INTRODUCTION TO ELECTRICaL
ENGINEERING TECHNOLOGY
By
Eng. ALAMIGA GERALD JOB
Email: [email protected]
0706436277, 0761137824
Cables
• Electric cables are current-carrying wires which are
bonded, twisted, or braided together in a single
assembly.
• These wires are made from electrically conducting
materials that are secured with one or more insulation
layers.
• The entire setup is called a Cable Assembly. These cables
carry electrical signals and aid the generation,
transmission, and distribution of electric power.
Cable components
• A cable is composed of three major components:
• Conductors:these are the electricity transmitting
wires in a cable. These are made from high conducting
metals like Copper and Aluminum which have low
resistance and can be used for high voltage
applications
• Insulators: The conducting wires are set apart using
insulation materials to prevent any abnormalities in the
current flow path. Being bad conductors of electricity,
these prevent short circuits and unwanted current flow
paths. In earlier times, paper, cloth, or rubber were
used as insulating materials, however, these are now
replaced with different synthetic polymers based on
their application. Examples: Polyethylene, Butyl
Rubber, etc.
• Sheath: These wires protect the cable from
atmospheric conditions like high moisture in the air,
chemical reactions, or fire attacks. Commonly used
sheaths are made from polyvinyl chloride (PVC).
Single core cable
• Only a single conductor or wire is used inside a cable.
• Basically, it will simply consist of a single wire
insulated in an external coating layer.
• Because a single conductor is used, it can be used with
a large and thick diameter. So, it is said to be more
reliable, flexible, and durable
Multi core cable
• In a multi-core cable, as the name defines, multiple
conductors or wires are used inside a cable.
• Basically, it will simply consist of multiple wires
insulated in an external coating layer.
• Because multiple wires are used, there is a limit on its
thickness and diameter.
• Mostly, the generally used ones are two-core, three-
core, and four-core ones
Differences between single core
and multi core cables
• The first and foremost major difference is that in a
single-core cable, a single conductor wire is used while
in a multi-core cable, multiple conductor wires are
used.
• Single core cables are best suitable for domestic and
home applications; whereas multicore cables are best
suitable for industrial applications.
• Single core cables are less prone to high-stress areas
and temperature, as compared to multi-core cable
which is more resistant to high stress and temperature.
One more major difference is its structural strength. It is easy to pull a
single wire than a bunch of wires. This shows that the structural
strength of single-core cable is less than multicore cable.
Multicore cable is costlier than single-core cable.
• A single-core cable is much stronger, more durable, and has high
electrical conductivity than a multicore cable.
• As there is only a single conductor in a single core cable, there are
fewer chances of short circuits and electrical damage than in a
multicore cable.
• Single-core cables are much easier to transport, lay out, and install
than multicore cables.
• Multicore cables are less prone to mechanical stress than single-core
cables.
Flexible cord cables
• Flexible cables, or 'continuous-flex' cables, are
electrical cables specially designed to cope with the
tight bending radii and physical stress associated with
moving applications, such as inside cable carriers.
Flexible cable is intended for installations with moving
equipment, electric appliances and for building sites
Busbar
• A busbar is a rigid piece of copper or aluminum, bolted
or housed inside switchgear, panel boards, and busway
enclosures for local high-current power distribution.
• Assignment
• What are the differences between a busbar and electric
cable?
Types of Cables
• Shielded Cables:
• These are used in applications involving high
voltage transmission like in security systems
installed in public spaces.
• One or more insulated wires are embedded inside a
conducting layer.
• The shield is consists of woven braided strands of
Copper or Aluminium and conducting layer of a
polymer which is overall enclosed in a jacket.
• This arrangement removes frequency irregularities
and other external interferences in devices.
Coaxial cables
• These are a type of shielded cables used to transmit
television and radio signals.
• An inner conducting core is shielded by concentric
conducting layers.
• These are separated by insulating layers and the whole
setup is enclosed in a jacket.
Fiber optic Cables
• Optical data signals are transmitted using these cables.
• Light-based technology is used to carry information
between two points.
• Thin strands of glass or plastic form the basic
composition in these types of cables.
• Internet signals are predominantly transmitted using
this cable type.
Twisted pair cables
• This cable type is predominantly used in telephone
cables to resist external disturbances.
• Two or more insulated wires are twisted together and
colour-coded in this cable type
Power cable
• This type of cable is used in power cords and extension
cables owing to their flexible usage.
• These comprise of one or more electrical conductors
clasped with a sheath.
• Predominantly used in transmitting electrical power,
these cables can be used overhead and also can be
buried underground.
• Flexible power cables are used in portable devices,
mobile tools, and machinery.
Properties of good cables
• Listed below are some standard properties of cable
wires:
• Strength and Flexibility: Wires must have great
insulation against external influences and should be
easily installable. Eg: telephone lines, cameras, etc.
• Fire Retardant: Fire accidents and exhausts can
cause damage to the wires. A fire-resistant material
of wires minimizes damage in times of fire attacks.
