T8B PDF

INDIAN RAILWAYS INSTITUTE OF
SIGNAL ENGINEERING & TELECOMMUNICATIONS

SECUNDERABAD - 500 017
T8B
TELECOMMUNICATION CABLES
Issued in October 2008

T 8B
TELECOMMUNICATION CABLES
Contents
Chapter Description Page No
1 Introduction of Underground cables 1
2 Constructional details and Utilities of paper 9

insulated cable
Constructioal details and utilities of polythene
3 19
insulated cable
4 Introduction of line planning 40
5 Cable laying procedure 51
6 Jointing procedure of paper insulated cable 69
Jointing procedure of polythene insulated
7 91
quad and paired cables
8 Local line plant records 101
9 Effects of electrification on Telecom circuits 111
10 Cables testing and fault localisation 117
11 Maintenance and inspection of cables 126
PREPARED BY P.BHATTACHARYA IMW2

APPROVED BY S.K.BISWAS, Sr. Professor Tele
DTP AND DRAWINGS K.SRINIVAS, JE II(D)
DATE OF ISSUE 26-07-2005
EDITION NO 01
NO. OF PAGES 130
NO.OF SHEETS 67
© IRISET
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www.iriset.ac.in
INTRODUCTION OF UNDER GROUND CABLES
CHAPTER - 1
INTRODUCTION OF UNDERGROUND CABLES
1.1 INTRODUCTION
Over the long periods, the Underground telecommunication cable plays a vital role by
providing a very clear and distinct voice. Various types of telecommunication cables are
being used depending upon the requirements of telecom circuits. In this chapter we will
see how the various types of cables vary in their characteristics and how they are being
used according to the requirements of railway telecom circuits.
1.1.1 Comparison of Underground Cables and Overhead Lines.
1. Numbers of ccts. are working through a bundle of wires of the underground cable
that is not possible through limited number of overhead line wires.
2. Communication through overhead line wires is noisier than underground cable.
1. 2 Glossary
1. Core: Everything inside the sheath of the cable.

2. Pair: Two wires forming a single circuit, held together by twisting,
binding, in Common jacket.
3. Quad: A structured unit employed in cable. A quad consists of four
separately insulated conductors twisted together.
4. Unit: A Unit is made up of number of pairs stranded together in layers.
5. Pitch/Lay: The axial distance required for one cable conductor or conductor
Strand to complete one revolution about the axis around which it
is cabled.
6. Marker Pair/Quad: The conductors having different markings on there insulation
to distinguish them from other conductors. The counting and
numbering of a pair/quad of a layer commences from the marker
pair/quad.
7. Reference Pair/Quad:
The conductors having different markings on their insulation to
distinguish them from other conductors. The counting and
numbering ends at the reference pair/quad.
8. Paper-Insulated Cable:
Cable in whom the conductors are insulated with a paper ribbon.
Either spirally or longitudinally is applied.
IRISET 1 TELECOMMUNICATION CABLES
9. Plastic-Insulated Cable:
Cable in which the conductors are insulated with Plastics, such as
polyethylene and polypropylene.
Note: PVC insulated conductors are not referred as Plastic-
Insulated Cables.
10. Impregnated: Permeated with a suitable protective material to keep out free
from moisture, etc.
11. Insulated: A non-conducting material that can offer a high and permanent
resistance, for separation from other conducting surfaces to the
passage of current.
12. Interference: Any electrical or electromagnetic disturbance, man-made or
natural, which causes, or can cause, undesirable response.
13. Intermediate Repeater: A repeater used other than at the end of a line.
14. Jacket: A covering over a cable. It is usually the outer component of a
composite sheath.
15. Jute: Cordage fibre [such as hemp] saturated with tar and used as a
protective layer over cable.
16. Dielectric: Any material used in a cable that will insulate one conductor from
another or from shield.
17. Dielectric Strength:
The maximum voltage that a dielectric can withstand with out
rupturing. Also called “electric strength” or “break-down strength.
18. Phantom Circuit:
A superimposed circuit derived from two suitably arranged pairs of
wires called side circuits. Each pair of wires is a circuit itself and,
at the same time, acts as one conductor of the phantom circuit.
19. Twisted Pair: A cable composed of two small-insulated conductors twisted
together without a common covering.
20. Underground Cable:
A cable installed below the surface of the earth in conduit or ducts.
Does not include cables buried directly in the ground.
21. Unit-type Cable:
A cable in which the pairs are first formed into bound units and
then the units are formed together to make the completed cable.
22. Water Barrier:
In a cable, the material, usually in the form of an axially laid
aluminium foil/polyethylene laminated film, placed immediately

inside the sheath. As an alternative, this may a moisture-resistant

material filling the spaces in the cable.
23. Serving: Of a cable, a wrapping applied around the core before it is lead-
covered, or over the lead if there is the armoured. Some common
serving materials are jute, cotton, or duck tape.
24. Sheath: A protective covering made of metals or plastics over the cable
core.
1.3 Formation of a Cable (Refer to Fig 1.1)
The copper conductors of the cable are obtained from thick copper rods by the wire
drawing machine. The individual wires are insulated either with paper/PVC are twisted
Fig.1.1 Stranding of Layers (Twin cable)
into units of pairs/quads. The required numbers of such units are stranded together to
make a circular core. The overall core is wrapped with an impregnated insulation paper.
The whole core is thoroughly dried and sheathed with a pipe of lead, lead alloy,
Aluminium or PVC. Generally lead/PVC sheath is most commonly used. Over the sheath
Hessian tape is wrapped through out its length along with bituminous compound. Steel
tape/wire is wrapped over the sheath for mechanical protection as armour.
In dry core cables the wires used are generally gauged by their weight per mile. The
present practice of indicating the size of the conductor’s cross-section is in “mm”.
The various sizes of the conductors used in cable are: - 0.4mm, 0.51mm, 0.63mm,
0.9mm and 1.2mm in the formation of trunk cable four wires twisted together is called as
Quad. Diagonally opposite conductors formed as one pair in a quad. The number of
quads identifies the cable. E.g.: 12 quads, 14 quads, 16 quads, and 18 quads.
For junction circuits between exchanges in the same local area the cable should be
0.9/1.2mm diameter [20/40 lbs/mile] conductor cables are used. Generally for audio
frequency trunk circuits 20/ 40-lbs/mile conductor cables are used. For local circuits
between telephone exchanges to subscribers in the same local area 0.4mm, 0.51mm or
0.63mm diameter conductor Cables are used.

1.4 Special Features of Telecom Cables
Unlike electrical noise, cross talk is the main criteria item in telecom circuits. Cross talk
arises chiefly from unbalanced electrostatic and electromagnetic couplings between the
pairs of conductors and sheath. These effects are respectively be measured in terms of
capacitance unbalance and mutual capacitance. At voice frequencies, capacity
unbalance is the major source of cross talk. In order to reduce the cross talk in cables,
insulated wires are twisted together on their own axis helical throughout its
length. Different twist lengths are used to transpose the circuits continuously with
respect to one another pairs/quads. After laying the cable, if unbalance capacitance is
persisting, can be reduced by introducing the external fixed capacitors. This process is
called as “BALANCING OF CABLES”. In star quad cables diagonally opposite
conductors are formed as one pair and two wires of the pair are kept at an equal
distance from the conductors of the remaining pair.
1.5 Electrical characteristics of Telecom Cables
The four primary constants

The four primary constants of cable should be taken into Consideration of designing the
circuits.
R = Series Resistance
L = Series self inductance
C = shunt capacitance
G = Shunt conductance [Leakage]
These four quantities per unit length of a pair of telephone lines are called primary
constants of the lines.
When alternating current flows through the lines, there will be voltage drop due to both
resistance and inductance and so they may be assumed to be present in series in the
lines and as capacitance and leakage are present between the lines, current is lost
through them during transmission. The former two may be assumed to form an
impedance in series with the lines and the latter two may be assumed to form an
admittance across the lines.
Z (Impedance)= R + jωL, and
Y (admittance)= G+ jωC
Secondary Constants
Characteristic impedance, Zo

The characteristic impedance of a infinitely long line for a given frequency is constant
and is given by
Zo = (Z/Y) 1/2 = [(R + j ω L) / (G + j ωC)] ½
When a line is of infinite length and the primary constants have the same uniform values
throughout, voltage and current diminish uniformly with the length of the line till they
become zero at infinite distance and so no energy is reflected back. So when its
characteristic impedance terminates a finite line, no energy is reflected back from the
terminated end.
Propagation constant, γ
Propagation constant γ = (ZY) 1/2 = [(R + jωL) (G+ jωC)] ½
The expression contains four primary constants and for a given frequency it is constant
for the line. It determines how the voltage or the current changes with distance along the
line. It is clear that it will have usually different values for different frequencies and so
voltage or current changes differently for different frequencies during transmission
trough lines and these usually gives rise to distortions. Currents and voltages undergo
change not only in magnitude but also in phase angle.
The real part is known as the attenuation constant = α
and imaginary part is known as the phase constant = β
γ= (α + j β)
Both attenuation constant and phase constant are dependent on frequency. For different
frequency components they will have usually different values and so they will arrive at
the receiving end at different times as velocity of propagation which is given by
V = ω/ β, will be different for different frequency components.
In telephone cables as the conductors are necessarily of thinner gauze and as the
conductors are run side by side both the values R and C are large compared to
values L and G and so the latter two quantities may be neglected in expressions for Z0,
γ, α and β. These expressions are simplified but distortions due to these constants
depending on frequencies are present in telephone cables.
At carrier frequencies, values of ωL and ωC are large compared to those of R and G

where R, L, G and C are primary constants of line and so R and G may be
approximately neglected.
So the expressions of Z0, β, α and v are simplified to,
Z0 = (L/C) 1/2, β = ω. (LC) 1 /2, α =R/ 2Z0 and v = 1/(LC)! /2.

Thus at carrier frequency, characteristic impedance, attenuation constant and velocity of

propagation are independent of frequency. Thus all types of distortions are automatically
eliminated at carrier frequency.
1.5.1 Distortionless condition
If there is to be no phase distortion, the velocity of propagation must be same for

different frequency components and should be independent of frequency.
The expression γ = (ZY) 1/2 = [(R + jωL) (G+ jωC)] ½ is simplified
to GL = RC, that indicates the distortion less condition and is known as Heaviside
Equation and there will be no phase distortion. The attenuation constant, α = (RG) 1/2,
Velocity constant, v = 1/(LC) 1/2 and characteristic impedance,
Z0 = (L/C) are independent of frequency and as such all the frequency components are
equally attenuated during propagation through line. All the different types of distortions
referred to above that are likely to be introduced during transmission through long lines
are thus eliminated when the condition GL = RC is satisfied.
1.5.2 Distiortionless condition in telephone cables
The above distortion less condition is not satisfied in usual cables. Usually the cables
contain a large number of conductors and wires are necessarily of smaller dimensions
and so the value of R is much high. Further, in the case of cable conductors that are at
closer distances and so d/r value becomes much lower. From expression for
capacitance and inductance it is clear that C value is much higher and L value is much
lower. The LG value has to be increased to satisfy the equation GL = RC.
1.5.3 Loading of underground cable
When the diameter of the conductors is increased, the value of R is reduced. This is not
possible considering it’s size and cost. If the value of G is increased, the transmission
loss will be increased which not be acceptable to a log distance transmission line.
Therefore, there is one way to increase the value of GL by increasing the value of L.
This is achieved by using the coils of suitable inductance value wound on dust cores are
placed in series with the lines at suitable intervals. This is called coil loading or lump
loading.

1.5.4 V.F balancing of underground cable
V.F balancing of underground cable is done to reduce noise and cross talk in cables.
This is necessary in RE cables because the cables carry a number of important circuits
and they are having repeaters at every 40-50 K.M.
The process of measuring the capacitance unbalances between various quads and
earth, within the quad and with adjacent quads and minimising the unbalances by
connecting condensers is called V.F. balancing.
Scope
These cover balancing of cross-talk capacitive couplings between side circuits of a quad
and those of adjacent quads and also of earth couplings, namely, the capacitance
unbalances between cable conductors and the cable metallic sheath (Earth).
Purpose
In any manufactured length of a cable, the capacitances between conductors of a quad,
between conductors of adjacent quads and those between conductors of a pair and the
cable sheath (Earth) are not perfectly balanced which gives rise to the capacitive
interference between various circuits and the circuits and earth. Balancing of these
capacitances is hence necessary to limit the cross-talk and to bring the cross-talk
attenuation within permissible values.Fig.2 shows the coupling capacitances of the
conductors of a quad
In the electrified sections, the capacitance unbalances between cable conductors and
the cable sheath (Earth) introduce appreciable noise in the circuits. It is, therefore,
necessary to reduce, as much as possible, the noise in the circuits.
(I) Earth Couplings:

el = Capacitance unbalance of side-circuit-1 with respect to sheath.
e2 = Capacitance unbalance of side-circuit-2 with respect to sheath.
(II) Cross-talk Couplings within a quad.
K1 = The capacitance unbalance of a side-circuit of a quad with respect to

the other side-circuit of the same quad.
K2 = The capacitance unbalance of phantom circuit with respect

Pair-1
K3 = The capacitance unbalance of phantom circuit with respect to pair- 2 of a

quad.
(III) Between adjacent quads:
K9 = The capacitance unbalance of side-circuit- 1 of quad- 1 with respect to

side-circuit 1 of quad -2.
K10 = The capacitance unbalance of side-circuit- 1 of quad- 1 with respect to
side-circuit- 2 of quad -2.
K11 = The capacitance unbalance of side circuit- 2 of quad- 1 with respect to
side circuit- 1 of quad- 2.
K12 = The capacitance unbalance of side-circuit-2 of quad- 1 with respect to
side circuit -2 of quad -2.
Where quad -1 and quad- 2 are adjacent quads.
The capacitance unbalances shall not exceed the values indicated in the Table 1.1
below:
Capacitance unbalance For full loading For half loading

K1 4OPF 2OPF
K9 to K12 4OPF 20PF
Table 1.1 Capacitance unbalance permissible limits
Note: While balancing by connecting balancing condensers the attempt should be to

reduce Kl and K9 to K12 values to the maximum possible extent.
Fig.1.2 Capacitance Network of Telephone quad

1.6 Classification of telecom cable Cables
For telecom circuits Cables are broadly classified into the following categories.
I. PCUT - Paper Core Unit twist Cables.

