kalpana industries limited

1
Kablo Sanayi ve Dış Ticaret Ltd. Şti
www.polycab.com.tr
KALPANA INDUSTRIES LTD.
TECHNICAL DATA SHEET
KI XL - 03 / KI-SC 10
TWO COMPONENT AMBIENT CURABLE POLYETHYLENE COMPOUND
FOR INSULATION OF LOW VOLTAGE POWER CABLE
DESCRIPTION :
KI polyethylene compound XL - 03 is a superior grade of silane pre-grafted low density
polyethylene compound. It is designed to be used as insulation of low Voltage Power
cable. Keeping in mind the stringent quality requirements, special attentions are paid to
maintain dust free environment during its manufacture. An enriched additive package
makes it highly scorch retardant and protects it against heavy metal induced
degradation.
KI-XL 03 is to be used in conjunction with KI-SC10, which contains a catalyst to
enhance the process of cross-linking in open environment, (no needs of sauna, CV
tube or steam bath).
These two components XL-03 & KISC are inert, when stored in a cool & dry place.
However when mixed extruded and exposed to moisture cross-linking takes place
rapidly. The components are therefore to be mixed just before consumption, usually in
the ratio of 95 parts of Grafted Polymer (XL-03) to 5 part of Catalyst Master batch
(KI-SC10).
Such system allows the compound to be extruded as a normal thermoplastic in a
conventional PE (or even PVC) extrusion line. In each case time of curing is to be
optimized as a function of thickness of insulation, concentration of catalyst and
atmospheric humidity.
Sahrayicedid Mah. Halk Sk. Ada Is Merkezi No : 50 Kat:5
Tel : + 90 216 302 5435
Fax : + 90 216 302 3905
www.polycab.com.tr
D:11 Kadikoy 34734 Istanbul
e-mail : info@polycab.com.tr
2
Kablo Sanayi ve Dış Ticaret Ltd. Şti
www.polycab.com.tr
TYPICAL PROPERTIES
A) XL-03
Sl.No
Properties
1.
Density
2.
Melt Flow Index
3.
Contamination
(Visual )
Typical
Value
0.923 - 0.928
Unit
gm / cc
gms / 10
Min.
0.8 - 1.0
No. / kg.
Less than 5
Test Method
ASTM -D-792
IS-10810 (Part 23)
KIL
B) XL-03 / KI-SC10 Combination
Mixed in proportion of 95:5 and extrude a tape of 1.0 mm thickness. Extruded tape kept
in open environment (Relative humidity ≈ 60 – 70 & temperature 27 – 30 °C) for 24 hrs
where cross-linking taking place.
Sl.
No.
1.
2.
3.
a)
b)
Properties
Unit
Tensile Strength
Elongation at Break
Hot Set @ 200 0C
Hot Elongation
Permanent
4.
a)
b)
Oven ageing at 135 0C,168 hrs.
Variation in Tensile Strength
Variation in Elongation at Break
5.
Volume Resistivity
6.
7.
Dissipation Factor @ 250 V 50
hz, 25 0C
Dielectric Constant @ 250V /
50hz, 25 0C
MPa
%
Typical
Value
16 - 19
500-600
IS - 10810 (Part-7)
- do -
%
%
80 - 100
± 5
IS - 10810 (Part-30)
- do -
%
%
Ohm
. cm
± 15
± 15
IS - 10810 (Part-11)
- do -
1 x 1016
IS - 1991
4 x 10-4
ASTM-D- 150
2.1 - 2.4
ASTM-D- 150
Sahrayicedid Mah. Halk Sk. Ada Is Merkezi No : 50 Kat:5
Tel : + 90 216 302 5435
Fax : + 90 216 302 3905
www.polycab.com.tr
Test Method
D:11 Kadikoy 34734 Istanbul
e-mail : info@polycab.com.tr
3
Kablo Sanayi ve Dış Ticaret Ltd. Şti
www.polycab.com.tr
CROSSLINKING WITH AMB. CURING CATALYST M.B. (KI-SC10)
The time of cross-linking of the insulation usually dependent on the following factors:
•
•
•
•
Catalyst concentration
Relative humidity
Temperature
Insulation thickness
Polyethylene absorbs water very slowly, means insulation thickness has a relatively
large influence on cross-linking speed.