• Long Life and Heat Resistance: Frequent
maintenance of wirings in public or private facilities
is not feasible. Wiring materials should hence be
capable of withstanding heat as per standards and
Non-toxic and Environment-Friendly: Based on the site
of installation, wiring materials must not contribute to
producing pollutants that can damage property and life.
Simple Usage: Complex circuits limit the application of
the wirings. Hence, for domestic and commercial uses, the
wirings are mostly comprehendible and outer insulation is
ensured for security reasons.
• Cost-Effective: Cables are the backbones of electrical
circuits. This makes it necessary to ensure they are
available at a fair price.
Cable Sheathing and Wires
• Non-metallic (or NM) 120-volt and 240-volt electrical
cables come in two main parts: the outer plastic
sheathing (or jacket) and the inner, color-coded wires.
• Cable Sheathing
The sheathing is a tough outer coat that binds the
inner wires together. The color of the sheathing
indicates the gauges (or thicknesses) of the wires
inside.
Cable sheath color codes
• White: White sheathing means that the inner wires are 14-gauge wires
intended for 15-amp service, used often for light circuits and some
receptacle circuits.
• Yellow: Yellow sheathing indicates that the wires are 12-gauge wires
intended for 20-amp service, typically used for ground-fault circuit
interrupter(GFCI), outlet circuits.
• Black: This is typically used for even larger devices that require 40 amps
to 60 amps, such as ranges, air handlers (with electric heating elements),
or to sub-feed a sub-panel
• Orange: Orange sheathing means that the wires are 10-gauge wires
intended for 30 amp service for larger devices like water heaters, air
conditioners, or dryers.
• Note: Printed numbers and words on the sheathing tell you the number
and the gauges of the wires within the sheathing.
Wire color codes
Direct current (DC) is used in cell phones, flashlights,
cars and solar panels. It can also be used for industrial
processes and to transmit large amounts of power from
remote locations.
Positive – red wire
Negative – black wire
• Ground – white or gray wire
AC power
AC Power
Alternating current (AC) is the power that comes out of
outlets in power homes and businesses.
Homes and offices: 120, 208 or 240 Volts
Phase 1 – Black wire
Phase 2 – Red wire
Phase 3 – Blue wire
Neutral – White wire
• Ground – Green, Green with a Yellow Stripe, or Bare Wire
• Industrial equipment: 277 or 480 Volts
• Phase 1 – Brown wire
• Phase 2 – Orange wire
• Phase 3 – Yellow wire
• Neutral – Gray wire
• Ground – Green, green with yellow stripe, or bare wire
Power distribution in small
buildings
• Small commercial or residential buildings have a very
simple power distribution system. The utility will own
the transformer, which will sit on a pad outside the
building or will be attached to a utility pole.
• The transformer reduces the voltage from 13.8kV down
to 120/240 or 120/208 volts and then passes the
electricity to a meter, which is owned by the utility and
keeps a record of power consumption
Electrical installation in small
buildings
• After leaving the meter, the power is transmitted into the building at
which point all wiring, panels, and devices are the property of the
building owner.
• Wires transfer the electricity from the meter to a panel board, which
is generally located in the basement or garage of a house. In small
commercial buildings, the panel may be located in a utility closet.
• The panel board will have a main service breaker and a series of
circuit breakers, which control the flow of power to various circuits
in the building.
• Each branch circuit will serve a device (some appliances require
heavy loads) or a number of devices like convenience outlets or
lights.
Current carrying capacity
• The current carrying capacity of an insulated conductor
or cable is the maximum current (number of ampheres)
that it can continuously carry without exceeding its
temperature rating. It is also known as ampacity.
• The formula for calculating current carrying
capacity is:
I = permissible current rating
∆Φ = Conductor temperature rise in (K)
R= Alternating current resistance per unit length of the conductor at
maximum operating temperature (Ω/m)
Wd = dielectric loss per unit length for the insulation surrounding the
conductor (W/m)
T1= Thermal resistance per unit length between one conductor and the
sheath (K m/W)
• T2 = thermal resistance per unit length of the bedding between sheath and
the armour (K m/W)
• T3 = thermal resistance per unit length of the external Sheath of the
cable (K m/W)
• T4 = thermal resistance per unit length between the cable surface
and the surrounding medium (K m/W)
• n = number of load-carrying conductors in the cable (conductors of
equal size and carrying the same load)
• λ1 = Ratio of losses in the metal sheath to total losses in all
conductors in that cable
• λ2 = ratio of losses in the armouring to total losses in all conductors
in that cable.
Fault current
• The fault current is the electrical current which flows
through a circuit during an electrical fault condition. A
fault condition occurs when one or more electrical
conductors short to each other or to ground.
Earthing
• Earthing is a safety measure to prevent electric shock
or damage to equipment by providing a low resistance
path for electric current to flow to earth in the event of
a fault.