II. PCQT - Paper Core Quad twist/trunk cables.
III. Derivation cable (Paper insulated quad cable)
IV. Polythin insulated twine twisted core for Telephone.
V. Polythin insulated quad dry cable (4/6 Quads).
VI. Polythin insulated quad Jelly filled Cable (4/6 Quads).
VII. Telecommunication Switchboard cable.
VIII. Double wire/Twine flat wire.
IX. Field service wire.
X. UTP-Unshielded twisted wire for data communication.
XI. STP-Shielded twisted wire for data communication.
XII. Co-axial cables.

CONSTRUCTION DETAILS AND UTILITIES OF PAPER INSULATED CABLE
CHAPTER - 2
CONSTRUCTIONAL DETAILS AND
UTILITIES OF PAPER INSULATED CABLE
2. 1 Introduction
The paper insulated copper cable has an important role in the filed of
telecommunication. This cable has been widely used for long distance telephony as well
as for local telephone network. It is required to know the important feature of this cable.
Without specific requirement, the use of this cable is limited.
Size of the wires
Following are the sizes of the wires and their corresponding loop
resistances/Transmission loss.
C Conductor (dia. in mm) 0.4 0.51 0.63 0.90 1.2
Maxim. Loop Resistance/Km 288Ω 182Ω 109.6Ω 54.83Ω 27.41Ω
Transmission loss/ loop Km .973dB .619dB .434dB
Table 2.1 Electrical Parameters of Underground cables
The size of conductor to be chosen will be decided by considering field condition and actual
requirement for distortion less transmission. Conductors of 0.4mm dia, 0.5lmm dia, and
0.63mm dia are used only for local telephone circuits where only loop resistance is the main
criteria.
2.1.1 Advantage and disadvantage of paper insulation
The type of dielectric used for insulating the conductors and their advantages/disadvantages are
given below.
Advantages Disadvantages
i) Air- spaced paper insulation has a low Dielectric i) Moisture entry will leads to low
constant. So, capacitance between the wires also Insulation.
low. Hence cross talk is less.
ii). The impregnated paper bulges out as moisture is
absorbed by it. So, direct penetration of water is
prevented.
Table 2.2 Advantages and disadvantages of paper insulation cables

2.2 Paper core unit twin cable (PCUT)
Paper core unit twin is a paired cable that has been used for local lead of telephone
connection. The speech quality of this cable is exceptionally good. This cable is
available in different sizes (3- pairs, 10-pairs, 20- pairs 30– pairs, 50- pairs, 100- pairs
and above). The pairs are arranged in different layers. The odd layers and even layers
are identified by the colour of rigs on the paper (red rings for odd layers and green rings
for even layer). In a pair the one ring on the paper indicates limb one and two rings
indicate limb two. Generally the cable is lead sheathed to protect the paper from low
insulation and screening the cable. Steel tape is used as armour of the cable. Now this
cable is not widely used for difficulty in jointing and frequent interruption of
communication for low insulation of paper core. Characteristic impedance of the twisted
paper core is 600 Ohms
2.3 Paper core guard twist cable (PCQT)
Formation of a quad in paper insulated quad cable.
A specified number of 0.9 mm diameter conductor quads shall form a centre of the cable
core and layers of quads around it. The Manufacturer shall determine the number of
layers. The polyethylene-insulated quads shall not be placed in the outer layer of quads.
The size of the cable is specified in a manner similar to that of a composite cable by
indicating the number of paper insulated and polyethylene insulated quads as illustrated
below:
l+m+n
Where “ l ”stands for zero number of carrier frequency quads. In Railways the zero
number of quads is not used for carrier. But in P&T the Zero number of quads was used
for carrier telephony.
'm’ stands for the number of voice frequency air spaced paper insulated quads(m = 12,
17 , 18 or 21 no. of paper quads). 'n' stands for the number of voice frequency
Polyethylene insulated quads(n = 2 or 3 no. of polythene quads)
In PCQT cable, a group of four wires around a fibre core at centre formed as Quad. The
fibre core assists to form the quad in circular shape and also increases the insulation
between the conductors by forming an air-gap.

In formation of a quad, A, B, C and D legs are used. Generally ring markings are printed
on impregnated insulated brown paper either in Red or Blue colour to identify the
individual quad conductors. The "A" leg contains ring markings of I, “B" 1eg contains
ring markings of II,”C” leg contains ring marking of III and “D” contains ring marking of
IIII. In a quad the wires of a pair are arranged diagonally opposite to each other as
shown in Fig. 2.1
Fig. 2.1 QUAD MARKING
Identification of pairs in a quad (Finland cable)
First pair – is marked with ring number of II & I and placed diagonally opposite.
Second Pair - is marked with ring number of III & IIII and placed diagonally opposite.
This type of wire formation is known as “Star Quad”. The red colour print of I, II, III and
IIII ring markings are formed as [Red] quad, likewise blue colour print of I, II, III and IIII
ring markings are formed as [Blue] quad. These two colour quads are alternatively
changes with each other quad in a layer.
To give uniform electrical properties the markings are arranged so that each wire has the
same amount of ink per unit of length as shown in Fig. 2.1
Each quad is spirally bonded with a cotton whipping, which can holds the quad together
and acts as a mean to identification of different quads and layers in a cable.

2.3.1 Counting method of layers
Fig 2.2 Quad numbering and Pair marking
The required number of quads, to make up the desired size of a cable is stranded into
layers. These layers are denoted as "even number" or "odd number" layers.
In any layer, to start the counting of quads a “ Marker Quad” for ending counting a
"Reference Quad" is so required. Therefore to identify these two quads from other
neighbourhood quads a separate identification has been given in ring marking colour as
well as in thread whipping colour.
Even Number Layer
Quad Ring marking Colour Thread whipping Colour

Marker quad Red Orange and White
Reference quad Blue Orange and White
Other quads Red & Blue alternatively Double White threading
Table 2.3

Odd Number Layer
Quad Ring marking Colour Thread whipping Colour

Marker quad Red Orange and Black
Reference quad Blue Orange and Black
Other quads Red & Blue alternatively Double Black threading
Table 2.4
An Aluminium foil paper is wrapped over the core to protect from moisture, above this
an impregnated insulation paper is wrapped as cushioning to the core and the
lead/Aluminium sheath is extruded over it for mechanical protection of the core.Fig.3
shows the different layers of paper quad cable.
Fig. 2.3 The end view of a typical Aluminum sheathed Underground cable
2.3.2 Formation of cable
Conductors
Each conductor shall consist of a solid wire of 0.9 mm nominal cross-sectional diameter
of plain annealed, high conductivity, uniformly drawn copper circular in cross-section,
uniform in quality and resistance and free from splits and other surface imperfections.
Dielectric
The paper and polythin insulation shall be of sufficient thickness to give the electrical
characteristics specified for the cable. The minimum thickness of the insulating paper
shall be 0.09 mm. The polyethylene insulation shall be covered with an extruded layer of
Nylon of uniform thickness to serve as a heat barrier to prevent softening of the
polyethylene insulation during aluminium sheath extrusion and cable joints. The
combined minimum thickness of the polyethylene insulation and nylon covering shall be
0.33 min.

Sheathing
The cable core complete with final layers of insulating paper and metallic paper tape
shall be surrounded by a close fitting sheath of extrude aluminium. The sheath shall form
a perfectly continuous tube, free from pinholes, joints, and defects of any kind. The
aluminium used shall be at least 99.5 % pure.
The minimum radial thickness of the aluminium sheath to ensure mechanical strength
shall be 1.4 mm. The thickness shall be increased, if required to ensure specified
reduction factor.
Bedding
An overlapping layer of compounded textile tape of fine quality or any other suitable
fibrous material shall be provided over the jacket prior to armouring.
Armouring
A galvanised mild steel tape shall be applied with a suitable open lay having a gap of not
more than 25% of the width of the tape in two layers, with the second layer applied
evenly over the first one in an identical manner to cover the gaps left in the first layer.
The thickness of each steel tape shall be not less than 0.5 mm. A layer of anti - corrosive
compound on the steel tape armouring is applied. Extruded black PVC overall jacket
containing not less than 2% evenly dispersed carbon black over the compounded steel
tapes
2.3.3 Resistance and insulation resistance
The maximum average loop resistance of a pair measured with direct current at 200 C
shall be 56 ohms per Km for the VF quads of 0.9 mm diameter copper conductors. The
nominal loop resistance of a pair shall be 55.2 ohms at 200 C.
The insulation resistance measured between conductor and all the other conductors
connected together to the sheath and earth, shall not be less than 10,000 meg-ohms per
kilometre when measured at 500 volts D.C after energising for one minute at a
temperature of not less than 150 C.
2.3.4 Dielectric Strength
a) Conductors with paper insulation

The insulation shall be capable of withstanding for two seconds without
intermittent or permanent breakdown, a 50 Hz AC potential of RMS value 500 V
applied between a conductors of the paper insulated quads and all the other
conductors in the cable connected together.
b) For all the conductors

When all the conductors are bunched together and a 50 Hz AC potential of RMS
value 2000 volts is applied between them and earthed sheath for two seconds,
there shall be no intermittent or permanent breakdown of the dielectric.
2.3.5 Mutual Capacitance of VF Quad
The mutual capacitance of paper insulated, VF quads shall have a nominal value of
0.041 microfarad per Km, in any length the average value of mutual capacitance of all
the pair shall not differ by more than ± 5% from the nominal value and the mutual
capacitance of any pair shall not differ by more than ± 1% from the nominal value.
For the polyethylene insulated pairs the nominal value of mutual capacitance shall be
0.05 microfarad per Km. with a tolerance of ± 5% for the average value and of ± 1% for
any individual value, from the nominal value.
2.3.6 Characteristic impedance
The characteristic impedance of air spaced paper insulated pairs when loaded shall be
1120 Ohms at 800 Hz. The characteristic impedance at 800 Hz polyethylene-insulated
pairs when unloaded, shall be (470 ± 10 %) Ohms. Unloaded paper insulated quad
cable of 20lb has an attenuation of approx.1.04dB per mile (6.5dB /km) and the
characteristic impedance “Z0” is approx.470 Ohms. When the cable pairs are loaded with
the loading coil, characteristic impedance value Z0 increases approximately from 470
Ohms to approximately 1120 Ohms and reduces the attenuation to 1/3 its unloaded
value. So the attenuation in the pairs in loaded condition is equivalent to 0.35dB/mile
(0.25/Km). As the characteristic impedance in the cable pair increases the voltage of the
signal increases and proportionately current decreases and transmission loss of signal
decreases through the cable for the reduction of I2 x R losses.
(Reduction Factor) Intrinsic screening Factor.

The intrinsic screening factor (reduction factor) for the cable shall be not higher than
0.10 in the field intensity range of 50-450 volts/Km.
Manufactured Lengths
The standard drum length shall be 460 meters ± 5 %.

2.4 Manufacture’s Identification Markings
Identification tape shall be placed under the sheath and shall give the following
information (repeating) at an interval not exceeding one metre in regard to (a) (b) and
(c).
(a) Manufacturer’s name,
(b) Year of manufacture,
(c) Marking to indicate the distance of any points of the cable from one of its
ends. Such marking shall be given at intervals of not exceeding 20 cms. ,
(d)"Indian Railways”.
The ends of each factory length of cable shall be marked red and green. The end at
which the sequence of quad identification is clockwise being marked red and the other
end marked green. The end marked red shall be the outer end of the drum length.
The cable ends shall be sealed immediately after the tests to prevent entry of moisture
and shall be so fastened and secured to the that during transit, transhipment and rolling,
neither the cable end sealing gets damaged nor does the cable get loosened or
displaced.
Each drum shall be stencilled in good oil paint giving the following particulars:
a) Drum Number,
b) Name of the Manufacturer,
c) Address of the Consignee,
d) Type, size, length and description of cable,
e) Year of Manufacture,
f) Net and gross weight,
g) Arrow to indicate the direction in which the drum can be safely rolled.
h) “ Store away from boils”,
i) “ Not to be slung except by bar through centre”.

2.5 Quad Allocation of (0+12+2) cable
SL. No Quad No. Name of the Ccts.

Paper Quads
1 Quad –1 Remote Control (RC)
2 Quad –2 Spare (RC)
3 Quad –3 Deputy Control. (Dy. CNL)
4 Quad –4 Traffic Control (TC).
5 Quad – 5 Traction Loco Control (TLC
6 Quad –6 Traction Power control (TPC).
7 Quad –7 Emergency Control (EC).
8 Quad –8 Engineering Control.
9 Quad –9 S & T Control.
10 Quad- 10/1 Level Crossing Gate.
11 Quad 11 Test Through (Repeater to repeater
12 Quad 12 Administrative Trunk
PET Quads
1 Quad-1 Block (Station to Station)
2 Quad-2/1 Block (spare)
3 Quad-2/2 For testing the cable
Table 2.5 Quad allocation of (0+12+2) cable
2.6 Derivation Cables:
For extending all control circuits and block circuits from main cable to various utilization
points like ASMs, Cabins, etc., the following types of derivation cables are used.
a) Derivation cable, paper insulated, lead sheathed and tape armoured size (0+7+0)
quads 20 lbs. per mile wire (0.9mm dia.).
b) Derivation cable, paper insulated, lead sheathed and wire armoured, size twin
(0+4+0) pair, 6 1/2 lbs. per mile wire (0.9 mm dia.).
c) Derivation cable, paper and polyethylene insulated lead sheathed and tape
armoured, size (0+9+3), 20 lbs. per mile wire (0.9 mm dia.).

d) The derivation cables are lead sheathed, with annealed copper conductors with
paper and polyethylene sheathed and tape armoured size 0+5+2, 20 lbs. per
mile wire (0.9mm dia).
The number of circuits that are required to be tapped largely determines the sizes of the
derivation cables. If the large numbers of circuits are derived from the main cable, the
derivation cable will be a larger size .So the size of the derivation cable depends on the
number of tapings to a particular station.

