability, and long service life.
The overall screen effectively reduces electromagnetic interference, ensuring accurate signal transmission in complex industrial systems. A continuous lead sheath offers superior protection against moisture ingress, chemical attack, and hydrocarbon exposure. Steel wire armour enhances mechanical strength, making the cable suitable for demanding installation conditions. The outer PVC sheath provides additional environmental and mechanical protection. These instrumentation cables are widely used where durability, signal integrity, and environmental resistance are essential.
- Standard BS EN 50288-7, IEC 60502-1 (General)
Construction
Technical Specifications
Quality Control
Application
Construction
XLPE Insulated, Overall Screened, Lead Sheathed, Wire Armoured,PVC Sheathed Cables
Conductor
Instrumentation cable shall have an annealed plain copper conductor or a tinned copper conductor. Depending upon cable application, conductor can be solid (Class-1), Stranded (Class-2), or flexible (Class-5) type as defined in BS EN / IEC 60228
Insulation
Instrumentation cable shall have PVC, XLPE, or HR-PVC insulation. Insulation material shall be selected based on the maximum operating temperature. PVC insulation is suitable for a continuous operating temperature of 70°C, whereas XLPE or HR-PVC is suitable for a continuous operating temperature of 90°C. Fire-rated / fire resistance instrumentation cables shall have Glass Mica Tape layer below insulation & shall have XLPE insulation.
Individual and Overall Screen
The screen is made of aluminum, mylar tape, + ATC drain wire. Aluminum mylar tape is made of aluminum with a thin layer of polyester. It helps in minimizing the crosstalk and prevents shorting.
Armour
Steel wire armour is applied to cables to shield against mechanical stresses and ensure that the core of the cable remains protected.
Inner and Outer Sheath
The sheath can be made of PVC, Polyethylene, or LSZH
Technical Specifications
Instrumentation Cables—XLPE Insulated, Overall Screened, Lead Sheathed, Wire Armoured,PVC Sheathed Cables(CU/XLPE/OSCR/LEAD/SWA/PVC)
Instrumentation Cables Main Specifications
Instrumentation Cables—XLPE Insulated, Overall Screened, Lead Sheathed, Wire Armoured,PVC Sheathed Cables(CU/XLPE/OSCR/LEAD/SWA/PVC)
| Conductor Size | Max. Conductor DC Resistance at 20°C for Plain Copper |
Max. Conductor DC Resistance at 20°C for Tinned Copper |
||
| Solid, Class - 1 & Stranded, Class - 2 |
Flexible, Class-5 | Solid, Class - 1 & Stranded, Class - 2 |
Flexible, Class-5 | |
| [mm2] | [Ω/km] | [Ω/km] | [Ω/km] | [Ω/km] |
| 0.50 | 36.72 | 39.78 | 37.434 | 40.902 |
| 0.75 | 24.99 | 26.52 | 25.296 | 27.234 |
| 1.00 | 18.462 | 19.89 | 18.564 | 20.4 |
| 1.50 | 12.342 | 13.566 | 12.444 | 13.974 |
| 2.50 | 7.5582 | 8.1396 | 7.7112 | 8.3742 |
