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PVC is Polyvinyl Chloride. This is a plastic that has the following chemical formula: CH2=CHCl (see
picture on the right).
Plastic covers a wide rage of synthetic or semi-synthetic polymerization products (i.e. long-chain
carbon-based "organic" molecules) which name refers to the fact that in their semi-liquid state they
are malleable, or have the property of plasticity.
PVC is a thermoplastic material.
Thermoplastic materials are those that can be melted again and again. These materials can be
heated to a certain temperature and will harden again as they cool.
After the First World War, there was a boom in new forms of plastics due to the
improvements in the chemical technology sector, including "polystyrene (PS)"
and "polyvinyl chloride (PVC)", developed by the I.G. Farben company of
Germany.
Nowadays, PVC is commonly used in the construction sector, for example in window frames and
shutters, pipe cabling and coating, etc.. Vinyl is also used in gramophone records, and that is why
we use the term vinyl records to refer to them. PVC can be used for tons of other applications from
industrial ware and widely used in the healthcare sector, to car spare parts, toys factory, food
packaging, raingear, etc. (This is described below).
PVC can be clear or colored, rigid or flexible, depending on the added compounds and final
application that needs to be achieved; For example there exists different PVC grades such as coast
or blow film, high impact, wire and cable grade, thermoforming, injection molding, rotational molding,
et
Rural Technology
A cable is either a stranded conductor ( single-conductor cable) or a combination of conductors insulated
from one another. The term cable is a general one and in practice it is usually applied only to the larger
sizes of conductors. A small cable is more often called a stranded wire or cord. Cables may be bare or
insulated. The insulated cables may be covered with lead, or protective armor.
Contents
[hide]
1 Types of Cables
1.1 1) According to
o
insulation:
1.2 2) According to
conductors material:
1.3 3) According to their
o
shapes:
o
1.5 5) According to
mechanical protection:
1.6 6) According to voltage
o
grade:
2 Uses of cables:
3 Current carrying capacity of wire or
cable
4 Conductor splices and terminal
connections
5 Striping the Insulation
6 Terminating
7 Types of terminal
8 What you have learnt
9 Terminal Question
9.1 Answer to InText
o
Questions
Types of Cables
Cables can be classified according to various factors given below:
1) According to insulation:
a. Cotton covered Cable. b. Silk coated Cable. c. Asbestos covered Cable. d. Rubber coated Cable. e.
PVC coated Cable.
4) According to cores:
a. Two core. b. Three core. c. Three and half core.
Uses of cables:
1. Small industries. 2. Big industries and factories. 3. Distribution lines. 4. Transmission lines (High
voltage cable). 5. Low voltage cables are used in domestic wiring for appliances.
It is a maximum safe value of current in amperes which can pass through a cable without generating heat
above room temperature. Any excess current flowing above safe value will result in heating of cable in a
very short duration which will damage the insulation and if persists for a long period will result in short
circuit. Any insulation will always have a short time over current capability but its not recommended to
use this capability under normal operating conditions.
Terminating
The common material, which is used to make an HRC fuse is glass, but this is not always the
case. Other chemical compounds are also used in HRC fuse manufacturing and construction
based on different factors. Its external enclosure is made fully airtight in order to avoid the effect
of atmosphere on the fuse materials. The major objection on HRC fuse is low and uncertain
breaking
capacity
of
semi-enclosed
fuse.
HRC
Construction and Operation
Require no maintenance.
Fuse
Heat being produced by the arc may affect the associated switches.
As fault occurs, the first element to be blown out is silver fuse and current is transferred
to tungsten wire. The travel of the plunger is set such a way that is not ejected from the
fuse body during fault conditions.
During single-phase fault on a three-phase system, the plunger trips the circuit breaker,
which opens all the three phases, i.e. it prevents single-phase supply as well.
The effects of the short circuit need to be considered in circuit breaker, which allow the
use of an inexpensive circuit breaker.
The fuse-tripped breaker is capable of dealing with small currents, which avoids the
necessity of replacing the fuse (except high current).
Low voltage H.R.C fuses are also available in a capacity of 16000A to 30,000A at 400V (Also
available in range of 80kA to 120kA) . HRC Fuses are also used for protection on low voltage
distribution systems against overload and short circuit conditions.
Look for the Underwriters Laboratories label on all electric devices to make sure they meet UL safety
standards.
Keep all electrical devices in good working condition. If a cord is frayed, have an electrician replace it or buy
a new device.
Make sure all bathrooms and kitchens have ground fault circuit interrupter outlets. GFCIs usually but not
always detect electrical faults and shut off electricity to the circuit before a device user is seriously harmed.
