CHAPTER ONE

ELECTRICAL ENGINEERING WIRING AND

INSTALLATION DESIGN

INTRODUCTION

Every electrical installation be it residential, commercial or industrial buildings is

preceded by a careful plan or design. Designs for building installations involves various
calculations based on several factors which includes; type of building, purpose of
building, physical building parameters. There are several Standards and regulatory
bodies such as the IEE (Institute of Electrical Engineers), BSS (British Standard
Specification), GWC (Ghana Wiring Code), IES (Illuminating Engineering Society)
and many more that regulate the electrical service design. Electrical design is the
process that involves planning, creating, testing, and installation of electrical equipment
in accordance with the approved regulations, the design includes lighting layout, power
layout, power distribution layout, fire prevention layout systems, public address system
and close circuit TV layout and voice and data communications layout design. Some of
the important topics covered in this course are: Lighting layout design, Power layout
design, Cables sizing, Protection system design. Electricity exists in a form that is
useful to exploit, however, it will also be important to install electricity as efficiently as
possible, and design of the power distribution system should be convenient so as to
reduce power losses and voltage drops. Every building or part of building apartment
illumination level varies in terms of illumination level, number of socket outlets,
accessories and electrical appliance. The illumination level of each portion is different
depending on the purpose it is really meant for. In electrical wiring design, many factors
are put into consideration. Some of these include safety, durability, flexibility of
installation, and cost of installation.

ELECTRICAL PRODUCT AND WORK STANDARDS

The generation, transmission, and distribution of electrical power are now deregulated,
but many rules, regulations, and standards still apply to the manufacture of electrical
equipment, the job site, and the installation of electrical systems. Many of these
standards are focused on safety issues, such as the elimination or avoidance of hazards
in working with or using electricity.
The installation of any inferior wiring devices or equipment, substandard workmanship,
or inadequate test and maintenance procedures could be the cause of fires or explosions
and result in the creation of electric shock hazards. There is a need for standards that,
when adopted, will serve as a basis for proper inspection and supervision. There are
regulatory standards, national consensus standards, product standards, installation
standards, and international standards.
The consensus standards include the National Electrical Code (NEC), the National
Electrical Safety Code (NESC), National Fire Protection Association (NFPA) 70B and
70E, and other NFPA standards, as well as American National Standards Institute
(ANSI) and the Institute of Electrical and Electronic Engineers (IEEE) standards.
Interested persons with requisite education, training, and background experience
volunteer their time and expertise to develop these standards. Some might be employees
of electrical product manufacturers, and others might be consultants or engineering
professors.
Some standards were developed specifically for electrical applications. These include
the National Electrical Code (NEC) (officially NFPA 70) and the National Electrical
Installation Standards (NEIS). In addition, the National Electrical Manufacturers
Association (NEMA) standards cover equipment design and construction, while the
Underwriters Laboratories Inc. (UL) standards cover safety provisions in the
manufacture of electrical devices, products, and accessories.
The National Fire Protection Association (NFPA), publisher of both the NEC and NESC,
has also developed standards related to electrical work including:

The NFPA has also developed standards for fire prevention, installation of sprinklers,
stacking materials, and a standard building code. The following organizations have also
developed standards that have a bearing on electrical work:

Individuals or organizations with a professional or business interest in these standards

can join these organizations to help support them and gain access to their newsletters
so that they can stay informed on any changes within the standards.
It is the responsibility of all electrical contractors, electricians, and installers in the field
to know which standards apply to any project taking place within any given location or
job site. It is also important to remember that not all standards that might apply to every
job site or location actually apply. A hazard assessment by the project supervisor or
licensed electrician must determine which standards apply at each workplace and that
they are followed.
Designers, engineers, contractors, electricians, or equipment stallers and all other
persons whose work is governed by one or more standards should be familiar with and
know how to apply the rules found in all of the applicable standards.

