HASETRI 1

CABLE
An electric cable consists of the following parts:

a) Metal Conductor carrying the electric current at high voltage mostly

copper or aluminium
b) Insulation - a bad conductor which prevents the direct contact or
unsafe proximity between the conductor and other object. Mostly
vulcanised Rubber or plastics like PVC, PE, XLPE or even paper.
c) Sheathing - A protective covering for the insulation to prevent the
insulation being damaged by outside influences.
It may consist of vulcanized rubber, plastics, on even metals like lead,
aluminium or steel armouring.

HASETRI 2
 MANUFACTURE
Formerly manufactured by laminating or lapping process, now made by
extrusion process either batch or continuous
Conductor

Rubber Compound Cross Extruder Cable taken in a pan

Tested and repaired Vulcanized in

steam autoclave
Rubber sheathing compound

Cable taken in a
Cross Extruder pan
Vulcanized in steam

CV Cure : Rubber coated cable from cross extruder enters into long tube
20-30 mtr long and exposed to high pressure steam 12-15 atm.
HASETRI 3
 COMPOUNDING – WIRE AND CABLES
The compounds used in wire and cable mnanufactured are classffied in
three main groups:

Insulation, integral insulation and jackets (sheathing)

• The insulation are compounds exhibiting superior electrical
properties. They require physical protection of a jacket.
• The integral insulation possesses similar electrical properties to the
insulation but is formulated to exhibit many of the protective
physical properties of the jacketing compounds.
• Jackets possesses properties necessary to protect underlying
insulation from the deteriorating effect of handling, wear and service
environment.

HASETRI 4
 INSULATION COMPOUNDS
Must have the followings:
i) High electrical insulation resistance
ii) High dielectric strength, low dielectric const.
iii) Low power factor
iv) High resistance to oxygen and heat
v) Ozone resistance (For high voltage cables - silent discharge can
occur around the cable).

NR : Used for low voltage cables like domestic cables for insulation and
sheathing, service temperature upto 75oC.
SBR-Special grade with low ash content, may sometime used. Service
temperature upto 90oC, (BS specification do not allow its use for
insulation.)
HASETRI 5
 INSULATION COMPOUNDS
Polybutadiene Rubber (BR) :
Though it possesses better insulation properties than NR or SBR it is
rarely used in insulation compounds because of its low T.S. in mineral
filler loaded compounds. It is used in Sheathing compounds for its Cold
Flex resistance, abrasion resistance and water resistance.
Butyl (IIR)
Used for low as well as high voltage cables because of its good
electrical insulation properties and ozone resistance.
EPDM
Excellent electrical insulation properties and ozone resistance. Used for
both insulation and Sheathing for low and medium voltage cables with
service temperature upto 100oC.

HASETRI 6
 INSULATION COMPOUNDS
Polychrloroprene Rubber (CR)
Electrical insulation properties are quite sufficient for low voltage
insulation applications. Due to cost its application restricted to
sheathing where flame resistance, ozone resistance and oil resistance
are important eg. As sheathing for cables in mines, trailing cables. Etc.
Nitrile Rubber (NBR)
Electrical insulation resistance of these rubber is low. Usage restricted
to sheathing. NBR/PVC (70:30) are used for coloured sheathing
compounds for cables for outdoor use.
Varying the ACN between 28-38% does not significantly affect the
dielectric properties.

HASETRI 7
 INSULATION COMPOUNDS
EVA
Suitable for insulation and sheathing compounds upto service
temperature of 120oC. Because of their high temperature resistance use
for cables for domestic appliances e.g. electric iron, heating ovens etc.
Silicone Rubber
Excellent electrical insulation properties, heat and ozone resistance.
Other rubber on burning leave a residue of carbon which is conducting
and the electrical insulation properties fail, while in Silicone rubber
cables, the burnt residue is silica which is still insulating. Use for marine
cable, aircraft cables, ignition cables of vehicles and all high
temperature cables (upto 180oC).