CONSTRUCTION DETAILS AND UTILITIES OF POLYTHENE INSULATED CABLES
CHAPTER - 3
CONSTRUCTIOAL DETAILS AND UTILITIES OF POLYTHENE

INSULATED CABLE
(Polythene insulated polythene sheathed jelly filled telephone cable with poly –al
moisture barrier)
3.1. INTRODUCTION
Before using of polythene insulated polythene-sheathed jelly filled telephone cable in

Indian Railway, the Paper Core Unit Twin Armoured cable of ITD Specification No S/WT-
101E (local) has been used for subscriber’s local loop. At present the PJ cables are
widely used for local loop and other networks due to improved technology and simplicity
in installation and maintenance. This cable has been used in Indian Railway as per IRS
Specification No – IRSTC-41/ 97.

Number of pairs:
The cable shall be of different sizes varying from 10 to 200 pairs and above with nominal
conductor diameter 0.5mm or 0.63mm or 0.9mm.The Standard cable sizes shall be
10,20 50 100 and 200 pairs armoured / unarmoured.
Conductor:
Each conductor shall consist of a solid round wire of annealed high conductivity copper,
smoothly drawn, normally circular in section, uniform in quality and free from defects.
Joints:
The joints in the conductor shall be either brazed or welded, and shall be kept to a
minimum junction resistance. The resistances of a 100cm length of conductor containing
joint shall not be more than 101.25% of that of an adjacent sample of conductor not
containing join.
Insulation:
Conductor insulation shall be polythene insulating grade and 100% virgin material as per
ASTM-D883.
Twining/Pairing
The two insulated conductors shall be twisted uniformly to form a pair.

Filling compound: (Petroleum Jelly)

A cable core shall be fully filled with suitable water resistant compound like jelly, which is
fully compatible with the polythin insulation, binders, and tapes used in the cable.
Core wrapping
After application of water resistant filling compound, a closed helical or longitudinal
lapping of a non hygroscopic and non wicking polyester tape or tape of any other
suitable materials shall be laid over the cable core.
Poly-Al Laminate moisture Barrier/Screen

Polythene coated aluminium tape shall be applied longitudinally on the core with a
minimum over lap of 6mm. Thickness of the aluminum tape shall be 0.2mm + or –10%
and that of polythene/ co-polymer coating on each side 0.05mm nominal. Thickness of
composite tape shall be 0.3mm + or - 15%.
Sheath
Cable shall be sheathed with polythene grade 03c or H03c as per BS: 6234, and
containing a suitable anti oxidant system. The material shall be virgin and meet required
specification. The sheath shall be reasonable circular and free from pin holes joints and
other defects. The thickness depends on the size of cable.
Armour:
The sheathed cable shall then be armoured with two applications of galvanized steel
tape conforming to IS: 3975 each applied helically in the same direction with gap in the
first tape of 25% + or – of the width of the tape, the second tape evenly covering the gap
of the first tape. Thickness of the galvanized steel tapes used in two applications
including zinc coating on each tape shall not be less than 0.5mm.
Jacket:
The armour cable shall be tightly jacketed with polythene conforming to the
requirements as specified for sheath.
3.1.2 DIE-ELEC STRENGTH
Conductors with polyethylene insulation

The insulation shall be capable of withstanding for two seconds, without intermittent or
permanent breakdown, a 50 Hz AC potential of RMS value 1000 volts applied between a

conductors of the polyethylene insulated quads and all the other conductors in the cable,
connected together.
3.1.3 Advantage and disadvantage of Polythene insulation as shown in table 3.1
Advantages Disadvantages
I) Entry of water will not lead to low I) Dielectric constant is more. So Cross talk is also
insulation. high.
ii) Should be careful, while doing wiped joints.
iii) Special sleeves are to be used for Jointing.
iv) Cannot be bunched tightly like paper Insulated
conductors
v) Water penetration will be faster. This has lead to the
invention of J/F cable
Table 3.1 Advantages and disadvantages of Polythene Insulation
3.1.4 The colour code of conductors in a pair

The colour code scheme followed for identifying the pairs in quad cable are
Pairs 1st wire 2nd wire Pairs 1st wire 2nd wire
(tip) (Ring) (tip) (Ring)
1 White Blue 11 Black Blue
2 White Orange 12 Black Orange
3 White Green 13 Black Green
4 White Brown 14 Black Brown
5 White Grey 15 Black Grey
6 Red Blue 16 Yellow Blue
7 Red Orange 17 Yellow Orange
8 Red Green 18 Yellow Green
9 Red Brown 19 Yellow Brown
10 Red Grey 20 Yellow Grey
Table 3.2 The colour code scheme of polythene insulated cables.
White, Red, Black and Yellow are called mate colour. The five pairs make one unit. In
this way there are four units of twenty pairs cable. A cable of 50 pairs and 100 pairs, the

twisted pairs shall be arranged in units of 10 pairs and 20 pairs respectively. 4 No of 50

pairs super unit shall be assembled to form a 200 pars cable.
Colour of binding tape
The different colours of the binding tape shall be readily distinguishable under lighting
conditions as per the Table 3.3
Unit number 1 2 3 4 5
Colour binder Blue Orange Green Brown Gray
Table 3.3 Colour of binding tape
3.2 Jelly filled cables - 4/6 Quads
3.2.1 Introduction
At the time of conversion of Non RE Area into RE Area of 25KVA Traction Line, the
Underground Paper insulated Quad Cables are utilized in place of Over-Head
transmission line of metallic wires to avoid the effect of induced EMF on Over Head
Alignment running parallel to the electrified traction lines. The underground paper
insulated Quad cables work excellently for good quality of speech.
In mid-nineties, Railway Board decided to go in for Optical Fibre Cable in place of main
telecom quad cable in RE works along with PE insulated 4-Quad Cable which was to be
used for the purpose of block working, L-xing gate communication and emergency
communication from emergency sockets. Specification No. IRS: TC 30-83 and 31-83
for PE insulated 4Quad cable hitherto being used in Axle counters was to be
amended/modified to include certain tests to meet the requirements of
telecommunication like cross talk and attenuation tests and thus specifications IRS: TC
30-96 (4 Quad Dry Telecom Cable) and 30-97 (4/6 Quad Jelly Filled Telecom Cable)
were framed, adopted and vendors developed.
Use of PE insulated Quad telecom cable, provides an efficient and economical

alternative for use in Control communication in non-RE area in place of overhead
alignment. As the circuits in Non-RE area are limited to section control, deputy control,
emergency control, tests circuit, block circuit, level crossing gate communication, the use
of 6 Quad cables to spec. IRS: TC 30-97 was considered most appropriate as main
media.

The OFC cables are being laid along with 4/6 Quad cables in RE and non-RE areas. All
most all the control and trunk circuits are working through the OFC. Only a limited no. of
circuits between two block stations are working through 4/6 Quads. Before, application
of the 4/6 Quad jelly-filled cables, the 4-quad dry cables (without jelly) of IRS-
specification No-TC-30-96 had been used for control, Axel counters, and Block
working. Especially where train control is working through overhead alignment,
maintained by BSNL. But the 4-quad dry cable is not found suitable for reliable working
due to water entry into the cable for which the cable insulation detoriates. The 4/6 quads
Jelly filled cable of IRS-Specification No- 30/2005 version-2 affected from 1/1/2006
has been introduced in place of 4 Quad dry cables in Indian Railways.
3.2.2 General specification of PET Quads cable

General specification for PET quad cables are as shown in table 3.4
1 Characteristic impedance 470 Ohms (Unloaded)

1120 Ohms (Loaded)
2 Cross sectional diameter of the PVC Insulated 0.9mm
Copper conductor
3 Insulation resistance of the PET Quad 5000 M Ohms
0
Measured By 500V DC. Megger 40 C and RH-60%.
4 Transmission loss when loaded 0.25dB. (Loaded)
0.619dB. (Unloaded)
Table 3.4 Electrical Parameters of a 4/6 PET quad cable
PRESENT STATUS
Based on the discussions and guidelines issued, various Railways decided to go in for
either of the two options: -
1. Conventional system like RE system with loading coils, balancing and repeaters
at 40-50 Kms.
2. Amplifier Equalizer System with repeater at all stations with balancing at the
stations and without loading the quad.

3.2.3 Conventional System
In RE paper insulated telecom cable, loading coils are provided to reduce attenuation,
balancing is carried out to reduce interference between different quads and isolation
transformers are provided to keep induced voltage within prescribed limits.
Since the characteristics of 4/6 polythene insulated quad cable are similar to RE cable, it
was possible to adopt the similar system design for 4/6 quad cable. However, since the
length of the quad cable in a drum is 500 metres/1000 meters, it was not possible to
adopt the distances specified for RE cable. As such, RDSO framed system design with
parameters as given below: -
3.2.4 RDSO framed parameter of 4/6 Quad cables

RDSO has framed specification for 4/6 quad cables as shown in Table 3.5
Sno. ITEM RE CABLE QUAD CABLE

1. Mutual 0.041 µf 0.05µf
Capacitance
2. Loading Coil 88mH/1.84 Km 118 mH/2Kms
3. Characteristic 1094.5 Ohms 1095.8 Ohms

Impedance
4. Attenuation 0.225 db/Km 0.224 dB/Km
(Loaded) (Loaded)
5. Cut off freq. 3905 Hz 2930 Hz
Table 3.5 RDSO framed parameters of 4/6 quad cable
3.2.5 Amplifier Equalizer System
The alternative to conventional system is Amplifier Equalizer System in which

loading coils and balancing in block section are eliminated and repeater equipment is
provided at every station to cater for equalization to compensate attenuation
characteristic of the cable.
Essential features of Amplifier Equalizer System are:
i. No loading and balancing in the block section but only at stations

ii. Repeater at all stations with active equalizers to compensate unequal attenuation
over voice frequency band.

iii. Multi way conference at all stations. (No need to reverse amplifier for radio
patching)
iv. Radio patch facility at all stations.
v. Phantom circuit on emergency for communication from block section to station
vi. Station bypass in case of complete failure of Power Supply.
vii. Remote monitoring and control from test room.
viii. All equipments including decoder in wall mounted dust free racks for installation
in ASM office
ix. 8 Way intercom facilities for Supervisors posted at stations with facility of call
from control.
x. Duplicate battery back up with changeover facility and provision of Solar Power
Panel to charge the battery in case of unreliable Power Supply.
The latest draft specification issued by RDSO for Amplifier Equalizer System is
RDSO/SPN/TC/34/2002 Version 2.
3.2.6 Communication problems faced on Quad Cable
While studying problems of control communication it has been observed that primarily
two types of problems are being encountered:
i. Problem of low insulation resistance in the quad cable and
ii. Problem of unreliable power supply at most of the stations for both the
Systems.
To circumvent the problem of low insulation resistance, universal jointing kits have been
developed and standardized for all types of joints in all types of quad cables. This shall
help in controlling the inventory and shall also prevent usage of incorrect jointing kits
thereby preventing failure of joints. This has also been communicated to the Railways
vide RDSO letter No. STT/RE/CJ/368 dated 12.3.2004.
3.2.7 4-Quad cable (Non RE Area)
The color scheme of polyethylene-insulated quads shall be as per the Table 3.6
Colour of insulation of conductor Name of Cct.
PE Quad No A-Wire B-Wire C-Wire D-Wire
Quad One White Orange Red Grey Section Control
Quad two White Blue Red Grey Dy.Control
Quad Three White Brown Red Grey Emergency control
Quad Four White Green Red Grey Block
Table 3.6 Colour scheme of PET quads

Wire A and B shall form a pair and similarly Wire C and D shall form another pair.
Conductors are diagonally opposite forming one pair and the remaining two diagonally
opposite conductors forming the second pair of the quad. The quad shall be held
together firmly by means of an open helical whipping of Ottin/nylon yarn or coloured tape
of suitable material of appropriate thickness.
3.2.8 Colour scheme for quads whipping.

Colour scheme for quad whippings for identifying the quads sequence as shown in
Table 3.7
Quad No Colour scheme.

Quad one Orange
Quad two Blue
Quad three Brown
Quad four Green
Table 3.7 Colour schem for quad whiping in 4-quad cable
A final closed helical lapping of polyethylene tape of 0.013 mm thickness shall be

applied over the cable core with at least10% overlap.
3.2.9 6-Quad cable (Non RE Area)
Colour scheme of conductor insulation & quad allocation of 6-Quad cable in non-RE
area is as shown in the Table 3.8
Color of conductor insulation

Quads No
A-Wire B-Wire C-Wire D-Wire Name of the circuit
Quad one Orange White Red Slate Section Control
Quad Two Blue White Red Slate Emergency Control
Quad Three Brown White Red Slate Dy. Control
Quad-Four Green White Red Slate Test Quad
Quad Five Yellow White Red Slate Block
Quad Six Black White Red Slate Pair-1-LC gate
Pair-2-Spare
Table 3.8 6-Quad cable colour scheme and quad allocation

The colour scheme of the quad whipping shall be as shown in Table 3.9
Quad-No Colour Scheme

Quad-1 Orange
Quad-2 Blue
Quad-3 Brown
Quad4 Green
Quad- 5 Yellow
Quad-6 Black
Table 3.9 6-Quad cable - colour code for Quad whipping
In RE area where distance is more than 1.5km, the same 4/6 Quad cables are used in
RE Area for Emergency control, Block ccts, level crossing gate and disaster
management. The quad allocation is differed from RE to non-RE.
3.2.10 Quads allocation of 4/6 JF quads in RE area for Emergency & Block
working
Allocation of quads for different circuits in 4/6 quad cable is as shown in the Table 3.10
Quads No Name of the circuits

1 Block circuits between two stations
2 Spare for Block circuits
3 4W –Emergency control
4/1 Block Proving Excel counter
4/2 Gate telephone
5 Block Proving Excel counter
6 Train Automatic Warning system
Table 3.10 Quads allocation of 4/6 quad cable
Inner PVC Sheath

The stranded cable core shall be followed immediately by a closely adhering extrude
PVC jacket of black gray colour. The nominal thickness of PVC sheath shall be 1.8 mm
and the smallest of the measured values shall not fall below the nominal by more than
0.2mm ± 0.2 thickness.