DESIGNING AN ELECTRICAL INSTALLATION

The designer of an electrical installation must ensure that the design meets the
requirements of the IEE Wiring Regulations for electrical installations and any other
regulations which may be relevant to a particular installation. The designer may be a
professional technician or engineer whose only job is to design electrical installations
for a large contracting firm. In a smaller firm, the designer may also be the electrician
who will carry out the installation to the customer’s requirements. The designer of any
electrical installation is the person who interprets the electrical requirements of the
customer within the regulations, identifies the appropriate types of installation, the most
suitable methods of protection and control and the size of cables to be used. A large
electrical installation may require many meetings with the customer and his
professional representatives in order to identify a specification of what is required. The
designer can then identify the general characteristics of the electrical installation and
its compatibility with other services and equipment. The protection and safety of the
installation, and of those who will use it, must be considered. An assessment of the
frequency and quality of the maintenance to be expected will give an indication of the
type of installation which is most appropriate. The size and quantity of all the materials,
cables, control equipment and accessories can then be determined. This is called a ‘bill
of quantities’. It is common practice to ask a number of electrical contractors to tender
or submit a price for work specified by the bill of quantities. The contractor must cost
all the materials, assess the labour cost required to install the materials and add on profit
and overhead costs in order to arrive at a final estimate for the work. The contractor
tendering the lowest cost is usually, but not always, awarded the contract. To complete
the contract in the specified time the electrical contractor must use the management
skills required by any business to ensure that men and materials are on site as and when
they are required. If alterations or modifications are made to the electrical installation
as the work proceeds which are outside the original specification, then a variation order
must be issued so that the electrical contractor can be paid for the additional work. The
specification for the chosen wiring system will be largely determined by the building
construction and the activities to be carried out in the completed building. An industrial
building, for example, will require an electrical installation which incorporates
flexibility and mechanical protection. This can be achieved by a conduit, tray or
trunking installation. In a block of purpose-built flats, all the electrical connections must
be accessible from one flat without intruding upon the surrounding flats. A loop-in
conduit system, in which the only connections are at the light switch and outlet positions,
would meet this requirement. For a domestic electrical installation an appropriate
lighting scheme and multiple socket outlets for the connection of domestic appliances,
all at a reasonable cost, are important factors which can usually be met by a PVC
insulated and sheathed wiring system. The final choice of a wiring system must rest
with those designing the installation and those ordering the work, but whatever system
is employed, good workmanship is essential for compliance with the regulations. The
necessary skills can be acquired by an electrical trainee who has the correct attitude and
dedication to his craft.

ON-SITE COMMUNICATIONS
Good communication is about transferring information from one person to another.
Electricians and other professionals in the construction trades communicate with each
other and the general public by means of drawings, sketches and symbols, in addition
to what we say and do.

Drawings And Diagrams

Many different types of electrical drawing and diagram can be identified: layout,
schematic, block, wiring and circuit diagrams. The type of diagram to be used in any
particular application is the one which most clearly communicates the desired
information. Now adays, many appropriate computer-aided design (CAD) software are
used in electrical drawings and diagrams. Some CAD programs are capable of
producing the proper forms and making the necessary calculations to produce material
lists and cost estimates based on the number and type of symbols placed on the drawing.
Some of the benefits of CAD electrical drawing are as follows:
1. It eliminates the tedious tasks of lettering and drawing uniform lines and symbols.
2. It saves time in the preparation of all types of electrical drawings.
3. It permits the transfer of large sections of drawings prepared originally for one
project to be reused on a different project.
4. It provides databases of “families” of master digitized drawings that can be
modified for reuse on other projects or become de facto templates for new drawings.
5. It makes rapid corrections of mistakes or oversights that have been discovered.
6. It makes rapid changes on completed and approved drawings to reflect field
changes such as the substitution of different equipment.
7. It reproduces corrected drawings rapidly for use in the field, eliminating concern
that work might be done against obsolete drawings, necessitating costly rework.
8. It permits work to be done on a specific drawing by two or more persons at separate
workstations within the same office or miles apart, because data can be transmitted
over networks to a master workstation. This permits two or more persons to
participate in the design work in real time.
9. It reduces the space required to store completed drawings, because digital data can
be stored on a centralized server, computer disks, or CD-ROMs.
10. It accelerates the distribution of drawings to all concerned parties: owners,
contractors, equipment manufacturers, and suppliers. The drawing data can be
transmitted over computer networks and printed out by the recipient, saving time
and delivery cost.
11. It provides a secure backup for all master drawings files if the drafting offices are
destroyed by fire or flood, saving the time and expense needed to reconstruct the
drawings from alternative sources.

Examples of the CAD software are AutoCAD, Dialux, ETAP, ReLux, Edraw,
Constructor, Microsoft Office Visio.

