I. Core Information of the Product Itself
(1) Analysis of Specification Parameters
The specification parameters of the E-Yy-J series copper core
PVC insulated power cables are the core basis for their adaptation to different scenarios. The identifiers "4X16, 4X25, 4X35, 4X50" contain clear technical implications.
"4X" indicates that the cable has a 4-core structure, including 3 phase lines and 1 neutral line (N line). It can meet basic safety specifications without the need for additional
Ground Wires, simplifying the wiring design of the power distribution system. This
Multi-Core integrated design not only reduces the number of cables during construction and lowers installation complexity but also reduces electromagnetic interference between cables through a unified insulation layer, improving the stability of power transmission.
The subsequent numbers (16, 25, 35, 50) represent the cross-sectional area of a single conductor (unit: square millimeters). This parameter directly determines the current-carrying capacity, impedance, and applicable power range of the cable. Specifically:
4X16 specification: At an ambient temperature of 30°C, the continuous current-carrying capacity is approximately 70A, with an adapted power of about 35kW. It is suitable for small industrial equipment (such as CNC machine tools, small compressors), branch power distribution in office buildings, and power supply for shops.
4X25 specification: The continuous current-carrying capacity is approximately 95A, with an adapted power of about 47kW. It can meet the power needs of medium-sized air conditioning systems, elevator machine rooms, and medium-sized production lines.
4X35 specification: The continuous current-carrying capacity is approximately 120A, with an adapted power of about 60kW. It is often used for the main power supply of large shopping malls, main power distribution in factory workshops, and zoned power supply in high-rise buildings.
4X50 specification: The continuous current-carrying capacity is approximately 150A, with an adapted power of about 75kW. It is suitable for the main incoming lines of industrial plants, large refrigeration equipment, and connecting lines of generator sets.
In addition, the rated voltage of this series of cables is 0.6/1kV, which conforms to the international general low-voltage power transmission standards and can be directly connected to civil and industrial low-voltage power grids. The insulation thickness increases with the conductor cross-sectional area (16mm² corresponds to an insulation thickness of 0.7mm, and 50mm² corresponds to 1.0mm), ensuring that cables of different specifications can withstand the same voltage level and avoiding the risk of insulation breakdown.
(2) Characteristic Applications and Scene Adaptation
The design of the E-Yy-J series cables fully considers the climatic characteristics and engineering needs of the Qatar region, forming distinct scene adaptability.
Industrial field: As an important industrial hub in the Middle East, Qatar's chemical, metallurgical, building materials and other industries have strict requirements for the stability of power transmission. The high current-carrying capacity of this series of cables can meet the instantaneous starting current requirements of large motors, furnaces and other equipment, and the chemical corrosion resistance of the
PVC Insulation layer can resist acid and alkali vapors and dust erosion that may exist in the factory environment. For example, in a large steel plant in Doha, the 4X50 specification cable is used to connect the cooling water pump system of the blast furnace, and its high-temperature resistance (long-term operating temperature ≤70°C) can adapt to the workshop environment temperature of 40-50°C.
Commercial and public facilities: Commercial complexes (such as Doha Mall), hotels, airports and other places in Qatar need to balance the safety and aesthetics of power supply. The 4-core structure of this series of cables can be directly buried in the conduit under the wall or floor, reducing the clutter of exposed wire laying; at the same time, the flame retardant grade of PVC material reaches UL94 V-0 standard, which can delay the spread of flame in case of short circuit, buying time for personnel evacuation. In the expansion project of Hamad International Airport, the 4X35 specification cable is used for the lighting and air conditioning main line of the terminal building, and its anti-aging performance can ensure stable operation for more than 15 years in the indoor dry environment.
Civil buildings: With the population growth in Qatar, residential projects have higher requirements for the cost performance of cables. The 4X16 and 4X25 specification cables have become the mainstream choice for villas and apartment buildings due to their moderate current-carrying capacity and cost. For example, in the new residential area in the suburbs of Doha, the 4X25 specification cable is used for the main incoming line of each household, which can support the simultaneous operation of high-power equipment such as air conditioners, water heaters, and kitchen appliances, avoiding overload tripping.
