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Electrical Basics: Presented By: Santosh Kumar Gouda
Electrical Basics: Presented By: Santosh Kumar Gouda
BASICS
Presented by : Santosh Kumar Gouda
IEC
NEC
BIS
References
IEEMA
Ministry of Power
CPRI
An electrical conduit is a tube used to protect and route electrical
wiring in a building or structure.
Conduit Pipes Electrical conduit may be made of metal, plastic, fiber, or fired clay.
Most conduits are rigid, but flexible conduits are also used for some
purposes.
Classification of Conduit Pipes
a) According to material:
I) Metal conduits.
2) Insulating conduits.
3) Composite conduits
Marking of conduits shall be repeated in regular intervals not longer than 3 meter but
preferably of 1 meter.
Rigid conduits shall be marked at least once on each manufacturing length, preferably 50
mm from one end.
Markings shall be checked by inspection and by rubbing lightly the marking by band for
15 seconds with a piece of cloth soaked with water and again for 15 seconds with a piece
of cloth soaked with petroleum spirit.
In no case shall the difference between the value measured and the average of the twelve values
obtained from the three samples exceed 0∙1 mm + 10 percent of the average value.
Tests for Conduit Pipe
Sl No Type of Test
01 Dimension Checking
02 Bend Test
03 Compression Test
04 Impact Test
05 Collapse Test
06 Resistance to Heat
07 Resistance to Burning
08 Electrical Characteristics
CABLES & WIRES
• Wire is a single electrical conductor, whereas a cable is a group of insulated wires wrapped in a
jacket.
• Wires are bare, twisted and are sometimes PVC insulated. But Cables are never bared, are always
insulated and wrapped in a jacket.
Type of wires
1) Solid Wire : A solid wire has a single conductor and is either insulated or bare and it is usually protected by a coloured
sheath
2) Stranded wire : A standard wire contains many thin wire strands that are twisted together
Type of Cables
Based on Voltage
Low-tension cables — up to 1000 V
High-tension cables — up to 11000 V
Super-tension cables — from 22 kV to 33 kV
Extra high-tension cables — from 33 kV to 66 kV
Extra super voltage cables — beyond 132 kV
Note : In India,nominal Extra High Voltage lines in vogue are ± 800 kV HVDC & 765 kV, 400 kV,
230/220 kV, 110 kV and 66 kV AC lines.
Type of cable based on cores
(i) Single-core
(ii) Two-core
(iii) Three-core
(iv) Four-core etc.
Types of cables based on Insulation Materials
• PVC Cables – 11 KV
• XLPE Cables - 220 KV
• Elastomeric Cables – 33 KV
Applications of elastomeric Cables: Welding Cables, Ship wiring cables, Pressure Tight Cables
and cables for submerged connection, Railways locomotives and coach wiring cables, mining cables,
Ship wiring, Defense applications,Earth moving machines etc.
Insulation material Max. operating temperature
XLPE 90°C
Polyethylene (PE) material itself has excellent dielectric strength, high insulation resistance, and a low
dissipation factor at all frequencies making it an ideal insulator, however it is limited in its temperature
range. Cross-linking the PE to become XLPE increases the temperature range of the insulation whilst
maintaining the electrical properties.
Comparison Study between PVC Cables & XLPE Cables
Sl No Properties PVC XLPE
01 Heat resistance Low ,Can High ,Can
withstand 160 °C withstand 250 °C
under SCC under SCC
02 Overloading Capacity _ Higher than PVC
T – Thermoplastic insulation
H – Heat resistance
HH – High heat resistance (up to 194°F)
W – Suitable for wet locations
N – Nylon coating, resistant to damage by oil or gas
X – Synthetic polymer that is flame-resistant
Coding of PVC Cables
Fire Resistant Cables: Fire resistant or fire rated cables are designed to maintain circuit
integrity and continue to work for a specified period of time under defined conditions.
Fire Survival/ Circuit Integrity Cable
An overview of Fire performance Cables
• Globally the norm is to use Low Smoke Zero Halogen (LS0H) wiring. It is only in India, where
Flame Retardant Low Smoke (FRLS) products are allowed.
• They are FR (Fire Retardant) cables, Fire Retardant Low Smoke (FRLS) cables,FRLSH cables, Low
Smoke Zero Halogen (LS0H) cables and Fire Survival (FS) cables/Circuit Integrity Cables/Fire
Resistant Cables.