Layout Drawings
These are scale drawings based upon the architect’s site plan of the building and show
the positions of the electrical equipment which is to be installed. The electrical
equipment is identified by a graphical symbol. The standard symbols used by the
electrical contracting industry are those recommended by the British Standard EN
60617, Graphical Symbols for Electrical Power, Telecommunications and Electronic
Diagrams. Some of the more common electrical installation symbols are given in Figue
1.1

Figure 1.1a Some EN 60617 installation symbols.

Figure 1.1b Some EN 60617 installation symbols.
 Figure 1.2 Layout drawing for electrical installation.

A layout drawing of a small domestic extension is shown in Figure 1.2. It can be seen
that the mains intake position, probably a consumer’s unit, is situated in the store-room
which also contains one light controlled by a switch at the door. The bathroom contains
one lighting point controlled by a one-way switch at the door. The kitchen has two doors
and a switch is installed at each door to control the fluorescent luminaire. There are also
three double sockets situated around the kitchen. The sitting room has a two-way switch
at each door controlling the centre lighting point. Two wall lights with built-in switches
are to be wired, one at each side of the window. Two double sockets and one switched
socket are also to be installed in the sitting room. The bedroom has two lighting points
controlled independently by two one-way switches at the door.
As-Fitted Drawings
When the installation is completed a set of drawings should be produced which indicate
the final positions of all the electrical equipment. As the building and electrical
installation progresses, it is sometimes necessary to modify the positions of equipment
indicated on the layout drawing because, for example, the position of a doorway has
been changed. The layout drawings indicate the original intentions for the positions of
equipment, while the ‘as-fitted’ drawing indicates the actual positions of equipment
upon completion of the job.

Detail Drawings
These are additional drawings produced by the architect to clarify some point of detail.
For example, a drawing might be produced to give a fuller description of the suspended
ceiling arrangements.

Schematic Diagrams
A schematic diagram is a diagram in outline of, for example, a motor starter circuit. It
uses graphical symbols to indicate the interrelationship of the electrical elements in a
circuit. These help us to understand the working operation of the circuit.
An electrical schematic diagram looks very like a circuit diagram. A mechanical
schematic diagram gives a more complex description of the individual elements in the
system, indicating, for example, acceleration, velocity, position, force sensing and
viscous damping.

Block Diagrams
A block diagram is a very simple diagram in which the various items or pieces of
equipment are represented by a square or rectangular box. The purpose of the block
diagram is to show how the components of the circuit relate to each other, and therefore
the individual circuit connections are not shown. Figure 1.3 shows the block diagram
of a space heating control system.

Figure 1.3 Space heating control system.

Wiring Diagrams
A wiring diagram or connection diagram shows the detailed connections between
components or items of equipment. They do not indicate how a piece of equipment or
circuit works. The purpose of a wiring diagram is to help someone with the actual
wiring of the circuit. Figure 1.4 shows the wiring diagram for a space heating control
system.

Figure 1.4 Wiring diagram for space heating control (Honeywell ‘Y’ plan).

Circuit Diagrams
A circuit diagram shows most clearly how a circuit works. All the essential parts and
connections are represented by their graphical symbols. The purpose of a circuit
diagram is to help our understanding of the circuit. It will be laid out as clearly as
possible, without regard to the physical layout of the actual components, and therefore
it may not indicate the most convenient way to wire the circuit. Figure 1.5 shows the
circuit diagram of our same space heating control system.
 Figure 1.5 Circuit diagram for space heating control (Honeywell ‘Y’ plan).

Supplementary Diagrams
A supplementary diagram conveys additional information in a way which is usually a
mixture of the other categories of drawings. Figure 1.6 shows the supplementary
diagram for our space heating control system and is probably the most useful diagram
for initially setting out the wiring for the heating system.

Figure 1.6 Supplementary diagram for a space heating system (Honeywell ‘Y’ plan).
Freehand Working Diagrams
Freehand working drawings or sketches are another important way in which we
communicate our ideas. The drawings of the brackets shown in Figure 1.6 were done
from freehand sketches. A freehand sketch may be done as an initial draft of an idea
before a full working drawing is made or, in the case of Figure 1.6, it may be used to
enable someone actually to make the bracket. It is often much easier to produce a sketch
of your ideas or intentions than to describe them or produce a list of instructions. To
convey the message or information clearly it is better to make your sketch large rather
than too small. It should also contain all the dimensions necessary to indicate clearly
the size of the finished object depicted by the sketch. You could practise freehand
sketching by drawing some of the tools and equipment used in our trade.

