Testing and Commissioning of

Power Systems

Module 4
laying of UnderGround Cables

ELECTRONICS AND
ELECTRICAL ENGINEERING
Type to enter text

sandeep s r

SJB
I N S T I T U T E O F T E C H N O LO G Y
MODULE 4
laying of UnderGround Cables

The cable drums shall be stored on a well drained, hard surface, so that the drums do not sink in the ground causing rot and
damage to the cable drums. Paved surface is preferred, particularly for long term storage.

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SECTION 1

Storage and Handling

Laying of Underground Cables: Inspection, Storage, Transportation and Han-
dling of Cables, Cable Handing Equipment, Cable Laying Depths and Clear-
ances from other Services such as Water Sewerage, Gas, Heating and other
Mains, Series of Power and Telecommunication Cables and Coordination with
these Services, Excavation of Trenches, Cable Jointing and Terminations Test-
ing and Commissioning. Location of Faults using Megger, Effect of Open or
Loose Neutral Connections, Provision of Proper Fuses on Service Lines and
Their Effect on System, Causes and Dim, and Flickering Lights.
Laying Of Underground Cables
Underground cables are, of course, meant to be installed or laid under the
ground. The reliability of underground cable network highly depends upon
proper laying of cables, quality of cable joints and branch connections etc.

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There are three main methods of laying underground cables, which are - (i) di-
rect laying, (ii) draw-in system and (iii) solid system. These three methods are
e x p l a i n e d b e l o w w i t h t h e i r a d v a n t a g e s a n d d r a w b a c k s .

Direct Laying Of Underground Cables
This method is the most popular as it is simple and cheap. The cables to be laid
using this method must have the serving of bituminised paper and hessian tape
so as to provide protection against corrosion and electrolysis. The direct laying
procedure is as follows.
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Laying Procedure
▪ A trench of about 1.5 meters deep and 45 cm wide is dug.
▪ Then the trench is covered with a 10 cm thick layer of fine sand.
▪ The cable is laid over the sand bed. The sand bed protects the ca-
ble from the moisture from the ground.
▪ Then the laid cable is again covered with a layer of sand of about
10 cm thick.
▪ When multiple cables are to be laid in the same trench, a horizon-
tal or verticle spacing of about 30 cm is provided to reduce the effect of mutual
heating. Spacing between the cables also ensures a fault occurring on one cable
does not damage the adjacent cable.
▪ The trench is then covered with bricks and soil to protect the cable
from mechanical injury.
Advantages
▪ Simpler and cheaper than the other two methods
▪ Heat generated in cables is easily dissipated in the ground.
Disadvantages
▪ To install new cables for fulfilling an increased load demand, com-
pletely new excavation has to be done which costs as much as the new installa-
tion.
▪ Alterations in the cable network are not easy.
 ▪ Maintenance cost is higher. Advantages

▪ Identifying the location of a fault is difficult. ▪ Repairs, additions or alterations to the cable network can be easily
made from manholes without re-excavation.
▪ This method can not be used in congested areas such as metro cit-
ies where excavation is too expensive. ▪ In this method, as the cables need not be armoured, the cable joint-
ing procedure becomes simpler.
Draw-In System
▪ Maintenance cost is quite lower.
In this method, cast iron or concrete pipes or ducts are laid underground with
manholes at suitable positions along the cable route. The cables are then pulled ▪ Fewer chances of fault occurrence due to the strong mechanical
into the pipes from the manholes. Usually, an additional pipe/duct is also pro- protection provided by the system.
vided along with the three cable ducts for carrying relay protection connections
Disadvantages
and pilot wires. Distance between the manholes should be such that pulling in
the cables is easier. At corners or while changing the direction of route, radius ▪ The initial cost is very high.
of the corners must be longer. The cables that are to be laid in this way need
▪ Due to unfavourable conditions for dissipation of heat, current car-
not be armoured but must be provided with the serving of hessian and jute in
rying capacity of the cables is reduced.
order to protect them when being pulled.


Solid System

In this method, the cable is laid into troughing of cast iron, stoneware, asphalt
or treated wood. When the cable is laid into the position, the troughing is filled
with a bituminous of asphaltic compound and then covered over. Cables to be
laid in this manner could be just lead covered as the troughing provides a good
m e c h a n i c a l p r o t e c t i o n .

This method is very rarely used nowadays as it is more expensive and requires
skilled labour and favourable weather conditions.

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Laying of underground cables 1 copper conductor, 2 plastic insulation, 3 common conductor covering, 4 ar-
mouring of steel strip, plastic sheath

The concentric conductor of the plastic cable in fig. 3.2. may be used as centre
conductor or protective conductor.

Consumers’ installations in the low-voltage range are very frequently con-

nected to the power supply networks by underground cables. In this, the tradi-
tional paper-insulated compound-impregnated cable is more and more replaced
by plastic-insulated dry cable.

At almost the same current-carrying capacity several advantages are offered

Fig. 3.2. Plastic cable with solid aluminium conductors
by plastic-insulated underground cables as compared to compound-
impregnated cables: 1 aluminium conductors, 2 plastic insulation. 3 common conductor cover, 4
concentric conductor of aluminium flat wires (armouring), 5 protection against
- o m i s s i o n o f t h e e x p e n s i v e l e a d s h e a t h i n g ,

corrosion, 6 plastic sheath
- the insulation value will not be reduced due to loss of compound.

- c o n s i d e r a b l y l o w e r w e i g h t .
 In lieu of the conductor material copper, becoming ever more expensive and
scarcer, more and more underground cable the conductor material of which con-
- s i m p l e r p r e p a r a t i o n ,

sists of aluminium is being applied.
- no problems in overcoming differences in height.
Power cables have standardized designations from which the construction and


type of cable may be seen!

3.1. Preparing cable laying

The first thing to be done before starting to lay the cable is to fix the cable
Fig. 3.1. Plastic sheathed cable with copper conductor route under consideration the tracts of land and rights of ownership and utiliza-

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tion. On principle the same is valid here as when fixing the route of an over- In difficult terrain a provisional ramp may serve as an auxiliary. By allowing
head line. the cable drums to drop down damages to the cables and cable drums may be
caused.


Cable drums are to be moved only in rolling direction. The rolling direction is
marked on the cable drum.

Prior to processing, the cable is to be tested for current flow!

In case of the cables showing damages to the insulation, in particular the exter-
Fig. 3.3. Fixing the cable route prior to running out the cable nal insulation, such cables must not be used. If necessary a sleeve will have to
be fited to the faulty point.
1 building to be connected, 2 improper cable route since damage will be caused
to ways, ornamental shrubs and banks of waters, 3 proper cable route along a 3.2. Underground laying of power cables
way without mentionable damages to the property
The cable drum is firmly placed on cable jacks or a cable car. Care has to be
Underground cables are laid in cable ditches. Depending on the properties of taken to position the cable drum horizontally only a few centimeters above the
the soil and the degree of danger to damaging the cables these cable ditches are ground. This will prevent the cable drum from slipping off laterally during the
from 70 to 120 cm deep. The base of the cable ditch must be so wide as to offer cable is run out. A braking device is to be provided at the cable drum.
sufficient space for the cables to be laid. The distance between cables is to be
During reeling off the cable should continuously run out under tension from
approx. 20 cm. In order to prevent damage to the cables they are placed on
above
sand, fine gravel or screened soil. The excavated soil stays beside the cable
ditch. After completion of cable laying it will serve to back-fill the remaining The cable has to be pulled off the drum opposite to the rolling direction indi-
ditch. cated on the cable drum. The cable must neither be kinked, nor must there be
formed loops or curls!
Prior to laying the cable the required cable and auxiliaries for this activity will
have to be provided. During this, special attention will have to be paid to the
transport of the cable drums. Unloading the cable drums is preferably to be
done by mobile crane or from a special trailer. Under no circumstances must
cable drums be dropped from a transport vehicle.

