Mannual
What do you know about XLPE cable compounds?
Actually, XLPE stands for cross linked polyethylene. Some properties of polyethylene, such as high chemical resistance and moisture resistance, are important features of this material. The high quality of thermal insulation makes it suitable for use in high voltage and high temperature conditions. Common uses for cross-linked polyethylene (XLPE) are in building piping (or piping) systems, as insulation for high-voltage cables, and as a replacement for polyvinyl chloride (PVC) and copper tubing in water pipes. In this article, we will have a brief introduction of cable compound and discuss the characteristics, advantages and application of XLPE
SELF CURABLE POLYETHYLENE COMPOND FOR INSULATION OF ARIAL BUNCHED CABLE
Description
DL XL LT /DL XL MB 03-01 is a cross linkable compound system designed for insulation of low voltage aerial bunched cables. This cable insulation compounding system, with a proper mixture of DL XL LT(95parts) and catalyst master batch DL XL MB 03-01(5parts), exhibit excellent thermo-oxidative stability. The combination is suitable for both copper and aluminum conductors. Sufficient anti-oxidant has been added to meet specific requirements.
application
SPECIAL FEATURES:
1. DL XL 03/DL XL MB 0301(S) insulation system offers:
a. Excellent processing properties
b. Outstanding curing speed
c. Excellent surface finish
d. Consistent quality
SPECIFICATION:
DL XL 03/ DL XL MB 0301(S), in blend meets the applicable requirements as below when processed using sound extrusion and testing procedure:
IS 7098 part 1
IEC60502-1
NFC 33-209
The standards referred to above is a short selection of standards and does not cover all applicable standards. Contact your DAILMER representative for additional information.
Technical Characteristics
A. DL XL 03
B. DL XL 03 / DL XL MB 0301(S)
Test procedure: after mixing in proportion of 95:5 and extruded into of 1.2 thickness, the tape is immersed in water at 95˚c for 3 hours. The testing is carried out after conditioning this tape for further 3 hrs. at ambient conditions.
Processing Guidelines
It is recommended to pre-heat the catalyst master batch and color master batch (if any) at 80 ̊c in hot air oven in 4-6 cm layer for 2-4 hours. The grafted polymer should be never preheated. The grafted polymer and master batch should be mixed at a ratio 93:7 at room temperature without shearing, just before consumption. Mixing in large quantities should be avoided, since any leftover premix cannot be stored. It is essential that extruder should not be kept idle when filled with DL XL 03/DL XL MB 03- 01(S) premix. It should be kept running at a low RPM if it is needed to be stopped for any reason like changeover of size etc. Typically the following process condition is used
This system is designed for processing with both, pressure or tube-on tooling. The use of a gradient cooling bath will improve the cable insulation physical properties further. Conductor preheating up to 100 ̊c is recommended when producing cables with a conductor up to 16 mm2 for good bonding and mechanical properties.
SELF CURING DATA
The above extruded product can be cross linked by keeping in ambient condition. Results will vary under different ambient condition
SIOPLAS COMPOUND FOR HIGH VOLTAGE APPLICATION
Description
DL XL HT /DL XL MB HT is a cross linkable compound system designed for High voltage power cables application up to 33 KV. This cable insulation compounding system, with a proper mixture of DL XL HT(95parts) and catalyst master batch DL XL MB HT(5parts), exhibit excellent thermo-oxidative stability. The combination is suitable for both copper and aluminum conductors. Sufficient anti-oxidant has been added to meet specific requirements.
application
Application:
DL XL HT / DL XL MB HT is designed for insulation of high voltage power cable up to 33 KV.
SPECIFICATION:
1. DL XL HT/ DL XL MB HT, in blend meets the applicable requirements as below when processed using sound extrusion and testing procedure:
a. IS 7098 part 2
b. IEC60502-1
c.IS10810
The Sioplas compound (DL XL HT/DL XL MB HT) to be extruded as a normal thermoplastic in PE extrusion line for insulation and suitable semi con compounds in semi con extrusion line with triple crosshead and longer water through for graded cooling. The crosslinking of extruded core is subsequently carried out by immersion in hot water or exposure to steam.in both cases, time of curing is to be optimized as a function of thickness of insulation, concentration of catalyst MB and temperature of water bath or steam. The standards referred to above is a short selection of standards and does not cover all applicable standards. Contact your DAILMER representative for additional information.