Have an electrician inspect an older homes wiring and make a recommendation about installing arc fault
circuit interrupters. An AFCI can detect a dangerous condition in a homes wiring and cut off power to the circuit
before a fire develops. Inspect electrical plate covers. Warm or discolored covers may indicate faulty wiring that
might catch on fire.
To protect small children, have an electrician install tamper-resistant receptacles, which have a built-in
shutter system that prevents children from inserting foreign objects into the slots. ESFI says these outlets will
prevent most of the 2,400 burns children get each year from outlets.
Never use an electric hair dryer or curling iron near a wet shower, sink or bathtub or while standing on a wet
or damp floor. Keep radios and televisions away as well. If a device falls into water, unplug the device before
removing it.
Unplug hair dryers, curling irons, hot rollers, electric razors, irons, and power tools when not in use.
To be on the safe side when using electrical devices while standing on concrete, wear rubber-soled shoes
that will not conduct electricity.
1
The Electrical Safety Foundation International (ESFI) sponsors National Electrical Safety
Month each May and focuses on reducing electrically related deaths, injuries and property loss.
NOVEC, headquartered in Manassas, Virginia, is a not-for-profit elec
This article is about electrical insulation. For insulation of heat, see Thermal insulation.
Electromagnetism
Electricity
Magnetism
Electrostatics[hide]
Electric charge
Static electricity
Electric field
Conductor
Insulator
Triboelectricity
Electrostatic discharge
Coulomb's law
Induction
Gauss's law
Electric flux / potential energy
Polarization density
Magnetostatics[show]
Electrodynamics[show]
Electrical network[show]
Covariant formulation[show]
Scientists[show]
Ceramic insulator used on railways electrified with 25kV AC overhead electrical catenary
3-core copper wire power cable, each core with individual colour-coded insulating sheaths all contained within an
outer protective sheath
An electrical insulator is a material whose internal electric charges do not flow freely, and therefore
make it impossible to conduct an electric current under the influence of an electric field. This
contrasts with other materials, semiconductors and conductors, which conduct electric current more
easily. The property that distinguishes an insulator is its resistivity; insulators have higher resistivity
than semiconductors or conductors.
A perfect insulator does not exist, because even insulators contain small numbers of mobile charges
(charge carriers) which can carry current. In addition, all insulators become electrically
conductive when a sufficiently large voltage is applied that the electric field tears electrons away
from the atoms. This is known as the breakdown voltage of an insulator. Some materials such
as glass, paperand Teflon, which have high resistivity, are very good electrical insulators. A much
larger class of materials, even though they may have lower bulk resistivity, are still good enough to
prevent significant current from flowing at normally used voltages, and thus are employed as
insulation for electrical wiring and cables. Examples include rubber-like polymers and most plastics.
Insulators are used in electrical equipment to support and separate electrical conductors without
allowing current through themselves. An insulating material used in bulk to wrap electrical cables or
other equipment is called insulation. The term insulator is also used more specifically to refer to
insulating supports used to attach electric power distribution or transmission lines to utility
poles andtransmission towers. They support the weight of the suspended wires without allowing the
current to flow through the tower to ground.
Contents
[hide]
2 Uses
Breakdown[edit]
When subjected to a high enough voltage, insulators suffer from the phenomenon of electrical
breakdown. When the electric field applied across an insulating substance exceeds in any location
the threshold breakdown field for that substance, the insulator suddenly becomes a conductor,
causing a large increase in current, an electric arc through the substance. Electrical breakdown
occurs when the electric field in the material is strong enough to accelerate free charge
carriers (electrons and ions, which are always present at low concentrations) to a high enough
velocity to knock electrons from atoms when they strike them, ionizing the atoms. These freed
electrons and ions are in turn accelerated and strike other atoms, creating more charge carriers, in
a chain reaction. Rapidly the insulator becomes filled with mobile charge carriers, and
its resistance drops to a low level. In a solid, the breakdown voltage is proportional to the band
gap energy. The air in a region around a high-voltage conductor can break down and ionise without
a catastrophic increase in current; this is called "corona discharge". However if the region of air
breakdown extends to another conductor at a different voltage it creates a conductive path between
them, and a large current flows through the air, creating anelectric arc. Even a vacuum can suffer a
sort of breakdown, but in this case the breakdown or vacuum arc involves charges ejected from the
surface of metal electrodes rather than produced by the vacuum itself. In case of some insulators,
the conduction may take place at a very high temperature as then the energy acquired by the
valence electrons is sufficient to take them into conduction band.
