Overcurrent effects on copper insulated PVC cables and fire resistance via thermal imaging and macrostructure analysis

Abstract

This study investigates the effects of overcurrent on copper (Cu) insulated polyvinyl chloride (PVC) cables, focusing on their thermal behavior and fire resistance. We utilized thermal imaging, macrostructural analysis, and Joule heating calculations to evaluate six cable samples subjected to various currents. Results showed that with increasing current, the temperature of the cables rose significantly. For example, the CC0 sample, with no current, had a temperature of 36 °C, while the CC110 sample, subjected to 110 A, reached 1,091 °C. Joule heating calculations indicated energy values ranging from 0 J for the CC0 sample to 7,260,000 J for the CC110 sample. Physical observations included minor deformations at 253 °C and complete insulation loss at 1,091 °C. These findings emphasize the critical need for managing overcurrent to prevent severe cable damage and enhance system safety. This research provides practical insights for optimizing cable design and improving thermal management, offering valuable contributions to electrical engineering practices.