SPECIAL FEATURES:
1. DL XL HT/DL XL MB HT insulation system offers:
a. Excellent processing properties
b. Outstanding curing speed
c. Excellent surface finish
d. Consistent quality
Technical Characteristics
A. DL XL HT
B. DL XL HT / DL XL MB HT
Processing Guidelines
It is recommended to pre-heat the catalyst master batch and color master batch (if any) at 80 ̊c in hot air oven in 4-6 cm layer for 2-4 hours. The grafted polymer should be never preheated. The grafted polymer and master batch should be mixed at a ratio 93:7 at room temperature without shearing, just before consumption. Mixing in large quantities should be avoided, since any leftover premix cannot be stored. It is essential that extruder should not be kept idle when filled with DL XL HT/DL XL MBHT premix. It should be kept running at a low RPM if it is needed to be stopped for any reason like changeover of size etc
What are the special characteristics of cross-linked polyethylene (XLPE)?
Compared to regular polyethylene, cross-linked polyethylene (XLPE) has improved properties that improve
its performance.
With its improved properties, XLPE wire does not melt easily and can withstand higher temperatures up to 120°C for a long time without losing its mechanical and chemical properties. The resistance of this material against wear and environmental stresses has increased.
Due to the high strength of XLPE insulated wire, it can be used in harsh conditions. XLPE insulation has a
longer lifespan compared to PVC insulation which is only suitable for low tension applications.
1. The features that distinguish xlpe cables are:
2. High flexibility
Excellent electrical, thermal and physical properties;
3. Excellent resistance to moisture and flame
4. Excellent resistance to crushing and thermal deformation
5. Being light weight
Durability and high resistance Continuous current carrying capacity More short circuits
High temperature tolerance
XLPE are good insulators for wires!
XLPE insulation or tubing is an excellent insulator for electrical cables and quickly eliminates other conventional options. XLPE cable insulation provides sufficient protection for bare copper wires to safely transmit electricity without resistance to weather, moisture and heat.
Why do XLPE power cables require less maintenance?
Bare copper wires perform very well when insulated with cross-linked polyethylene – and efficiency increases too! The improved performance of XLPE power cables is increasing rapidly, and XLPE power cables are widely accepted in many industries. Their improved resistance to water makes XLPE power cables also ideal for use in electrical work or projects. XLPE power cables do not melt when exposed to high temperatures and their improved mechanical properties allow them to carry more load per unit area without breaking or tearing.
Types of PVC Cables
ST-1 Compound: This is a genera- purpose sheath compound designed for cables operating at a maximum rated conductor temperature of 70˚C . It is commonly used in standard applications where high heat resistance is not a critical requirement.
Description
AILMER offers PVC Compound ST-2 for cable industry for Sheathing applications. The products conform to the various national & international quality guidelines like IS: 5831/1984, BS: 7655, IEC: 60502
TYPICAL PROPERTIES
Cable manufactured with PVC Compound ST-2 according to standard manufacturing process meets IS: 5831/1984, BS: 7655, IEC: 60502
*Test specimen made after milling the granules and then compression mould 170 °c for 15 min with 250
PROCESSING
The compound should preferably processed in tube on Die or pressure extrusion. Typical process parameters are recommended range 120°c-170°c.This is the guideline temperature range; actual temperature should be optimized by the user depending upon the other processing variables. The screw must have a good homogenizing capacity. Preheating of granules at 70±/5°c is always advisable for better processing.
PVC Compound ST-2 FR
Description
Dailmer offers PVC Compound ST-2 FR for cable industry for Sheathing applications. The products conform to the various national & international quality guidelines like IS: 5831/1984.
TYPICAL PROPERTIES
Cable manufactured with PVC Compound ST-2 FR according to standard manufacturing process meets IS: 5831/1984.
Test specimen made after milling the granules and then compression mold 160 °c for 15 min with 250
PROCESSING
The compound should preferably processed in tube on Die or pressure extrusion. Typical process parameters are recommended range 120°c- 170°c.This is the guideline temperature range; actual temperature should be optimized by the user depending upon the other processing variables. The screw must have a good homogenizing capacity. Preheating of granules at 70±/5°c is always advisable for better processing.