Outdoor engineering: Although Qatar has a dry climate with little rain, sandstorms are frequent, so the weather resistance of cables is crucial. The PVC insulation layer of this series of cables has undergone anti-ultraviolet treatment, which can resist strong sunlight and sand wear when laid outdoors directly or in bridges. In the supporting power grid transformation around the 2022 World Cup venues, the 4X50 specification cable is used for the connecting line between the outdoor transformer and the venue, and its cold resistance (minimum operating temperature -15°C) can also cope with the occasional low temperature weather in Qatar's winter.
(3) Material and Process Details
1. Conductor Material: High-purity electrolytic copper (purity ≥99.95%) is used, which is processed into round single wires through continuous casting and rolling process. The conductivity of high-purity copper can reach 100% IACS (International Annealed Copper Standard), which is much higher than that of ordinary recycled copper (about 85% IACS), which can significantly reduce resistance loss during transmission. For example, when the 4X50 specification cable is running at full load, the power loss per kilometer is only 3.5kW, while the loss of the same specification low-purity
Copper Cable can reach more than 5kW, which can save a lot of electricity costs in long-term use.
The conductor stranding process adopts a regular stranding method, in which multiple single wires are stranded into a bundle according to a certain pitch. This not only enhances the
Flexibility of the conductor (bending radius ≥12 times the cable outer diameter), facilitating laying in narrow spaces, but also reduces the skin effect (the phenomenon that high-frequency current is concentrated on the conductor surface), improving the transmission efficiency under high-frequency current.
2. Insulation layer material: Temperature-resistant polyvinyl chloride (PVC) is selected, and its performance is optimized by adding plasticizers, stabilizers and flame retardants. Among them, the stabilizer can prevent PVC from decomposing to produce hydrogen chloride gas (strongly corrosive) at high temperatures, ensuring that the insulation layer does not harden or crack when the cable works at a long-term temperature of 70°C; the flame retardant can achieve self-extinguishing after leaving the fire (extinguishing time ≤10 seconds) by inhibiting the combustion reaction or forming a flame-retardant carbon layer, which meets the fire protection specifications of civil buildings in Qatar.
The extrusion process of the insulation layer adopts three-layer co-extrusion technology, which uniformly coats the molten PVC material on the conductor surface, and the thickness deviation is controlled within ±0.1mm. This high-precision processing can avoid defects such as bubbles and impurities in the insulation layer, ensuring that the insulation resistance is ≥100MΩ·km (at 20°C), effectively preventing electric leakage or short circuit accidents.
3. Sheath layer (if any): Some models of cables are wrapped with
PVC Sheaths to further enhance mechanical protection performance. The sheath layer adopts a black formula (adding carbon black), which has stronger anti-ultraviolet ability and is suitable for outdoor laying scenarios. The sheath and the insulation layer are bonded by an adhesive to avoid delamination during laying.
(4) Production Process and Quality Control
The production process of E-Yy-J series cables strictly follows the ISO9001 quality management system, covering the whole process of raw material inspection, conductor processing, insulation extrusion, cabling, finished product testing, etc.
Raw material inspection: Each batch of electrolytic copper must be tested for purity by spectral analysis, and PVC particles must be tested for melt index (to ensure stable processing performance) and anti-aging performance (after 100°C × 168 hours heat aging test, the tensile strength retention rate is ≥80%). Unqualified raw materials are directly rejected to control quality from the source.
Conductor processing: Continuous annealing process is adopted. By controlling the annealing temperature (600-700°C) and cooling rate, the hardness of the
Copper Conductor is ensured to be moderate (Vickers hardness HV ≤80), which not only avoids insufficient flexibility caused by excessive hardness, but also prevents excessive softness from affecting mechanical strength.
Insulation extrusion: The temperature of the extruder is controlled in sections (140-160°C in the feeding section, 170-190°C in the melting section, 180-200°C in the die head section) to ensure full plasticization of PVC materials. At the same time, the online diameter monitoring system detects the thickness of the insulation layer in real time, and automatically alarms and stops for adjustment when the deviation exceeds the limit.
