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Introduction
High temperature electrical cables are designed for use in extreme thermal conditions while also having high electrical conductivity and mechanical strength. High temperature cables are crucial to industrial settings because they provide reliable power and control signals over distances where standard electrical cables would fail. High temperature cables can transmit and deliver power and control signals at temperatures between -73°C and 1200°C.
High temperature cables are manufactured using advanced insulation materials such as PTFE, FEP, PFA, silicone rubber, fiberglass, ceramic fibre, and alumina fibre. As a result, these specialised cables can withstand heat, chemicals, nuclear, flame and radiation. Many industries utilise high temperature electrical cables for their most critical operations; steel and glass manufacturing, aerospace, automotive, petrochemical, and electric power generation are among them. When selecting which conductor materials, insulation types, and protecting layers to use on high temperature cables, care must be taken to ensure that they will continue to operate uninterrupted in the most demanding thermal environments.
About High Temperature Cables
High-Temperature Cable is an electric conductive multi-layered conductor for continuous use in extremely hot environments up to 1200 °C. The cable uses special conductive materials such as Annealed Bare Copper, Tinned Copper, Silver Plated Copper, Nickel Plated Copper, and Pure Nickel, and insulating materials that stand up to high temperatures, such as PTFE, Silicon, Fiberglass, and Ceramic Fiber. The cable is available in both single/multi-core and single/multi-pair forms with a voltage rating of up to 1100V. Additionally, High-Temperature Cables can be supplied with optional heat barrier tapes, screening techniques, and stainless steel wire braiding for better performance and protective capabilities in harsh industrial conditions.
Features Of High Temperature Cable
- Wide range of operating temperatures: Extreme temperature ranges of operation (-73°C to 1200°C) depend on the insulation material selected. All insulations are available in either alumina fibre, ceramic fibre, fiberglass, polyimide, PTFE, FEP, PFA, PEEK, ETFE, silicon rubber, and XL-ETFE.
- Excellent chemical resistance: All insulation materials have excellent chemical resistance to acids, alkalis, oils and solvents, as well as aggressive chemicals.
- Low smoke emission and flame retardant properties: Low smoke emission characteristics are inherent in all insulation materials; therefore, they can be safely used in safety-critical applications.
- High thermal stability: Insulation materials retain electrical and mechanical properties at elevated temperatures after prolonged exposure.
- Radiation resistance: All insulation materials will withstand high levels of radiation; therefore, they are suitable for use in the nuclear and aerospace industries.
- Low dielectric constant: All insulation materials have a low dielectric constant, which means they offer very little signal loss while still providing superior electrical performance.
- No halogenated materials: All insulation materials are available in non-hazardous materials (silicon, FEP, PTFE, ETFE and PFA).
- Flexible construction: The flexible construction of the insulation materials enables easy installation into even the most complex routing.
- Thinner insulation profiles: The high dielectric strength of all insulation materials permits use of thinner insulation walls without compromising electrical safety.
- Versatile conductor materials: The conductor material types available are: ABC, tinned copper, silver plated copper, nickel plated copper, pure nickel, NPC 27%.
- Increased screening protection: Individual and overall screening will protect from electromagnetic interference through the use of either aluminum foil or mesh braid.
High-Temperature Cable Applications
- Steel Production: In steel production, furnace management, induction heating systems, and hot rolling mill, the cables must be able to carry temperatures as high as 800°C.
- Glass Production: Glass-making operations such as furnace, tempering and forming each work under a high temperature environment.
- Ceramic and Refractory Products: During the manufacture of ceramics and refractories, kilns and firing areas operate at high temp; within the scope of all types of ceramics, or flexibility of ceramic processing equipment.
- Chemical and Fertilizer Production: Chemical reaction tanks, chemical distillation points and chemical processing machinery will require equipment that can handle the high temperatures involved.
- Power: Turbine control systems, magnet coils and measuring devices used for thermal, nuclear & other types of boilers.
- Oil and Gas: Downhole temperature measuring devices, refinery heating products, and petrochemical manufacturing equipment.
- Cement: Rotary kilns, clinker cooler systems, and equipment for transporting high-temperature components.
- Metals: Continuous temperature measuring technology for heating treatments, and annealing and casting furnaces and other manufacturing equipment.
- Nuclear: Instrumentation associated with reactors, monitoring products that withstand radiation exposure, and safety branches used for managing critical components.
Why is Tempsens the Leading Manufacturer for High-Temperature Cables?
- With 35+ years experience, since its formation in 1990, our company has developed a wealth of knowledge in thermal and cable solutions designed to withstand extreme environments.
- Manufacture to Global Standards: Our products are designed and manufactured to meet JSS 51034, JSS 51038, MIL 16878, ASTM B298, IEC and many other global standards.
- Export to 70+ Countries: Our strong international presence and reputation for excellence have gained us numerous export excellence awards.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to High Temperature Cables.
High temperature cables utilize select types of insulation made from materials including PTFE, fiberglass, ceramics, silicone rubber, or alumina fibers.
The operating temperature ranges for the various types of insulation are: alumina fibers can handle up to 1200°C; ceramic fibers can handle up to 800°C; fiberglass can handle up to 550°C; polyimides can handle about 310°C; PTFE and PFA cables can handle up to about 260°C; and silicone rubber has a maximum operating temperature of about 180°C.
The conductor materials for high temperature cables are selected from among annealed bare copper, tinned copper, silver plated copper, nickel plated copper, pure nickel, and NPC 27% alloy based on the temperature and performance of the application.
Operating temperature, voltage grade, conductor size, environmental factors, chemical exposure, degree of flexibility required and relevant standards must all be taken into consideration when selecting a high temperature cable. Refer to the manufacturer’s specifications for assistance in making the best selection.