Armouring
The armouring shall consist of wires/strips and shall be applied over the inner sheath.
The armouring shall consist of galvanized round steel wire of 1.4 mm diameter. For
cable of diameter of more than 13 mm the armouring shall consist of galvanized steel
strips of dimensions 4 X 0.8 mm.
When joints in Armour wire/strips are necessary, they shall be brazed or soldered and
any surface irregularity shall be removed. The joint in any wire/strip shall not be less
than 300 mm from a joint in any other armour wire/strip in the completed cable.
Overall PVC Jacket (Outer sheath)

A closely adhering extruded PVC jacket of black colour shall be applied over the
armouring. The thickness of PVC outer sheath, determined by taking the average of a
number of measurements shall be not less than the nominal value (ts) of 1.8 mm and the
smallest of the measured values shall not fall below the nominal value (ts) by more than
0.2 mm +0.2 ts.
3.2.12 Marking
The ends of each factory length of cable shall be marked Red and Green. The end at
which the sequence of quad identification is clockwise being marked red and the other
end marked green.
Each drum shall be stencilled in good oil paint giving the following particulars:
1. Drum number.
2. Name of the manufacturer.
3. Address of the consignee.
4. Length and description of cable.
5. IRS Number.
6. Year of manufacture.
7. Net and gross weight.
8. Arrow indicates the direction to safely roll the drum.
9. Precaution in handling the drum
a. Stay away from boiler.
b. Not to be slung except by a bar through center

3.3 Comparative study of conventional and amplifier equalizer system.

On going through the performance report as well as various measurements and study
conducted on both the systems, following advantages and disadvantages are brought
out in Table 3.11
Sno CONVENTIONAL SYSTEM AMPLIFIER EQUALISER SYSTEM
1 In addition to derivation joints for The system does not need any joint in
emergency sockets, loading coil joints are between the stations except normal
required at every 2 Kms. and condenser Joint/Derivation joint for Emergency socket
joints at every 1 Km. in between loading at every 1 Km.
coil joints. Experience shows that only
derivation joints gives problems in both the
system.
2 Since repeater is at every 40-50 Kms. the Since the equipment is installed at every
power supply requirement is not critical at station, reliable power supply requirement
every station. is critical. Hence solar power back up has
been made mandatory in RDSO
specification.
3 Voice level variation is there at every The voice level is kept at almost zero dBm
station since the repeater is placed at at every station since the
every 40-50 Km. but it is within the amplifier/equalizer equipment is placed at
permissible limit. every station. However, system being
analog, the noise level is additive in the
entire section but the same is restricted
with sharp cut off filters.
4 The problem of attenuation and frequency For the section more than 20 Km. the
response is taken care of by providing system needs loading and balancing
loading coil and condenser joints. condenser. However, the equipment can
be installed at L.C. gate if the section is
more than 20 Km.
5 For radio patching, amplifiers need to be Every station equipment works like a
reversed and therefore every repeater repeater having 4 way branching network
station requires to be manned due to and therefore, radio patching does not
directional problem. However, S.C.Rly. has need the reversal of amplifier and to that
designed a circuit for reversing the extent the continuous manning of station is
direction of amplifiers through remote not required.
control.
6 Since the repeaters are placed at every Remote monitoring and control facility is
40-50 Kms., no need is felt for remote available from Test Room to monitor the
monitoring and control. parameters of the equipment at every
station.
7 There is no facility of Intercom at present. The system has inbuilt 8 line intercom for
providing communication to the Sr.
Supervisors at selected wayside stations
as a additional facility.
8 The cost of the system per Km. is Rs.1.92 The cost of the system per Km. is Rs.1.88
lacks. lacks, which is approx. 2% cheaper than
conventional system.
Table 3.11 Comparative Study of Conventional and Amplifier-Equaliser system

3.3.1 Development of digital control communication on quad cable

Introduction
Ministry of Railways constituted a committee of officers on the recommendation of 31st
TCSC to examine and study the system to be adopted for Control Communication on
Quad Cable on Indian Railways vide Letter No. 2004/Tele/LF/1 dated 5.2.2004
The committee observes that digital communication on quad cable is presently possible
by deploying DSL modem and the technology is available from various vendors. At
present, only 2 Mbps is possible to be achieved on a pair of conductor for a maximum
length of about 8 Kms.
However, with the compromise of number of channels, the length can be increased to
about 12 Kms for a channel capacity of 8 to 10 channels. No trial record is available at
present for achieving longer section more than 10 Kms for working on DSL modem that
may be required in most of the block sections in Non RE area. The requirement of
omnibus control circuit is also to be met with DSL modems for which no such trial has
been conducted in Indian Railways.
With above in view, trial on DSL technology has to be conducted on a section involving
5-6 block sections to ascertain its suitability for omnibus working and also to ascertain
maximum block section length on which the system can function with a minimum
channel capacity of 8.Since both Conventional and Amplifier Equalizer Systems are
working satisfactorily over Railways, Railways may adopt any one of the systems.
Since the characteristics impedance of quad cable is 470 ohms, Way side Station
Control and H.Q Control Equipments should have 470-ohm termination port in addition
to 1120 & 600 ohms. Proper Jointing Kit as per latest RDSO specification. Control
communication on composite cable comprising of 4/6 fibers and 4 Quad can also be
considered. This shall enable similar control communication system for both RE as well
as Non RE Area.
3.4 Telecommunication switch board cable
IRS Specification No: – TC-24-1991. This specification requires reference to the

following Indian Railway Standard (IRS), Indian Standard (IS) and ITD specifications as
shown in Table 3.12

IRS: TC-24-1991 PVC Insulated cables for Railway Signaling

IS: 5831-1970 PVC Insulation and sheath of electric cable
ITD: S/WS- 113C Cable Switch Board – PVC
IS: 8130 The conductor for insulated electric cable and flexible cable.
Table 3.12 Switch Board cable standards specification
3.4.1 Conductors
Each conductor shall consist of a solid wire of annealed high conductivity tinned copper
approximately circular in cross section, uniform in physical, mechanical and electrical
properties. The conductor shall be free from spills, splits and defects of any other kind
and shall conform to specification IS: 8130 as mentioned in Table 3.13. The conductor
shall be uniformly coated with tin. Characteristic impedance is 600 Ohms
Nominal Maximum Radial Max. over all dia.

Nominal weight of resistance at thickness of of the insulated
dia.in (mm) conductor in 200C insulation in conductor
Kg/km Ohms/km (mm)
0.5 1.76 92.00 0.18 1.00
0.6 2.52 64.00 0.18 1.12
Table 3.13 Specification of Conductor
3.4.2 Insulation
Each conductor shall be insulated with PVC type 2-Hard insulation conforming to IS-
5831. The PVC shall be applied by extrusion process and shall form a compact
homogenous uniform core. The PVC insulation shall have distinct colour (Single colour
or multicolour) for identification of each conductor.
The colour of PVC insulation for the twisted pairs in the cable shall be as per Table 3.14

Conductor -2 Conductor -2
Pairs Conductor-1 Pairs Conductor-1
Mate Colour Mate Colour
1 Blue White. 11 Blue-Orange White.
2 Orange White. 12 Blue-Green White.
3 Green White. 13 Blue-Brown White.
4 Brown White. 14 Blue-Slate White.
5 Slate White. 15 Orange-Green White.
6 Blue-White White. 16 Orange-Brown White.
7 Orange-White White. 17 Orange-Slate White.
8 Green-White White. 18 Green-Brown White.
9 Brown-White White. 19 Green-Slate White
10 Slate White White. 20 Brown-Slate White
Table 3.14 Colour of PVC insulation for identification of 20 pairs cable.
For sixty pairs cable, each unit consists of 20 pairs and there are all-together three units.
Mate colour of each unit is White, Red and Yellow respectively. The colour scheme of 1st
wire of all other units is same as shown above for the first unit.
Twining: Two insulated conductors shall be uniformly twisted together with a right hand
lay which shall not exceed 100mm.Twisted pair shall be laid up to form a compact and
symmetrical cable. The lay of any two adjacent pairs shall be so chosen as to reduce the
cross talk to the minimum possible extent. The cable core consisting of the required
number of twisted pairs shall be stranded in concentric layers. The cable core shall be
lapped with polythene tape.
Ripcord: A non-metallic suitable ripcord shall be laid longitudinally under the sheath. It
shall provide an effective means of ripping the sheath longitudinally to facilitate the
removal.
Sheath: The cable shall be sheathed with PVC Type-6 general purpose sheath
conforming to IS: 5831. The minimum sheath thickness of the cable shall be as per the
following Table 3.15.

Size of Minimum sheath thickness in mm Max. Over all dia. in mm

cable A B A B
I With conductor With con. With con. With con.
d dia.0.5mm. Dia.0.6mm Dia.0.5mm Dia.0.6mm.
e 6p 0.65 0.65 5.6 6.6
n
11p 0.75 0.75 10.1 10.5
t
21p 0.75 0.75 11.5 11.7
i
30p 0.90 0.90 13.5 15.5
f
42p 0.9 1.10 16.0 17.2
i
51p 1.10 1.10 16.5 19.5
c
63p 1.10 1.50 19.2 20.8
a
101p 1.40 1.40 20.8 23.8
t
Table 3.15 Sheath thickness to IS:5831
Identification mark: The PVC sheath shall be prominently embossed on the outside
with IRS cable and the name/code of the manufacturer at intervals not exceeding
30cms to enable identification of the cable.
The embossing shall be distinct and of such size that it is visible to naked eyes from a
distance of not less than 1 meters.
The cables shall be supplied in standard lengths of 100/200/500 meters. A tolerance of

+ or - 5%of the standard real coil length is permissible.
The cable shall be wound on suitable wooden drums/rolls /coils and shall be strong
enough to withstand the stress and strain of transportation and handling.
Use
The switchboard cable is vastly used in indoor wiring of Exchange installation, OFC
network installation, for temporary connection with RE. Cable to restore the failure in
the cable, pothead joint to the RE. Cable at the termination point and other necessary
inter connections for different installations.

3.5 DOUBLE DROP WIRE/TWINE FLAT WIRE IS 434-PART-1/1964) 230V/440V
This wire is used to extend one Telephone connection from outside distribution box to
inside the house up to the Telephone instrument. It is available in copper conductor of
0.5mm and 0.9mmdia.The standard lengths of the cable’s coil are of 100 Mtrs, 200 Mtrs
and 500 Mtrs.
In this wire L1 and L2 are separated by PVC insulation hence prevent short circuit.
To extend the cable further direct joint is to be made from L1 to L1 and L2 toL2 of
another coil and use the PVC tape to avoid short circuit.
3.6 FIELD SERVICE CABLE (FS) IS-694-PART /1964
This wire is used to extend telephone connection from out side DB to telephone
instrument for out door applications. During emergencies like Railway accidents, Floods,
Cyclones, etc., this cable is extensively used to provide temporary connections of the
telephones as per requirement. This is single core twin twisted of size 7/0.375mm. Out
of 7 strands three strands are steel and four strands are copper with single PVC core
called as L1. One more length to be taken as L2. This is available in length of 500Mtrs.
and 1Km drum lengths. Steel strands will provide additional mechanical strength.
3.7 DATA COMMUNICATION CABLE
For data communication, two types of cable are used for LAN network:
i. UTP: Unshielded twisted pair

ii. STP: Shielded twisted pair.
3.7.1 UTP
This type of cable used in I.E.E.E (Institute of electronic and electrical engineering)
10BaseT Ethernet LANs. UTP wire offers an economical alternative for both Ethernet
and Token ring net works.
This cable is less expensive than shielded twisted pair, less bulky and is also easier to
work with. It is, limited to segments no longer than 100 meters and generally does not
transmit as fast as its shielded relative. Unshielded twisted pair cabling comes in
different grades that are assigned to five standards categories created by the Electronic
Industries Association and the Telecommunications Industries Association (EIA/TIA).

1. Category-1 covers voice grade UTP that is that carry voice but not data.
This is typical telephone cable.( 0.5 or 0.63mm in dia)
2. Category-2 covers data grade UTP that transmits at up to 4 Mbps. This type
of cable is used in some ring topologies.
3. Category- 3 covers data-grade UTP that transmits at up to 10 Mbps. This is
the cable required for 10Base T Ethernet.
4. Category-4 covers data grade UTP that transmits at up to 16Mbps. This is
used in some Token Ring networks.
5. Category- 5 covers data grade UTP that transmits at up to 100Mbps. This is
the type of cable required for 100Base X Ethernet based on
twisted pair wiring.
Conductor: Each conductor is made up of annealed copper of dia. 0.9mm.and PVC

insulated.
USE: UTP cable is connected with the connector known as RJ-45. Eight no. of wires are
connected to the connector. Thick Ethernet cable is also used to connect 15-pin
connector known as DB-15 or DIX
3.7.2 STP
For high-speed data, the STP cables are used. The application of this cable is widely
found in SDH rack wiring. In this cable each twisted pair is shielded and an earth wire is
drawn along with it. Ten twisted pairs are to be bundled together and enclosed in a
protective jacket to form a thicker cable. Bellow the jacket a tape of aluminium foil is
used as a screen. Each conductor is made up of annealed copper of 0.9mm.or 0.6mm
dia. and PVC insulated.
3.8 COAXIAL CABLE
Coaxial cable often called coax is the round and flexible cable. Four separate elements
are identified, by the cross-sectional view. In the center there is a copper wire, carrying
the signal. Encasing this wire is a layer of non-conducting insulation made up of PVC or
Teflon. Outside the insulation, forming a protective sleeve around the conducting wire
and its insulation, another layer made up of a braided mesh of copper or Aluminium.
This layer protects the transmitted signal from the electromagnetic interference known
as noise that can distort the transmitted signal. Finally outside the braided sleeve is an

outer shield or jacket, made of either PVC or a fire resistant material such as Teflon. In
addition to these main components, a coaxial cable can also include one or more no
conducting foil layers outside the insulation. If there is one layer of foil, the cable is
referred to as dual shielded. If there is two foil layers sandwiched between two layers of
braided shielding, the cable is referred to as quad shielded.
The coaxial cable comes in various forms for networking
a. Thin Ethernet or thin wire: Ethernet is based on the 3/8-inch coaxial cabling known
as RG-58. This Thinned cabling can carry a signal for
about 185 meters. Above this the signal begins to
degrade.
b. Thick Ethernet: is based on less flexible coaxial cabling about ½ inch
thick. Also known as RG-8. Thick net cabling can carry
signals farther than Thinned cabling about 500meters
and thus is often used as the backbone connecting. Thin
Ethernet LANs Coaxial cable is connected with the BNC
(Bayonet Neill Concelman) connector to make
connection with the equipment.
3.8.1 RF Coaxial Cable
The co-axial cable radiates the least power and picks up interfering signals to the least
degree. The usual impedances are 40-50 ohms and 70-80 ohms, so the diameter
remains reasonably small. The optimum conductor diameter ratios for different
transmission line properties will vary from one to infinity, if the outer diameter “D” of the
outer conductor is kept constant and inner diameter “ d’” is varied. Cross sectional view
of co-axial cable is shown in Fig. 3.1
Fig. 3.1 Cross sectional view of co-axial cable
A single compromise ratio is also desirable for certain fields of use because it simplifies
manufacturing and merchandising problems. These considerations have led to

standardization, in effect, of a single co-axial conductor diameter ratio for high frequency
and microwave application. This ratio (2.3) results in a nominal characteristic impedance
of about 50 ohms. The medium between conductors is assumed to be a gas.
The relation ship between conductor diameter ratio and characteristics impedance is
based on the equation:
Z0 = 138 Log 10 (D/d) (1)
Attenuation and attenuator
For given frequency and conducting material the total high frequency resistance “ R” of a
co-axial transmission line is proportional to the inverse sum of the individual conductors.
R ~ (1/d + 1/D) .. (2)
This equation shows that minimum resistance of a line of given outer conductor diameter
D occurs when ratio D/d approaches unity. Minimum resistance dies not, however,
accompany minimum attenuation. As the conductor diameter ratio approaches unity the
resistance approaches 0.435 times the resistance of a line having minimum attenuation.
Minimum attenuation, commonly referred to as loss in a coaxial transmission line, occurs
when ratio D/d is 3.592.This ratio corresponds to a characteristic impedance of 76.64
ohms.
As the conductor diameter ratio drops below the minimum attenuation ratio of 3.592 the
line resistance continues to decrease but the current required to transmit the same
power through the line rises. For ratios below 3.592 the I2R losses mount at a rate that is
faster than the rate at which the resistance decreases. The attenuation constant of the
line and not the resistance alone determines the overall attenuation.
The attenuation constant α of a high frequency transmission line is