Figure 1.6 Bracket supports for conduits and trunking.

One-Line Diagrams
One of the most important drawing types for the design of a new electrical system or
modernizing an existing system is the one-line drawing. It uses single lines and standard
symbols to show electrical wiring or busbars and component parts of an electric circuit
or system of circuits. The one-line drawing differs from the wiring diagram in that it
does not specify device (receptacle, switch, luminaire, etc.) locations or switch
locations for controlling those devices.
The one-line diagram in figure 1.7 gives an overview of a complete system and how it
works. For example, a three-phase load requires three wires, and each wire has its own
pole of a control switch and one overcurrent device. It is not necessary to repeat this
information three times on the diagram; one line shows what happens to all the three
wires.
 Figure 1.7 typical one-line electrical diagram.

Power Riser Diagrams

Power riser diagrams are single-line diagrams showing electrical equipment and
installations in elevation. Figure 1.8 is an example drawn for a combined office and
warehouse. It shows all of the electrical equipment and the connecting lines for service
entrance conductors and feeders. Notes identify equipment, the size of conduit
necessary for each feeder, and the number, size, and type of conductors in each conduit.
 Figure 1.8 Power riser diagram for a combined office-warehouse building

Electrical Detail Drawings

Electrical detail drawings are prepared as separate sheets to give the installer more
complete details of a specific, nonstandard installation requirement. Figure 1.9 is a
detail drawing of a section through the wall of an office warehouse. it provides details
of how and where hanger fittings and boxes are to be placed between a column and
insulation to support a run of bus duct.
Any set of electrical drawings might require additional “blowup” drawings of certain
technical details that ate not clearly indicated on small-scale drawings, particularly plan
view. It includes both mechanical and architectural details. Other drawings might show
section views of special foundations or footings, or suspension systems for electrical
equipment.
These detail drawings might be drawn by the consulting architectural or engineering
firm on complex projects, but they might also be supplied by the manufacturer of the
equipment or hardware to be installed. The consulting firm will collate these drawings
into the related set with appropriate sheet numbers.
 Figure 1.9 Electrical construction detail for hanging a busway

Shop Drawings
Many items of electrical equipment such as motors and motor control cabinets are
standardized by the manufacturer, and the outline and footprint dimensions are included
in their catalogs. However, large, costly electrical equipment such as high-voltage
switchgear, transformers, motor control centers, HVAC (heating, ventilating, and air
conditioning) system, and elevators are usually drawn by the manufacturer and
furnished prior to the delivery of the equipment. They might also include installation
and maintenance manuals custom-prepared for the specific project.
The architect/engineer requires dimensional outline information to lay out the location
of the equipment on the elevation drawings and check for any possible interference
conflicts that could develop. For example, the equipment must be positioned to provide,
safe easy access to the equipment for routine maintenance. Allowance must be made
for the swing radii of all doors, and adequate space must be allowed for maintenance
personnel to gain access to the equipment through removable cover panels as well as
enough room to work.
In some cases, special concrete footings must be prepared with specified lag bolts for
anchoring the equipment before it is delivered. This work must be completed and the
concrete must be sufficiently cured to accept the load when the equipment arrives on
the site.
Shop drawings also are helpful for the contractor responsible for installing heavy
equipment, so any required cranes or other heavy moving equipment will be on the site
prior to the delivery of the equipment. In addition, the contractor must make sure that
any existing openings in the walls or doorways are wide and high enough to provide
adequate clearance for the entry of the equipment. Advance information will give the
contractor enough time to install any conduit, cable trays, or plumbing that would be
difficult or excessively costly to install after the equipment is in place.
As-built drawings that include detailed “factory-wired” connection diagrams will assist
the installer in performing any “field wiring.” Later they will be important if any
commissioning procedures or final acceptance testing is required. These drawings will
then become part of a maintenance file to assist the maintenance personnel in the
performance of any troubleshooting that might be required at a later date, after the
equipment is operational. These drawings and any operation and any operation and
maintenance manuals are essential documents of record that will be useful for making
any later additions to the facility.