PVC Compound ST-2 FRLS
Description
Dailmer offers PVC Compound ST-2 FR for cable industry for Sheathing applications. The products conform to the various national & international quality guidelines like IS: 5831/1984.
TYPICAL PROPERTIES
Cable manufactured with ST-2 FRLS according to standard manufacturing process meets (ST-2 IS 5831)
Test specimen made after milling the granules and then compression mould 170 °c for 15 min with 250
PROCESSING
The compound should preferably processed in tube on Die or pressure extrusion. Typical process parameters are recommended range 155°c-185°c ±10%.This is the guideline temperature range actual temperature should be optimized by the user depending upon the other processing variables. The screw must have a good homogenizing capacity. Preheating of granules at 70±/5°c is always advisable for better processing.
PVC TYPE-C HR (85 D) Compound
Description
Dailmer offers PVC TYPE-C HR Compound for wire & cable industry applications. The products conform to the TYPE-C HR (IS 5831)
TYPICAL PROPERTIES
Cable manufactured with TYPE-C HR Compound according to standard manufacturing process meets (IS 5831)
Test specimen made after milling the granules and then compression mould 170 °c for 15 min with 250
PROCESSING
The compound should preferably processed in tube on Die or pressure extrusion. Typical process parameters are recommended range 110°c-170°c.This is the guideline temperature range; actual temperature should be optimized by the user depending upon the other processing variables. The screw must have a good homogenizing capacity. Preheating of granules at 70±/5°c is always advisable for better processing.
PVC TYPE-A RDSO Compound
Description
Dailmer offers PVC TYPE-C HR Compound for wire & cable industry applications. The products conform to the TYPE-C HR (IS 5831)
application
1.Cables: For both power and communication cables used in railway systems.
2. Insulation: For railway electric cables and other electrical components.
TYPICAL PROPERTIES
Cable manufactured with TYPE-A Compound according to standard manufacturing process meets (IS 5831)
Test specimen made after milling the granules and then compression mold 170 °c for 15 min with
PROCESSING
The compound should preferably processed in tube on Die or pressure extrusion. Typical process parameters are recommended range 110°c- 170°c.This is the guideline temperature range; actual temperature should be optimized by the user depending upon the other processing variables. The screw must have a good homogenizing capacity. Preheating of granules at 70±/5°c is always advisable for better processing.
PVC TYPE-D Compound
Description
DAILMER offers PVC TYPE-D Compound for wire & cable industry applications. The products conform to the TYPE-D (IS 5831) PVC Type D insulation is a specific type of insulation material primarily used for electrical wiring and cables. PVC stands for Polyvinyl Chloride, a widely used thermoplastic material. The "Type D" designation typically refers to the material's specific characteristics, which may include a focus on performance in terms of durability, resistance, and temperature stability. As an insulating material, PVC prevents the flow of electricity, ensuring safety in electrical systems by preventing short circuits and electrical faults.
TYPICAL PROPERTIES
Cable manufactured with TYPE-D Compound according to standard manufacturing process meets (IS 5831)
Test specimen made after milling the granules and then compression mould 170 °c for 15 min with 250
PROCESSING
The compound should preferably processed in tube on Die or pressure extrusion. Typical process parameters are recommended range 110°c-170°c.This is the guideline temperature range; actual temperature should be optimized by the user depending upon the other processing variables. The screw must have a good homogenizing capacity. Preheating of granules at 70±/5°c is always advisable for better processing.
PVC skin coating compound
Description
Skin Coating Compound-Type A IS 5831/TI-1 BS 7655 PVC skin compound refers to a specific type of polymer blend designed for the production of flexible and durable plastic materials, often used for creating skins or surfaces that require both flexibility and resilience. Here’s a general breakdown of its composition PVC (Polyvinyl Chloride) Skin Compound is a specially formulated thermoplastic material used in the insulation of wires and cables. It is applied as an outer layer (skin) for cables to provide enhanced protection and insulation properties.
TYPICAL PROPERTIES
Cable manufactured with PVC SKIN Compound according to standard manufacturing process meets IS: Skin Coating Compound-Type A IS 5831/TI-1 BS 7655
Test specimen made after milling the granules and then compression mould 170 °c for 15 min with 250