α = R/2Z0 .. (3)
Substituting Z0 from eq.-1

α = R/276Log10(D/d) .. (4)
But from Eq.2R is proportional to [(1/d) + (1/D)]. Substituting this for R in Eq. 4, we
obtain
α = K (1/d)+(1/d)/Log10 (d/d) .. (5)
Where K is a proportionality factor. The conductor diameter ratio corresponding to

minimum attenuation is obtained by minimizing α with respect to D/d

The increase in attenuation as a result of departing from the optimum ratio lf 3.592 is
obtained from Eq.5 when proportionality factor K equals Log3.592/(3.592+1) or 0.121
A coaxial transmission line will withstand maximum applied voltage between conductors
when their diameter ratio is 2.718,which corresponds to a characteristics impedance of
59.93 ohms. This is determined by minimizing the formula for the voltage gradient at the
surface of the inner conductor, where breakdown first occurs, with respect to D/d. The
gradient g in voltage per cm. at the surface of the inner conductor is:
g = 2E/dloge (D/d) .. (6)
Where E is the applied voltage and e is the Napierian base (2.718)

Maximum power carrying capability of a concentric transmission line occurs when the
conductor diameter ratio equals √e or 1.648, which corresponds to a characteristic
impedance of 29.94, ohms. This assumes that the frequency is within a range (usually
below about 50mc) where voltage breakdown rather than overheating of the inner
conductor governs the maximum power rating of the line. This ratio is also optimum from
the power-carrying standpoint at higher frequencies under most conditions of pulsed
operation where the average power is small as compared to the peak power.
In order to calculate the maximum power-carrying capability ratio, based on a limiting
voltage gradient on the inner conductor, we note first that the applied voltage across a
transmission line terminated in its characteristic impedance and the power P on the line.
E = √pz0 .. (7)
But the characteristic impedance as given by Eq. 1 may also be expressed as

Z0 = 60 loge (D/d) .. (8)
Substituting into Eq. 7

Z0 = √60P x √loge (D/d) ..(9)
Eq. 6 gives the gradient at the surface of the inner conductor for a given applied voltage.
Substituting the above equivalent for E into Eq.. 6 we obtain the following expression for
the gradient at the surface of the inner conductor for a given power.
g = 2√60P/ d √ loge ( D/d ) ..(10)

The conductor diameter ratio that permits the transmission of a given power with
minimum voltage gradient, and hence maximum power transmission when voltage
gradient is the limiting factor, as given in Eq. 10, with respect to D/d. We then obtain
(D/d) = √e = 1.648. The square root of the reciprocal of the gradient as expressed in Eq.
10 gives a quantity which is proportional to the ratio of the power carrying capability of
the line to that of a line having a maximum capability, based on minimum voltage
gradient on the surface of the inner conductor.
3.6.4 Uses of different types of cable in table form (refer to Table 3.16):
Sno Types of cable Purpose of use

1 Paper insulated quad cable Control and Block circuit working in RE area
Aluminium Sheathed (0+12+2;
etc.)
2 Paper insulated quad cable Derivation cables of Control and Block ccts.
Lead sheathed (0+4+0; 0+5+2; in RE area
etc.)
3 Paper insulated twisted pairs For local loop of extension telephone lines in
cable lead sheathed. RE and non RE area
4 6/4 Quad polythene insulated Control and Block ccts. Working in RE and
jelly field Cable -armoured/un- non RE area and also for data
armoured. communications
5 Paired twisted polythin For local loop of extension telephone lines
insulated jelly filled cable
armoured (5,10,20, 50,100
pairs)
6 Co-Axial cable For high speed data communication
7 D-8 field cable, Twine cores flat Temporarily extension of telephone
cable connection during disaster and auto
telephone connection from CT box to
telephone
8 Switch boar cable For indoor wiring in Exchange, Repeater and
(4,5,6,10,20,60,100 pairs) restoration of cable fault temporarily using it
as a tip cable.
9 Cat-3; Cat-5; Cat-6 For LAN Net work for data communication
Table 3.16 Summary of cables and its application

INTRODUCTION OF LINE PLANNING
CHAPTER - 4
4.1. Elementary subscribers’ line network
The subscribers’ line network forms the link between the equipment in the telephone
exchange and the suscribers’telephone instruments. This network invariably consists of
underground telephone cables laid from the exchange to the various localities served by
the exchange. The cable pairs are terminated in suitable Distribution Points. The
distribution points may be external and mounted on poles or internal and fitted inside
buildings.
4.1.1 Need for planning
The cost of the underground cables forms a substantial portion of the cost of the
telephone system and the manner in which the cable network is arranged and the cable
provision made does affect appreciably this cost as well as the quality of service
rendered to the subscribers. The need, therefore, arises for proper planning and
provision of the underground telephone cables.
4.1.2 Purpose of planning
The purpose of a planned local network is to ensure that cable pairs from the exchange
are made available in the most economical manner for giving telephone connections as
and when and at the place where the demands for such connections arise. The
planning work can, therefore, be considered in its two broad aspects namely (i)
anticipation of telephone demands and (ii) determination of an economical and
convenient manner in which cable provision could be made to meet these demands.
4.1.3 D.P (Distribution point)
From distribution points the telephones are distributed at different locations of a building
or the point from where the overhead lines and cables are connected for telephones in
different locations. At distribution point, the cable termination boxes or tag blocks are
connected to make connection to the field service wires or to the switchboard cables to
extend connection to the telephones.

Grouping of D.Ps: The common point where the cable from a number of Dip’s can be
grouped together, then from that point to the exchange, the total overprovision required
would be much less since the area covered is much larger.
The number of year’s growth for which provision is made in advance is called the
planning period. An economic planning period is necessary for economical use of the
local cable.
The grouping of DP’s will thus result in a saving in cable costs .The total number of
cable pairs on the exchange side of such a grouping point will therefore, be much less
than that on the D>P’s side. This process of grouping will thereafter be referred to as
cable reduction and the grouping point as the cable reduction point.
4.1.4 Methods of providing Flexibility
I. Cross connection
II. Multiple teeing
III. A combination of cross connection and multiple teeing
The method of cross connection is widely used and teeing may be adopted for small cable.
4.1.5 pillar and pillar area
Provision of flexibility between D.P’s.by means of cross connection requires the cable
pairs from the exchange and D.P sides to be terminated at the cable reduction point.
The pairs will be terminated in cable terminal boxes (abbreviated CT box) suitably
mounted on frames inside a steel casing or shell. A jumpering field will also be provided
so that a pair from the exchange side can be jumped to any pair on DP side. This
flexibility unit will be called a pillar .The pillar enables the fluctuations, within the
group of DP’s served through it to be met. The area for which the distribution is done
through the pillar will be called a pillar area. The maximum number of secondary cable
pairs that can be connected to a pillar is 100 pars.
4.1.6 Cabinet and cabinet area
In the same manner as DP areas are grouped together to form a pillar area, the pillar
areas can also be further grouped to form a bigger block of territory with a
correspondingly greater reliability of forecast and lower economic planning period and
the cable to the exchange side planned with increasing certainty and economy. This will
represent a second stage of cable reduction. The bigger block will be termed a cabinet

area and the flexibility unit for providing the flexibility at the second stage will be called a
cabinet. The distribution cabinet contains cross connecting frames by which conductors
from the primary cable can be connected to secondary cable conductors. By making the
cabinet airtight and using desiccating agents, the disadvantages of low insulation can be
avoided.
4.1.7 Distinctions between cabinet and pillar
The cabinets and pillars are of identical construction and appearance and are available
in a number of standard sizes. The distinction between cabinet and a pillar arises
primarily from the function performed by the flexibility unit rather than from the
appearance or size. The term pillar will invariably be used to signify the first stage of
flexibility i.e. between DP’s and the term cabinet to signify the second stage of flexibility
i.e. between pillars.
The cable layout of a large exchange system will consist of a primary network, a
secondary network and a distribution network. The distribution network ends in
distribution points, which are connected to the secondary network through distribution
cables at a flexibility point, which can be pillar or a special type of cable joint. Similarly
the secondary network ending in flexibility pints are connected to the primaries at the
cabinets or other types of flexibility points. The primaries are connected direct to
exchange. From the distribution points the subscribers are fed by short lengths of aerial
lines that are erected only after a firm demand is placed for a connection. These aerial
lines should be as short as possible. At distribution points two types of cable terminals of
capacities 10 pairs and 20 pairs respectively are used.
4.1.8 Economic planning periods for primary, secondary and distribution

networks.
Exchanges up to ultimate capacity of 500 lines the economic planning period as

described bellow.
i) Routs having rate of growth unto 5 pairs per annum Planning

period: 20 years
ii) Routs having rate of growth over 5 pairs per annum Planning
period: 20 years

Medium and large size exchanges having over 500 ultimate connections.
i) Primary cables: Growth rate of routes 20 pairs to 100 pairs per annum.
Planning period: 5 years at a time
ii) Secondary cables: The annual rate of growth in the secondary routs vary from 5to
20
Planning period: 10 years at a time.
iii) Distribution cables: The annual rate of growth of distribution cables
Will vary from 0.5 to 5 pairs.
Planning period: 20 years at a time.
4.1.9 Flexibility arrangements for different sizes of exchanges
For purposes of this instruction, telephone systems in India will be divided into three
categories.
Small size: capacity up to 499 connections
Medium size: capacity 500 to 1000 connection
Large size: capacity over 1000 connection
Flexibility arrangements for the above types of exchanges will be made as follows:
1. Inner zone: For all sizes of exchanges distribution points that can be fed by
cables of lengths up to 440 yads. from the exchange, will have no flexibility
arrangements. They will be fed direct from the exchange by cables provided on a
tapering basis. The area thus served constitutes the inner zone.
2. Outer zone: In the case of small systems distribution cables laid for 20 years will
feed the outer zone and pillars will be used for affording flexibility. To effect
economy primary and secondary networks will be combined into one, and cables
will be provided from the exchange on a 10 year basis up to the flexibility points
viz., the pillars. If the cables coming to flexibility point are small in size no pillar
will be provided but teeing will be done. In the case of medium and large
exchanges cabinets and pillars will be used to flexibility. Primary, secondary and
distribution cables will be provided for 5, 10 and 20 years respectively

A typical layout of cable shown in Fig.1 (Measurements are in meters)
INNER JONE
100
20 CABINET
20
10 PILLAR
75
50 100
50 20
EXC 200 200 50

100
10
50
20
Pillar
75
20
20
Fig. 4.1 Typical layout of cable distribution
4.2 Planning procedure
a) Gauge of conductors
After the exchange position is fixed, the first step is to divide the exchange area into the
0.5 mm 0.63 mm and 0.9 mm conductor areas. With the exchange as center, concentric
circles are drawn to show the limits up to which 0.5 mm 063mm and 0.9 mm conductor
cables would be laid. The radius of these circles is obtained by dividing the maximum
limits allowed for each gauge of cable with a factor of 1.4 to allow for curved and zigzag
routes. These circles indicate the gauge of cable with which the DPs lying within these
areas are to be connected to the exchange.
b) Location of distribution points.
c) Location of pillars: For every 80 ultimate subscribers, there is one pillar of capacity
100+100.
d) Cabinets: Each cabinet should cater for say, 300 to 600 connections ultimately. 3 to
6 pillars will be fed from one single cabinet.