| Conductor Size | Insulation Thickness | |||
| 90V | 300V | 500V | 1000V | |
| [mm2] | [mm] | [mm] | [mm] | [mm] |
| 0.50 | 0.20 | 0.26 | 0.44 | 0.70 |
| 0.75 | 0.20 | 0.26 | 0.44 | 0.70 |
| 1.00 | 0.26 | 0.26 | 0.44 | 0.70 |
| 1.50 | 0.30 | 0.35 | 0.44 | 0.70 |
| 2.50 | - | - | 0.53 | 0.70 |
| Conductor Size | Mutual Capacitance | Max. Continuous Operating Temperature | Inductance to Resistance Ratio (L/R) |
||
| XLPE | PVC | XLPE or HR - PVC | PVC | ||
| [mm2] | [nF/km] | [nF/km] | [°C] | [°C] | [μH/Ω] |
| 0.50 | 150 | 250 | 90 | 70 | < 25 |
| 0.75 | 150 | 250 | 90 | 70 | < 25 |
| 1.00 | 150 | 250 | 90 | 70 | < 25 |
| 1.50 | 150 | 250 | 90 | 70 | < 40 |
| 2.50 | 150 | 250 | 90 | 70 | < 60 |
| Number of Pair | Cable OD | Cable Weight | Drum Length | ||||||||
| 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | ||
| [Nos] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [m] |
| 1 | 14.0 | 14.5 | 14.5 | 15.5 | 16.5 | 540 | 570 | 600 | 655 | 750 | 1000 |
| 2 | 16.5 | 17.5 | 18.5 | 19.5 | 22.5 | 730 | 840 | 895 | 980 | 1345 | 1000 |
| 5 | 19.5 | 20.5 | 22.0 | 23.5 | 27.0 | 990 | 1110 | 1290 | 1500 | 1910 | 1000 |
| 10 | 25.0 | 27.0 | 28.0 | 30.5 | 36.5 | 1605 | 1840 | 1990 | 2285 | 3310 | 1000 |
| 20 | 30.0 | 32.5 | 35.0 | 38.5 | 44.5 | 2225 | 2630 | 3060 | 3670 | 4950 | 1000 |
| 30 | 35.0 | 38 | 40 | 44 | 3015 | 3560 | 3960 | 4725 | 500 | ||
| Number of Triad | Cable OD | Cable Weight | Drum Length | ||||||||
| 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | ||
| [Nos] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [m] |
| 1 | 14.0 | 14.5 | 15.0 | 16.0 | 17.5 | 570 | 605 | 635 | 700 | 870 | 1000 |
| 2 | 18.0 | 18.5 | 19.5 | 21.5 | 24.0 | 860 | 930 | 995 | 1220 | 1525 | 1000 |
| 5 | 21.5 | 23.0 | 24.0 | 25.5 | 29.0 | 1240 | 1415 | 1530 | 1755 | 2260 | 1000 |
| 10 | 27.0 | 29.0 | 30.5 | 33.5 | 39.5 | 1900 | 2145 | 2345 | 2805 | 4040 | 1000 |
| 20 | 33.0 | 36.5 | 38.5 | 42.0 | 2730 | 3395 | 3785 | 4540 | 500 | ||
| 30 | 38.5 | 42.0 | 44.0 | 3700 | 4385 | 4905 | 500 | ||||
| Number of Quad | Cable OD | Cable Weight | Drum Length | ||||||||
| 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | 0.5mm² | 0.75mm² | 1.0mm² | 1.5mm² | 2.5mm² | ||
| [Nos] | [mm] | [mm] | [mm] | [mm] | [mm] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [kg/km] | [m] |
| 1 | 14.5 | 15.0 | 16.0 | 16.5 | 18.5 | 605 | 655 | 695 | 760 | 955 | 1000 |
| 2 | 20.5 | 22.5 | 23.5 | 25.0 | 28.5 | 1035 | 1300 | 1390 | 1580 | 1990 | 1000 |
| 5 | 25.0 | 26.5 | 28.0 | 30.0 | 35.5 | 1600 | 1830 | 1980 | 2265 | 3245 | 1000 |
| 10 | 32.5 | 35.5 | 38.0 | 41.5 | 49.5 | 2495 | 2975 | 3430 | 4065 | 5790 | 1000 |
| 20 | 41.0 | 44.0 | 46.5 | 3960 | 4515 | 5110 | 500 | ||||
| 30 | 48.0 | 5310 | 500 | ||||||||
Note: Cable OD and Cable weight are subject to change based on the latest manufacturing practice.