ELECTRICAL GRAPHIC SYMBOLS

Electrical engineers and designers generally follow accepted standards for the basic
electrical and electronic symbols. These electrical symbols can be classified as those
used on connection and interconnection diagrams and those used on elementary or
schematic diagrams.
Connection and interconnection symbols represent complete electrical devices such as
switch outlets, receptacle outlets, lighting fixtures or luminaires, and auxiliary systems.
These symbols take the form of relatively simple geometric shapes modified with lines
and letters inside or outside of them.
Figure 1.10 includes a selection of electrical connection and interconnection symbols
recommended by the American national standards institute (ANSI) for use on
architectural drawings.
CAD electrical drafting software contains a library of symbols that can be accessed
from a menu, downloaded, and dragged into position on the face of the screen as needed.
Figure 1.10 Graphic symbols for electrical wiring diagrams.
Drawing Line Widths and Styles
Line widths and styles convey different kinds of information on engineering and
architectural drawings. For example, dashed lines have one meaning and dotted lines
another. Center lines of alternating short and long segments divide drawing elements,
and dashed lines with uniform segments and spaces show physical connections between
drawing elements.
Electrical engineers have generally agreed on the line conventions that represent wires,
cables, conduit, and wiring within conduit, as shown in figure 1.11. For example,
branch circuit power wiring is represented as a solid line, while both switched and
control wiring are represented by broken lines, abbreviations inserted within breaks in
the lines, such as “EM” for “CT” for cable tray, identify their functions. Home runs
from electrical devices to panels are represented as lines with arrowheads.
However, there is no enforcement of generally acceptable line drawing standards within
the industry. Unless the draftsperson is required to follow a company style or style is
mandated by the client, there are many possible variations of the line samples shown in
the figure. For example, some drawings show branch circuit wiring as heavy lines and
control wiring as fine lines.

Figure 1.11 lines used to indicate wiring on electrical drawings

Electrical and Electronic Schematic Symbols:
Another group of symbols, called elementary/schematic symbols, is used on electrical
one-line and schematic drawings as shown in figure 1.12. These symbols are used in
drawing circuits such as for motor starters or the wiring inside appliances or building
service equipment.

Figure 1.12a Graphical symbols for electrical schematics.

Figure 1.12b Graphical symbols for electrical schematics.
Figure 1.12c Graphical symbols for electronic schematics.
 CHAPTER TWO

CONDUCTORS AND WIRING ACCESSORIES

Conductors and Insulators

Electrical conductors are substances or materials used to convey or allow the free flow
of electric current. Insulators on the other hand, are substances or materials that resist
the flow of electric current.

Materials considered as good electric conductors are:

1. Silver 6. Zinc
2. Copper 7. Platinum
3. Aluminum 8. Iron
4. Nickel 9. Lead
5. Brass 10. Tin

Various kind of insulators:

1. Rubber 7. Latex
2. Porcelain 8. Asbestos
3. Varnish 9. Paper
4. Slate 10. Oil
5. Glass 11. Wax
6. Mica 12. Thermoplastic

There is no such thing as perfect conductor, or perfect insulator, because conductors,

insulator, and resistor, are resistive materials. Good conductors are those substances
with extremely low resistance to current flow. A perfect insulator does not exist, because
all insulators become electrically conductive when a sufficiently high voltage is applied
that the electric field tears electrons away from the atoms.

Conductor Insulators
Electrical conductors are made un numerous types designated by letters according to
the kind of insulation used. The conductor insulator serves as physical shield of the wire
against heat, water and other elements of nature. Insulation is rated by voltage from 300
to 15000 volts. If the insulation used is above its specified rating, the risk of breakdown
is high which might cause short circuit and arcing that may result to fire. Ordinary
conductor wires for buildings are normally rated at 300 or 600 volts.
Some Common Terms in Electrical Materials.
⚫ Ferrous: A word used to describe all metals in which the main constituent is iron.

⚫ Non-ferrous: Metals which do not contain iron are called non-ferrous. They are
non-magnetic and resist rusting. Copper, aluminium, tin, lead, zinc and brass are
examples of non-ferrous metals.

⚫ Alloy: An alloy is a mixture of two or more metals. Brass is an alloy of copper and
zinc, usually in the ratio 70–30% or 60–40%.

⚫ Corrosion: The destruction of a metal by chemical action. Most corrosion takes

place when a metal is in contact with moisture.

