Unit – II Electrical Wires and Underground Cables

Conductors – Definitions and Explanation

Conductors are materials that allow the flow of electric current due to their low electrical
resistance. Various types of conductors are used in electrical systems, each designed for
specific applications.

1. Wire

● Definition: A single strand or thin rod of metal (typically copper or aluminum) that
conducts electricity.
● Explanation:
o Wires are used in electrical circuits to carry current from one point to another.
o They are available in different thicknesses and insulation types depending on
voltage and current requirements.
● Application: Used in residential and industrial wiring, electronic circuits, and power
distribution.

2. Cable

● Definition: A bundle of multiple wires, often insulated separately and enclosed in an

outer protective sheath.
● Explanation:
o Cables provide enhanced mechanical strength and flexibility.
o They are classified based on voltage levels (low voltage, medium voltage, and
high voltage).
● Application: Used for power transmission, data communication, and underground
wiring.

3. Bus Bar

● Definition: A thick strip or bar made of copper or aluminum that distributes electrical
power within a system.
● Explanation:
o Bus bars reduce wiring complexity and improve power distribution efficiency.
o They are available in solid, hollow, or laminated forms.
● Application: Used in switchgear, power substations, distribution panels, and
industrial plants.
4. Stranded Conductor

● Definition: A conductor made of multiple small wire strands twisted together to form
a single wire.
● Explanation:
o Provides greater flexibility compared to solid conductors.
o Reduces skin effect at high frequencies, making them suitable for AC
applications.
● Application: Used in extension cords, automotive wiring, and portable power
tools.

5. Armoured Cable

● Definition: A cable that has a protective metallic layer (usually steel or aluminum) to
shield it from mechanical damage.
● Explanation:
o Armouring prevents accidental cuts, crushing, and environmental damage.
o It can be single-core or multi-core depending on the application.
● Application: Used in underground wiring, industrial power distribution, and
hazardous environments.

6. Flexible Cable

● Definition: A type of stranded conductor cable designed to withstand repeated

bending and movement.
● Explanation:
o Typically made of thin copper strands covered with flexible insulation.
o Ideal for portable electrical appliances.
● Application: Used in power cords, robotic arms, and electric vehicles.

7. Solid Conductor

● Definition: A single, continuous piece of metal wire that carries electricity.

● Explanation:
o Provides better conductivity than stranded wires due to a lack of air gaps.
o Less flexible but more durable in fixed installations.
● Application: Used in house wiring, electrical panels, and distribution boards.

8. PVC Wire
 ● Definition: A wire insulated with Polyvinyl Chloride (PVC) to protect it from
environmental damage.
● Explanation:
o PVC insulation is heat-resistant, flame-retardant, and waterproof.
o Available in single-core and multi-core variations.
● Application: Used in house wiring, industrial control panels, and electrical
appliances.

9. CTS Wire (Cab Tyre Sheath Wire)

● Definition: A type of insulated wire with a tough rubber or PVC sheath for added
durability.
● Explanation:
o Used for exposed wiring where mechanical protection is necessary.
o Common in older electrical installations.
● Application: Found in domestic wiring and temporary electrical setups.

10. LC Wire (Lead-Covered Wire)

● Definition: A wire covered with a lead sheath to provide protection against

mechanical damage and moisture.
● Explanation:
o Historically used before the development of modern PVC and XLPE cables.
o Lead sheathing makes it heavy and difficult to handle.
● Application: Previously used in underground power cables and industrial
installations.

11. FR (Fire Retardant) Wire

● Definition: A wire with insulation that resists ignition and prevents flame spread.
● Explanation:
o Composed of flame-resistant PVC or halogen-free materials.
o Essential for fire-prone areas to improve safety.
● Application: Used in commercial buildings, hospitals, and emergency exit
lighting.