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Fig. 3.6. Support by idlers of cable being run out
When laying cable, preferably devices for mechanical cable laying wil
l have to be employed. For that purpose winches and cable handling machinery
are to be taken.
Cable handling machinery is to be employed in case of long and winding
routes.
When laying cable by means of a winch the cable will be joined to a pulling
rope by means of a cable stocking of metal.
The pulling speed is to be slowly and flexibly adapted to the tensile force of the
cable, in which case
the permissible tensile forces must not be exceeded!
In distances of 5 m idlers are to be positioned on which the cable runs. In
curves angular idlers will have to be arranged. If application of machinery for
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cable laying is not feasable the cable will have to be pulled off manually. The
cable is carried with the arms spread downwards.
Fig. 3.7. Position of workmen during running out the cable
1 workmen, 2 supervisor
Cables must not be carried on the shoulder because the permissible minimum
bending radius may be exceeded resulting possibly in ruptures of cable or insu-
lation. Cables must not be dragged over the ground or other obstacles!
During cable laying the permissible minimum bending radius will have to be
observed.At temperatures below 4°C cable is not to be laid any longer. Cables
will become brittle at low temperatures and will be easily broken. In urgent
cases also at low temperatures cable may be run out, if the cable is warmed up
beforehand, e.g. by means of a heater fan.
Cables will be covered in cable ditches by bricks or concrete ducts resp. cable
covering hoods. Cables may also be laid into cable ditches embedded in sand
without cover. However, in this instance the route of the cable must be marked
by an approx. 10 cm wide yellow plastic tape, placed 30 cm above the cable.
This exemption holds, however, for cables with a concentric conductor only.
Cables being laid into the ground without cover must be dug in at least 1 m
deep!
If cable covering hoods are being employed the cable will have to be sur-
rounded by sand. Existing cavities between cable and covering hood will ob-
struct heat dissipation from the cable to the soil.
Beneath streets resp. roads cables are being passed, laid in cement ducts. There
are cement ducts for 1 to 4 draughts. They are made of concrete and are to be
put together without a gap between them.
Beneath railway tracks cables are to be laid in tubes 1.50 m deep. Alongside
gas pipelines cables are being laid in a distance of approx. 25 cm.


Fig. 3.8. Cement duct with 3 draughts
Fig. 3.9. Cable covers
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1 bricks, 2 cable covering hoods
Also in the instance of crossing other cables, e.g. telecommunication cables,
both cables are to be protected mechanically. Each 3 to 5 m the laid cables will
be marked. For that purpose plastic cable marking tape is being used.
Colour and printing on the cable marking tape will inform about
- v o l t a g e

- c a b l e t y p e a n d n u m b e r o f c a b l e a s w e l l a s

- cross section.
Before cutting sheathed cable, the sheath of the cable will be tied on both sides
of the cut. For that purpose “endless bindings” are made of firmly wound
twine. The principle of such a binding may be seen from fig. 3.10. For cutting
hand hack saws or strength-saving cable shears are being employed.
Within buildings the outer jute cover of cables is to be completely removed for
reasons of fire protection!
Fig. 3.10. Cutting of a lead-sheathed cable with jute envelope and representa-
tion of an endless binding at the cable
1 pull twine by flat pliers until the twine’s upper end is in the binding, thereaf-
ter cut end at the binding
For drawing or correcting the cable layout plan, cables, cable joints, under-
passes as well as particular crossings and exposures will have to be surveyed
prior to back-filling the cable ditch. The cable ditch will be back-filled by 30
cm thick layers of soil. Each layer will have to be compacted.
Fig. 3.11. Simplified segment of a cable layout plan and cable marker with in-
formation on longitudinal extension
1 switchgear, 2 consumer’s installation, 3 cable, 4 site of cable laying machine,
5 sites for placing cable drums along the route, 6 direction of earth excavation,
7 crossing with pipeline, 8 street underpasses, 9 streets, 10 cable marker
The position of cables in ground without fixed reference points is marked by
cable markers.
They consist of ashlar or concrete and bear an abbreviation.
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3.3. Removal of insulation layers from cable
Prior to making conductive connections at the cable, the individual insulation
layers will have to be removed.
Processing plastic insulated cable is quite simple. For a cable according to fig.
3.2. the following working steps will be taken:
1. Removal of plastic sheath
Take measurements; by dismantling device make longitudinal incision in plas-
tic sheath; make the circular cut; pull off sheath.
2. Bringing out the concentric conductor
Deflect the individual armouring wires and bunch the wires
3. Cutting of sheet
Nick the sheet by triangular file just above the deflected armouring and tear off
4. Removal of the common conductor cover
Make longitudinal incision by dismantling device; make circular cut; fan out
conductor; tear off common conductor cover; clean conductor’s plastic insula-
tion from adhering residues of plastic material.
Fig. 3.12. Removal of insulation layers from a cable with concentric conductor
1 plastic sheath, 2 cable fixing clamp, 3 concentric conductor, 4 common con-
ductor cover, 5 plastic insulation, 6 conductor, 7 clip 10 x 1 mm in a distance
of approx. 120 mm, 8 cable terminal

For removal of the insulation layers from paper-insulated compound-
impregnated lead-sheathed cable the following working steps are to be taken:
(see fig. 3.13.)
1. Make tie and remove the external jute cover.
2. Fit collar out of a piece of armouring sheet, cut the armouring by filing and
remove same.
3. Remove cushioning layer.
4. Clean lead sheathing by a non-inflammable dissolvent.
5. Solder on copper strand to lead sheath.
6. Make circular incision on lead sheath; make parallel incision in lead sheath;
roll-back the loose strip by flat pliers; tear off lead sheath along circular cut;
slightly widen the upper edge of the remaining lead sheath.
7. Tie off the belt insulation; unwind and tear off belt insulation.
8. Spread conductors and cutt off fillers.
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9. Tie off conductor insulation; remove conductor insulation; clean conductors;
finally deflect conductors.
Fig. 3.13. Working steps on removal of insulation layers at paper-insulated
lead-sheathed cable
Special care has to be taken in soldering on the earthing strand. For this pur-
pose propane gas soldering devices or a blow lamp for soldering are being em-
ployed. The lead sheath and the copper strand to be soldered on are to be
cleaned from all oxides. The lead sheath may be cleaned by scraping with a
stripper. The copper strand is to be tautly placed around the lead sheath and the
soldering surface to be wetted by soldering flux. Solder tin stick is to be laid on
in pieces and to be shaped like a bulb by means of a dampened rag after thor-
oughly warming the soldering surface.
Caution! In case of too much warming of the lead sheath at one point, perfora-
tions of the lead sheath may result!

 For making the sleeve joint both ends of the cable must overlap each other for
approx. 50 cm and run towards the sleeve’s end as an s-shaped load reducing
curve.

Sleeve bodies of grey cast iron are split. The upper and lower parts of the
sleeve will be bolted together after accommodating the cable.

Fig. 3.14. Copper strand soldered onto lead sheath

1 lead sheath, 2 copper strand, 3 soldering surface 


3.4. Cable joints and terminations

For protecting cables from ingress of humidity into the insulation, for mechani-
cal protection as well as for preventing cable impregnating compound to
emerge from compound-impregnated cables, conductor connections at cables
are being made by means of sleeves and cable terminations.
Sleeves serve for connecting cables to each other. Connecting sleeves and tee
joints are discerned.
Cable terminations are being installed at points of the cable where transition
from cables to open-ended line systems, e.g. bus bars takes place.
There are differences in respect to the construction of sleeves and terminations.
Practically sleeves and cable terminations of cast iron, plastic and cast resin are
being used.
Fitting of cable sleeves takes place in the cable ditch. For easing the work of
the cable fitter providing a work pit is recommended.
Fig. 3.15. Placement of cable in front of a connecting sleeve
1 cable ditch, 2 working pit, 3 ends of cable, 4 cable sleeve, 5 flatly placed
brick
The outer cover of the cable extends into the inner end of the sleeve’s housing.
Each opening of the sleeve for entering the cable will be sealed by a bitumi-
nous felt batting wrapped around the cable.
The lengths of the lead sheath and of the belt insulation in case of paper-
insulated lead-sheathed cables to be stripped are dependent on the cable cross
section. The connection of the conductor ends to each other can be achieved by
stamping, soldering, welding or screwing. Stamped connections can be made in
a very simple and firm way by sliding a stamping tube on to the prepared con-
ductor ends which will - similar as in case of stamped terminals - conductively
connect both conductor ends after stamping. Within the sleeve the conductors
are insulated and spaced by means of stems.

