Wiktor Wise
Industrial electric cables are crucial for ensuring the safety, efficiency, and durability of electrical installations in construction. They are designed to withstand harsh environments, heavy loads, and demanding conditions on construction sites. There are various types of industrial cables, including power cables, control cables, data cables, fire-resistant cables, and armoured cables. These cables are used for power distribution, transmitting signals and data, and protecting against electrical, mechanical, and environmental stresses. They can be made from different materials, such as PVC, XLPE, or EPR, and are measured in volts, with low, medium, and high-voltage cables serving different purposes. Single-conductor cables have one metal conductor surrounded by insulation, while multiconductor cables are safer in environments with mechanical hazards. Industrial cables are essential for the success and sustainability of construction projects, requiring compliance with safety standards and adherence to advancements in cable technology.
| Characteristics | Values |
|---|---|
| Purpose | Transporting electrical energy from one point to another |
| Configuration | Based on national and international regulations |
| Types | Low voltage, medium voltage, high voltage, power, control, data, fire-resistant, armoured, specialty, flexible, single-conductor, multiconductor, coaxial, fiber-optic, ribbon, welding, high-security halogen-free, polyurethane, etc. |
| Applications | Industrial facilities, public places, variable frequency drive, installations with risk of mechanical aggression, fire and explosion risk areas, automation, manufacturing, food and beverage plants, chemical plants, clean rooms, construction, etc. |
| Materials | Copper, aluminium, steel, thermoplastic, PVC, polyethylene, chlorinated polyethylene, thermoplastic elastomer, rubber, polyurethane, etc. |
| Properties | Flexibility, abrasion resistance, corrosion resistance, electrical conductivity, signal integrity, tensile strength, temperature resistance, etc. |
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What You'll Learn
Cable shielding and jacketing
Industrial electric cables are used to transmit electrical energy, data, and signals from one point to another. They find applications in various fields, including general industry, public installations, infrastructures, and power transmission. The design and configuration of these cables depend on their specific applications and must adhere to national and international regulations.
The cable jacket, or insulation, covers and contains the electric flow within the conductor. It is typically made of thermoplastic material due to its ability to soften and become formable when heated. Different jacket materials offer unique advantages, such as PVC's flame resistance, polyethylene's suitability for wet locations, and chlorinated polyethylene's toughness and chemical resistance. The jacket's thickness determines the cable's voltage rating, and higher operating temperatures allow for increased current-carrying capacity.
Additionally, cable jacketing can be customized to meet specific requirements. For instance, the EXRAD 1000-volt battery cable features an irradiated cross-linked elastomer (XLE) jacket that isolates stray currents. It also complies with EU standards for high-voltage cables due to its bright orange colour. Furthermore, zipper tubes can be used as cable jackets to bundle multiple cables together while providing effective shielding against electromagnetic interference.
In conclusion, cable shielding and jacketing play crucial roles in the performance and protection of industrial electric cables. By utilizing different shielding and jacketing materials and designs, manufacturers can tailor cables to specific applications, ensuring compliance with regulations and optimizing functionality in various industrial contexts.
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Conductor wires and plating
An electrical cable consists of multiple wires encased in a single covering. The conductor is the core of the cable that transports electrical current in one or more directions of flow. It is mostly made of metal due to metal's high conductivity. The most common conductor materials include aluminium, copper, and high-strength alloys. Copper is the best conductor for cables in industrial settings because it is compatible with a variety of plating options.
The cable manufacturer can coat the surface of each wire strand with a thin layer of tin to increase corrosion resistance, particularly in wet or humid environments. Copper conductors can also be coated with nickel to increase corrosion resistance and expand the operating temperature range. Silver-plating is another option that enhances conductivity and widens the wire's operating temperature range.
Single-conductor industrial cables have the advantage of reduced bulkiness, making them easier to route in tight spaces. However, they have limited abrasion resistance and high susceptibility to electrical noise unless shielding is added. Multiconductor cables, on the other hand, offer customisability and the ability to group multiple "legs" into a single "trunk".
The insulation surrounding each conductor is a critical component of an electrical cable. It is made of non-conductive material and serves to separate each conductor, preventing damage and determining the electrical properties of the cable. The thickness of the insulation influences the voltage rating, and insulation that can operate at higher temperatures can carry more current without failing.
The outer covering of an industrial cable, known as the jacket, provides protection against fire, installation hazards, and other hazards. Common materials for cable jacketing include PVC, polyethylene, chlorinated polyethylene, thermoplastic elastomer, rubber, and polyurethane. These materials offer varying benefits, such as flame resistance, flexibility, toughness, and abrasion resistance.