a) Cable plans and maps
After finalizing the cable plan the whole scheme should be incorporated on the detail
map. This map should shown the existing DPs, the existing cables wherever they are re-
arranged, the proposed DPs to be opened immediately and in future, the proposed
cables to be laid immediately and the route of cables to be laid to link up the future DPs.
Fundamental plan
In addition to the cable plan mentioned above, a straight line chart should be prepared
showing in detail all the existing cables and Dps as also the proposed ones. The relief
cables to be laid at various dates should all be clearly shown with the year of relief noted
against each instalment. This chart will be fundamental plan for the long-term cable
scheme.
b) Cable Records:
The primary secondary and distribution cable records should be maintained.
4.2.1 CONSTRUCTIONAL FEATURES OF CABINETS AND PILLAR
Both the cabinets and pillars are fabricated steel or cast iron casings enclosing a
framework on which cable terminal boxes are mounted. The cabinet or pillar has doors
for easy access to the cable terminal boxes. The door is provided with suitable locking
arrangements. It is provided with a lining of suitable rubber or other material so that
rainwater cannot percolate inside. On its inner face a cardholder is provided to hold the
cabinet cards that give detailed of connections of cables in the CT boxes. The sides and
the door are provided with ventilation openings fitted with special pockets for inserting
filters to prevent ingress of dust and insects. In cabinets of airtight design, containers for
keeping desiccating agents like silica gel are provided.
The following sizes of cabinets and pillars have been standardized: 300 pairs, 500 pairs,
700 pairs, 1000 pairs, and 1400pairs. The number of pairs indicated is the total number
of cable pairs to be terminated including the exchange side and on the distribution side
4.2.2 Cable Termination at cabinets and pillars
The CT boxes are invariably wired up with tail cables beforehand (i.e. they are mounted in
the cabinets or pillar). The primary, secondary or distribution cables are subsequently (i.e.
after mounting the CT Boxes in cabinets or pillars) jointed to one or more of the tail
cables. If the number of tail cables to be taken into a joint is inconveniently large, as in the
case of a large primary cable, the jointing may be done in two stages, the large cable
being first jointed to 2 or 3 short pieces of smaller size cable and the each of the latter
jointed to 2 or more cable tails. Indian Railways has a wide range of capacities of
Exchanges and the need of planning is different for different Exchange.
The Exchanges of various capacities those require pillar, cabinet and DP are shown in the
following Table 4.1: -
Exchange Areas to be served in to full fill the

Sno. Cabinet Pillar DP
capacity Railway’s needs
1 128 Ports Indoor: - office ---- ---- 20Pr.,
Complex 10Pr.
& 5Pr.
2 256 Ports Indoor & out door: - ---- 100 20Pr.,
Offices, utility service centers and Pr., 10Pr.
residential complexes of Railway colony 50 & 5Pr.
within in the radius of 2kms. Pr.
Incoming and out gong Junction and
Tie- line- 5Kms.
3 512 P0rts Indoor & out door: - 100 20Pr.,
Offices, utility service centers and Pr., 10Pr.
Tie- line- 5Kms
4 1024 Indoor & out door: - 100 20Pr.,
Ports Offices, utility service centers and Pr., 10Pr.
Tie- line- 5Kms
5 2048 Indoor & out door: - 200 Pr. 100 20Pr.,
residential complexes of Railway colony 100 Pr. 50 & 5Pr.
within in the radius of 2kms. Pr
Tie- line- 5Kms Indoor & out door: -
Offices, utility service centers and
residential complexes of Railway colony
within in the radius of 4kms.
Tie- line- 8Kms
Tie- line- 8Kms(loop resistance 1500
Ohms max.)

Tie- line- 8Kms
Table 4.1 Cable terminators requirement depending upon capacity of exchanges
4.2.3 Telephone Network Layouts

The planning of telephone’s network of the different sizes of exchanges can be
explained through the following layout diagrams of Fig. 4.2, 4.3 & 4.4
DP PILLAR DP
DP 5P 50 Pr 20P
20P
50P
PILLAR 50PX2
50 Pr DP
DP PILLAR DP 10P
20P 100Pr & 20P
50Pr
DP DP
100P
50Prx
DP 5P 10P
5P
r
DP
5P DP
A/EXCHANGE 5P
DP DP
10P 512 PORTS
20P
DP
20P
100Pr
50Prx
DP
10P
2
DP
20P PILLAR DP DP
100Pr & 20P 5P
DP
10P 50Pr
100Pr
PILLAR DP
100Pr & 50Pr 10P
50Pr
DP
5P
DP PILLAR
DP DP 5P 100Pr & DP
20P 5P 50Pr 5P
50Pr
DP
20P DP
DP 5P
DP 5P
PILLA 20P
DP R DP
20P 5P
Fig. 4.2 Layout of 512 ports of exchange

DP DP DP
20 Pr. 10 Pr. 20 Pr. DP
20 P
PILLAR DP PILLAR 100P

DP 100 Pr., 20 Pr. 100 Pr., PILLAR
20 Pr. 50 Pr. 50 Pr. 100Pr
50P
100P
50P
100P
50P DP
CABINET 20P
DP 200 Pr., DP
5 Pr. 100 Pr. 10 Pr.
DP
20 Pr. 100Px 2
200P
A / EXCHANGE
DP CAPACITY DP
20 Pr. 1024 PORTS 20 Pr.
DP
100Px 2
5 Pr.
DP
CABINET 20 Pr.
200 Pr.,
100 Pr. 50Px 2
PILLAR
100 Pr., 100P
50 Pr. PILLAR
DP 100 Pr., DP
20 Pr. 50 Pr. 20P
DP
20P DP
5P
PILLAR
DP 100 Pr., DP
DP 20P 20P
50 Pr.
5P
Fig. 4.3 Layout of 1024 ports of exchange

DP
A/EXCHANGE 20P DP
DP 5Pr.
128 PORTS
20P
PILLAR
50 Pr.
20Pr.
Tie line DP
20P
50Pr.
A/ EXCHANGE DP
DP DP
256 PORTS 5Pr.
20P 20P
RAX
DP
20P
DP 100Pr.
10P
PILLAR
100 Pr. DP
20P
DP
DP
20P
5Pr.
DP
5Pr.
Fig. 4.4 Layout showing the exchange of 256 ports Tie with 128 ports of exchange
4.2.4 Layout of cable with Tee Joints
In the case of small size cables, teeing may be adopted to give flexibility. The Tee joints
have the disadvantage that they introduce additional attenuation in the subscriber’s
circuit .The Tee joints, however, are particularly advantageous in the exchange areas
where such facilities as external extensions, party line connections etc. are commonly
required. Fig. 4.5 shows a tee joint. Here the primary cable of 30 pairs comes from the
exchange to a tee joint.

10 pairs DP-1
TEE JOINT
10 pairs
10 pairs
EXC 30 PAIRS
10 pairs
DP-2
Fig. 4.5 Tee joint

At tee joint 10 pairs cable is individually connected to Dp-1 & DP-2 from the primary
cable. Remaining 10 pairs cable is commonly available to both the DPs.

CABLE LAYING PROCEDURE
CHAPTER - 5
5.1 SELECTION OF ROUTE FOR LAYING CABLES
The chief points to be considered in choosing a route are-
a) Shortest length possible.

b) Cheapest for laying.
It is cheaper to lay the cable along footpaths, as the sub soil is easier to dig there, thus
reducing the cost of digging.
For a primary or secondary cable, that side of the street that presents the least obstacles
and fewest road crossings is naturally chosen but future expansion and utilization of the
cables are also decision factors.
It is necessary to inspect the nature of the soil and avoid whenever possible the laying
cables in the following situation.
a) Made up group, consisting of ashes slag, clinker etc.

b) Heavily fertilized soil that may contain acid salts, electrolyte.
c) Proximity to such system that generates stray current should be avoided as far as
possible.
d) In laying cables due regard should be given to the underground properties of other
departments such as electric light and power mains, water and gas mains, sewers,
drains etc.which should be avoided as far as possible.
e) Clearance from power cables
Where underground cables are laid close to power cables, the minimum desirable
horizontal and vertical separation between the alignment of the departmental cable and
the power cable is 0.6 meters; but in no case shall this be less than 46 cm for single core
power cables and 30 cm for multi core power cables. The power cables and telecom
cables should as far as possible cross at right angle to each other.
f) Allowance for future development

When ever troughs or ducts are laid to take cables through, under existing services or at
road crossings, sufficient provision should be made for any additional cables that may
have to be laid to meet future demands.
5.2 METHODS OF LAYING UNDERGROUND CABLES
Method of lying
a) Laying direct in the ground

b) Drawing through ducts
c) Laying solid
Laying direct in the ground
This method of laying cables is comparatively simple and cheap, and is the one that is
widely used. It involves digging a trench in the ground and directly laying the cable on a
bedding of soft earth free from corrosive elements at the bottom of the trench, covering
the cable with a layer of soft earth, placing warning bricks centrally over the soft earth
covering and finally filling up the trench. When the soil contains appreciable quantities of
stones or pieces of rock, sand may be used for the bedding and covering below the layer
of bricks.
Drawing through ducts
In this system, also known as the draw in system, one or more ducts are laid together,
according to anticipated requirements and a single or more cables according to size are
drawn through each pipe or duct. Manholes are provided at definite intervals. The initial
cost of lying of ducts is high. The system is generally used only in difficult location such
as crossings railway bridges culverts and in such situations where subsequent
excavation of a trench is both very expensive and inconvenient.
Laying solid
This method involves laying a cable in trough made in the excavated trench, filling the
trough completely with molten bituminous compound, providing warning bricks on top
after the compound has set and then back filling with earth. Laying solid is higher cost
than lying direct.

Cable laying at road crossing
At road crossings cables should be laid in pipes. Pipes should be laid with a slight slope
from the centre to the sides of the road to prevent collection of water. Trenching across
roadways, for laying cable may be by manual excavation, thrust boring or tunnelling. On
minor roads, which can be temporarily closed to traffic, it is possible to open up across
the entire width of the road.
Roadways that are broad may be open for half their width, allowing the other half for
use of traffic. The second half of the width should be opened after laying pipes and
reinstating the first half of the trench.
One or more spare pipes may be laid, through which a cable can be drawn when
required. It will be advantageous to leave a GI wire about 5mm diameter in the pipe for
drawing the cable.
In the case of small bridges and culverts, where there is a likelihood of their subsequent
expansion and remodelling, cable should be laid with some curve on both sides of the
culvert or the bridge to make some extra length available for adjustment of cable at the
time of reconstruction of the culvert or the bridge.
On the long bridges cables should preferably be laid in G.I. troughs. This facilitates
pulling-in of the cable, as pulling-in long length of cable through many pipes is difficult
and may cause damage to the cable. The cable should be laid with slight loop at
intervals. Cable should never be laid solid on bridges. These precautions are necessary
to allow longitudinal expansion of the cable due to temperature changes; as otherwise,
the cable may be strained excessively and may ultimately break. A layer of glass wool in
the trough shall surround the cable. Joints should be avoided, as far as possible, in the
middle of the bridge. At the end of the bridge the cable should be gradually sloped down
to normal trench depth through pipes. This is necessary to protect the cable from theft
and damage by pedestrians or vehicular traffic.
Whenever a cable has to cross a railway track it should be laid in iron pipes of not less
than 75mm diameter at a minimum depth of 1.25 meters below rail level. The pipeline
should extend on both sides of the Railway track for sufficient distance to enable repairs
to the cable being undertaken without the necessity of disturbing the formation under the
Railway track.

5.2.1 TRENCHING, BACKFILLING AND REINSTATING FOR LAYING OF LOCAL

CABLES
Trenching and ducting for laying underground cables can be made by a) manual
excavating b) thrust boring c) excavating with mechanical tools and d) trench laughing.
Manual excavation is normally employed in most of the cases. Manual excavation can
be done by means of pick- axes, pharaohs, and crowbars depending on the nature of
the soil. When rock or concrete is to be broken, special methods such as chisel and
sledgehammers may be employed.
Thrust boring is suitable for use in urban and built up areas generally, to avoid
excavation and reinstalment of long continuous made up surfaces which may be
expansive.
Depth of trench
The cable trench should be carefully excavated to such a depth, that after the cable is
laid, the distance between the top of the cable and top of the trench is not less than
60cms.Cast or wrought iron pipes into which cable is drawn or laid must not be less than
45cms from top of trench. The measurement is taken from the upper surface of the pipe.
Should the trench be located in a bank, measurements of the depth of trench must be
taken from the ground level at the foot of the bank. If obstructions or very hard rock
make it impracticable to lay the cable to the minimum depth of 60cms then some
additional form of protection like concrete tiles, or split cast iron pipes should be provided
to damage to the cable due to crushing or subsequent excavation. Where such tiles are
used, a layer of soft soil must be laid on top of the cable under the tiles. The minimum-
bending diameter of the armoured cable during lying is 15 times the diameter of the
cable.
Width of the trench
The width of the trench should be such that workmen can get down and work within it
and a width of 30cm to45cm is recommended. If more than one cable is to be laid in the
same trench they should be laid side by side with a distance of about 5cms.between
them.