• For example if there is an electrical fault in an
appliance such as a cooker then the fault current flows
to earth through a protective conductor.
• A protective device such as a fuse or relay switch in the
consumer unit switches off the electric supply to the
cooker rendering it safe
Bonding
• Bonding is simply a term used for connecting together
all the metallic parts that are not supposed to be
carrying electric current to the same electrical
potential.
• This means that no electrical current can flow between
these parts. The primary reason for bonding is to
prevent a person getting a shock when they touch two
metal pieces of equipment at different potentials.
• By earthing these bonded elements it protects people
and equipment from harmful electrical faults.
Cable selection
• Cable size selection is based on four main factors:
• Current carrying capacity
• Voltage regulation
• Short circuit rating
• Maximum earth loop impedance
• The current carrying rating
It is determined by the conductor size and the thermal heating
of the cable. The cable spacing, application and insulation
materials are relevant to the dissipation of this heat.
• Voltage regulations
• Voltage regulation is not usually a problem with well-
designed electrical power systems but the voltage drop
incurred with excessively long cable runs needs to be
accounted for.
• Short circuit ratings
• Short circuit ratings are based on the maximum current
withstand capability of the cable in a short circuit condition.
The cable should be capable of withstanding this current
without thermal damage until the fault condition can be
switched to safety through a device like a circuit breaker of
fuse.
• Maximum earth loop impedance
• The earth loop impedance has to be low enough to alow suffcent current to
flow in the fault loop to cause the protectve device to operate and disconnect
the suppy within the specifed time when a faut of negligible impedance
occurs between an active and a protective earthing conductor. To
Types of joints
• Branch Joint: Branch joints can be used for outdoor,
indoor, underground or submerged cable jointing. It is
most suited to join cables in the range of 1 to 5 cores
that are polymeric, low voltage and non-shielded.
These can be either ‘T’ or the ‘Y’ type.
• Transition Joint:Transition joints are suited for all
voltage levels, construction and insulation materials of
cables. A one core cable can be safely connected to a
three core cable through this joint. They act as
important medium for connecting the old paper-
insulated cable technology with polymeric cables
• Straight Joints: This type proves useful when a need
is felt for extending cable pieces in any application.
They are suited for outdoor, indoor, underground and
submerged cable jointing.
• Pot End Joints: These types of joints are used in
situations which require secure termination of power
cables that are live and need to be abandoned
temporarily or on a permanent basis for some reason or
the other.
Cable termination
• The electrical cable termination is the physical and
electrical connection of a cable end that connects to
another cable, or to the terminal of the equipment.
• The cable terminations are often designed to enable
the physical and electrical interconnecting of two cable
ends, or a cable end and a terminal on the equipment.
• The methods used to terminate the cables vary
according to the type of cable, type of connector and
application.
• The common type of terminations are crimp
connection, soldered connection, compression
termination, and wire-wrapping connection, direct
connection, loop or eye connection.
Crimped termination
• Crimped terminations offer a robust and efficient
method for connecting conductors.
• This technique involves using a crimping tool to
compress a metal sleeve or ferrule around the
conductor and secure it tightly.
• The compression creates a gas-tight and electrically
conductive joint that resists pull-out forces, making it
suitable for applications requiring mechanical strength.
Compression termination
• Compression terminations, as the name suggests, rely
on compressive forces to establish secure connections.
• These terminations often utilize mechanical connectors
with bolts or setscrews to apply pressure on the
conductors. The pressure forces the conductive
materials together, creating an intimate and reliable
contact interface.
Direct connection
• Direct connection uses connector blocks or junction
blocks, ideal for solid and stranded connectors in
particular. The insulation must be adequately stripped
back to get the right connection but no more than this
to ensure bare conductor is not exposed outside the
terminal point.
• A connector pin is then screwed down onto the exposed
section of the conductor end. This is a robust type of
termination which allows for quick easy replacement of
the cable.
Soldered termination
• Soldered terminations represent a classic and reliable
method of creating electrical connections.
• This technique involves melting a filler metal, known as
solder, and applying it to the joint between two
conductors. As the solder cools and solidifies, it creates
a secure and durable bond, facilitating the smooth flow
of electricity.
Wire wrap termination
• Wire wrap terminations provide a unique and
reliable method for creating connections on a variety of
electronic components, such as integrated circuits and
connectors.
• This technique involves precisely wrapping a thin, solid
wire around a conductive pin or post, securing it in
place. The sharp edges of the wrapping tool penetrate
the wire’s insulation, establishing a gas-tight
connection.
Insulation Displacement
Terminations (IDT)
• Insulation Displacement Terminations
(IDTs) present a convenient and efficient way to
terminate conductors without the need for stripping
insulation. These terminations typically consist of a
connector with sharp blades or teeth that pierce the
insulation when the conductor is inserted, making
direct contact with the conductor’s core.
Course work
1. Briefly explain the various application of cables.
2. Give some of the Institution of Electrical Engineers
(IET) regulations in relation to wiring.