Cabling process: The 4-core conductors are stranded according to a symmetrical structure, and the pitch ratio is controlled at 16-20 times (the ratio of pitch to cable outer diameter), ensuring that the cabled cable has good roundness and the cores are evenly stressed when bending. Inert materials (such as polypropylene rope) are filled during the stranding process to avoid mechanical damage caused by gaps inside the cable core.
Finished product testing: Each batch of cables must undergo a number of tests, including:
Through strict process control and testing, the ex-factory pass rate of this series of cables remains above 99.5%, which fully meets the network access standards of Kahramaa (Qatar General Electricity Corporation).
II. General Product Information
(1) Packaging Specifications
To ensure that the cables are not damaged during transportation and storage, the E-Yy-J series adopts a standardized packaging scheme:
Packaging materials: The main body uses galvanized steel reels (diameters are 800mm, 1250mm, 1600mm according to the cable length). The edge height of the steel reel is ≥150mm to prevent the cable from falling off. The surface of the steel reel is coated with anti-rust paint, which can resist salt spray erosion during sea transportation (in line with ASTM B117 salt spray test standard, no rust for 48 hours). The outer layer of the cable is wrapped with two layers of waterproof kraft paper, and then covered with PE film (thickness 0.12mm) to form a moisture-proof barrier, adapting to the storage needs of Qatar's high humidity season (summer humidity can reach 60-70%).
Packaging marks: A label is fixed on the side of the steel reel, indicating the product model (such as E-Yy-J 4X25), length (such as 100m/reel), rated voltage, production date, batch number and quality inspection qualification mark. At the same time, the label is printed with Arabic and English bilingual instructions for easy identification by local customers in Qatar. Each reel of cable is also accompanied by a product certificate, including raw material batch, test data and other traceability information.
Packaging specifications: According to customer needs, cables can be custom-packaged in 100m, 200m, 500m or 1000m/reel. For large-length orders (such as 1000m/reel), the center of the steel reel is equipped with a high-strength wooden sleeve to facilitate loading and unloading by forklifts or cranes; small-length packaging (100m/reel) is added with plastic handles for easy manual handling.
(2) Transportation and Logistics Solutions
According to Qatar's geographical location (southwest coast of the Persian Gulf) and customer needs, the transportation solutions are divided into sea transportation, land transportation and air transportation:
Sea transportation: As the main transportation method, it departs from Chinese ports (such as Shanghai, Guangzhou) and arrives at Doha Port, Qatar via the Strait of Malacca and the Arabian Sea, with a voyage of about 25-30 days. During transportation, the cable reels must be fixed in the container (using steel strip binding, at least 4 fixed points per reel) to avoid shaking and collision during navigation. Desiccants (5kg per 20-foot container) are placed in the container to prevent the cables from getting damp due to the high humidity environment at sea.
Land transportation: Suitable for transshipment from neighboring countries (such as Saudi Arabia, the United Arab Emirates) or distribution within Qatar. Closed trucks are used for transportation, anti-slip mats are laid in the carriage, and buffer cotton is used to isolate the cable reels. During summer transportation (the daytime temperature in Qatar can reach above 45°C), the trucks are equipped with sunshades to avoid accelerated aging of the cable insulation layer caused by direct sunlight.
Air transportation: For emergency orders (such as project rush repairs), direct flights from major airports in China (Beijing, Shanghai) to Hamad International Airport in Doha take about 12-15 hours. Air cargo must meet air transportation standards, with each reel of cable weighing no more than 300kg, and "handle with care" and "moisture-proof" aviation labels are affixed on the packaging.
Logistics tracking: All orders provide full logistics tracking services, and customers can query the location of the goods and the estimated arrival time through the system. After arriving at Doha Port, we assist customers in completing customs clearance procedures (providing certificates of origin, packing lists, commercial invoices and other documents) and arrange local cooperative logistics companies to deliver the goods to the designated location (such as construction site warehouses, factories).
(3) Shipping and Delivery Process
The shipping process is centered on "on-time, accurate and traceable", with the following specific steps:
Order confirmation: After the customer places an order, the sales team confirms the product specifications, quantity, delivery date and price within 24 hours, and signs a formal contract (including Arabic and English versions). For customized needs (such as special length, packaging), the technical department must issue a feasibility plan within 3 working days.