Leveling
The bottom of the trench should be carefully levelled and freed from stones, but if
gradients or changes or depth are unavailable, they should be gradual.
Paying of cable
There are two methods of paying out cables:
a) By moving the drum along the trench, the cable is put into the trench. One end of the
cable is held strongly by the men and the drum is slowly moved out, putting the drum
on the wheel.
c) By keeping the drum stationary. The cable is paid out by mounting the cable drum on
cable wheels or cable jack at the end of the trench. The wheel or jacks are kept
stationery in position and the cable is pulled off from bottom side of the drum along
the trench.
For long length of cables the pulling tension should be applied over the whole length of
the cable. For this purpose men should be posted at frequent intervals to support and
pull the cable. After the cable is paid out, it is carefully lowered into the trench.
5.3 Precautions while laying the Telecommunication Cable
1. Cables lay in suburban roads of cities, or along the main roads, or at railway yards, it
should be protected with bricks. The bricks should be placed over the cable separated by
a few inches of soft soil and sand.
2. Care should be taken about gradual slope which approaches the deeper portion of the
trench, but not by a sudden drop in level of trench, may damage the cable.
3. Care should be taken to avoid any injury to jute covering or armour while laying the cable.
4. Care should be taken to remove sharp stones, or metallic pieces in the cable trench
while drawing the cable or back filling the trench.
5. While laying the cable in ducts all abrupt curves in the en-route must be avoided.
Whenever it is happened to cross the electric cables, water pipes etc, the cable should

be drawn underneath to the above items with an extra protection of pipe to the cable
should be provided exactly at crossing point.
6. In no case should a faulty cable be laid without clear rectification of fault.
7. While selecting the cable route, it is always preferable to choose the straight line.
8. Sufficient loose should be provided on both sides of the bridges and culverts to avoid the
breakage of cable due to expansion.
9. At Level Crossing Gates minimum 3 meters of loose cable should be coiled to meet the
future needs.
10. While planning itself sufficient care should be taken to the cable joints, that should never
be placed on bridges, culverts or at slope areas
11. While planning itself sufficient care should be taken that the jointing places should never
be selected nearer to the water logging areas.
12. While laying the cable, it should not be tight in the trench; otherwise the conductors may
be broken.
13. Cable route markers should be provided at every 20 meters in straight-line route, at
curvatures and at joints with proper markings, to facilitate future attention.
14 While laying the cable along the railway track, in non-RE area a minimum distances of
2.75 meters and in RE area a minimum distance of 5.75 meters from the centre of the
track should be maintained.
15. Care should be taken for good jointing to provide sufficient over lap at joints.
5.3.1 Handling of cable and cable drum
A crane should be used, if available, when unloading drums of cables from a lorry or a
railway wagon, and the drums should be carefully lifted and deposited on the ground.
Hoisting should be done only by passing a stout iron bar or chain through the central
holes in the flanges and stringing it to the crane hook. For unloading a large number of
cable drums from railway wagons attempts should be made to requisition of cranes from

the concern department. If arcane is not available the drums should be carefully rolled
down a suitably arrange ramp. When a large number of cables are to be loaded or
unloaded, erecting a strong tripod and using a chain pulley will be found to be very
advantageous, quantities of straw are sometimes used successfully to break the force of
any impact when unloading. But under no circumstances should a drum be dropped to
the ground as the shock may cause serious internal damage to the cable. The drum
should always be rolled in the direction of the arrow indicated on the cable drum.
Otherwise the coils will tend to unwind and the cable may damage.
CORRECT METHOD OF LIFTING DRUM INCORRECT METHOD OF

LIFTING DRUM
USE OF WEDGES TO PREVENT ROLLING
TRESTLE RUN WAY BOARD REST METHOD OF UNLOADING CABLE DRUM FROM
TRUCK
HANDLING OF CABLE DRUM
Fig. 5.1 Handling of Cable drum

Inspection
On receipt of cable drums they should be visually inspected to detect any damage
suffered during transport. If inspection leaves any doubt, it may be unwound from drum
and inspected thoroughly as well as electrical and pressure tests taken.
Storage
The site chosen to storage of cables on drums should not be low lying where water is
liable to stagnate. All drums should be stored in such a manner as to leave sufficient
space between them for air circulation and inspection. It is desirable for the drums to
stand over sleepers or bricks placed directly under the flanges. In no case should the
drums be stored on the flat i.e. with the flanges horizontal as this leads to rotting of one
face of the drum and great difficulty in subsequent handling.
Movement of cable drums
Where drums of cables are required to be moved over a short distance of a few yards
only, they may be rolled in the direction of the arrow indicated on the flange of the drum.
If the cable is to be transported over longer distances it should be mounted on cable
wheels and rolled to the site of work, Alternatively, lorries with low loading platforms may
be used for taking the drums to the work spot as shown in the above Fig. 5.1
Underground cables should never be bent to a smaller radius than nine times the
overall cross sectional diameter of the cable and the bending should be done
slowly.
5.4 Cable route and joint indicators
Route indicators are used to make the routes of the cables. Joint indicators are used to
make position of the joints on the cable. Their presence facilitates location of the cables
during maintenance operation. Constructional features of both the indicators are the
same. The joint indicator is marked with an extra letter J to distinguish it from the route
indicator.
Types of indicators
a) Type – A: Consisting of a cast iron disc welded to an angle iron as shown in
Fig.2 below

b) Type – B: This is made of cast iron or cement concrete as shown in Fig. 5.2
below
c) Type – C: These are made of reinforced concrete.
IR
TLE
I.R
Telecom
Cable
Joint
Ground
Type-A Type-B
Fig. 5.2 Cable route indicator
Spacing of indicator
The indicators should be placed about 200metres apart on a straight course, at every
joint and at every point where the direction of the cable route change.
Route indicators are used to remember the cable route. Joint indicators are used to mark
the position of joints on the cables. Their presence facilitates the location of cables
during maintenance operations. The cable route indicators should be provided at every
20 meters, on straight-line route and at every joint.

5.5 UNDERGROUND TELECOMMUNICATION CABLE ROUTE SURVEY

(EXTRACT FROM RE MANUAL)
The survey is divided in two parts:

1) Preliminary
2) Detailed survey.
5.5.1 Primary cable route survey
a) Selecting the route in general.

b) Deciding the number of VF repeater stations.
c) Deciding number of cable huts.
d) Working out the requirement of circuits, which are to be provided in the main cable
and to prepare the circuit diagrams and cable chart.
e) Deciding the size and assessing the length of main cables required.
f) Working out the requirements of heavy tools and plants required depending upon
the nature of the territory, availability of roads along the track etc.
g) Assessing the special problems of the section such as type of soil, long cuttings,
new embankments, water logged areas, types of major bridges, major yards,
approach cables for linking etc.
h) Collecting details of the existing telecommunication facilities and the additional
requirements due to electrification and preparing tentative tapping diagram.
i) Deciding the size and assessing the length of derivation cables required.
j) Assessing the number of different types of joints required.
k) Assessing the number of track crossings and other protective works required to be
done.
l) Composition of the soil and whether special protection of cable is necessary.
m) Repeater station and cable hut equipment.
n) Measuring instruments.
o) Transport vehicles, need for the execution of work
5.5.2 Location of repeater station and cable huts
The repeater stations are generally spaced at 40 to 50 Km. intervals. Generally the
power supply should be available at the station where a repeater is located. The cable
huts shall be provided at all the stations in order to reduce the induced voltage within the
specified limits

5.5.3 Size and length of telecom main cable:
Spare quads to the extent of 15% to 30% may be catered for depending on the future
needs.
Assessment of the main cable length:
a) Route length of the section +

b) Contour allowance 2.5%
c) Jointing allowance 1%
d) Approaches to repeater stations and cable huts 1.5%( maximum distance of
cable hut from cable route will be 150 m.
e) Yard allowance depending upon the local conditions in big yards
f) Special feature such as hilly terrain, water logged area, and other features
requiring diversions in cable route—as required.
g) Maintenance spares including working spare----10%.
5.5.4 Size and length of derivation cable
The standard sizes in use are:
(0+7+0), (0+5+2), (0+9+3)

The length of derivation cable required for each size may be based on an average length
of derivation cable worked out for tapping. When the distance of feeding point is
abnormally long, the length of derivation cable is added separately.
Number of joints:
On the basis of the total length of the main cable, the number of straight-through joints,
loading coil joints and condenser joints should be calculated which would be in the ratio
of 2:1:1. To the number of joints so calculated, the following percentages should be
added for the working allowance at fault etc.
1) For straight through joints 20%
2) 5-T joints 15%
3) 10-T and 20-t joints 20%
4) Condenser joints 15%
5) Loading coil joints 10%

5.6 Detailed cable route survey
5.6.1 Preparation of main cable route plan
For Preparation of main cable route plan, “ 5 Km charts” should be prepared which
covers a length of 3 Km. Of the route .The horizontal scale is 10 cm = 1Km.
Based on the OHE location Survey plan, the locations of ASM’s office, cabins, OHE
switching posts, etc. should be marked on the charts. The name of the location should
be put in the LOC column and the change in the Change column (CH). At every 10cm.
(1Km) the Km. Post number should be written and its exact equivalent change as per
OHE survey plan entered in the CH column. The equivalent change is required for
working out the length of the main cable required. The name of station should be shown
against the location of the stationmaster’s office.
Based on the OHE survey, the serial number and the length of culverts, bridges and
level crossings should be marked on the Track Line of the cable route plan. The survey
party should be supplied with prints of “5Km. Charts” with the above details entered for
enabling them to mark the route, and other details after surveying.
The following are the guidelines for finalizing the route and preparation of the
cable route plan:
Measurement of “special terrains” like approach to repeater station/cable hut, long

bridges, big yards, sharp diversions in the cable route from its parallel course along the
main railway tracks due to obstruction, cuttings etc. The measurement of “straight
runs” of cable route along the Railway track is not necessary. For the “straight runs” on
the cable route, an allowance of 3.5% of drum length should be made for the contours,
jointing etc. and each drum length should be considered to cover a route length of 0.965
x cable drum length. A drum length of 460 m should thus cover a trench length of 0.965
x 460 = 444 m. On this basis the full drum lengths should be plotted on the route plan,
marking the position of joints (Other than T- joints) at the end of the drum length.
The cable route should be started from a repeater station. A termination allowance of 5
m. cable length inside the repeater station/cable hut building should be made, in addition
to a length of about 20 m. being kept in a pit just outside the building.
It should be ensured that both special terrains and straight runs should consist of full
drum length, so that the position of joints (other than T-joints) is fixed without difficulty in
both cases.

The separation distance of the cable route from the nearest track (a reference track
should always be the main line) on the straight runs should be 10 m. The deviation from
this standard separation of 10 m. should be kept to the minimum. Separation distance
should be marked on the straight runs portion of the cable route plan (5 Km. Charts) at
intervals of not more than 250 m. In addition, the separation distances at points of
change in the cable route such as diversions, track crossings approach to bridges,
culverts etc. should invariably be marked on the cable route is clearly defined. For
special terrains the separation distances should be marked at as close intervals as is
considered necessary depending on the site conditions.
The survey party should visit each location such as cabins, SM’s offices, loco sheds,
pump houses, gate and verify the details collected during the preliminary survey of all
the existing telecommunication facilities, and additional telecommunication facilities to be
provided due to RE such as toppings on traction power control, traction loco control,
remote control and emergency control circuits. For emergency control circuit, in addition
to the general tapping to be provided at every 1 to 1.2 Km., the details of tapping
specifically required by the electrical engineering department for their switching posts
such as sub-sectioning posts, sectioning posts, traction sub-stations and isolated
locations etc. should be collected well in time. The exact location of the various tapping
on the emergency control should then be worked out taking into consideration the
tapping to be essentially provided at specific locations for electrical engineering
department so as to ensure that the distance between consecutive emergency socket
post does not exceeds 1 to 1.2 Km.
The potion of each tapping should thus be finalized and a final tapping diagram
prepared.
The repeater or cable hut building should be nearer to the Railway track as far as
possible. There should be a suitable approach road for the cable to enter and leave the
repeater or cable hut. The selected site of the building should be a wide area to build up
a good earthling system for the equipment.
5.6.2 Preparation of joint schedules
The joint schedule indicated the location of each proposed T-joint with respect to the
OHE mast and change of the location. All the details required for preparing the joint
schedule should be taken from the cable route plan.

A temporary suitable site for storing of cable drums should be selected. From there the
cable drums will be shifted to a particular place for lying of cable. The location of site for
unloading of each drum should be noted with respect to telegraph posts and recorded in
a register. A wooden peg should also be driven at each of the selected sites in order to
locate it at the time of unloading each drum without doing actual measurements. There
is definite direction in which the outer end of the cable on a drum should be pulled .The
drums should be so unloaded as the cable is always pulled away from the control office
while paying it out from the drum mounted over jacks or a drum stand.
5.6.3 Derivation cable route charts:
The survey party should decide the best route for derivation cable for each tapping and
separate route and Tapping Details chart for the derivation cable should be prepared.
The length of the derivation cable required should be determined by measurement
between the main cable and the location of CVT box making an allowance of 2 m for T-
joint about 5 m. extra to be kept in the form of coils just outside building such as ASM’s
office, cabins, OHE switching posts etc. For cabins where cable is to be terminated on
the first floor, additional length should be catered for.
For emergency tapping a termination allowance of 2 m is sufficient without any extra coil.
Lengths required for the emergency telephone connections at SSP, SP etc. from the
derivation cable termination inside the building should be worked out separately.
The number of T- joints is to be worked out from the tapping diagram. The length and
size of each derivation cable should be entered in the main cable route plan in the
appropriate column. The following points should be specially kept in view while deciding
the derivation cable route. The Railway derivation cables cannot be used for TPC
tapping in Grid sub-station.
Special lengths for long girder bridges:
For long girder bridges, special length of main cable may be required (length more than
460m). This is to avoid the location of a joint on such bridges, on slopes leading to
bridge abutments and on top of deep cuttings etc, These details regarding the
approaches to the bridges should be worked out and the exact length required in each
case should be intimated to the head office to be included in the placement of order for
supply of cables.

Main cable termination
The number of main cable terminations should be worked out.
5.6.4 Earth Resistively measurement
The measurement of earth Resistivity between adjacent sectionalising points (repeater

station and cable hut) is made at interval of 5 Km along the proposed cable route and
the average earth Resistivity for cable section is to be worked out,
5.6.5 Material required for protective works:
Cable is buried at the depth of 0.8 m and no special protection is required in plain normal
territory except provision of warning bricks over the cables within the station limits. For
platforms, culverts, crossing of tracks, level crossings and roads etc., special protection
for the cables are required. For special protection the following procedures are adopted
and their detail particulars are mentioned in the drawings as given bellow.
1. For Girder bridges – M.S. Troughing. Drg. S&T/RE/78/2/76 and RE/42/172

(Refer Fig 5.3 and 5.4)
2. For cable entries to cabins, ASM’S office etc. through G.I. pipes Drg. No.
RE/S&T/ ALD/SK//161/81
3. For routes over the culverts - steel pipes Drg. No. RE/S&T/ ALD/SK//160/81
4. For routes over arch bridges – brick channelling Drg. No. RE/S&T/
ALD/SK//162/81
5. For route over rocky areas – through chase. Drg. No. RE/S&T/
ALD/SK//301/85,302/85, 303/85 and304/85 with alternative A
6. For routes under bed of culverts – Acc pipes. Drg. No. RE/ S&T/ ALD
/Sk/162/81

2 METRES
70m
60m
50m m
CABLE TROUGH
2 METRES
COVER
8m m
32m m
2m m
150m m
115m
83m m
74m m
STRAP
Fig. 5.3 Cable trough (GI.) for girder bridge (DRG. S&T /RE/78)

To accommodate width of the

bridge 8m
8m m
BOTTOM FLANGE 6mm
L
5
10
TO BE PLAN
DRILLED L
50mm
8m
HOLES TO SUIT
016mm TOP
FLANGE
80mm
WASHER
NO TO SCALE
185mm
16x185
13
30m
8
m
60m
24
THIS EDGE mTO FLANGE
FOR BRIDGE GIRDER
GRIP
Fig. 5.4 Mild steel channel for trunk fixing Drg. S&T/ RE/ 78/No 2/76

SCHEDULE OF CABLE TROUGH MATERIALS
SCHEDULE OF MATERIAL
SL. NO. DESCRIPTION NO.REQD.
1 TROUGH 2 METERS LONG 1
2 COVER 2 METERS LONG 1
3 STRAP 2
4 BOLT HEX HEAD 6 MM X 32 MM 4
5 NUTS FOR ABOVE SIZE 4
6 LOCK NUT FOR SERIAL NO. 4 4
7 DISH WASHER FOR SERIAL NO.5 2
8 PLAIN WASHER FOR SERIAL NO. 4
All materials to be hot dip galvanized. No welding shall be done on any component for
fabrication. Cable trough to be fitted telescopically
MILD STEEL CHANNEL DIMENSION
SL.NO. NAME SIZE QUANTITY

1 CHANNEL LX100X50 1
2 J BOLT 16X185 2
3 a NUTS 16mm DIA 2
b NUTS 16mmDIA 2
4 SPRING WASHER 17mm DIA 2
Note: -
1. Weight of channel 9.2 Kg./ metres.