⚫ Thermoplastic polymers: These may be repeatedly warmed and cooled without

appreciable changes occurring in the properties of the material. They are good
insulators, but give off toxic fumes when burned. They have a flexible quality when
operated up to a maximum temperature of 70°C but should not be flexed when the
air temperature is near 0°C, otherwise they may crack. Polyvinylchloride (PVC)
used for cable insulation is a thermoplastic polymer.

⚫ Thermosetting polymers: Once heated and formed, products made from

thermosetting polymers are fixed rigidly. Plug tops, socket outlets and switch plates
are made from this material.

⚫ Rubber: is a tough elastic substance made from the sap of tropical plants. It is a
good insulator, but degrades and becomes brittle when exposed to sunlight.

⚫ Synthetic rubber: is manufactured, as opposed to being produced naturally.

Synthetic or artificial rubber is carefully manufactured to have all the good qualities
of natural rubber – Flexibility, good insulation and suitability for use over a wide
range of temperatures.

⚫ Silicon rubber: Introducing organic compounds into synthetic rubber produces a

good insulating material which is Flexible over a wide range of temperatures and
which retains its insulating properties even when burned. These properties make it
ideal for cables used in fire alarm installations such as FP200 cables.

⚫ Magnesium oxide: The conductors of mineral insulated metal sheathed (MICC)

cables are insulated with compressed magnesium oxide, a white chalk-like
substance which is heat-resistant and a good insulator and lasts for many years.
However, the magnesium oxide attracts moisture and, therefore, the cable must be
terminated with a special moisture excluding seal.

⚫ Copper: It is a very good conductor, is non-magnetic and offers considerable

 resistance to atmospheric corrosion. Copper toughens with work, but may be
annealed, or softened, by heating to dull red before quenching. Copper forms the
largest portion of the alloy brass, and is used in the manufacture of electrical cables,
domestic heating systems, refrigerator tubes and vehicle radiators.

Copper conductors: multiple beneficial properties, including:

• High electrical conductivity, Electrical installation
• High tensile strength,
• High ductility,
• Corrosion resistance,
• Good thermal conductivity,
• Solderability,
• Resistance to electrical overloads,
• Compatibility with electrical insulators, and
• Ease of installation.

⚫ Aluminium: It is a very good conductor, is non-magnetic, offers very good

resistance to atmospheric corrosion and is notable for its extreme softness and
lightness. It is used in the manufacture of power cables. The overhead cables of the
National Grid are made of an aluminium conductor reinforced by a core of steel.
Copper conductors would be too heavy to support themselves between the pylons.

⚫ Tungsten: Tungsten's many alloys have numerous applications, including

incandescent light bulb filaments, X-ray tubes (as both the filament and target),
electrodes in TIG welding, superalloys, and radiation shielding. Tungsten's
hardness and high density give it military applications in penetrating projectiles.

⚫ Brass: Brass is a non-ferrous alloy of copper and zinc which is easily cast. it is
often used in the electrical and plumbing trades. Taps, valves, pipes, electrical
terminals, plug top pins and terminal glands for steel wire armour (SWA) and MI
cables are some of the many applications.

⚫ Cast steel: Cast steel is also called tool steel or high-carbon steel. Cast steel is used
to manufacturer tools. Hammer heads, pliers, wire cutters, chisels, files and many
machine parts are also made from cast steel.

⚫ Mild steel: Mild steel is also an alloy of iron and carbon but contains much less
carbon than cast steel. Mild steel is the most widely used metal in the world, having
considerable strength and rigidity without being brittle. Ships, bridges, girders,
motorcar bodies, bicycles, nails, screws, conduit, trunking, tray and SWA are all
made of mild steel.

⚫ Zinc: Zinc is a non-ferrous metal which is used mainly to protect steel against
corrosion and in making the alloy brass. Mild steel coated with zinc is sometimes
 called galvanized steel, and this coating considerably improves steels resistance to
corrosion. Conduit, trunking, tray, SWA, outside luminaires and electricity pylons
are made of galvanized steel.

⚫ XLPE: Cross-linked polyethylene, commonly abbreviated PEX or XLPE, is a

form of polyethylene with cross-links. It is formed into tubing, and is used
predominantly in building services pipework systems, hydronic radiant heating and
cooling systems, domestic water piping, and insulation for high tension (high
voltage) electrical cables. PEX has become a common alternative to polyvinyl
chloride (PVC), chlorinated polyvinyl chloride (CPVC) or copper tubing for use as
residential water pipes.
⚫ PAPER: Electrical insulation papers are paper types that are used as electrical
insulation in many applications due to pure cellulose having outstanding electrical
properties.