Production scheduling: After confirming the order, the production planning department enters the task into the ERP system and arranges production according to the priority of the delivery date (the production cycle of regular orders is 7-10 days, and that of large orders is 15-20 days). Customers can check the production progress in real time through the system (such as "conductor processing in progress", "insulation extrusion completed").
Ex-factory inspection and shipping: After production, the quality inspection department conducts final sampling inspection (randomly select 3 reels of cables for withstand voltage test per batch), and issues an ex-factory report after passing. 24 hours before shipment, the customer service team sends a "shipping notice" to the customer, including the logistics tracking number, estimated arrival time at the port and receiving precautions.
Delivery and acceptance: After the goods arrive at the customer's designated location, the customer must check on the spot whether the packaging is intact and whether the quantity is consistent with the order. If the packaging is damaged or the product is damaged, it is necessary to feedback within 24 hours and provide photo evidence, and we will arrange replacement or return (the relevant costs shall be borne by us). After passing the acceptance, the customer signs the "receipt confirmation form" to complete the delivery.
(4) Sample Service
To help customers confirm product performance, free sample services are provided, with the following specific processes:
Sample application: Customers can submit sample applications through email, phone or online platform, indicating the required specifications (such as 4X25), quantity (usually 1-2 meters) and purpose (such as testing, display). No fee is required for sample application, but the receiving address and contact information must be provided.
Sample preparation: Samples are cut from qualified products, with a length of 2 meters (which can meet the requirements of conventional testing). The insulation layer at both ends is stripped 5cm to expose the conductor, facilitating customers to conduct conductivity tests. The sample packaging uses anti-static bags, with a simple test report (including DC resistance, insulation resistance and other parameters) attached.
Sample delivery: Samples are delivered by international express (such as DHL, FedEx), with air transportation as the default (freight is borne by us), and the delivery time is about 3-5 days. After delivery, the express tracking number is provided for customers to track.
Sample feedback: After receiving the samples, if customers have questions about performance, the technical team provides 7×24-hour consulting services, which can help interpret test data or provide guidance on testing methods. Based on the sample test results, customers can adjust the order parameters to ensure that the final product fully meets the requirements.
(5) After-sales Service and Technical Support
After-sales service covers the entire life cycle of the product, with the following specific contents:
Quality assurance: The product provides an 18-month warranty period (calculated from the date of acceptance). If a fault occurs due to the product's own quality issues (such as insulation layer cracking and conductor oxidation) during the warranty period, free replacement or repair services will be provided. For man-made damage (such as mechanical damage and improper installation), paid maintenance will be provided, and only the cost will be charged.
Technical consultation: A professional technical team (including Arabic translators) is available to provide customers with installation guidance, model selection suggestions and troubleshooting services. For example, for different laying environments (such as underground direct burial and bridge laying), a cable current-carrying capacity correction coefficient table (considering factors such as soil thermal resistance and air temperature) is provided; during the construction process, remote guidance on wire stripping, crimping and other operations can be provided to avoid performance problems caused by improper installation.
On-site service: For large-scale projects (such as stadiums and industrial parks), technical personnel can be dispatched to Qatar to provide on-site services, including:
Customer feedback handling: A 24-hour after-sales hotline (supporting Arabic and English) is set up. After receiving customer feedback, we will respond within 1 hour and provide a solution within 24 hours. For major quality problems, special personnel will be arranged to deal with them on-site within 48 hours. A customer satisfaction survey is conducted every year to collect improvement suggestions and continuously optimize products and services.
Spare parts: A spare parts warehouse is set up in Doha to store cables and accessories of common specifications (such as cable terminals and intermediate joints). Customers can purchase them at any time to shorten the maintenance cycle. For discontinued models, 5-year spare parts supply guarantee is provided to ensure the continuous operation of customers' old equipment.
III. Summary
The E-Yy-J series 4X16, 4X25, 4X35, 4X50 copper core PVC insulated
Power Cables have become the preferred products in Qatar's power engineering due to their accurate specification parameters, material technology adapted to Qatar's environment, and perfect full-process services. From industrial production to civil construction, from product design to after-sales support, every link is centered on customer needs, not only meeting technical standards but also taking into account actual application scenarios, providing a reliable guarantee for Qatar's power infrastructure construction.
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