11


Fig. 3.16. Sectional view of a connecting sleeve at a plastic cable with concen-
tric conductor
1 cable, 2 lower portion of sleeve, 3 upper portion of sleeve, 4 lid, 5 compres-
sion clamps, 6 earthing socket, 7 bituminous felt batting, 8 flexible earthing
strand, 9 stems, 10 sealing compound
The concentric conductors and lead sheath of the cables are being connected to
each other.
It is also very important to include the sleeve body into the earthing system.
When installing service tap boxes the main cable needs not be cut!
Cable sealing compound by which the sleeve is completely sealed is easily
melted and highly insulating. It will have reached its processing temperature if
bubbles do not raise any more in the melting container. Then further heating
must be stopped. If during heating the sealing compound foam is created on the
surface it will have to be stirred until the foam subsides. Foam means humidity
in the sealing compound reducing the insulating capacity of the sealing com-
pound considerably.
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After approx. 10 minutes the sealing compound is to be poured carefully
through the lid of the sleeve. Since the sealing compound will shrink during the
cooling process, refilling will have to be done.
In case of cable terminations to be sealed by sealing compound the same proc-
ess will be applied as when preparing a cable sleeve.
In the instance of plastic-insulated cable sealing by cable termination is re-
quired only if ingress of humidity may take place!
Making cast-resin terminations is simpler than fitting cable terminations sealed
by sealing compound.
Also in this case it will be important to seal the cable when working with
paper-insulated lead-sheathed cable. This will be achieved if the conductor insu-
lation, the belt insulation and approx. 10 mm of the metal sheathing are being
wrapped in two layers of PVC-tape. Each layer of PVC-tape with an overlap of
50% is provided with a coat of PVC-adhesive. For this termination no box
body, but a mould only will be required. Into this mould, being arranged
around the cable and sealed, a mixture of synthetic resin and silica sand will be
poured.
The mould’s concentric position around the cable must be paid attention to!
If strictly observing the mixing ratio and the curing time the casting will be per-
manently hardened after approx. 24 hours. Then the mould may be removed
and the casting be cleaned (de-burring).


Fig. 3.17. Cable termination of cast resin
 ceived special training only! The completed cables will be fixed by a double-
tongued mounting clip (see fig, 3.12.) or other mounting elements, e.g. an an-
gle iron, in front of the connection point.

3.5. Making of conductor connections

Conductor connections on cable terminations are quite frequently made via ca-
ble terminals.

In case of the traditional methods of connection like soldering, welding or

clamping of cable terminals to conductors no absolute safety for an unobjection-
able connection will be given.

Stamped connections have replaced these traditional types of connection.

Stamping is distinguished by reliability of the procedure, durability of the con-
nection also under unfavourable conditions as well as by uncomplicated han-
dling of the stamping tools. For the stamping of cable terminals mechanical
1 cast resin, 2 cast resin and silica sand, 3 conductor insulation covered by hand stampers, or in case of bigger cross sections, hydraulic stamping devices
PVC-tape, 4 belt insulation with binding (4 windings), 5 lower PVC-banding, 6 are being employed.
copper strand, 7 stamped cable terminal, 8 metal sheath, 9 external protective
1 stamping head, 2 safety valve, 3 pressure hose, 4 pressure reducing valve, 5
cover
pump lever, 6 pressure tank, 7 pump handle, 8 bearing grip
Synthetical resins are chemically aggressive. For protecting the skin and the
clothes, protective apparel will have to be worn when making terminations of
cast-resin. During this work the eyes are particularly endangered. They are to
be protected by safety goggles.

Fitting of Cable sleeves and cable terminations is a responsible work. Voca-

tional experience and special knowledge will be required. Due to this, cable
sleeves and terminations should in principle be mounted by experts having re-

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 1 Pressure tank of the stamping head, 2 space for stamping inserts, 3 hose con-
nection, 4 screw cap, 5 piston

Stamping inserts being matched to the type of cable and cross section of the
conductor will be fitted into the stamping tools.

There are two different types of stamping inserts:

- s t a m p i n g i n s e r t s f o r V- g r o o v i n g

- stamping inserts for hexagonal stamping.

V-grooving is on principle applied to copper conductors only!

Cable terminals are marked with information about the size of the diameter of
the connecting pin and the conductor’s diameter.

Fig. 3.20. Stamping inserts



1 V-grooving, 2 hexagonal stamping
Fig. 3.19. Stamping head of a hydraulic stamping tool
The stamping inserts for the cable terminal are in any case to match the cable
terminal.

14
The designations of suitable stamping inserts are to be taken from the tables in
the valid regulations.
When stamping on cable terminals the following fitting process is to be ad-
hered to:
1. Cutting conductor lengthwise
The conductor is to be matched to the length of the cable terminal up to the con-
necting pin. It is to fill out the cable terminal. The elongation of the cable termi-
nal’s connection during hexagonal stamping has also to be considered. It has to
be subtracted from the length of the conductor. Depending on the cross section
in question this change of length may be between 3 and 5 mm.


Fig. 3.21. Cable terminal prior to and after stamping
15
2. Removal of the conductor’s insulation and cleaning of the contact surfaces.
The outside of the conductor and the inner contact surfaces of the terminal’s
barrel must be metallic-bright. Contaminated conductors and barrels of termi-
nals will have to be cleaned from adhering dirt and oxides by wire brush.
Every conductor has to be cleaned only just prior to the stamping process, max.
10 minutes beforehand!
3. Entering the conductor into the barrel of the terminal
Difficulties which may arise in that process are best overcome by chamfering
the conductor laterally or by fixing a taut wire binding adjacent to the cut sur-
face which will have to be removed after having entered the conductor into the
cable terminal’s barrel. Segmental conductors are to stamped circularly by the
corresponding stamping inserts prior to putting on the cable terminal.
Fig. 3.22. Entering the conductor into the cable terminals barrel by means of a
wire binding
4. Stamping on the cable terminal
V-grooving is to be performed so as to have the local impression situated at the
upper or lower side of the terminal’s barrel aproximately in the centre. In par-
ticular, maintenance of the required stamping depth has to be observed. This
will be achieved when the stamping jaws of the stamping insert will have
closed or corresponding markings have been reached.

 If after closing of the stamp jaws further pressure is exerted on the stamping
tool this will unconditionally lead to heavy damage at the stamp inserts or the
stamping device itself (risk of accident!)!

Stamp jaws which are not completely closed do not warrant a durable electrical
connection (restamping to be done!)!

Lapping the conductors, which has been dealt with in section 3.4. on process-
ing of paper-insulated lead-sheathed cables, takes place after fitting the cable
Fig. 3.23. V-grooving of the upper or lower sides
terminals.
In case of hexagonal stamping of aluminium conductors the stamping insert
For soldering of cable terminals there are some restrictions. Soldering of cable
has to be applied in between the stamping marks on the cable terminal. If two
terminals should be turned to only if stamped terminals cannot be applied.
stampings are to be made, stamping will be started at the point nearest to the
terminal lug. The burrs resulting from hexagonal stamping at the cable terminal
will have to be removed.

How to proceed when soldering cable terminal is to be taken from fig. 3.25.
and 3.26.Fig. 3.25. Soldering a cable terminal

Fig. 3.24. Connection to cable terminal of aluminium conductors with one or a) prepared conductor, b) conductor with cable terminal slid on, c) soldering on
two hexagonal stampings the cable terminal: 1 flame-proof batting, 2 solder, 3 heating nozzle, 4 cable ter-
minal

16
When soldering on cable terminals the connecting area around the lug of the
cable terminal is continued to be heated until the soldering tin laid on starts to
flow. So much solder is put on to the soldering surface that all parts of the con-
ductor in the total area are covered by tin which must show a mirror reflection.
In no case so much solder is to be brought on the soldering surface resp. heat-
ing is continued so long that the solder flows through the cable terminal into
the conductor!
Soldering cable terminals requires extensive special skills and is therefore to be
carried out by especially qualified experts only.