FS Cables - public buildings and constructions (such as hospitals, theatres, shopping developments,
tunnels, mass transit railways, oil & petrochemical plants, power stations and computer
installations) where the danger to life, equipment and structures may be greatly increased in the
event of a power failure due to fire.
Current Rating of Cable
The current rating of the cable is defined as the maximum current carrying capacity of the power cable under normal
operating condition. The current rating of power cable decided the upper limit of power transfer by a cable. It mostly
depends on the insulation temperature and electrical resistance of the conductor. The cable rating is classified under three
headings. These are
Voltage Rating
The voltage rating of a cable refers to the maximum voltage to which it may be connected (and have running through it).
If the voltage rating is exceeded, the insulation between cable cores, or between a cable core and earth, may break down
and cause a short circuit or a fire.
A typical voltage rating is 0.6/1 kV. This means that a cable with this rating is capable of withstanding a voltage of 0.6 kV
(600 volts rms) between the conductor and earth, and 1 kV (1000 V rms) between adjacent conductors.
Oxygen Index
‘Oxygen index’ is the minimum concentration of oxygen in an oxygen/nitrogen mixture in which the material will
burn.
Size
The size of a cable is usually known as the total cross sectional area (CSA) of the conducting material in each core and is
expressed in square millimetres.
The size of the cable can also be referred to as the number of strands followed by the diameter of each strand (i.e.
number of strands/diameter of each strand (in mm)).
A typical three core flexible cord used in portable appliances (such as a kettle or toaster) has three insulated cores.
The total nominal cross sectional area of each core is 1 square mm, so the 'size' of the cable is 1 square mm.
Each core consists of 32 strands of 0.02 mm diameter copper wire. Therefore the size of the cable could also be written as
(32/0.02).
Cable Construction
The construction and material of the power cables are determined by three main factors:
• Conductor
• Conductor screen
• Insulation
• Insulation Screen
• Conductor Sheath
• Filler
• Bedding/Inner Sheath
• Individual screen (Instrumentation cables)
• Drain Wire (Instrumentation cables)
• Overall Sceen (Instrumentation cables)
• Armour
• Outer Sheath
• Protective Layer
1. Conductors
Electrical conductors are types of metals that allows the electric current to flow through it. The
electric conductor is made up of different metals like aluminium, copper, gold,silver etc. and their
alloys.
Copper :
Copper which at 20°C has a resistivity of 1/58 = (0.017 241....) ohm mm2/m is said to have a conductivity of
100 percent IACS ( International Annealed Copper Standard )
Aluminum:
Aluminium has 61% of the conductivity of copper. The cross sectional area of an aluminium
conductor must be 56% larger than copper for the same current carrying capability.
Aluminum Conductor
O Grade : Annealed – Applies to product which has been heated to produce the lowest strength
condition to improve ductility and dimensional stability
O - Annealed
HB - Half-hard
HD - Hard
Annealing – is the process of gradually heating and cooling the conductor material to make it more malleable
and less brittle.
Coating – surface coating (eg. tin, nickel, silver, lead alloy) of copper conductors is common to prevent the
insulation from attacking or adhering to the copper conductor and prevents deterioration of copper at high
temperatures. Tin coatings were used in the past to protect against corrosion from rubber insulation, which
contained traces of the sulfur used in the vulcanising process.
Conductivity – 97 to 100 %
Aluminium conductors for welding cables have not been assigned any
class number.
Copper Conductor
1) Resistance Test
2) Persulphate Test
3) Annealing Test
Aluminum Conductor
1) Annealing Test
2) Tensile Test
3) Wrapping Test
4) Resistance Test
Comparison Chart between Aluminum & Copper Conductor
/°C
g/cm3
2.Conductor screen
• The Main Purpose of Conductor Screen is to maintain a uniformly divergent electric field, and to contain the
electric field within the cable core.
• Conductor Screen is semi-conducting material because Semi-conducting materials do not conduct electricity
well enough to be a conductor but will not hold back voltage. It “smoothes” out the surface irregularities of
the conductor. The conductor shield makes the voltage on the inside of the insulation the same
Materials: Extruded thermoset semi-conducting compound, carbon paper and carbon loaded polymer.
3.Insulation
• Insulation is a nonconductive material, or a material resistant to the flow of electric current. It is often called a
dielectric in radio frequency cables.
• Insulation resists electrical leakage, prevents the wire’s current from coming into contact with other conductors and
preserves the material integrity of the wire by protecting against environmental threats such as water and heat.