APPLICATION OF ELECTRICAL MATERIALS

Most cables can be considered to be constructed in three parts: the conductor which
must be of a suitable cross-section to carry the load current; the insulation, which has
a colour or number code for identification; and the outer sheath which may contain
some means of providing protection from mechanical damage.

Types of cables
◆ PVC insulated and sheathed cables: Domestic and commercial installations use
this cable, which may be clipped direct to a surface, sunk in plaster or installed in
conduit or trunking. It is the simplest and least expensive cable. The conductors are
covered with a colour-coded PVC insulation and then contained singly or with
others in a PVC outer sheath.

◆ PVC/SWA cable: PVC insulated steel wire armour cables are used for wiring
underground between buildings, for main supplies to dwellings, rising sub-mains
and industrial installations. They are used where some mechanical protection of the
cable conductors is required. Around this sheath is placed an armour protection of
steel wires twisted along the length of the cable, and a final PVC sheath covering
the steel wires protects them from corrosion. The armour sheath also provides the
circuit protective conductor (CPC) and the cable is simply terminated using a
compression gland.

◆ MI cable: A mineral insulated (MI) cable has a seamless copper sheath which
makes it waterproof and fire and corrosion-resistant. These characteristics often
make it the only cable choice for hazardous or high-temperature installations such
as oil refineries and chemical works, boiler houses and furnaces, petrol pump and
fire alarm installations. It is colour-coded orange for general electrical wiring,
white for emergency lighting or red for fire alarm wiring.
◆ FP 200 cable: FP 200 cable is similar in appearance to an MI cable in that it is a
circular tube, or the shape of a pencil, and is available with a red or white sheath.
However, it is much simpler to use and terminate than an MI cable. FP 200 is
available in 2, 3, 4, 7, 12 and 19 cores with a conductor size range from 1.0 to
4.0mm.

◆ High-voltage power cables: The cables used for high-voltage power distribution
require termination and installation expertise beyond the normal experience of a
contracting electrician.

◆ High-voltage overhead cables: Suspended from cable towers or pylons, overhead

cables must be light, flexible and strong. The cable is constructed of stranded
aluminium conductors formed around a core of steel stranded conductors.

Wires and Cables

Wires and cables are the terms that are frequently used in the electrical and
communication fields. But people tend to get confused about both the terms as they
look similar, but are quite different.

List Some of The Basic Differences Between Wires and Cables

The basic key difference between wires and cables is that a wire is a single conductor
whereas a cable is a group of conductors. Although, these conductors are made of a
common material- copper or aluminum. Usually, the wires are bare and are twisted. But,
some of the wires are coated with thin PVC layer. And in case of cables, they run
parallelly and are twisted or bonded together to form a single case. For the safety
purpose, an inner and outer sheath is made.

Wire
A wire is measured by diameter. According to the diameter of the wire, it will be
measured by a gauge number. The smaller the gauge number, the thicker the wire. The
perfect gauge that is used in residential applications is 10 & 20. But, do keep in mind
that big wires carry more current and can damage household appliances by burning the
fuse.

Types of Electrical Wires

1. Solid – A solid wire is a wire with one metallic strand. It has a single conductor and
is either insulated or bare and it is usually protected by a coloured sheath. This wire
offers a lower resistance and is best to use in higher frequencies.
2. Stranded – consist of a group of twisted wires which form a metallic string. A
standard wire contains many thin wire strands that are twisted together. These wires are
used where the flexibility is required, standard wire can be used over a long period of
time. Comparatively, the standard wire has larger cross-sectional area than the solid
wire.

Cable
A cable may be made of two or more wires, which can be either stranded or solid. Like
wires, calbes have different sizes and applications and are colour coded as well.
contains a hot wire carrying the current, a neutral wire to complete the loop and a
grounding wire as well. A cable is classified by the total number of wires it is made up
of and their gauge.

Types of Electrical Cables

1. Twisted pair cable – A twisted pair cable includes 2 cables that are twisted together.
This twisting can avoid the noise produced by magnetic coupling and thus it is used
to carry signals. Twisted pair cable is generally used in data communication and
telecommunication.