Fig. 3.26. Cable terminal finished by soldering
1 plastic tube or tape
ARMOURING AND SERVING
All multicore cables liable for mechanical damage and all HV cabkes (irrespec-
tive of the situation of installation) shall be armoured. Where armouring is un-
avoidable in dingle core cables, either the armour should be made of nonmag-
netic material, or it should be ensured that the armouring is not shorted at termi-
nations, thus preventing the flow of circulating currents therein.
17
1.3.2 Short runs of cables laid in pipes, closed masonary trenches and similar
protected or secured enclosures need not be armoured.
1.3.3 PVC and XLPE cables, when armoured, shall have galvanized steel wires
(flat or round) for armouring.
1.3.4 Paper insulated cables shall have for armouring, a double layer of steel
tape for normal applications. Steel wire armouring is preferred where the ca-
bles are liable to tensile stresses in applications such as vertical runs, sus-
pended on brackets or laid in soil that is likely to subside.
1.3.5 Serving over armouring in paper insulated cables shall consist of a com-
plete layer or layers of suitable compounded Hessian materials.
SELECTION OF CABLE SIZES
1.4.1 The cable sizes shall be selected by considering the voltage drop in the
case of MV (distribution) cables and Current carrying capacity in the case of
HV (feeder) cables. Due consideration should be given for the Prospective
short circuit current and the period of its flow, especially in the case of HV ca-
bles.
1.4.2 While deciding upon the cable sizes, derating factors for the type of cable
and depth of laying, grouping, ambient temperature, ground temperature, and
soil resistivity shall be taken into account.
1.4.3 Guidance for the selection of cables shall be served from relevant Indian
Standards such as IS:3961 (Part-1)-1967 for paper insulated lead sheathed ca-
bles, IS: 3961 (Part-2)-1967 for PVC insulated and PVC sheathed heavy duty
cables, IS: 5819- 1970 for recommended short circuit ratings of high voltage
PVC cables, IS: 1255-1983 on code of practice for installation and mainte-
nance of power cables upto and including 33KV rating etc.
STORAGE AND HANDLING
(i) The cable drums shall be stored on a well drained, hard surface, so that the
drums do not sink in the ground causing rot and damage to the cable drums.
Paved surface is preferred, particularly for long term storage.
(ii) The drums shall always be stored on their flanges, and not on their flat
sides.
(iii) Both ends of the cables especially of PILCA cables should be properly
sealed to prevent ingress/ absorption of moisture by the insulation during stor-
age.
(iv) Protection from rain and sun is preferable for long term storage for all
types of cables. There should also ventilation between cable drums.
(v) During storage, periodical rolling of drums once in, say, 3 months through
90 degrees shall be done, in the case of paper insulated cables. Rolling shall be
done in the direction of the arrow marked on the drum.
(vi) Damaged battens of drums etc. should be replaced as may be necessary.
1.5.2 Handling
(i) When the cable drums have to be moved over short distances, they should
be rolled in the direction of the arrow marked on the drum.
(ii) For manual transportation over long distances, the drum should be mounted
on cable drum wheels, strong enough to carry the weight of the drum and
18
pulled by means of ropes. Alternatively, they may be mounted on a trailer or on
a suitable mechanical transport.
(iii) For loading into and unloading from vehicles, a crane or a suitable lifting
tackle should be used. Small sized cable drums can also be rolled down care-
fully on a suitable ramp or rails, for unloading, provided no damage is likely to
be caused to the cable or to the drum.
INSTALLATION
(i) Cables with kinks, straightened kinks or any other apparent defects like de-
fective armouring etc. shall not be installed.
(ii) Cables shall not be bent sharp to a small radius either while handing or in
installation. The minimum safe bending radius for PVC/XLPE (MV) cables
shall be 12 times the overall diameter of the cable. The minimum safe bending
radius for PILCA/XLPE (HV) cables shall be as given in Table-II. At joints and
terminations, the bending radius of individual cores of a multi core cable of
any type shall not be less than 15 times its overall diameter.
(iii) The ends of lead sheathed cables shall be sealed with solder immediately
after cutting the cables. In case of PVC cables, suitable sealing compound/tape
shall be used for this purpose, if likely exposed to rain in transit storage. Suit-
able heat shrinkable caps may also be used for the purpose.
Route
Before the cable laying work is undertaken, the route of the cable shall be de-
cided by the Engineer-in-Charge considering the following.
(i) While the shortest practicable route should be preferred, the cable route
shall generally follow fixed developments such as roads, foot paths etc. with
proper offsets so that future maintenance, identification etc. are rendered easy.
Cross country run merely to shorten the route length shall not te adopted.
(ii) Cable route shall be planned away from drains and near the property, espe-
cially in the case of LV/MV cables, subject to any special local requirements
that may have to be necessarily complied with.
(iii) As far as possible, the alignment of the cable route shall be decided after
taking into consideration the present and likely future requirements of other
services including cables enroute, possibility of widening of roads/lanes etc.
(iv) Corrosive soils, ground surrounding sewage effluent etc. shall be avoided
for the routes.
( v ) R o u t e o f c a b l e s o f d i f f e r e n t v o l t a g e s .
 ate authorities, such as, Municipal authorities, Department of telecommunica-
(a) Whenever cables are laid along well demarcated or established roads, the
LV/MV cables shall be laid farther from the kerb line than HV cables.
(b) Cables of different voltages, and also power and control cables shall be
kept in different trenches with adequate separation. Where available space is
restricted such that this requirement cannot be met, LV/MV cables shall be laid
above HV cables.
(c) Where cables cross one another, the cable of higher voltage shall be laid at
a lower level than the cable of lower voltage.
1.6.3 Proximity to communication cables
19
Power and communication cables shall as far as possible cross each other at
right angles. The horizontal and vertical clearances between them shall not be
less than 60cm.
1.6.4 Railway crossing
Cables under railway tracks shall be laid in spun reinforced concrete, or cast
iron or steel pipes at such depths as may be specified by the railway authorities,
but not less than 1m, measured from the bottom of the sleepers to the top of the
pipe. Inside railway station limits, pipes shall be laid upto the point of the rail-
way station limits, pipes shall be laid upto a minimum distance of 3m from the
center of the nearest track on either side.
1.6.5 Way Leave
Way leave for the cable route shall be obtained as necessary, from the appropri-
tion, Gas Works, Railways, Civil Aviation authorities, Owners of properties etc.
In case of private property, Section 12/51 of the Indian Electricity Act shall be
complied with.
1.6.6 Methods of laying
The cables shall be laid direct in ground, pipe, closed or open ducts, cable trays
or on surface of wall etc. The method(s) of laying required shall be specified in
the tender schedule of work.
1.6.7 Laying direct in ground 1.6.7.1 General
This method shall be adopted where the cable route is through open ground,
along roads/lanes, etc. and where no frequent excavations are likely to be en-
countered and where re-excavation is easily possible without affecting other 1 . 1 K V .

services. (b) When more than one tier of cables is unavoidable and vertical formation

1.6.7.2 Trenching of laying is adopted, the depth of the trench in (ii) a above shall be increased by
30cm for each additional tier to be formed.
( i ) W i d t h o f t r e n c h

The width of the trench shall first be determined on the following basis Where no sand cushioning and protective covering are provided for the cables
as per 2.6.7.3(i)(b), 2.6.7.3(vii)(c) and 2.6.7.3(ix)(d) below, the depth of the
. (a) The minimum width of the trench for laying a single cable
trench as per (ii)(a) and (b) above shall be increased by 25cm.
s h a l l b e 3 5 c m

(iii) Excavation of trenches

. (b) Where more than one cable is to be laid in the same trench in (a) The trenches shall be excavated in reasonably straight lines. Wherever there

h o r i z o n t a l
 is a change in the direction, a suitable curvature shall be adopted complying

with the requirements of clause 2.6.1(ii).

formation, the width of the trench shall be increased such that the inter-axial (b) Where gradients and changes in depth are unavoidable, these shall be grad-

spacing between the cables, except where otherwise specified, shall be at least ual.

20cm. The bottom of the trench shall be level and free from stones, brick bats etc.

© There shall be a clearance of at least 15cm between axis of the end cables (d) The excavation should be done by suitable means-manual or mechanical.
and the sides of the trench. The excavated soil shall be stacked firmly by the side of the trench such that it

(ii) Depth of trench may not fall back into the trench.

The depth of the trench shall be determined on the following basis (Refer fig- (e) Adequate precautions should be taken not to damage any existing cable(s),

ure 1): - (a) Where the cables are laid in a single tier formation, the total depth pipes or any other such installations in the route during excavation. Wherever

of trench shall not be less than 75cm for cables upto 1.1KV and 1.2m for ca- trickd, tiles or protective covers or bare cables are encountered, further excava-

bles above tion shall not be carried out without the approval of the Engineer-in-Charge.

