CABLES
A cable may be defined as a length of insulated conductor solid or stranded of two or more such
conductors each provided with its own insulation, the conductor material commonly used is copper or
‘alluminium.
Most cables are constructed in three parts i.e. the conductor which must be of suitable cross section to
carry the load current, the insulation and the outer sheath which may contain some means of providing
protection from mechanical damage . The insulation is determined by the voltage and the cross
sectional area is determined by the current.
CONDUCTORS
These are made of either copper or aluminium and may be stranded or solid. Stranded conductor is
more flexible and conductor sizes from 4.0mm2 to 25mm2 contain 7 x1.35mm diameter strands. A
conductor in electrical works means a material which will allow the free flow of electrical current along
it and which presents very little resistance to the current e.g. resistance of copper is 17.24µΩ and
aluminium 28.5µΩ. If a conductor’s length is increased the conductor resistance is increased. This can be
calculated using the formula R= ρl/a. where ρ is the resistivity of the conductor material , l is the length
and a is the cross sectional area of the conductor
INSULATION
The main function of the insulation is to confine the electricity o the conductor. Insulation must have a
high resistance
Type of insulation used is pvc, rubber, MI, etc.
INSULATION RESISTANCE
This is the resistance in ohms between the live parts of the installation and the earth measured through
the insulation of the conductors, etc. The insulation resistance can be calculated using the formula R’
=ρ’l’/a’ where ρ is the resistivity of the insulating material, “a” is the thickness of the insulating material
and L’is the length of the wire. The longer the length of the wire the less the insulation resistance.
Generally the insulation resistance is measured than calculated.
TYPES OF CABLES
1) PVC insulated PVC sheathed cables—these are used in domestic and commercial installations.
They may be clipped on surfaces direct or sunk in plaster or installed in conduit and trunking.
The conductors are covered with a colour coded PVC insulation and then contained singly or
with others in a PVC outer sheath.
2) PVC steel wire armored cable--- These cables are used for wiring under ground between
Buildings for the main supplies to dwellings, rising sub mains and industrial installations. They
are used where mechanical protection of cable conductors is needed (protection against
vibration, impact and collision). The galvanized armour may be used as the circuit protective
conductor (cpc). The cable is terminated using cable glands.
3) MI cables (MIMC, MICC) ---- The cable has seamless copper sheath which makes it water tight,
fire proof and corrosion resistant. It is mostly used for hazardous and high temperature
installations of up to 250oC such as oil refineries, chemical works, boilers and furnaces. The copper
conductors are embedded in a white powder magnesium oxide which is non combustible, non
ageing and is hygroscopic i.e. absorbs moisture from the surrounding air. It has a long life
expectancy. It can operate indefinitely at 250oC although specification indicate 70oC to 105O C
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4) Flat twin ad earth cables ---- These are used as weather deck cable to supply power to
consumers from over head lines in domestic installation. These cables can also be used to supply
power to socket outlets and lighting circuits.
5) Rubber insulated cables –They are used in areas where temperatures may not exceed 85 o C.
They are used for heavy duty situations.
6) Silicon rubber insulated cables--- They are used where temperatures may not exceed 150 0C.
They can be used for fire alarm circuits, security and emergency lighting circuits or where there
is need for circuit to function in fire situations.
7) Polychlorophrene sheathed cables--- These are mostly used in farming installations within areas
which may contain corrosive elements.
8) Overhead cables- aluminium uninsulated cables are suspended on pylons .The cables are
stranded conductors formed around a core of steel stranded conductors so as to provide tensile
strength.
9) Cross linked cable (EXPLE) mostly used for high voltage reticulation as an underground cable.
can operate continuously at 90oc
10) PILC (paper insulated lead ---- It is used for medium and high voltage supply.
DIVERSITY FACTOR
Diversity factor is an important factor in the designing of an installation and its final cost. It may be
used to determine the maximum load an installation. It is applied to mains and sub mains cables
and associated switch gears so as to reduce:-
(a) The cross sectional area of the cable
(b) The capacity of the control switch gear.
The factor is based upon the assumption that the whole of the connected loads of an installation will not
be switched on at the same time.
As it is rare to have al heating elements working at the same time, diversity is applied to calculate the
circuit cable size as follows:
The first 10A of the total rated current of the connected cooking appliance, plus 30% of the remainder of
the total rated current, plus 5A.if there is a socket outlet on the cooker control unit.
E.g. The full load rating of a 240V cooker is 12KW. Calculate using diversity the assumed current
demand. The cooker control unit has a socket outlet.