Relative
humidity
%
Temperature
°C
Insulation
Thickness
mm
Time to reach 100 % hot
elongation,
days
50
23
0.7
1
50
23
1.0
2
50
23
1.6
7
It is evident from the above table, the grafted polymer (GP) and catalyst master batch
(KI-SC10) makes it possible to crosslink with in a practical condition and acceptable
time frame even at ambient temperature. In practice, the addition of water to the cable
core drum by spraying further reduces curing time.
Sahrayicedid Mah. Halk Sk. Ada Is Merkezi No : 50 Kat:5
Tel : + 90 216 302 5435
Fax : + 90 216 302 3905
www.polycab.com.tr
D:11 Kadikoy 34734 Istanbul
e-mail : info@polycab.com.tr
4
Kablo Sanayi ve Dış Ticaret Ltd. Şti
www.polycab.com.tr
PROCESSING GUIDELINES :
1.
It is recommended to dry the Catalyst Master batch and Colour Master batch ( if
any ) at 60 0C in air oven in 4 - 6 cm layers for 8 -12 hours. The Grafted Polymer
should never be pre-heated.
2.
The Grafted Polymer and Catalyst Master batch should be manually mixed at a
ratio of 95 : 5 at room temperature without shearing, just before consumption.
Mixing in large quantities should be avoided, since such leftover premix can not
be stored.
3.
During extrusion, following temperature profile is suggested :
Barrel Zone
150 - 180 0C
Head
180 0C
Dies
190 - 195 0C
4.
Recommended start-up procedure is given below :
a)
b)
Ensure that the screw, barrel and tools are thoroughly cleaned.
Start up slightly lower temperature profile. Allow the frictional heat to build-up to
desired temperature and remain steady thereafter.
Flush with virgin LDPE ( film grade ). Adjust eccentricity and wall thickness
inserting conductor.
Replace LDPE with XL-03 / KISC premix. Increase line speed to
optimum.
Adjust temperature to obtain a smooth surface finish.
Avoid thermal shock by sudden cooling. Keep sufficient distance between diehead and water trough to allow air cooling. Avoid inlet water being too cold.
c)
d)
e)
5.
It is important that extruder should not be kept idle for more than 15 minutes
when filled with XL-03 / KISC premix.
6.
During tubing extrusion, build-up of stress should be avoided, size of the core
point should be carefully selected to keep the Draw Down Ratio (DDR) below
2:1 in case of small sizes. For higher sizes of the core, DDR may be increased
slightly. It is also recommended that a land be in place, with its length
approximately same as that of the finished diameter of the core.
Sahrayicedid Mah. Halk Sk. Ada Is Merkezi No : 50 Kat:5
Tel : + 90 216 302 5435
Fax : + 90 216 302 3905
www.polycab.com.tr
D:11 Kadikoy 34734 Istanbul
e-mail : info@polycab.com.tr
5
Kablo Sanayi ve Dış Ticaret Ltd. Şti
www.polycab.com.tr
STORAGE :
The shelf life of the product exceeds 4 months from the date of production, subject to
following condition ;
* Storage temperature not generally exceeding 25 0C
* Away from direct sunlight and weathering
* Closed and unbroken bags
* Use of compound within 3 - 4 hours after bags are open
PACKAGING :
The product is available in 25 kg moisture - resistant bags.
Information provided in this bulletin is given in good faith. It is recommended to be used only
as a general guideline. The end-user is well advised to verify at his end the fittest of this
product to his specific needs, available technology and test method. KIL accepts no liability in
manufacturing defects of end product, nor can give any guarantee of results.
Sahrayicedid Mah. Halk Sk. Ada Is Merkezi No : 50 Kat:5
Tel : + 90 216 302 5435
Fax : + 90 216 302 3905
www.polycab.com.tr
D:11 Kadikoy 34734 Istanbul
e-mail : info@polycab.com.tr