(f) Existing property, if any, exposed during trenching shall be temporarily sup-
ported adequately as directed by the Engineer-in-Charge. The trenching in such

20
cases shall be done in short lengths, necessary pipes laid for passing cables
therein and the trench refilled in accordance with clause 2.6.7.4.
(g) It there is any danger of a trench collapsing or endangering adjacent struc-
tures, the sides may be left in place when back filling the trench.
(h)Excavation through lawns shall be done in consultation with the Department
concerned.
Laying of cable in trench
(i) Sand cushioning
(a) The trench shall then be provided with a layer of clean, dry sand cushion of
not less than 8cm in depth, before laying the cables therein.
(b) However, sand cushioning as per (a) above need not be provided for MV
cables, where there is no possibility of any mechanical damage to the cables
due to heavy or shock loading on the soil above. Such stretches shall be clearly
specified in the tender documents.
© Sand cushioning as per (a) above shall however be invariably provided in
the case of HV cables.
(ii) Testing before laying
All the time of issue of cables for laying, the cables shall be tested for continu-
ity and insulation resistance (See also clause 2.8.1)
(iii) The cable drum shall be properly mounted on jacks, or on a cable wheel at
a suitable location, making sure that the spindle, jack etc. are strong enough to
21
carry the weight of the drum without failure, and that the spindle is horizontal
in the bearings so as to prevent the drum creeping to one side while rotating.
(iv) The cable shall be pulled over on rollers in the trench steadily and uni-
formly without jerks and strain. The entire cable length shall as far as possible
be laid off in one stretch. PVC/XLPE cables less than 120sq.mm. size may be
removed by “Flaking” i.e. by making one long loop in the reverse direction.
Note: - For short runs and sizes upto 50sq.mm. of MV cables, any other suit-
able method of direct handing and laying can be adopted without strain or ex-
cess bending of the cables.
(v) After the cable has been so uncoiled, it shall be lifted slightly over the roll-
ers beginning from one and by helpers standing about 10m apart and drawn
straight. The cable shall then be lifted off the rollers and laid in a reasonably
straight line.
(vi) Testing before covering
The cables shall be tested for continuity of cores and insulation resistance (Re-
fer clause 2.8.1) and the cable length shall be measured, before closing the
trench. The cable end shall be sealed /covered as per clause 2.6.1 (iii)
( v i i ) S a n d c o v e r i n g

Cables laid in trenches in a single tier formation shall have a covering of dry
sand of not
less than 17cm above the base cushion of sand before the protective cover is
laid.
In the case of vertical multi-tier formation, after the first cable has been laid, a
sand cushion of 30cm shall be provided over the base cushion before the sec-
ond tier is laid. If additional tiers are formed, each of the subsequent tiers also
shall have a sand cushion of 30cm as stated above. Cables in the top most tiers
shall have final sand covering not less than 17cm before the protective cover is
laid.
Sand covering as per (a) and (b) above need not be provided for MV cables
where a decision is taken by the Engineer-in-Charge as per sub clause (i)(b)
above, but the inter tier spacing should be maintained as in (b) above with soft
soil instead of sand between tiers and for covering.
Sand cushioning as per (a) and (b) above shall however be invariably provided
in the case of HV cables.
(viii) Extra loop cable
(a) At the time of original installation, approximately 3m of surplus cable shall
be left on each terminal end of the cable and on each side of the underground
joints. The surplus cable shall be left in the form of a loop. Where there are
long runs of cables such loose cable may be left at suitable intervals as speci-
fied by the Engineer-in-Charge.
(b) Where it may not be practically possible to provide separation between ca-
bles when forming loops of a number of cables as in the case of cables emanat-
ing from a substation, measurement shall be made only to the extent of actual
volume of excavation, sand filling etc. and paid for accordingly.
(ix) Mechanical protection over the covering
22
(a) Mechanical protection to cables shall be laid over the covering in accor-
d a n c e w i t h

(b) and (c) below to provide warning to future excavators of the presence of
t h e c a b l e

and also to protect the cable against accidental mechanical damage by pick-axe
blows etc.
(b) Unless otherwise specified, the cables shall be protected by second class
brick of nominal size 22cmX11.4cmX7 cm or locally available size, placed on
top of the sand (or, soil as the case may be). The bricks shall be placed breadth-
wise for the full length of the cable. Where more than one cable is to be laid in
the same trench, this protective covering shall cover all the cables and project
at least 5cm over the sides of the end cables.
© Where bricks are not easily available, or are comparatively costly, there is no
objection to use locally available material such as tiles or slates or stone/
cement concrete slabs. Where such an alternative is acceptable, the same shall
be clearly specified in the tender specifications.
(d) Protective covering as per (b) and (c) above need not be provided only for
MV cables, in exceptional cases where there is normally no possibility of subse-
quent excavation. Such cases shall be particularly specified in the Tender speci-
fications.
(e) The protective covering as per (b) and (c) above shall, however invariably
be provided in the case of HV cables.
Back filling Laying of single core cables

(i) The trenches shall be then back-filled with excavated earth, free from stones (i) Three single core cables forming one three phase circuit shall normally be
or other sharp ended debris and shall be rammed and watered, if necessary in laid in close trefoil formation and shall be bound together at intervals of ap-
successive layers not exceeding 30cm depth. proximately 1m.

(ii) Unless otherwise specified, a crown of earth not less than 50mm and not (ii) The relative position of the three cables shall be changed at each joint at the
exceeding 100mm in the center and tapering towards the sides of the trench time of original installation, complete transposition being effected in every
shall be left three consecutive cable lengths.

to allow for subsidence. The crown of the earth however, should not exceed 10 Route markers
Cms so as not to be a hazard to vehicular traffic.
(i) Location
(iii) The temporary re-statements of roadways should be inspected at regular
Route markers shall be provided along the runs of cables at locations approved
intervals, particularly during wet weather and settlements should be made good
by the Engineer-in-Charge and generally at intervals not exceeding 100m.
by further filling as may be required.
Markers shall also be provided to identity change in the direction of the cable
(iv) After the subsidence has ceased, trenches cut through roadways or other route and at locations of underground joints.
paved areas shall be restored to the same density and materials as the surround-
(ii) (a) Plate type marker
ing area and –re-paved in accordance with the relevant building specifications
to the satisfaction of the Engineer-in-Charge. Route markers shall be made out of 100mm X 5mm GI/ aluminium plate
welded / bolted on 35mm X 35mm X 6mm angle iron, 60cm long. Such plate
(v) Where road beams or lawns have been cut out of necessity, or kerb stones
markers shall be mounted parallel to and at about 0.5m away from the edge of
displaced, the same shall be repaired and made good, except for turfing /as-
the trench.
phalting, to the satisfaction of the Engineer-in-Charge and all the surplus earth
or rock shall be removed to places as specified. (b) CC marker

Alternatively, cement concrete 1:2:4 (1 cement:2 coarse sand: 4 graded stone

aggregate of 20mm in size) as shown in figure 2 shall be laid flat and centered
over the cable. The concrete markers, unless otherwise instructed by the

23
Engineer-in-Charge, shall project over the surrounding surface so as to make cable enters and leaves the crossing. This is particularly important for HV ca-
the cable route easily identifiable. bles.

( c ) I n s c r i p t i o n
 (iii) When pipes are laid cutting an existing road, care shall be taken so that the
The words ‘CPWD-MV/HV CABLE’ as the case may be, shall be inscribed on soil filled up after laying the pipes is rammed well in layers with watering as
the marker. required to ensure proper compaction. A crown of earth not exceeding 10cm
should be left at the top. (iv) The temporary re-instatements of roadways
Laying in pipes / closed ducts
should be inspected at regular intervals, particularly after a rain, and any settle-
1.6.8.1 In locations such as road crossing, entry in to buildings, paved areas ment should be made good by further filling as may be required.
etc. cables shall be laid in pipes or closed ducts. Metallic pipe shall be used as
(v) After the subsidence has ceases, the top of the filled up trenches in road-
protection pipe for cables fixed on poles of overhead lines.
ways or other paved areas shall be restored to the same density and material as
1.6.8.2 the surrounding area in accordance with the relevant CPWD Building Specifica-
tions to the satisfaction of the Engineer-in-Charge.
(i) Stone ware pipes, GI, CI or spun reinforced concrete pipes shall be used for
cables in general; however only GI pipe shall be used as protection pipe on 1.6.8.5 Manholes shall be provided to facilitate feeding/drawing in of cables
p o l e s .
 with sufficient working space for the purpose. They shall be covered by suit-
(ii) The size of the pipe shall not be less than 10cm in diameter for a single ca- able manhole covers. Sizes and other details shall be indicated in the Schedule
ble and not less than 15cm for more than one cable. of work.