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Cable insulation
Insulation is an essential component of any electrical cable, covering the wire and preventing current leakage. It is made of a non-conductive material, such as plastic, rubber, or fluoropolymers, and it keeps the electricity within the wire, protecting it from the surrounding environment. The type of insulation used depends on the wire's targeted application.
Polyvinyl Chloride (PVC)
PVC is a widely used insulation material known for its versatility, resistance to flame, moisture, and abrasion, and its ability to withstand exposure to various chemicals. It operates within a temperature range of -55°C to 105°C and is suitable for both heavy and thin-wall uses. However, it exhibits high attenuation and capacitance loss, and its flexibility is below average.
Ethylene Propylene Rubber (EPR)
EPR insulation is commonly used in medium and high-voltage power cables and offers excellent thermal and electrical characteristics, flexibility, and resistance to heat, moisture, and chemicals. Its operating temperature range is -50°C to 160°C, and it is often used in temporary installations and mining applications.
Polyethylene (PE)
PE is an inflexible material used for cable insulation when high-speed transmission and low capacitance are required. It is resistant to soldering, cracking, and solvents, with an operating temperature range of -65°C to 80°C.
Cross-Linked Polyethylene (XLPE)
XLPE is a subtype of PE insulation that offers improved mechanical strength, temperature resistance, and resistance to chemicals and solvents. It is commonly used in medium and high-voltage power distribution cables, including underground power cables and industrial cables.
Polyurethane (PUR)
PUR insulation is a flexible material used for electrical cables in low-temperature and marine environments. It is resistant to moisture, chemicals, and abrasion, with an operating temperature range of -60°C to 90°C. While it is a durable material, it has poor electrical properties, making it more suitable for cable jacketing than insulation.
Silicone
Silicone insulation provides excellent flexibility and temperature resistance, with an operating range from -60°C to 180°C. It is used in industries requiring high-temperature resistance, such as automotive and aerospace.
Fluorinated Ethylene Propylene (FEP)
FEP insulation is commonly used in plenum cable and military applications. It can be foamed to improve data transmission and reduce weight.
Ethylene Tetrafluoroethylene (ETFE) and Ethylenechlorotrifluoroethylene (ECTFE)
ETFE and ECTFE are stronger and more flexible insulation materials than FEP, and they can be made thermoset through irradiation. They lack some of the electrical advantages of FEP but improve data transmission and reduce weight.
Polyvinylidene Fluoride (PVDF)
PVDF is a flexible, lightweight, and thermally stable insulation material that is also resistant to chemicals, heat, weather, abrasion, and fire. It is a low-cost option used in a wide range of industries.
Modified Polyphenylene Ether (MPPE)
MPPE is a thermoplastic material used in the automotive industry. It is lighter than PVC, reducing fuel consumption, and is halogen-free and flame-retardant. It also has high dielectric properties and is recyclable.
Low Smoke Zero Halogen (LSZH)
LSZH solutions are designed to minimise smoke and toxic gas emissions during a fire, making them ideal for places like airports, schools, and hospitals.
Polytetrafluoroethylene (PTFE)
PTFE, commonly known as Teflon, is a fluorocarbon polymer with excellent electrical properties, including high dielectric strength and low dielectric constant. It is chemically inert, heat resistant, and performs well in extreme temperature conditions. PTFE-insulated wires are used in aerospace, military, and high-frequency signal transmission applications.
Rubber
Rubber insulation provides excellent flexibility, durability, and resistance to heat, oil, chemicals, and abrasion. It is made from natural or synthetic rubber compounds.
Fiberglass
Fiberglass insulation is made of fine glass fibres woven or braided into a flexible or rigid structure. It offers excellent thermal resistance, high-temperature tolerance (up to 482°C), and resistance to chemicals and moisture. It is used in high-temperature industrial equipment, furnaces, and ovens.
Cable Shielding
Cable shielding is a conductive material surrounding a wire or cable to contain electrical energy and prevent signal interference with nearby cables. Popular types of electrical cable shields include foil and braid. Foil provides 100% coverage, is lightweight, easy to terminate, and effective at high frequencies. Braid offers stronger protection against low-frequency interference and has a longer flex life.
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Cable voltage and applications
Electric cables are measured in volts, and depending on their voltage rating, they are divided into different groups. Low-voltage cables, for instance, have a voltage of up to 750V and are used in a variety of applications. They are designed with thermoplastic and thermoset coatings and according to harmonized standards. The next group is another set of low-voltage cables with a voltage of up to 1000V. These are used for industrial power installations in various fields, including general industry, public installations, and infrastructures. They are designed according to international standards such as UNE, IEC, BS, and UL.