Uses[edit]
A very flexible coating of an insulator is often applied to electric wire and cable, this is
called insulated wire. Since air is an insulator, in principle no other substance is needed to keep
power where it should be. High-voltage power lines commonly use just air, since a solid (e.g. plastic)
coating is impractical. However, wires that touch each other produce cross connections, short
circuits, and fire hazards. In coaxial cable the center conductor must be supported exactly in the
middle of the hollow shield in order to prevent EM wave reflections. Finally, wires that expose
voltages higher than 60 V can cause human shock and electrocution hazards. Insulating coatings
help to prevent all of these problems.
Some wires have a mechanical covering with no voltage rating[citation needed]e.g.: service-drop, welding,
doorbell, thermostat wire. An insulated wire or cable has a voltage rating and a maximum conductor
temperature rating. It may not have an ampacity (current-carrying capacity) rating, since this is
dependent upon the surrounding environment (e.g. ambient temperature).
In electronic systems, printed circuit boards are made from epoxy plastic and fibreglass. The
nonconductive boards support layers of copper foil conductors. In electronic devices, the tiny and
delicate active components are embedded within nonconductive epoxy or phenolic plastics, or within
baked glass or ceramic coatings.
In microelectronic components such as transistors and ICs, the silicon material is normally a
conductor because of doping, but it can easily be selectively transformed into a good insulator by the
application of heat and oxygen. Oxidised silicon is quartz, i.e. silicon dioxide, the primary component
of glass.
In high voltage systems containing transformers and capacitors, liquid insulator oil is the typical
method used for preventing arcs. The oil replaces air in spaces that must support significant voltage
without electrical breakdown. Other high voltage system insulation materials include ceramic or
glass wire holders, gas, vacuum, and simply placing wires far enough apart to use air as insulation.
Overhead conductors for high-voltage electric power transmission are bare, and are insulated by the
surrounding air. Conductors for lower voltages in distribution may have some insulation but are often
bare as well. Insulating supports called insulators are required at the points where they are
supported by utility poles or transmission towers. Insulators are also required where the wire enters
buildings or electrical devices, such as transformers or circuit breakers, to insulate the wire from the
case. These hollow insulators with a conductor inside them are called bushings.
Material[edit]
Insulators used for high-voltage power transmission are made from glass, porcelain or composite
polymer materials. Porcelain insulators are made from clay, quartz or alumina and feldspar, and are
covered with a smooth glaze to shed water. Insulators made from porcelain rich in alumina are used
where high mechanical strength is a criterion. Porcelain has a dielectric strength of about 410
kV/mm.[1] Glass has a higher dielectric strength, but it attracts condensation and the thick irregular
shapes needed for insulators are difficult to cast without internal strains. [2] Some insulator
manufacturers stopped making glass insulators in the late 1960s, switching to ceramic materials.
Recently, some electric utilities have begun converting to polymer composite materials for some
types of insulators. These are typically composed of a central rod made of fibre reinforced
plastic and an outer weathershed made of silicone rubber or ethylene propylene diene monomer
rubber (EPDM). Composite insulators are less costly, lighter in weight, and have
excellent hydrophobic capability. This combination makes them ideal for service in polluted areas.
However, these materials do not yet have the long-term proven service life of glass and porcelain.
Design[edit]
The electrical breakdown of an insulator due to excessive voltage can occur in one of two ways:
A puncture arc is a breakdown and conduction of the material of the insulator, causing
an electric arc through the interior of the insulator. The heat resulting from the arc usually
damages the insulator irreparably. Puncture voltage is the voltage across the insulator (when
installed in its normal manner) that causes a puncture arc.
A flashover arc is a breakdown and conduction of the air around or along the surface of the
insulator, causing an arc along the outside of the insulator. They are usually designed to
withstand this without damage. Flashover voltage is the voltage that causes a flash-over arc.
Most high voltage insulators are designed with a lower flashover voltage than puncture voltage, so
they flash over before they puncture, to avoid damage.
Dirt, pollution, salt, and particularly water on the surface of a high voltage insulator can create a
conductive path across it, causing leakage currents and flashovers. The flashover voltage can be
reduced by more than 50% when the insulator is wet. High voltage insulators for outdoor use are
shaped to maximise the length of the leakage path along the surface from one end to the other,
called the creepage length, to minimise these leakage currents.[3] To accomplish this the surface is
moulded into a series of corrugations or concentric disc shapes. These usually include one or
more sheds; downward facing cup-shaped surfaces that act as umbrellas to ensure that the part of
the surface leakage path under the 'cup' stays dry in wet weather. Minimum creepage distances are
2025 mm/kV, but must be increased in high pollution or airborne sea-salt areas.