HASETRI 8
 HIGH VOLTAGE CABLES
Ozone resistance
Ozone generation due to carona discharge

IIR
Normal high voltage cable insulation
EPM/EPDM
Ignition cable.
Silicone rubber
NR
IR Low voltage insulation 440V (Max 1 KV)
SBR

CSM CM
Very low voltage cables - 250 V
EVA
CR Very low voltage, Oil resistance cable
NBR Conducting compounds.

HASETRI 9
Ohm’s Law
The Current flowing through any conductor is directly proportional to the
voltage across it and inversely proprotional to the property of the
element called resistance. I = E/R
I = current in amp, E = Potential in volts, R = Resistance in ohms
Resistivity-Conductivity
The resistivity or specific resistance of a material is the electrical
resistance offered by an element of the material having unit length and
unit cross sectional area.
The reciprocal of resistance is conductance. C (mhos) = 1/R,
The resistance of a segment of the path is proportional to its length,
inversely proportional to its cross sectional area and proportional to a
specific property of the material of the segment called resistivity (p).
R = pL/A , p (ohm-cm) = RA/L
Reciprocal of resistivity is conductivity (mho-cm)

HASETRI 10
Dielectric Strength
The dielectric strength of a material is the electrical stress required to
puncture a sample of known thickness. It is expressed in terms of
volts/mil thickness
The dielectric strength of a rubber compound is involved whenever the
compound is used as an insulating material. It should be far below the
breakdown point.
Dielectric constant/Specific inductive Capacity (SIC)
Dielectric constant is a specific property of an insulating material that is
both defined and measured by the ratio of the electrical capacity of a
condenser having that material as the dielectric to the capacity of the
same condenser having air as the dielectric. The dielectric constant of
a vacuum is unity. Dry air has a constant slightly higher; but for most
practical purposes it is considered as unity.
Two parallel plates of conducting material separated by an insulating
material, called the dielectric, constitutes an electric condenser.

HASETRI 11
These two plates may be electrically charged by connecting them to a
source of direct current potential. The amount of electrical energy that
can be stored in this manner is called the capacitance of the condenser,
and is a function of the voltage, area of the plates, thickness of the
dielectric and the characteristic property of the dielectric material called
dielectric constant. The unit of capacitance is farad.

The capacitance of the condenser in terms of physical dimensions and

the dielectric constant of the insulation is given by the equation:
C = 0.0885KA/t
C = Capacitance in micro farads
K = Dielectric constant of the insulation
A = Area of the plates in square centimeters
t = Thickness of the insulation in centimeters.
The dielectric constant of a rubber compound is increased considerably
by small amount of absorbed water. Hence, wire insulation for
communication generally must have dilectric constant as stable as
possible in presence of water or moisture.
HASETRI 12
 POLYMER
Volume Dielectric Dielectric Dissipation
resistivity Strength Constant factor (tan)
(P) mho/cm KV/cm X10 -3

IIR 1016 220 2.6 0.85

EPM 1016 250 2.6 0.85
Si 1016 220 3.2 12
NR 1016 210 3 17
IR 1016 175 3 5.5
SBR 1015 260 3.1 19
CSM 1014 180 6.5 24
EVA 1013 250 4 36
CR 1011 225 6.2 185
NBR 109 165 20 > 1000
Requirements for electrical Insulation
1) Good volume resistivity 3) Low die electric constant
2) Good di-electric strength 4)Low Power Factor

HASETRI 13
 FILLERS
• Carbon black reduce the electrical insulation resistance.
• In insulation compounds only white mineral fillers are used.
• In white or coloured sheathing compounds Precipitated Silica can be
used.

