03 - Extrosion Section

Training Report Production Department
__________________________________________________________________________________________________________________________________________________
3. Extrusion Section
3.1 Introduction
The Extrusion section function is insulate the conductor from the any behind air and
insulate the conductor from the others conductors.
This stage is very important stage in manifactor the cables because the ability of using
this cable mainly depend on the insulation stage.
The Extrusion section made insulation to the L.V. cables and for H.V. cables made in the
C.V. section and this will be described in other chapter.
Extrusion Section
L.V. Cables M.V. & H.V. Voltage
Fig. 3.1 Insulation section
3.2 Type of Material
The material is divided two main parts

1- Thermoplastic material.
2- Thermosetting material.
The difference between the two material is that the 1st can be recycled but the other
can't.
Thermoplastic such as PVC and thermosetting such as XLPE
The XLPE material consists of PE (polyethylene) with Catalyst material and by operating
condition it's converted to XLPE
There are types of materials are used in insulation section but the materials which used
to insulation the cable are
1- PVC (polyvinyl chloride)
2- XLPE (Cross Linked Polyethylene)
__________________________________________________________________________________________________________________________________________________
20
__________________________________________________________________________________________________________________________________________________
The material is used for insulation depend on the type of screw which used in insulation,
bedding or sheathing process.
And we will find the different between the materials that we used in this table
Items PVC XLPE

Cost Cheaper than XLPE More Expensive than PVC
Made in Egypt Imported
Recycling Yes No
Operating
70°C 90°C
Temperature
Density From 1.4 to 1.6 g/cm3 0.92 g/cm3
Cooling The conductor pass cool water Must be pass in hot water 60°C
trough 14°C in cooling system to 10m from cooling system
Generally materials are used in Extrosion section as follows
1- PVC (polyvinyl chloride)

2- XLPE (Cross Linked Polyethylene)
3- LDPE (Low Density polyethylene)
4- LLDPE (Low Liner Density polyethylene)
5- MDPE (Medium Density polyethylene)
6- HDPE (High Density polyethylene)
7- LSOH (Low smoke zero halogen)
8- LSHF (Low Smoke halogen free)
The material (LLDPE, MDPE and HDPE) are used for sheathing
The material (LSHF and LSOH) are used for insulation
And the recycled PVC is used for bedding (inner covering), if wanted PE for bedding so
used MDPE.
Properties of cable insulation
1- Must have specific resistance.

2- Must be high dielectric strength (KV/mm)
3- Rigid and flexible.
__________________________________________________________________________________________________________________________________________________
21
__________________________________________________________________________________________________________________________________________________
4- Must non flammable.
3.3 Extrusion Machine Components
Pay Off Caterpillar Extruder Cooling Trough
Take up Caterpillar Spark Tester
Fig. 3.1 Insulation Machine Block Diagram
The main component of each Extrusion machine can be summarized as follow
1- Pay off this feed the machine with conductor.

2- Caterpillar the aim of this part to pull the conductor, there are two caterpillars one
at the beginning the machine and other at the end, the speed of two caterpillar
must be synchronized.
3- Extruder it's consists of screw, barrel and crosshead the screw part consists of five
zones which used to heat the insulation material PVC or XLPE before going to the
crosshead of the machine, the head part consists of four heaters
4- Cooling trough it is necessary to cool it before going into the reel.
5- Spark Tester it's apart that response of the test insulation its idea that applied DC
voltage reached to 10 KV to test the insulation of the wire.
6- Take up the reel is ready to go to the assembly process.
__________________________________________________________________________________________________________________________________________________
22
__________________________________________________________________________________________________________________________________________________
Fig. 3.1 Extrusion Method
3.4 Tooling of head
1- Tube tooling
T1 inner diameter of tip = C1 (diameter of conductor of pay off X 1.1)
D1 inner diameter of die = T2 outer diameter of T1 X ([3 to 4] thickness of insulation)
2- Pressure tooling
T1 inner diameter of tip = C1 (diameter of conductor of pay off + [0.3 to 0.5] mm)
D1 inner diameter of die = C2 desired diameter after insulation
Fig. 3.2 Tooling of Head Method
__________________________________________________________________________________________________________________________________________________
23
__________________________________________________________________________________________________________________________________________________
3.5 EGYTECH Extrusion M/Cs
Fig. 3.3 Insulation Line
3.5.1 NMB 80

Processes made : Insulation

Diameter of the cable from 0.5 mm2 to 10 mm2 it's better to run 10 mm2 cable
in the BM 100 because it is too heavy, therefore in general it is preferred to
insulate cables from 1 mm2 to 6 mm2

Materials used in this machine : PVC and XLPE

The next conductors are insulated with this machine: stranded ,flexible and
solid.