Quality Control
Instrumentation Cables—XLPE Insulated, Overall Screened, Lead Sheathed, Wire Armoured,PVC Sheathed Cables(CU/XLPE/OSCR/LEAD/SWA/PVC)
Raw Material Test
Raw Material Test ensures consistent quality of CU/XLPE/OSCR/LEAD/SWA/PVC instrumentation cables from the source. Copper conductors are evaluated for conductivity, mechanical strength, and surface quality. XLPE insulation materials undergo thermal aging and mechanical testing. Screening components are inspected for conductivity and structural consistency. Lead sheath materials are tested for thickness uniformity and corrosion resistance. Steel wire armour is checked for tensile strength, while PVC sheath materials are tested for flame retardancy and durability. Only materials meeting specifications are released for production.
Process inspection
Process Inspection controls quality throughout the manufacturing of CU/XLPE/OSCR/LEAD/SWA/PVC instrumentation cables. Insulation extrusion is monitored for thickness and concentricity. Overall screening is inspected for coverage continuity. Lead sheathing is carefully controlled to ensure complete moisture sealing. Armouring and PVC sheathing processes are checked for mechanical integrity and dimensional accuracy. Continuous in-process inspections maintain stable quality across all production stages.
Finished Product
Finished Product Testing confirms the safety and performance of CU/XLPE/OSCR/LEAD/SWA/PVC instrumentation cables. Electrical tests verify resistance and insulation integrity. Mechanical tests assess armour durability and bending capability. Lead sheath integrity tests confirm moisture protection. Final visual inspection ensures correct construction and marking before shipment.
Application
These instrumentation cables are suitable for refineries, offshore platforms, underground installations, power generation facilities, and industrial automation systems requiring moisture and chemical resistance.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
Wires and Cables packaging (1)
Wires and Cables packaging (2)
Wires and Cables packaging (3)
Wires and Cables packaging (4)
Wires and Cables packaging (5)
Wires and Cables packaging (6)
Wires and Cables packaging (7)
Wires and Cables packaging (8)
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What are the advantages of power cables and overhead lines?(1) Reliable operation, because it is installed in a hidden place such as underground, it is less damaged by external forces, has less chance of failure, and the power supply is safe, and it will not cause harm to people; (2) The maintenance workload is small and frequent inspections are not required; (3) No need to erect towers; (4) Help improve power factor.
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Which aspects should be considered when choosing the cross section of a power cable?(1) The long-term allowable working current of the cable; (2) Thermal stability once short circuited; (3) The voltage drop on the line cannot exceed the allowable working range.
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What are the measures for cable fire prevention?(1) Use flame-retardant cables; (2) Use fireproof cable tray; (3) Use fireproof paint; (4) Fire partition walls and fire baffles are installed at cable tunnels, mezzanine exits, etc.; (5) Overhead cables should avoid oil pipelines and explosion-proof doors, otherwise local pipes or heat insulation and fire prevention measures should be taken.
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What should be paid attention to during the transportation and handling of cables?(1) During transportation, loading and unloading, cables and cable reels should not be damaged. It is strictly forbidden to push the cable reels directly from the vehicle. Generally, cables should not be transported and stored flat. (2) Before transporting or rolling the cable reel, ensure that the cable reel is firm, the cable is wound tightly, the oil pipe between the oil-filled cable and the pressure oil tank should be fixed without damage, the pressure oil tank should be firm, and the pressure indication should meet the requirements.
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What inspections should be carried out for the acceptance of cable lines?(1) The cable specifications should meet the regulations, the arrangement should be neat, no damage, and the signs should be complete, correct and clear; (2) The fixed bending radius of the cable, the related distance and the wiring of the metal sheath of the single-core power cable should meet the requirements; (3) The cable terminal and the middle head should not leak oil, and the installation should be firm. The oil pressure of the oil-filled cable and the meter setting should meet the requirements; (4) Good grounding; (5) The color of the cable terminal is correct, and the metal parts such as the bracket are completely painted; (6) There should be no debris in the cable trench, tunnel, and bridge, and the cover should be complete.
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