KEI manufactures HT XLPE cables up to 220KV conforming to National and International Standards at Bhiwadi plant. KEI has State of Art HT cable plant with German technology. The manufacturing capability is upto 220KV.
We have CCV line with a Single point triple extrusion and computerized sophisticated control and monitoring systems. The CCV line was imported from Machinenbau Scholz GMBH & Co KG, a pioneer in this technology and have supplied more than 250 lines world over.
HT plant is complete with heavy duty machines for wire drawing and conductor making, laying up, armouring , sheathing and packing.
The process commences with a compacted circular conductor being fed from the pay off stands into the extruder on elevated platform. The conductor passes through extruder’s crosshead, it is covered first with 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 vulcanizing line known as CCV line (Continuous Catenary Vulcanising) and the XLPE insulated core is cured in the process. In CV line inert atmosphere is maintained by the Nitrogen gas which is at high pressure and high temperature.

This process is popularly known as Single point Triple extrusion CDCC(Completely Dry Cured and Cooled Curing) Process.
Over the cured core a copper screening is provided by lapping of copper tape or for special requirements a layer of copper wires is provided. Core is tested for Partial Discharge and then as per requirement; the cores are laid up with fillers, provided with inner sheath, armoured and sheathed. Sheath can be of PVC, HDPE, FRLS, ZHFR, PCP or CSP compound.

KEI manufacturing plant and process ensures great 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.

Triple Extrusion and CDCC process ensure contamination free cores. All three layers are bonded and core has least eccentricity and ovality. Insulation itself is free of micro voids and with negligible moisture content.

To control the manufacturing process the line has been provided with many sophisticated instruments and servo controls all monitored by the computer. Important systems are:

X Ray Non touch sensors of SIKORA make for thickness and dimensional control. This system continuously measures the dimensions of insulated cores. Unit has capability to measure multilayer dimensions in all directions and record and analyse the data on line.
CCV tube has a Touch Less Sag control system. This ensures no marks/lines on core unlike older lines.

Computerised control system ensures optimum efficiency, fast start up, synchronized operations of compound feeds, three extruders, CCV line gas temperature zones, pay off and takeup.
Nevertheless KEI XLPE cables compare better than those produced with older plants when checked for Microvoids, Moisture content, PD levels, dielectric strength.
We have strict Quality plan and fully equipped Testing laboratory to ensure cables of best quality are produced as per the design and specifications prescribed. Cables have been type tested as per International Standards

. Inventory and production plans are controlled by BANN ERP system. This ensures reliable and prompt delivery and operational efficiency.
KEI offers variety of designs to suit different installations viz. Aerial Bunched cables, Water tight construction, Stainless steel armouring, for Offshore and Ship installations etc.
We have many satisfied customers from many countries and diverse industry. We shall announce the expansion of our range beyond 220KV very soon.