• The safety and effectiveness of the wire depend on its insulation.
The insulating materials used in cables should have the following properties:
Rubber : Rubber may be natural and synthetic. Its relative permittivity is between 2 and3; dielectric strength is 30
KV/mm.
Vulcanized India Rubber (VIR): It is prepared by mixing India rubber with mineral matter such as sulphur, zinc
oxide, red lead etc. though vulcanized process improve the non-hygroscopic and other properties like strength,
durability, resilience, elasticity etc;but it still reduces its specific insulation resistance. The main drawback is that
owing to sulphur content it attacks copper.
Impregnated Paper: It is prepared from wood pulp rags or plant fibers by a suitable chemical process. It is quite
cheap, has low capacitance, and high insulation resistivity.The only disadvantage is that it is hygroscopic, and even
it is impregnated with compound, it absorbs moisture, which lowers insulation resistance.
Polyvinyl Chloride (PVC): This is a synthetic compound and is processed with certain material known as
plasticizers. It is inert to oxygen and almost inert to alkalies and acid and therefore its use is preferred over VIR
Polyethylene: Polyethylene is a straight chain polymer derived from ethylene. Its electrical property is very good.
The maximum operating temperature under the short circuit is 100°C. It has limited use in power cables.
Cross-linked polyethylene: Low density polyethylene, when vulcanized under controlled conditions, results in
cross-linking of carbon atom and the compound produced is a new material having high melting point with light
weight, small dimension and good mechanical strength.
Varnished Cambric (or Empire Tape): This is cotton cloth impregnated and coated with varnish. The cambric is
lapped in the form of tap on to the conductor and its surface is coated with petroleum jelly compound to give easy
sliding of the surface.
Gutta –percha: It is similar to rubber but it becomes soft at about 65°C. It is non-hygroscopic but cannot withstand
even medium voltages.
Silk and cotton: This is used in low voltage cables. The conductor may have a single layer or double layer covering
depending upon the requirements of service. Silk and cotton covered wire are usually used for instruments and motor
winding.
Enamel Insulation: The wire used on the coils of meters, relays, small transformers, motor windings, and so forth,
is called magnet wire. This wire is insulated with an enamel coating.These wires are cheaper than silk and cotton
covered wires and therefore for low voltage machine and instruments enameled wires are used. Enamel insulation is
liable to crack.
4. Insulation Screen
• An extruded layer of semi conducting is applied over the insulation layer to insure that the electric stress is
homogenous around the insulated core. The semi conducting layer shall be firmly bonded to the outer layer
of the insulation layer.
• The purpose of insulation screen is to reduce voltage stress at the interface between the conducting and
insulating component.
Materials : Extruded thermo set semi-conducting compound, Carbon paper and carbon loaded polymer.
5.Conductor Sheath
A conductive sheath / shield, typically of copper tape or sometimes lead alloy, is used as a shield to keep electromagnetic radiation in, and also provide a path for
fault and leakage currents (sheaths are earthed at one cable end). Lead sheaths are heavier and potentially more difficult to terminate than copper tape, but
generally provide better earth fault capacity.
.
6 Filler
The interstices of the insulated conductor bundle is sometimes filled, usually with a soft polymer material.
An individual screen is occasionally applied over each insulated conductor bundle for shielding against noise / radiation and interference from other conductor
bundles. Screens are usually a metallic (copper, aluminium) or semi-metallic (PETP/Al) tape or braid. Typically used in instrument cables, but not in power cables.
9. Drain Wire (Instrument Cables)
Each screen has an associated drain wire, which assists in the termination of the screen. Typically used in
instrument cables, but not in power cables.
Drain wires are used in cables in conjunction with a metallic shield to ensure effective grounding. The
drain wire serves to complete an electrical circuit from the shield and carry unwanted electrical
noise to ground away from the circuit.
The drain wires are usually tinned copper conductors. The tin coating helps prevent dissimilar metal
reaction between the copper conductor and an aluminum screen.
The materials for the sheath are selected for resistance to water, oil, sunlight, underground conditions, chemical vapors,
impact, or high temperatures
13.Termite Protection
For underground cables, a nylon jacket can be applied for termite protection, although sometimes a phosphor bronze tape
is used.
Types of Cables & their structural arrangements
Low Voltage Power & Control Cables
FAS Cable
Low Voltage Instrumentation Cables
Medium & High Voltage Power Cables