12. Size of Wire According to BIS (Bureau of Indian Standards)

● The BIS (IS: 694) standard specifies wire sizes based on cross-sectional area (mm²).
● The size determines the current-carrying capacity of the wire.
 Wire Size Current Rating Common
(mm²) (Amps) Applications
1.0 mm² 11-13 A Lighting circuits
1.5 mm² 16 A Residential wiring
2.5 mm² 22-25 A Power sockets
4.0 mm² 28-32 A Air conditioners
6.0 mm² 36-40 A Industrial motors
High-power
10 mm² 50-55 A
appliances

Tools Used for Measuring Wire Size

To ensure the correct wire size for electrical applications, the following measuring
instruments are used:

1. Wire Gauge
o A calibrated tool used to determine the gauge (thickness) of the wire.
o It has slots of different sizes corresponding to standard wire gauges.
2. Micrometer
o Measures the diameter of the conductor with high accuracy.
o Useful for small and precision wires.
3. Vernier Caliper
o Measures the cross-sectional dimensions of solid and stranded wires.
o More versatile than a micrometer.
4. Multimeter
o Used to measure resistance and indirectly determine wire gauge.
o Helps verify wire continuity and insulation resistance.

Conclusion

Conductors are the backbone of any electrical system. Different types of wires and cables
serve specific purposes, such as flexibility, insulation strength, and environmental
protection. Proper selection of wire size based on BIS standards and using accurate
measuring tools ensures safe and efficient electrical installations.

Classification of Cables – A Brief Introduction

Cables are classified based on voltage level and construction type to suit different
applications. Below is a brief introduction to these classifications.

1. Classification Based on Voltage Level

a) Low-Tension (LT) Cables

 ● Definition: Cables designed to carry voltages up to 1 kV (1000V).
● Construction:
o Typically single-core or multi-core.
o Insulated with PVC, XLPE, or rubber.
● Applications:
o Residential and commercial wiring.
o Power distribution in buildings.
o Connection of small industrial motors.

b) High-Tension (HT) Cables

● Definition: Cables designed for voltage levels between 1 kV and 33 kV.

● Construction:
o Uses strong insulation layers like XLPE (Cross-Linked Polyethylene).
o Often armoured for mechanical protection.
● Applications:
o Industrial power distribution.
o High-power electric motors.
o Underground and overhead transmission.

c) Extra High-Tension (EHT) Cables

● Definition: Cables that operate at voltages above 33 kV up to 400 kV.

● Construction:
o Thick insulation (XLPE or oil-filled) to prevent breakdown at high voltages.
o Copper or aluminum conductors with multiple shielding layers.
● Applications:
o Power transmission over long distances.
o Used in substations and grid networks.

2. Classification Based on Construction Type

a) Solid Type Cables

● Definition: Cables with a solid, dry insulation system, free from fluid or gas filling.
● Construction:
o Insulation materials: PVC, XLPE, or rubber.
o No oil or gas filling, making them simpler and easier to install.
● Applications:
o Used in residential and commercial electrical installations.
o Low and medium voltage power distribution.
b) Oil-Filled Cables

● Definition: Cables filled with insulating oil to enhance heat dissipation and prevent electrical
breakdown.
● Construction:
o The conductor is surrounded by paper insulation and a metal sheath.
o Oil is continuously circulated to maintain insulation.
● Applications:
o Extra-high voltage (EHV) power transmission.
o Used in substations and long-distance transmission lines.

c) Gas-Filled Cables

● Definition: Cables filled with pressurized gas (such as SF₆ or nitrogen) to improve insulation.
● Construction:
o The conductor is insulated with a layer of paper or synthetic material.
o The gas prevents moisture absorption and enhances cooling.
● Applications:
o Used in underground power transmission and high-voltage applications.
o Suitable for submarine cables and critical electrical installations.