2. Multi-conductor cable – This cable has 2 or more than 2 conductors which are
insulated and their purpose is to protect the signal integrity. Both twisted pair cables
and multi-conductor are known as balanced line configuration cables.

3. Coaxial cable – A coaxial cable has an inner conductor which is surrounded by a

parallel outer foil conductor which is protected by insulating layers. In the cable, the 2
conductors are being separated from each other by an insulating dielectric. These cables
are generally used in TV cable as its performance is more stable than the twisted pair
cable.

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4. Ribbon cable – it is often used in computers and peripherals. It is quite flexible and
can only handle low voltage applications.

5. Fibre optic cable – The fibre optic cable transmits the signals through a bunch of
glass threads and comparatively, it has a greater bandwidth than metal conductors and
that means they can carry more information and data. For this reason, fibre optic cables
are used instead of traditional copper cables.

Advantages of Wire
Using solid wire is perfect in case of higher frequencies and it offers low resistance and
cost. And the stranded wire shows high resistance to the metal.

Advantages of Cable
Cables are heavy duty, well insulated and have higher strength.

Rules that apply to both:

1. Damaged or torn wires or cables must be replaced.
2. Assure that all the cables and wires are polarised and have safety closures.

3. Keep the wires and cables out of reach of children.

4. Avoid placing wires and cables where they can easily be a trip hazard.

New (Harmonised) Fixed Cable Core Colours: IEE Regulation (BS 7671, 2008)
Cable core colours from 31st of March 2004 onwards.
✓ Single phase brown phase conductors blue neutral conductors and green combined
with yellow for earth conductors (just like the existing flexible cords).

✓ Three phase brown, black and grey phase conductors, blue neutral conductors and
green combined with yellow for earth conductors.

✓ Extensions or alterations to existing single-phase installations do not require

marking at the interface between the old and new fixed wiring colours. However,
a warning notice must be fixed at the consumer unit or distribution fuse board
which states:
 Caution – this installation has wiring colours to two versions of BS 7671. Great
care should be taken before undertaking extensions, alterations or repair that all
conductors are correctly identified.

Alterations to three-phase installations must be marked at the interface L1, L2, L3

for the lines and N for the neutral. Both new and old cables must be marked. These
markings are preferred to coloured tape and a caution notice is again required at
the distribution board. Appendix 7 of BS 7671: 2008 deals with harmonized cable
core colours.

BS 6346, BS 5467 or BS 6724

Cable Type Old Core Colours New Core Colours

Single-core Red or black Brown or blue

Two-core Red, black Brown, blue

Three-core Red, yellow, blue Brown, black, grey

Four-core Red, yellow, blue, black Brown, black, grey, blue

AMPACITY OF ELECTRICAL CONDUCTORS
Ampacity is defined as the ability of the wire or conductor to carry current without
overheating. Conductor resistance to current floe, generate not only heat but also
contribute to the voltage drop expressed in the following equation:
Voltage drop in wire = circuit current x resistance of wire
Power loss in wire = circuit current x voltage drop
P = I x (IxR)
P = I2R

This power loss being converted into heat, must be dissipated. A small wire diameter
can safely carry more current in proportion to its weight. The use of copper wire is most
preferred.
Conductor ampacity is determined by the maximum operating temperature that its
insulation can withstand continuously without heating. Current flow and conductor’s
resistance normally generates heat. Thus, the operating temperature depends upon the
amount of current flow, wire resistance, and environment. Environment refers to either
enclosed or open condition on which the wire is placed.
The ampacity or ability of the conductor to carry load, increases as the sizes of
conductor increases. If the more than three conductors are inserted into a conduit, the
temperature also increase and it requires derating of the conductors ampacity

Table 2-1 Current Carrying Capacity Derating Factors

Number of conductors in a Derating factor
raceway
4 to 6 0.80
7 to 24 0.70
25 to 42 0.60
43 and above 0.50

Derating of conductors ampacity: means the full amount of allowable ampacity, is

reduce to a certain percentage due to the environmental condition it is exposed of and
the number of wires placed inside the conduit. The current rating or wire in a free air
environment is higher that those placed inside the conduit. Concomitant with this, if the
ambient temperature is above 300C, the allowable ampacity will be reduced by the
factors given in table 2-1.