Effect of Fillers
NR 100, ZnO S, St.Acid 1, MBT+DPG 1.5, S = 1.5
Pbw Volume Resistivity
(ohm.cmx10-15)
C-Black 50 (ISAF 1.25x103, HAF 4.5 x 104)
ZnO 240 2.74
Calcined Clay 110 4.3
T102 155 4.2
Ppt. CaCo3 115 2.58
Whiting 110 1.44
T102 155 1.16
Lithophone 185 1.50
Talc 115 7.20
China Clay 100 0.57
HASETRI 14
 ACCELERATORS
Effect of Accelerators
NR 100, ZnO .25, Act. CaCo3 36, Talc 36, P.wax 2, St.Acid 0.3, A/o 1,
Acc 1.3, S 1.5
Cure Time Volume Resistivity @ 20oC
(ohm.cmx10-15)
DPG 90 0.4
MBT 35 11.4
ZMBT 35 24.3
CBS 35 0.2
TMTM 12 44
ZDEC 4 44
TMTD 3 14.4

Basic accelerators like DPG, DOTG are not preferred in insulation compound.

HASETRI 15
 PVC V/S. RUBBER
• PVC gives fast and cheap production - no vulcanization is necessary
and copper conductor does not require tinning. PVC insulation is
resistant to ozone and many oils and solvents. The dielectric
strength is similar to that of rubber, insulation resistance is lower.
Satisfactory at 250-660 Volts.
• Rubber insulated cables are suitable for use at higher temperature
upto 85oC (IIR).
• Silicone Rubber upto 150oC without serious diminution of electrical
properties.
• PVC Insulation upto 70oC.
• Silicone Rubber insulation is only suitable for higher temperature
than NR or SBR even if destroyed by ignition, the remaining ash is
sufficiently non-conducting for emergency use.
• CR protective sheathing is suitable for trailing cable.
HASETRI 16
 NR INSULATION (UPTO 250 V)
PLC 100 RMA1 100 Ts, Mpa - 12.2
Act. Whiting 40 Activated whiting 50 M-300, Mpa - 8.2
Calcined clay 40 Talc 50 EB% - 420
Talcum 25 Calcined clay 50 IRHD - 68
ZnO 25 Par. Wax 2
Paraffnic oil 3 TMQ 1 Ageing for 120 hr @ 80oC
St.Acid 0.75 MBTS 1 TS, Mpa - 12.2
ZMBT 1.5 TMTD 1 EB% - 390
TMTD 1.5 Sulphur 0.5 IRHD - 73
Sulphur 0.8 St.Acid 0.5
TMQ 2.0 ZnO 20

Cure at 130oC - 15’

Cure at 140oC - 15’`

HASETRI 17
 GENERAL PURPOSE IIR EPDM INSULATION (HEAT
INSULATION FOR HEAT RESISTANCE CABLE)
RESISTING CABLES (MEETING
IS 6380 SPEC - FOR GP1 & GP2)
EPDM 100 CV Cure @ 200oC in
Butyl rubber 100 Steam, 60Sec
Calcined Clay 80 ZnO 5 TS,MPA 7.0
Par. Wax 5
Vaseline 5 Polyethylene 10 EB% 360
MT Black (N990) 5 Wax
Aerosil 5 TMQ 5 SHA 69
ZnO 5
p-quinone dioxime 4 Paraffinic Oil 30 Air Bomb Ageing 42
(50%)
hrs/127oC 5.5 atoms
MBTS 4
Calcined clay 150 TS, % +6
Red Lead (Pb3O4) 6
Sulphur 0.15 change
Vinyl Silane 1 EB%, % -8
Cure @ 164 for 10’ change
TS. Mpa 5.9 DCP (40% 5
EB % 660
TAC 1.5
HASETRI 18
 STRIPPABLE SEMI-CONDUCTIVE LAYER FOR XLPE CABLE
EVA 88
NBR 12
Processing aid 3
Zn Stearate 1
TMQ 1
C-Black N472 (XCF) 40
C-Black N220 (ISAF) 40
MC Wax 10
TAC 6
DCP 40% 2
CV Cure @ 200oC 10’
TS Mpa 9.6
EB% 320
IRHD 84
Vol. Resistivity, Ohm-cm. 5.5x102