Max. line speed 1000 m/min

Spark detector is installed to verify that the insulation has no faults.

Pay off: two units with reel of maximum diameter of 1000 mm and minimum
diameter of 630 mm and maximum weight of 1 Ton.

This machine has no caterpillars instead it is using two cabstands to apply
tension to the conductor.

Take up: two units with reel of maximum diameter of 1000 mm and minimum
diameter of 630 mm and maximum weight of 1 Ton one units is in operation
and the other one is standing by as a backup.
3.5.2 NMB 100


Processes made : Insulation and sheathing

Diameter of the cable:
__________________________________________________________________________________________________________________________________________________
24
__________________________________________________________________________________________________________________________________________________
a- Copper conductors from 10 mm2 (round) to 35 mm2 (round and sector).

b-Aluminum with 50 mm2.


The next conductors are insulated with this machine: stranded.


Spark detector is installed to verify that the insulation has no faults in this
machine if alarm enabled the machine stop immediately.


This machine has no caterpillars instead it is using two cabstands to apply
tension to the conductor.

3.5.3 NMB 120


Processes made : Insulation, bedding and sheathing

Diameter of the cable: copper or aluminum conductors from 5 mm2 (round) to
57 mm2 (sector or round).






This machine has two caterpillars.

3.5.4 NMB 150


Processes made : Insulation, bedding and sheathing

Diameter of the cable: copper or aluminum conductors from 11 mm2 (round) to
115 mm2 (sector or round).

Materials used in this machine : PVC and XLPE, low smoke material ……etc.



Pay off: one unit with reel of maximum diameter of 3400 mm and minimum


Take up: one unit with reel of maximum diameter of 3400 mm and minimum
__________________________________________________________________________________________________________________________________________________
25
__________________________________________________________________________________________________________________________________________________
3.5.5 NMB 160


Processes made : Bedding and sheathing

Diameter of the cable : copper or aluminum conductors from 10 mm 2 (round)
to 130 mm2 (sector or round).

Materials used in this machine : PVC and recycled material (just for bedding).





3.6 comparisons between the M/Cs
Item BM80 BM100 BM120 BM150 BM160

Insulation Insulation Insulation
Processes bedding and
Insulation and bedding and bedding and
mode sheathing
sheathing sheathing sheathing
For cu 10
mm2
Size of the 0.5 mm2 5 mm2 11 mm2 10 mm2
to 35 mm2
cable to 6 mm2 to 57 mm2 to 115 mm2 to 130 mm2
for AL 50
mm2
PVC and PVC and
Materials PVC and PVC and Recycled
XLPE and XLPE and
used XLPE XLPE PVC
LSHF LSHF
Max. linear
1000 m/min 400 m/min 200 m/min 150 m/min 140 m/min
speed
caterpillar no no two two two
__________________________________________________________________________________________________________________________________________________
26

03 - Extrosion Section

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

03 - Extrosion Section

Uploaded by

Copyright:

Available Formats

Training Report Production Department

L.V. Cables M.V. & H.V. Voltage

Fig. 3.1 Insulation section

3.2 Type of Material

The material is divided two main parts

Items PVC XLPE

Made in Egypt Imported

Generally materials are used in Extrosion section as follows

1- PVC (polyvinyl chloride)

Properties of cable insulation

1- Must have specific resistance.

4- Must non flammable.

3.3 Extrusion Machine Components

Pay Off Caterpillar Extruder Cooling Trough

Take up Caterpillar Spark Tester

Fig. 3.1 Insulation Machine Block Diagram

The main component of each Extrusion machine can be summarized as follow

1- Pay off this feed the machine with conductor.

Fig. 3.1 Extrusion Method

3.4 Tooling of head

Fig. 3.2 Tooling of Head Method

3.5 EGYTECH Extrusion M/Cs

Fig. 3.3 Insulation Line

3.5.2 NMB 100

a- Copper conductors from 10 mm2 (round) to 35 mm2 (round and sector).

3.5.3 NMB 120

3.5.4 NMB 150

3.5.5 NMB 160

3.6 comparisons between the M/Cs

Item BM80 BM100 BM120 BM150 BM160

You might also like