Cap and pin insulator string (the vertical string of discs) on a 275 kV suspension pylon.
Suspended glass disc insulator unit used in cap and pin insulator strings for high voltage transmission lines
Types of Insulators[edit]
These are the common classes of insulator:
Pin type insulator - As the name suggests, the pin type insulator is mounted on a pin on the
cross-arm on the pole. There is a groove on the upper end of the insulator. The conductor
passes through this groove and is tied to the insulator with annealed wire of the same material
as the conductor. Pin type insulators are used for transmission and distribution of
communications, and electric power at voltages up to 33 kV. Beyond operating voltage of 33 kV,
the pin type insulators become too bulky and hence uneconomical.
Suspension insulator - For voltages greater than 33 kV, it is a usual practice to use
suspension type insulators, consisting of a number of glass or porcelain discs connected in
series by metal links in the form of a string. The conductor is suspended at the bottom end of
this string while the top end is secured to the cross-arm of the tower. The number of disc units
used depends on the voltage.
Strain insulator - A dead end or anchor pole or tower is used where a straight section of line
ends, or angles off in another direction. These poles must withstand the lateral (horizontal)
tension of the long straight section of wire. In order to support this lateral load, strain insulators
are used. For low voltage lines (less than 11 kV), shackle insulators are used as strain
insulators. However, for high voltage transmission lines, strings of cap-and-pin (suspension)
insulators are used, attached to the crossarm in a horizontal direction. When the tension load in
lines is exceedingly high, such as at long river spans, two or more strings are used in parallel.
Shackle insulator - In early days, the shackle insulators were used as strain insulators. But
now a day, they are frequently used for low voltage distribution lines. Such insulators can be
used either in a horizontal position or in a vertical position. They can be directly fixed to the pole
with a bolt or to the cross arm.
Bushing - enables one or several conductors to pass through a partition such as a wall or a
tank, and insulates the conductors from it.[4]
Cut-out
construction, so that an overvoltage causes a puncture arc through the glass instead of a
flashover. The glass is heat-treated so it shatters, making the damaged unit visible. However the
mechanical strength of the unit is unchanged, so the insulator string stays together.
Standard disc insulator units are 25 centimetres (9.8 in) in diameter and 15 cm (6 in) long, can
support a load of 80-120 kN (18-27 klbf), have a dry flashover voltage of about 72 kV, and are rated
at an operating voltage of 10-12 kV.[5] However, the flashover voltage of a string is less than the sum
of its component discs, because the electric field is not distributed evenly across the string but is
strongest at the disc nearest to the conductor, which flashes over first. Metal grading rings are
sometimes added around the disc at the high voltage end, to reduce the electric field across that
disc and improve flashover voltage.
In very high voltage lines the insulator may be surrounded by corona rings.[6] These typically consist
of toruses of aluminium (most commonly) or copper tubing attached to the line. They are designed to
reduce the electric field at the point where the insulator is attached to the line, to prevent corona
discharge, which results in power losses.
Discs
(kV)
34.5
46
69
92
115
138
161
11
196
13
230
15
287
19
345
22
360
23
A recent photo of an open wire telegraph pole route with porcelain insulators.Quidenham, Norfolk, United Kingdom.
History[edit]
The first electrical systems to make use of insulators were telegraph lines; direct attachment of wires
to wooden poles was found to give very poor results, especially during damp weather.
The first glass insulators used in large quantities had an unthreaded pinhole. These pieces of glass
were positioned on a tapered wooden pin, vertically extending upwards from the pole's crossarm
(commonly only two insulators to a pole and maybe one on top of the pole itself). Natural contraction
and expansion of the wires tied to these "threadless insulators" resulted in insulators unseating from
their pins, requiring manual reseating.
Amongst the first to produce ceramic insulators were companies in the United Kingdom, with Stiff
and Doultonusing stoneware from the mid-1840s, Joseph Bourne (later renamed Denby) producing
them from around 1860 and Bullers from 1868. Utility patent number 48,906 was granted to Louis A.
Cauvet on 25 July 1865 for a process to produce insulators with a threaded pinhole: pin-type
insulators still have threaded pinholes.
The invention of suspension-type insulators made high-voltage power transmission possible. Pintype insulators were unsatisfactory over about 60,000 volts.[citation needed]
A large variety of telephone, telegraph and power insulators have been made; some people collect
them, both for their historic interest and for the aesthetic quality of many insulator designs and
finishes. One collectors organisation is the US National Insulator Association, which has over 9,000
members.[8]
Insulation of antennas