Medium-voltage cables have a voltage ranging from 1 kV to 36 kV and are used to distribute electricity from electrical substations to transformer stations. They are generally insulated with EPR or XLPE polymeric insulation. EPR insulation is used for cables ranging from 4 kV to 34 kV, while XLPE is used for voltages of 600V and above. Medium Voltage cable type RHZ1 with XLPE insulation is halogen-free and non-flame propagating, making it suitable for energy transportation and distribution in medium-voltage networks.
High-voltage cables have a voltage of 36 kV and above and are used to transport electricity from generating plants to electrical substations. They are also used in instruments, ignition systems, and alternating and direct current (AC and DC) power transmission. These cables have additional internal layers in the insulation system to control the electric field around the conductor, which is necessary for voltages of 2000V and above to prevent electrical stress.
The rated voltage of a cable is a fundamental metric that serves as a reference voltage for defining electrical tests. It is expressed as the combination of two values, Uo/U, in volts. Uo is the Root Mean Squared (r.m.s) value between any insulated conductor and 'earth' (the metal covering or surrounding medium), while U is the r.m.s value between any two-phase conductors of a multicore cable or a system of single-core cables.
In addition to voltage, there are other factors to consider when selecting the right cable for a specific application. These include temperature rating, electrical reliability, mechanical strength, mechanical flexibility, and corrosion resistance. The jacketing and insulation material are critical factors in determining these properties.
Different types of cables are used for specific applications. For instance, control cables are used for fixed or mobile installations, such as small household appliances, interconnection of machine parts, signalling and control systems, and power supply connections. They are designed to be flexible and shielded to transmit signals effectively in environments with high levels of electromagnetic interference.
Ribbon cables, also known as zip-wire cables, are used for transmitting sensitive signals over long distances without compromising data accuracy. They have a unique design where each conductor is individually insulated, simplifying cable management and reducing the risk of tangling.
Coaxial cables are suitable for industrial settings requiring high-frequency applications. They provide excellent shielding and signal integrity for transmitting electrical signals with low loss.
Twisted pair cables, invented by Alexander Graham Bell, eliminate electromagnetic interference (EMI) by cancelling out external sources.
Fiber-optic cables are ideal for industrial applications requiring high bandwidth and immunity to electromagnetic interference.
Aluminium cables are suitable for power transmission and can be installed indoors, outdoors, or underground.
Steel-reinforced cables are used in installations with a risk of mechanical aggression, while armoured cables are used in places with rodents or a risk of fire and explosion.
Rubber cables are versatile and can be found in both fixed industrial installations and mobile services.
Welding cables use a rubber sheath to allow high currents to be transmitted between the welding generator and the electrode.
High-security halogen-free (LSZH) cables are suitable for wiring electrical panels and public places, as they produce low smoke and corrosive gas emissions in case of fire.
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Cable flexibility and durability
The flexibility of a cable is determined by its construction and materials. Single-conductor cables, for instance, offer increased flexibility due to their reduced bulkiness. However, they have limited abrasion resistance and higher susceptibility to electrical noise. In contrast, multiconductor cables provide customizability and better protection against electromagnetic interference.
To enhance flexibility, high strand counts and rope lay stranding construction are recommended. While rope lay stranding is the most flexible, it is also the most expensive. Concentric stranding is a more affordable option for achieving a high flex life. Additionally, eliminating multi-layers ensures a uniform bend radius, reducing overall stress on the cable.
The choice of insulation and jacketing materials also plays a vital role in flexibility and durability. Materials with high dielectric strength allow for thinner walls, increasing flexibility. Soft materials with a low durometer rating, such as thermoplastic elastomers, provide greater flexibility and resistance to low temperatures. PVC and neoprene are commonly used for insulation and jacketing in flexible cables.
The durability of industrial electric cables is crucial to their performance and longevity. Cables with aluminium or steel reinforcement are suitable for installations with a risk of mechanical aggression or fire and explosion hazards. High-security cables with low smoke and corrosive gas emissions are designed for emergency circuits and public distribution networks. Cable armoring, using strong metals, protects against crushing and impact forces.
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Frequently asked questions
The "D" in industrial electric cable typically refers to the nominal voltage of the cable, which is measured in kV (kilovolts).
The letters in the designation code indicate the cable's design and intended use. For example, “U" means the cable is rated for underground use, while “SIS" stands for switchboard or panelboard wire.
Some other common acronyms for electric cables include:
- MCM: Refers to the cross-sectional area of a wire.
- MTW: Machine Tooling Wire, used for internal wiring in appliances.
- MV-105: Medium Voltage cable with a maximum temperature of 105°C.
- NEC: National Electrical Code published by the National Fire Protection Association.
Electric cables are measured in volts and categorized into groups based on their voltage capacity. For example, low-voltage cables are up to 750V or 1000V, medium-voltage cables are from 1kV to 36kV, and high-voltage cables are above 36kV.