Comparison Table of Cables

Voltage
Classification Insulation Type Applications
Range

Low-Tension (LT) Cables Up to 1 kV PVC, XLPE House wiring, small motors

1 kV – 33 Industrial distribution, high-power

High-Tension (HT) Cables XLPE, Armoured
kV motors

Extra High-Tension (EHT) 33 kV – 400

XLPE, Oil-Filled Power transmission, substations
Cables kV

Solid Type Cables LT & HT PVC, XLPE General wiring, commercial use

Paper Substations, long-distance

Oil-Filled Cables HT & EHT
insulation, oil transmission

Gas (SF₆, Underground, high-voltage

Gas-Filled Cables HT & EHT
Nitrogen) transmission

Conclusion

Cables are classified based on voltage capacity and insulation type, ensuring safe and
efficient power distribution. Low-tension cables are common for household wiring, while
high and extra high-tension cables are used for industrial and power transmission
applications. Oil-filled and gas-filled cables provide enhanced insulation for high-voltage
systems.

Cable Insulation Materials – A Brief Introduction

Cable insulation materials are used to protect conductors from electrical leakage, mechanical
damage, and environmental factors like heat, moisture, and chemicals. Below are some
commonly used insulation materials in electrical cables.

1. Vulcanized Rubber (VIR)

● Definition:
Vulcanized India Rubber (VIR) is a natural or synthetic rubber that has undergone
vulcanization (treatment with sulfur) to enhance its strength, flexibility, and heat
resistance.
● Properties:
o High insulation resistance.
o Good mechanical strength and flexibility.
o Heat-resistant up to 85°C.
● Applications:
o Historically used in house wiring and industrial wiring.
o Replaced by PVC due to cost and aging limitations.

2. Polyvinyl Chloride (PVC)

● Definition:
A thermoplastic material used as a standard insulation in modern cables due to its
durability and fire resistance.
● Properties:
o Flame-retardant and self-extinguishing.
o Resistant to moisture, oil, and chemicals.
o Operating temperature range: -10°C to 70°C (Normal PVC), up to 105°C
(Heat-resistant PVC).
● Applications:
o Household wiring, industrial wiring, and flexible cables.
o Used in low and medium-voltage power cables.

3. Cross-Linked Polyethylene (XLPE)

● Definition:
A thermosetting polymer obtained by cross-linking polyethylene molecules,
improving thermal and electrical properties.
 ● Properties:
o Higher thermal stability than PVC (operates up to 90°C, withstands 250°C
in short circuits).
o Excellent mechanical strength and resistance to water and chemicals.
o High dielectric strength, making it ideal for high-voltage applications.
● Applications:
o Used in high-voltage (HV) and extra-high-voltage (EHV) cables.
o Found in industrial power distribution and underground cabling.

4. Impregnated Paper

● Definition:
A paper-based insulation material soaked in oil or synthetic resin to improve dielectric
properties and moisture resistance.
● Properties:
o High dielectric strength for high-voltage transmission.
o Good thermal stability but requires oil impregnation to prevent drying.
o Needs a metallic sheath (usually lead) for moisture protection.
● Applications:
o Historically used in underground high-voltage power cables.
o Replaced by XLPE due to maintenance issues.

Comparison Table of Cable Insulation Materials

Insulation Operating Common

Type Key Features
Material Temperature Applications
VIR High flexibility,
Thermosetti Older house wiring,
(Vulcanized Up to 85°C heat-resistant,
ng industrial wiring
Rubber) aging issues
-10°C to 70°C Fire-resistant, House wiring,
PVC (Polyvinyl Thermoplast
(105°C for HR moisture-proof, flexible cables,
Chloride) ic
PVC) low cost industrial cables
High thermal High-voltage (HV)
XLPE (Cross- Up to 90°C
Thermosetti stability, and extra-high-
Linked (Short circuit:
ng chemical and voltage (EHV)
Polyethylene) 250°C)
water-resistant power cables
High dielectric Underground
Impregnated
Paper-based Up to 70°C strength, requires power cables, HV
Paper
oil impregnation transmission lines

Conclusion

Different insulation materials are chosen based on voltage rating, thermal properties,
flexibility, and environmental conditions.
● PVC is widely used for household and industrial wiring due to its affordability.
● XLPE is preferred for high-voltage power transmission due to its excellent
thermal and dielectric properties.
● VIR and impregnated paper insulation were historically significant but are now
largely replaced by PVC and XLPE.