Solution: actual full load demand P = V x l, I = P/V = 12 000W/ 240V = 50A
Assumed demand using diversity : l =10 +30( 50- 10)/100 +5
I =10 +(30 x 40)/100 +5, I =(10 +12 + 5)A I =27A
From the above instead of selecting a cable rated at 50 A ,a cable rated at 27A is used and the circuit
protective device has also been reduced to 30A
VOLTAGE DROP
This can be defined as the voltage loses experienced in a cable due to the length of the cable and the
rated current.
Cables experience different types of voltage drops. The recommended voltage drop should not exceed
4% of the normal voltage of the supply. Different voltage drops are experienced on different types of
cables and conductors when certain values of current are being carried. The voltage drop is thus tabled
in mV per ampere per meter. The length is a factor that may result in high voltage drop. I.e. voltage drop
varies with length. Voltage drop depends on the cross sectional area, the ambient temperature, i.e. the
higher the temperature, the higher the resistance and then the higher the I 2R loses.
The total voltage drop in a cable is then the product of:
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mV x design current x length of run in meters
1000
When given that the length of a conductor is 10m and the current passing through it is 12 amps and the
mV is 42 then the Voltage Drop will be
Vd = 42 x 12 x10) /1000. =504/100 = 5, 04 Volts. mV is the millivolts drop per meter
% voltage drop will then be 504/240 = 2.1% hence the voltage drop is less than 4% over a distance of
10meters.
AMBIENT TEMPERATURE
This is the air temperature or other medium in which the cable or the equipment is to be used.
The maximum demand of the cable
This is the power that the cable may carry without damaging it.
CABLE SELECTION FEATURES
Cables are designed to be used in different environments and to carry certain currents which the cables
can sustain without being damaged. The following may be considered when selecting some cables for
use:
a) the design current (Id) and rating of the protective device(s)
b) control of the voltage drop (not to exceed 4% of supply voltage). Vd may be found using the
formula : Vd= factor x design current x length of cable
c) circuit disconnection and shock protection
d) thermal constraints (and ambient temperature correction factor where necessary)
e) the place where the cable is to be used
f) cable rating (lt). this can be determined as follows: lt =current rating of the protective device/Any
applicable correction factor
g)
PROCEDURE FOR SELECTING A CABLE
1) choose the type of cable most suitable for the particular installation
2) determine the most suitable size of the cable as follows:
a) calculate the design current of the circuit LB
b) Choose the type of current rating, IN of the circuit protective device
c) Divide IN by the ambient temperature correction factor if necessary
d) Further divide by the grouping correction factor if necessary
Divide again by the thermal insulation correction factor if necessary (0.75 when in contact with thermal
insulation on one side and 0,5 when surrounded by thermal insulation)
The result will be the minimum current rating of the cable lZ
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CAUSES OF CABLE FAULTS
1) mechanical damage- this occur when the cable is insufficiently protected or mishandled at the
time of installation, poor workmanship of cable jointing
2) Dampness: When the level of water is near to the cable laid on the ground, dampness of paper
insulation in the cable may be experienced which may damage the sheath.
3) Mechanical puncturing: this occurs when the cable is damaged during excavation works using
picks, crowbars etc.
4) Overloading or temperature rise: Rise in temperature will affect the insulation of the cable.
5) Chemical action: due to chemicals in the soil corrosion on the cable may occur
TESTING FOR FAULTY CABLES
1) Murray loop test- this carried out so as to locate the position of a fault in a cable without digging
the whole route trench. It is based upon the Wheatstone bridge principle.
2) Phase to phase fault test
3) Fall of potential test
4) Capacity test
PROCEDURE FOR MAKING A RESIN JOINT
(1) Make sure size of the kit you are going fits on the cable to be joined.
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(2) Read the instruction manual and understand before cable preparation.
(3) Remove the Outer PVC sheath on both cables as per instruction manual.
(4) Proceed and terminate the armour wires on both cables.
(5) Mark the inner PVC sheath and remove it without damaging the inner cores.
(6) identify your conductors, insert your spreaders and mark the centre for the ferrule (connector)
(7) Cut the cores and remove the insulation as per Instruction manual.
(8) Push the ends of the conductors to be joined in the connector (ferrule) and press connector with
crimping tool. Apply insulation tape on the joints
(Note if the connector insulation is heat shrink slide it in BEFORE crimping. If the insulation is tapping
type proceed with crimping.)
(9) After applying the insulation continue your armour wires (earth) with the earth braid and mechanical
connectors provided.
(10). Cut the ends of the canister provided and clip it on centrally over the joint.
(11) Seal the ends with insulation tape thoroughly to prevent the compound from escaping.
(12) Thoroughly mix the compound as per instruction and pour the contents in the canister.
(13) The joint is now complete.
You can test and energize immediately.
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