(iii) Where steel pipes are employed for protection of single core cable feeding Cable entry into the building
AC load, the pipe should be large enough to contain both cables in the case of
Pipes for cable entries to the building shall slope downwards from the building.
single phase system and all cables in the case of poly phase system.
 The pipes at the building end shall be suitably sealed to avoid entry of water,
(iv) Pipes for MV and HV cables shall be independent ones. after the cables are laid.

Road crossings 1.6.8.7 Cable-grip / draw-wires, winches etc. may be employed for drawing ca-

(i) The top surface of pipes shall be at a minimum depth of 1m from the pave- bles through pipes / closed ducts.

m e n t l e v e l w h e n l a i d u n d e r r o a d s , p a v e m e n t s e t c .

(ii) The pipes shall be laid preferably askew to reduce the angle of bend as the

24
1.6.8.8 Measurement for drawing/ laying cables in pipes/ closed duct shall be
on the basis of the actual length of the pipe / duct for each run of the cable, irre-
spective of the length of cable drawn through.
Laying in open ducts
1.6.9.1 Open ducts with suitable removable covers (RCC slabs or chequered
plates) are generally provided in sub-stations, switch rooms, plant rooms, work-
shops etc. for taking the cables. The cable ducts should be of suitable dimen-
sions for the number of cables involved.
(i) Laying of cables with different voltage ratings in the same duct shall be
avoided. Where it is inescapable to take HV & MV cables same trench, they
shall be laid with a barrier between them or alternatively, one of the two (HV
&MV) cables may be taken through pipe(s).
(ii) Splices or joints of any type shall not be permitted inside the ducts.
(i) The cables shall be laid directly in the duct such that unnecessary crossing
of cables is avoided.
(ii) Where specified, cables may be fixed with clamps on the walls of the duct
or taken in hooks/brackets/troughs in ducts.
Where specified, ducts may be filled with dry sand after the cables are laid and
covered as above, or finished with cement plaster, specially in high voltage ap-
plications.
The arrangement of laying the cables in cradles is permitted only in the case of
cables of 1.1KV grade of size exceeding 120sq.mm. In such cases, the cables
may be suspended on MS flat cradles of size 50mmX5mm which in turn shall
25
be fixed on the wall by bolts grouted into the wall in an approved manner at a
spacing of not less than 60cm.
Laying on cable tray
This method may be adopted in places like indoor substations, air-conditioning
plant rooms, generator rooms etc. or where long horizontal runs of cables are
required within the building and where it is not convenient to carry the cable in
open ducts. This method is preferred where heavy sized cables or a number of
cables are required to be laid. The cable trays may be either of perforated sheet
type or of ladder type.
Perforated type cable tray
(i) The cable tray shall be fabricated out of slotted/perforated MS sheets as
channel sections, single or double bended. The channel sections shall be sup-
plied in convenient lengths and assembled at site to the desired lengths. These
may be galvanished or painted as specified. Alternatively, where specified, the
cable tray may be fabricated by two angle irons of 50mmX50mmX6mm as two
longitudinal members, with cross bracings between them by 50mmX5mm flats
welded/bolted to the angles at 1 m spacing. 2mm thick MS perforated sheet
shall be suitably welded/bolted to the base as well as on the two sides.
(ii) Typically, the dimensions, fabrication details etc. are shown in figure 3A,B
and C.
(iii) The jointing between the sections shall be made with coupler plates of the
same material and thickness as the channel section. Two coupler plates, each of
minimum 200mm length, shall be bolted on each of the two sides of the chan-
nel section with 8mm dia round headed bolts, nuts and washers. In order to
maintain proper earth continuity bond, the paint on the contact surfaces be-
tween the coupler plates and cable tray shall be scraped and removed before
the installation.
(iv) The maximum permissible uniformly distributed load for various sizes of
cables trays and for different supported span are given in Table IV. The sizes
shall be specified considering the same.
(v) The width of the cable tray shall be chosen so as to accommodate all the
cables in one tier, plus 30 to 50% additional width for future expansion. This
additional width shall be minimum 100mm. The overall width of one cable tray
shall be limited to 800mm.
(vi) Factory fabricated bends, reducers, tee/cross junctions, etc. shall be pro-
vided as per good engineering practice. (Details are typically shown in figure
3). The radius of bends, junctions etc. shall not be less than the minimum per-
missible radius of bending of the largest size of cable to be carried by the cable
tray.
(vii) The cable tray shall be suspended from the ceiling slab with the help of
10mm dia MS rounds or 25mmX5mm flats at specified spacing (based on Ta-
ble III). Flat type suspenders may be used for channels upto 450mm width
bolted to cable trays. Round suspenders shall be threaded and bolted to the ca-
ble trays or to independent support angles 50mmX50mmX5mm at the bottom
end as specified. These shall be grouted to the ceiling slab at the other end
through an effective means, as approved by the Engineer-in-Charge, to take the
weight of the cable tray with the cables.
(viii) The entire tray (except in the case of galvanized type) and the suspenders
shall be painted with two coats of red oxide primer paint after removing the
dirt and rust, and finished with two coats of spray paint of approved make syn-
thetic enamel paint.
(ix) The cable tray shall be bonded to the earth Terminal of the switch bonds at
both ends.
(x) The cable trays shall be measured on unit length basis, along the center line
of the cable tray, including bends, reducers, tees, cross joints, etc. and paid for
accordingly.
Ladder type cable tray
(i) The ladder type of cable tray shall be fabricated of double bended channel
section longitudinal members with single bended channel section rungs of
cross members welded to the base of the longitudinal members at a center to
center spacing of 250cm.
(ii) Alternatively, where specified, ladder type cable trays may be fabricated
out of 50mmX50mmX6mm (minimum) angle iron for longitudinal members,
and 30mmX6mm flat for rungs.
(iii) Typical details of fabrication and dimensions of both the types of trays are
shown in figure 4A,B,C and D.
(iv) The maximum permissible loading, jointing of channel sections, width of
the cable tray, provision of elbows, bends, reducers, horizontal tee/ cross junc-
tions etc. suspension of cable tray from the ceiling slab; painting and measure-
ment of the cable tray shall be as per sub-clauses (ii) to (x) below clause
2.6.11.2, except that the overall width of one cable tray may be limited to
800mm.

26
1.6.11.4 Cables laid on cable trays shall be clamped on to the tray at suitable
intervals as per Table-III.
Cable identification tags
Whenever more than one cable is laid / run side by side, marker tags as ap-
proved, inscribed with cable identification details shall be permanently at-
tached to al the cables in the manholes / pull pits / joint pits / entry points in
buildings / open ducts etc. These shall also be attached to cables laid direct in
ground at specified intervals, before the trenches are backfilled.
JOINTING
(i) Before laying a cable, proper locations for the proposed cable joints, if any,
shall be decided, so that when the cable is actually laid, the joints are made in
the most suitable places. As far as possible, water logged locations, carriage
ways, pavements, proximity to telephone cables, gas or water mains, inaccessi-
ble places, ducts, pipes, racks etc. shall be avoided for locating the cable joints.
(ii) Joints shall be staggered by 2m to 3m when joints are to be done for two or
more cables laid together in the same trench.
Joints pits
(i) Joint pits shall be of sufficient dimensions as to allow easy and comfortable
working. The sides of the pit shall be well protected from loose earth falling
into it. It shall also be covered by a tarpaulin to prevent dust and other foreign
matter being blown on the exposed joints and jointing materials.
(ii) Sufficient ventilation shall be provided during jointing operation in order to
disperse fumes given out by fluxing.
27
Safety precaution
(i) A caution board indicating “CAUTION – CABLE JOINTING WORK IN
PROGRESS” shall be displayed to warn the public and traffic where necessary.
(ii) Before jointing is commenced, all safety precautions like isolation, dis-
charging, earthing, display of caution board on the controlling switchgear etc.
shall be taken to ensure that the cable would not be inadvertently charged from
live supply. Metallic armour and external metallic bonding shall be connected
to earth. Where “Permit to work” system is in vogue, safety procedures pre-
scribed shall be complied with.
Jointing materials
(i) Jointing materials and accessories like conductor ferrules, solder, flux, insu-
lating and protective tapes, filling compound, jointing boxes, heat shrinking
joint kit etc. of right quality and correct sizes, conforming to relevant Indian
Standards, wherever they exist, shall be used.
(ii) The design of the joint box and the composition of the filing compound
shall be such as to provide an effective sealing against entry of moisture in addi-
tion to affording proper electrical characteristic to joints.
(iii) Where special type of splicing connector kits or epoxy resin spliced joints
or heat shrinkable jointing kits are specified, materials approved for such appli-
cation shall be used. Storing as well as jointing instructions of the manufacturer
of such materials shall be strictly followed.
Jointer

Jointing work shall be carried out by a licensed/ experienced (where there is no

licensing system for jointers) cable jointer.