NBR & MC Wax give easy peeling effect from the XLPE insulations

HASETRI 19
 HALOGEN FREE, FLAME HEAVY DUTY SHEATHING FOR HEAT
RESISTANT SHEATHING RESISTING CABLE BASED ON NBR/PVC
NBR/PVC 100 ZnO 5
EVA 98
St. Acid 0.8 S 0.3
Processing aid 3
Antiozonant DDA 1 FEF 10 TMTD 2.5
Zinc Stearate 1
Aluminium Hydroxide 160 Ppt Silica 30 MBTS 1
Silane A 72 (Vinyl 1 Quartz Flower 40 CV Cure @ 200oC, 80’
Silane Coupling agent)
Estr Plasticizer 20 TS, MPa 16.3
Zinc borate 10
TAC 3 TMQ 1 EB, % 780
DCP 40% 6 A/O MB 1 M-300, Mpa 5.5
Cure in steam @
200oC, 60’ 6PPD 1 Tear, N/mm 12
TS. Mpa 13.4 Sb2O3 5
EB % 140
1 RHD 79 P.Wax 3

HASETRI 20
CR SHEATHING FOR HEAT GENERAL PURPOSE, OIL RESISTANCE
RESISTANT CABLE & FLAME RESISTANCE SHEATH

CR 100 CR 100 ETU 1

MgO 4 Lt. MgO 4 MBTS 0.5
St.Acid 1 St.Acid 1
C-Black N550 30
Calcined Clay 80 FEF Black (N- 40 CV cure @
Ester Plasticizer 12 550) 200oC in
P.wax 5 steam, 60’
ZnO 5 Soft Clay 110
ETU 1
MBTS 0.5 Ester 10 TS, Mpa 11.2
CV Cure @ 200oC in Plasticizer
steam – 60’ Naph. Min. oil 10 EB, % 410
Ts, % Mpa 14.3 Antioxidant 2 Tear N/mm 5.5
EB, % 460 P.wax 5
Air bom, 42 WB/127oC
Ts, % Change -44 ZnO 5
EB, % change -46
HASETRI 21
 SPECIAL PURPOSE CABLE
Cable Insulation Sheathing
Application
1. Ship wiring EPDM/IIR EVA, CM, CR, NBR/PVC (Heat flame
& Ageing)
2. Mining EPDM/IIR, CM CR (Flame & Mechanical)
3. Railway NR/CR CR (Mechanical, weather &
Signalling Moisture)
4. Loco & rolling EPDM/IIR EPDM, CM (Ageing, Mechanical &
stock wiring Weather)
5. Naval Ship Silicone rubber , EPDM, CM (Heat, Ageing, Flame &
wiring EPDM, CM, IIR fir)
6. Welding NR NR/CR (Mechanical)
electrode leads
7. X-Ray tube EPDM EPDM, CM, CR (Electrical)
supply
8. Ignition Silicone rubber, EVA, CM (Oil, Heat & Electrical)
CM, EPDM

HASETRI 22
 CURING SYSTEM

NR/SBR High resistance to Antioxidant: Vulkanox HS In Insulation

(Insulation heat and ageing Vulkanox MB
compound) required. Semi EV Antiozonant: (Sheathing compound)
system or thiuram
cure in addition Black Vulkanox 4010 NA
that curing Compound:
characteristics. Coloured Antiozonant AFD
Pan Cure C.V.Cure Compound OSW 110
Vulkacit 2 M
Vulcacit F + Thiuram 2.25
For IIR Compound:
Sulphur
Thiuram MS Merkaptok 0.5-1 Cure System P-quinonedioxime, Red Lead
Thiuram/C S = 0.4-0.8 Vulkacit DM/C
For Buna AP:
Best ozone resistance
Per-oxide cure system
Baypren :
Vulkacit NPV/C ZnO+MgO
Vulkanox OCD/DDA: AFD

HASETRI 23
 SILICONE RUBBER INSULATION
Silopren HV/22160 U 100
Silopren Cross linking agent CL50 1.5
Cure at 120oC for 10’
TS, MPa
8.5
EB, % 450
Ageing 10 days/200oC
TS, Mpa
5.2
EB, % 340
Suitable for pressure less vulcanization.
For Vulcanisation under pressure
HASETRI
DCP (95%) = 0.6 - 0.8 in place of CL-50 - 10’ @ 170oC. 24