Cable work with joints

(i) About 3m long surplus cable shall be left on each side of joints as laid down
in clause 1.6.7.3 (viii).

(ii) Insulation resistance of cables to be jointed shall be tested as per clause

1.8.1. Unless the insulation resistance values are satisfactory, jointing shall
not be done.

(iii)(iii) Cores of the cables must be properly identified before jointing.


(iv) Where cable is to be jointed with the existing cable, the sequence
should be so arranged as to avoid crossing of cores wile jointing.

(v) Whenever the aluminium conductor is exposed to outside atmosphere, a

highly tenacious oxide film is formed which makes the soldering of aluminium
conductor difficult. This oxide film should be removed by using appropriate
type of flux.

(vi) The clamps for the armour shall be clean and tight.

Jointing procedure

While it would be necessary to follow strictly the instructions for jointing fur-
nished by the manufacturers of cables and joint kits, a brief on the jointing pro-
cedures is given for general guidance in Appendix F.

28
SECTION 2

Testing of Cables

T E S T I N G
 Testing before backfilling

Testing before laying
All cables shall be subjected to the above mentioned tests, before covering the
All cables, before laying, shall be tested with a 500V megger for cables of cables by protective covers and back filling and also before taking up any joint-
1.1KV grade, or with a 2500/5000V megger for cables of higher voltage. The ing operation.
cable cores shall be tested for continuity, absence of cross phasing, insulation
resistance from conductors to earth / armour and between conductors.

29
Testing after laying
(i) After laying and jointing, the cable shall be subjected to a 15 minutes pres-
sure test. The test pressure shall be as given in Table VI. DC pressure testing
may normally be preferred to AC pressure testing.
(ii) In the absence of facilities for pressure testing as above, it is sufficient to
test for one minute with 1000V megger for cables of 1.1KV grade and with
2500/5000V megger for cables of higher voltages.
Cable fault location
is required anywhere where the fault cannot be seen. This is a multi-step proc-
ess that must be performed as safely and as quickly as possible to prevent cus-
tomers going without power.
Step 1 - Cable isolation and safety procedures: A cable fault is nearly always a
permanent fault. This means that the cable in question will be in a condition
where the protection devices at one or both ends of the cable will have tripped,
leaving the cable isolated but NOT earthed (grounded).
The first task is for the authorised person on the site to make the cable safe by
isolating and then earthing (grounding) one or both ends. Only after the appro-
priate procedures have been carried out can any testing personnel be allowed to
approach the cable and prepare for testing.
Step 2 - Cable identification: Where multiple cables exist, cable identification
testing will identify the correct cable to work on. Clear identification before a
cable is cut is intrinsic to safe maintenance work. Any mistakes here can be fa-
tal and may cause much longer outages for the connected customers.
30
Step 3 - Cable tracing: When an underground cable is first laid, it rarely runs in
a straight line, but rather meanders in depth and direction. Cable tracing is done
to determine that the route of the cable is following the expected path.
Step 4 - Fault identification: The first major procedure is to determine the
phase on which the fault has occurred and if it is of low or high resistance. This
test determines the correct technique, and therefore equipment, needed to diag-
nose the fault. Typically, if the fault is found to be below 100 Ohms, a low volt-
age pulse (eg: 40 V) from a TDR (time domain reflectometer) can be used. If
the fault is a higher resistance (> 100 Ohm), a low voltage pulse will likely not
see it. For these types of faults, an impulse generator (shock discharge) or
bridge, will be necessary.
Step 5 – Fault prelocation: A reliable and precise pre-location method is neces-
sary to locate a cable fault quickly and efficiently. Good pre-location can deter-
mine the fault position to within a few percent of the cable length and will re-
duce pinpointing time to a few minutes.
Remember:
a) If it is a low resistance fault, pre-location is likely to be the only means nec-
essary for location.
b) For high resistance faults, ARM (arc reflection) or ICE (impulse current)
techniques on an SWG (surge wave generator) should be used. Alternatively,
the decay method with an HV DC tester (bridge) can be used for pre-location.
Step 6 - Pinpointing: The aforementioned test methods will get the operator
within 5% distance of the fault. Acoustic pinpointing techniques must be em-
ployed at this stage in order to narrow the margin of error to 0.1%. In most
cases, shock discharge generators are used for pinpointing in conjunction with
acoustic methods. The discharge creates a loud noise, which is pinpointed pre-
cisely using an acoustic pinpointing device. This device evaluates the time dif-
ference between the acoustic signal (speed of sound) and the electromagnetic
(nearly the speed of light) impulse of the shock discharge. When the shortest
time difference is indicated, the exact fault location is revealed.
Step 7 - Re-energisation of the cable: Once all testing and repairs are com-
pleted, the Safety/Testing documentation is cancelled and the cable is handed
back to the appropriate operators so they can reinstate it and re-energise the
loads on the newly repaired cable.
Effect of loose neutral connections:
loose neutral wire can cause abnormal arcing around its point of connection,
usually resulting in the neutral wire becoming unusually hot, burning its insula-
tion off and even causing damage to its surroundings.
A loose neutral wire is also the cause of the majority of electrical fires.
Arcing occurs because the loose wire does not make consistent contact. Some-
times it does make contact and sometimes it doesn’t. This can happen due to a
variety of factors, such as an outside supply wire swaying in the breeze (if the
wire or its connections are damaged), or it can happen inside due to changes in
temperature, electrical load, or mechanical disturbance.
Every time the connection is made or broken, an arc forms. Usually this arc is
very brief, but it is very hot and so it causes some damage every time. Thus the
condition of the connection gets worse over time. At some time that can’t be
31
predicted, a large long-lasting arc may occur. This can cause damage to the sur-
roundings, and it can start a fire.
A resistive neutral is closely related to a loose neutral. A resistive neutral oc-
curs when the neutral is connected, but it’s not a very good connection. Good
connections have extremely low electrical resistance, but a resistive neutral con-
dition has an intermediate resistance — its resistance is low enough to conduct
some electricity, but too high to conduct as well as it’s supposed to. This poor
connection has several damaging and dangerous effects.
One effect is that a loose or resistive neutral can cause abnormally high and
low voltages to occur in the house wiring. For example, a cardinal sign of a re-
sistive neutral is that lights will get brighter than normal at odd times, such as
when another circuit is turned on, or when an appliance cycles on. A resistive
neutral won’t always cause the lights to get abnormally bright, but when it hap-
pens, it’s a pretty reliable indication that you have a resistive neutral. If you are
aware of a situation in which the lights get abnormally bright when other cir-
cuits are used, you should call the power company and report that you believe
that there is a problem with the neutral connection. They know this can be very
dangerous, so they will likely treat it as a high-priority situation.

Another effect of a resistive neutral connection is that the connection becomes
hot. As a result, it can overheat its surroundings and even start a fire. Even if it
doesn’t do either of these right away, it will tend to get worse over time be-
cause heat accelerates the aging of the wire, its insulation, and surrounding ma-
terials.
Another very dangerous effect of a loose or resistive neutral is that it can can
lead to electrical shocks and even electrocution. The ways this can happen are
extremely unpredictable and depend on exactly how your house is wired and
the exact conditoin of the wiring. Here is a real example: if one resident of a
certain house was in the shower when another resident used the garbage dis-
posal, the first resident would feel a mild electrical tingle. No one else in the
house could feel it. This turned out to be due to neutral wire at the electrical
pole that was nearly broken. Only three strands of wire were still connected.
Had the remaining strands been allowed to deteriorate further, someone would
have been electrocuted. This is just one example of why it’s important to get
immediate attention for problems with neutral connections.
Fuses on service lines:
Why do I need main fuse services?
It is important for the rating of the main fuse in your place of consumption to
be correct so that you can use electricity without any problems. The main fuse
has two functions – it provides fire protection by switching off in the event of a
short circuit, and it determines how many household appliances you can use at
any one time. The higher your main fuse rating, the more electrical appliances
you can use at the same time and the higher their wattage can be.
You will need our main fuse services if:
your fuses keep blowing, as this means that the main fuse amper-
age in your place of consumption is too low and you should increase it;
the main fuse amperage is higher than you need, meaning that you
could save on costs by lowering the amperage of the main fuse if you are using
a package with a fixed fee;
32
you would like to replace your old main fuse with a more up-to-date and reli-
able main fuse, with the same amperage;
You want to transfer from a single-phase to a three-phase network connection.
I n c r e a s i n g t h e a m p e r a g e o f a m a i n f u s e

The procedure for increasing the amperage of the main fuse is the same as for
connecting to the power network. If the amperage at the place of consumption
is too low, the amperage of the main fuse should be increased.

When the amperage of a main fuse is increased, the fuse is changed at its exist-
ing location, while the supply point is not relocated. The prices for increasing
the main fuse amperage are listed on the network connection page.

If the main fuse cannot be changed at its existing location, perhaps because
there is no junction box or fuse base that meets the requirements or because the
cables are old, you will have to upgrade your main fuse box and, if necessary,
the electrical system inside your house. Once the required work has been done,
we will install a main fuse of the amperage you have requested in the upgraded
j u n c t i o n b o x .

If you plan to improve the electrical system in your house or are already doing
so, you can also ask us to relocate your supply point in addition to increase the
amperage of the main fuse. We usually install a junction box at the border of
the property and install a main fuse of the amperage you have requested. A
cost-based fee of 1000–1500 euros will be charged for relocating the supply
p o i n t .

How much does it cost to increase the amperage of the main fuse?

The fee depends on how many additional amperes you want to buy and on the
distance between the supply point and the substation.
If the distance from a low voltage substation is up to 400 metres, one ampere A d d i n g m a i n f u s e s

costs 156.00 euros (including VAT). If you have two or more supply points on your property, they can be added or
m e r g e d .

If the connection point is more than 400 metres from the low voltage substa-
For example, when a house has a single-phase connection with a 16 A main
tion, we will calculate the fee for increasing the amperage of your main fuse
fuse and an ancillary building has a three-phase connection with a 16 A main
based on the actual costs of the main fuse replacement; there may be additional
fuse, these main fuses can be added to form a three-phase connection with a 32
costs for network renovation work.


There is no main fuse for medium voltage network connections. The cost of
increasing network transmission capacity is always based on actual costs. D i v i d i n g a m a i n f u s e


R e p l a c i n g m a i n f u s e s

You can replace your main fuse with one with higher nominal amperage, for The division of the nominal amperage of the existing main fuse with the con-

example you could replace a thermal fuse with a circuit breaker or an older sent of the owner between consumers on the same cadastral unit or between

type circuit breaker with a newer type. We do not change the location of the new cadastral units created by the division of a cadastral unit – for example, if
a new home or other building is built on a property or if an existing building is
supply point and main fuse when we replace the main fuse.

divided between co-owners who want separate network connections. When a


cadastral unit is split, there are two ways that a new property can obtain a net-
How much does it cost to replace a main fuse?
work connection:
The fee for replacing a main fuse of up to 63 A is 45.76 euros.
Connection of a new place of consumption
The fee for replacing a main fuse of over 63 A is cost-based and depends on the
Division of the main fuse of a cadastral unit being divided. This is an option if
cost of equipment, materials and work.
the existing main fuse amperage is too high. It is unreasonable to divide a main
A d d i n g a n d d i v i d i n g m a i n f u s e s
 fuse with an amperage under 32 A.
An existing main fuse can be divided when a property is divided. Main fuses
How much does it cost to add or divide the amperage of a main fuse?

o n t h e s a m e p r o p e r t y c a n b e a d d e d .

The price of the service depends on the actual cost of equipment, materials and

 work.

33
Causes of Dim and Flickering Lights:
It can be scary moving to a new house or apartment, especially if the establish-
ment is old to the neighborhood. Sometimes the doors creak a little more than
you’re used to, or the cabinets don’t shut all the way, or the appliances fail to
operate correctly. When I first moved to my new/old apartment, I faced all of
these minor annoyances. However, none were as alarming as one peculiar phe-
nomenon: every time I used my microwave, the lights would flicker and dim
until my food was done cooking. While my meal was always properly warmed
and the lights always went back to normal, it was still a little unsettling. Was
this indicative of a larger problem? Below, we’ll review the cause of my situa-
tion, as well as some other common reasons house lights go dim (other than
your light dimmer switch, of course!).
Overloaded Circuit
If your lights dim when you are running an appliance, such as a dryer, air condi-
tioner, or microwave like in my case, check to see if the lights are on the same
circuit as the appliance. You might be simply dealing with an overloaded cir-
cuit – meaning your circuit is outdated or wired to run more appliances than it
can handle. This is typically the case if you are living in an older abode. Al-
though annoying, overloaded circuits due to appliance usage are common and
not typically a danger. However, if you find that your lights are dimming be-
yond the use of the appliance, or if the appliance is tripping your circuit
breaker, another reason could be behind the dimming. It’s time to call an electri-
cian.
34
Problems with the Power Grid
Has your area experienced some bad weather lately? A transformer may have
blown, or the service feed coming into your house may have been interrupted.
Both are common occurrences during a storm. The problem may even be at the
local utility substation. Brownouts (all-around dim lights) are not as common
as blackouts, but they can happen when there is a city-wide power shortage or
an unusually high demand for power.
Improper Wiring
Another reason your lights could be dimming unexpectedly is because the wir-
ing throughout your home is outdated or insufficient to handle the amount of
current it uses. When the electrical service has a demand for too much current,
the voltage can drop, causing your lights to dim. Many older houses have this
problem; they simply weren’t built to handle the electrical loads of today’s
modern household, which typically features many devices or appliances that all
require large amounts of power. If this is the case, you may require new wiring
or a new service – ask an electrician.
Loose or Corroded Neutral Wire
If the lights in your house are fluctuating between bright and dim, you could
have a more serious problem on your hands. You might have a loose or cor-
roded neutral wire in your circuit breaker. The circuit breaker contains three
wires: the first is red or black (the "hot" wire) the second is white (the "neutral"
wire) and the third is a green or bare (the "ground” wire) which is only used for
safety purposes. The first two wires are responsible for providing power to
your household circuit. The neutral wire simply provides a return path to earth
ground in the electrical panel to complete the circuit. A broken neutral wire
means that the return path to the electrical panel is incomplete, which can
Interactive 1.1 Module 4
cause imbalances in the two main power wires. When your lights brighten they
are receiving too much voltage, and when they are dimming, they are receiving
too little. If this problem worsens, your electrical devices could end up receiv-
ing far too much or too little power and become damaged. Loose or bad connec-
tions are the major cause of fires and other safety hazards. Contact an electri-
cian as soon as possible.

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incididunt ut labore et dolore magna aliqua.

35
Movie 1.1 Module 4 Review 1.1 Module 4

Question 1 of 5
If the length of a cable is increased, its capacitance

A. decreases.

B. increases.

C. remain same.

D. none of the above.

Check Answer

36
Grooving

! ! long, narrow cut or indentation in a surface, as the cut in a board to receive the
tongue of another board (tongue-and-groove joint), a furrow, or a natural indentation on an
organism.

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Paved surface

covered with a firm surface suitable for travel, as with paving stones or concrete. a small
paved courtyard. covered with a hard layer of something. shelves paved with marble.

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Trench

dig a trench or trenches in (the ground).

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Underground Cables

Cable designed to be place underground, either directly buried or in conduit. Underground

cable must be specially designed to protect against moisture, rodents, cable-seeking back-
hoes, and other earth-moving equipment.

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Way Leave

a right of way granted by a landowner, generally in exchange for payment and typically for
purposes such as the erection of telegraph wires or laying of pipes.

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