2. Channel to be supplied with 2 coats of primer red oxide.
3. All dimension in millimetres.
4. An arrow to be punched on the top of J Bolt to indicate direction of bend.
5. Length of channel will be decided according to width B.G Girder by engineering in
charge.

JOINTING PROCEDURE OF PAPER INSULATED CABLE
CHAPTER - 6
6.1 Introduction
Underground Telecommunication cables are manufactured in the lengths of 1000 Metres

or 500 Metres. To increase the length of the communication media to the required
length, the available cable lengths are to be jointed compulsorily. Therefore cable
jointing is unavoidable to meet the need. But cable jointing is a highly skilled job and
should be done with all precautions. Any defect in the joint may leads to the total failure
of all the circuits. Joints are very vulnerable points in a cable network, so efforts should
be made to do the perfect joint strictly as per the specifications.
The tools and materials required for making cable joints, the procedure for making
cable-joints on paper-insulated or polythin insulated cables are discussed in this
Chapter.
The two methods of conductor joints are:
(i) By ”Butt" Jointing

The conductor held together inside a split copper sleeve and soldered. Over the
split copper sleeve rubber tubing or plastic sleeve is slipped on. In the case of the
former an adhesive tape pressed on to the jointed portion serves as an additional
protection.
(ii) By Soldering
The conductors are twisted and soldered. The twisted portion is then immersed in
silicon grease filled sleeve so that the entire twisted portion up to the PET
insulation is well covered by the sleeve
6.2 Cable Jointing Material for paper insulated quad/paired cable
Plumbing metal / wiping solder.
Wiping is a special method of soldering the joint of lead sheath section or sleeve to
another section of a cable. The joints should be the water, and air tight. Depending upon
the size of the cable the joint should be strong enough, which decides the considerable
mass of solder to be used. While wiping the telephone cable joints, the copper
conductors absorbs more heat may damage the soldering of wire joints. Therefore some
skill and practice is required to make satisfactory wiped cable joint.
6.2.1 Essential properties of wiping solder
• The melting point of the wiping solder must be sufficiently below the sheath metal
used for the cable.
• The solder should have an extended plastic temperature range to permit the molten
alloy being worked into shape with minimum use of the blowlamp
• The plumbing metal used for cable jointing has the following composition as shown
in Table 6.1
Tin 31 to 32 percent
Antimony 1.7 to 1.8 per cent
Impurities iron, arsenic etc 0.25 per cent
Lead Remaining per cent
Table 6.1 Composition of plumbing metal

Note: - At any cost the impurities should not deteriorate the properties of the
sheath.
• In Railways, wiping solder is purchased after being inspected by
RDSO/RITES.Plumber’s metal is normally available in blocks/rods of approximately
2 KGs (51bs)
• The quantity of Plumber’s metal, that required for plumbing a cable joint is about 1-kg
or 2 ½ lbs., for every one-inch diameter of the sleeve. Thus a 5 centimetres or 2
inches diameter sleeve may requires about 2-kg or 5 lbs of plumber’s metal per
sleeve.
Rough solder (abrasive solder)
While the cable sheath is of aluminium, the rough solder is used for tinning the
aluminium so that the plumbing metal can effectively hold on the aluminium to solder the
lead sleeve.
Paper sleeves
• Paper sleeves are used for enclosing and insulating the exposed jointed conductors.
• They are in different sizes to cater for the different gauges of wire, like 20 lbs, 40 lbs
etc.
• A sufficient number of appropriate sizes of paper sleeves should be thoroughly dried
in a drying tin sheet kept over a fire brazier.
• All the materials used in the joint should likewise be dried before being using in the
joint.
6.3. Important Stages of making a Cable Joint
Testing of Cable ends
Before making any cable joint, both the lengths of cable must be tested
thoroughly for insulation, continuity, break, crossing or any other damages and
for mechanical soundness of the cable.
6.3.1 Cable Sheath Cleaning
• Generally before jointing the both cables, half-a-metre length of ends are cut, to
avoid the unnecessary complications like moisture entering or low insulation at the
beginning of the cable.
• After duly cutting or testing the cable ends, the external jacket, armour and inner
jacket should be removed and clean the sheath.
• The armour should be tied up by a GI binding wire at distance of 50 millimetres from
the cutting point to avoid the looseness of the armour on both the ends of the cable.
• Ingress of moisture into the cable may be prevented to a certain extent by putting
silica gel over the cable core near cut ends of lead sheath.
6.3.2 Arrange pairs/quads
♦ the After removing of lead sheath from cable, a twine thread loop is made over the
core with insulating paper, as nearer to the lead sheath as possible
• The outer wrapped paper may be removed by cutting the surplus paper near to the
tie.
• The outside layer pairs are to be fanned out and separated from the inside layer; tie
a twine thread not to mix together.
• The fanned out layer pairs first of all twisted together as individual pair, to avoid the
mix of conductor with other pair conductors.
• Another tie is made around the remaining layers at about 5 mm distance away from
the previous tie and it should be continued up to the end of all layers provided in that
cable.
• In quad type cable, the whipping thread of individual quad should be tied round to
itself.

• This facilitates the process of keeping the quads distinct and ensures that the quad
formation is not disturbed.
• Then the quad rings are inserted over each quad to identify the number.
• On completion of the above operations dried paper sleeves should be threaded over
individual conductor of the cable on one side of the joint in readiness to cover the
each conductor jointing.
Protection to the splice
High quality paper tapes cover the whole splice. Cloth tape is then applied on to the
splices so that the whole splice including the exposed portion of the sheathing is also
covered.
Wiping of aluminium sheathed cables
The tenacious layer of oxide over the aluminium sheath and the poor
Wetability of Aluminium to low temperature-melting solders is basic properties that
render the soldered joints on aluminium sheath cables comparatively difficult. Therefore,
to overcome this difficulty, an abrasive solder removes the oxide film and then the
sheath is jointed to lead sheath by “stick solder” method, as against the conventional ‘pot
and laddle’ method adopted for lead sheathed cables.
Anti- corrosive protection
The aluminium sheath, which gets exposed in the joints, is protected either by a multiple
layer or self-bonding plastic tapes or by an anti-corrosive lacquer.
6.3.7 Twisting of conductors:
• The jointing of wires may be commenced either from the centre or from the
outermost layer.
• Jointing from the centre is advisable too small to middle size cables, for easy
accesses to both sides of the joints.
• Jointing from the outermost layer is applicable to large cables where the jointed inner
layers would hinder access to the conductors in the outer layers.
• For minimising the cross talk between circuits it is essential that the wires should not
be crossed between the pairs.
• It is necessary that conductors are connected A wire to A wire and B to B of the
same pair until unless it is mentioned in the jointing schedule.

• The two wires are brought together and are given two full twists with the paper
insulation.
• The insulating paper tape is then removed and the bare wires are now given ten
complete twists.
• The surplus wire is neatly trimmed off with a pair of nippers.
• The total length of twisted portion, which should be about 25 mm or one inch, is then
folded down and the paper sleeve drawn over the joint so as to cover the portion of
the joint completely.
• While jointing two different gauges of conductors by using a smaller paper sleeve as
normally used for the larger conductor the twist should always be folded on the
smaller size conductor.
6.3.4 Soldering Conductors
• The method of soldering joints is to apply the solder to approximately millimetre or

1/5th inch of the twist at the tip as shown in Fig. 6.1
• The quickest method is to solder a number of joints at one time. A row of twisted
joints can be made leaving each at right angle to the wire, then soldered, folded
back and covered with paper sleeves before another batch is commenced.
• For jointing of polyethylene-insulated conductors a split copper sleeve is used and
a butt joint is made and soldered.
• This butt joint is then covered with PVC sleeve and then by heat-sealing tape.
• The position of the joints of the conductors should be staggered so that the paper
sleeves systematically against each other.
• They should not be any overlap indiscriminately, to cause an unnecessary increase
in the diameter of the joint, which is called splicing.
Fig. 6.1 Soldering Wire joint
Dry-up Joint bunch

• After the wires have been jointed, they should thoroughly be dried by means of a
charcoal brazier.
• Care must be taken to avoid scorching the paper, for that reason the fire should not
be placed too nearer to the joint.
• It is essential that the joint be absolutely dry.
6.3.5 Packing the joint
• The bunch of sleeves may be tied at two or three places with twine thread.
• A cotton tape or paper tape should then be wrapped around the joint.
• The wrapping should start from very near to the lead sheath and be done with 25 to
35 % overlap.
• Wrapping should be done twice over and tied at two or three places with twine
thread.
• The tape muslin or paper should be thoroughly dried before application.
• A slip of paper with the date of jointing and particulars of any faulty pairs written in
black with ineligible ink should be placed in the middle of the joint before wrapping it
with cotton tape.
• In order to make sure that the joint is perfectly dry, it is dried again after application
of the tape. Lastly the lead sleeve is brought into position, dressed down, and wiped.
6.3.6 VARIOUS TYPES OF JOINT IN RE CABLES
The R.E. Main Telecommunication cable is received in lengths of 465 metres. So there
will be a main cable joint at every 465 mitres intervals. The various types of joint are
shown in Fig. 6.2. These joints are systematically arranged as
(i) Straight joints

(ii) Condenser joint
(iii) Loading coil joint.
(iv) In addition to main cable joints there will be a number of derivation joints for
giving connection to the wayside stations.

i) Normal Joints
Normal joints are straight through joints connecting two ends of a cable. This consists
of a lead sleeve for accommodating the splice and cast iron box to afford mechanical
protection to the joint. The inner space is filled with waterproof compound.
ii) Condenser Joints

The condenser joints are provided in the middle of a loading section. It consists of a lead
sleeve sufficiently large in size to connect the lead wires connected to the various quads
for the purpose of connection of condenser for balancing purpose.
Over the wiped lead sleeve a cast iron box provides mechanical protection, the
interspaced between the lead sleeve and the cast iron box being filled with waterproof
compound.
iii) Loading Coil Joints

Loading coil joints normally supplied by the manufacturers contain the requisite number
of loading coils kept inside a metal box. The lead wires from the individual coils are
taken out through punched holes through a guide plate, the colour code of the lead wires
determining the identity of numbering of each quad.
iv) Building out network

To compensate the shortfall length of Loading Section of a cable, an RLC circuit is
provided. The mounting of circuit is done inside a brass box with lead wires taken out to
be connected to the main cable pairs.
(ii) Termination Joints

The termination joints are required inside the repeater stations and cable huts where
main cables are to be terminated. The two methods that are being followed are,
• By directly terminating the main cable on a cable head, which will be filled with a
moisture proof, compound. The cable head is mounted on a cabinet provided for
this purpose.
• The main cable can be directly taken and jointed with a tip cable, which in turn
will be connected to the equipment side.
vi) Derivation Joints

These are transformers joints for tapping the various railway control circuits, to the
various utilisation points. According to the requirements of the tapping points the
requisite amount of transformers are wired inside a brass casing. The derivation side of

the transformer windings are connected to the derivation cable and the main side of the
transformer windings are connected to the main cable. A typical transformer joint
connection in shown in Fig. 6.3
Fig 6.2 Various types of joints
TRANS
RECEIVE
1120:1120
1120:1120
Derivation
transformer
WAYSIDE RECEIVE WAYSIDE TRANS

TO DERIVATION CABLE TO DERIVATION CABLE
Fig. 6.3 Method of connecting the derivation transformer with main cable Quad in
main cable

The type of transformer used will depend upon the type of circuit. The Table 6.2 shows
the transformers of different ratios.
The ratio of impedance matching Name of the ccts. where it is used

transformer
1120: 1120 For V.F. circuits (Independent Ratio)
1: 2 For Signalling (Ringing Voltage)
1120: 600 For terminations of 2 wire circuits.
1120: 470 For Block circuits.
Insertion loss of VF Transformer As per IRS-TC 60-93 0.6dB maximum
Table 6.2 VF transformers and its application
Casings for joints
There are three different types of casings available for:

• Straight through joints
• Condenser joints
• Loading coil joints.
Proper care should be taken to protect the joints with casings and filling them with
moisture proof Bitumen compound.
6.4. LOADING OF UNDERGROUND CABLES

The transmission loss in underground cables is higher than the Overhead conductors.
The transmission loss in the cable is reduced drastically by increasing the inductance of
cable pair (to attain the conditions of a loss less line). The process of increasing the
inductance is called LOADING.
Fig.6.4 Loading coils and Mutual capacitance
It will be seen from the Fig. 6.4 that the loading coils and mutual capacitance of the
conductors are so arranged that low-pass filter section be created one, which has an
appreciable amount of resistance in its elements.
The circuit will pass, therefore, frequencies only below a certain value depending upon
the relation between L and C, where L is the inductance of each loading coil and C is the
cable pair capacitance between adjacent coils.
The practical problem, therefore, is to find a system of loading and spacing between
coils that will give transmission improvement as well as a satisfactory cut-off frequency.
Velocity of propagation is, as stated earlier, also an important consideration, while the
characteristic impedance must be kept down to a value such that direct connection to an
open wire line or to a terminal equipment of 600 ohms impedance does not cause
excessive reflection.
6.4.1 Effect of using 88 mH loading coil (R.E.Cable loading practice)
The object of loading cables for voice frequencies is almost solely for the purpose of
reducing the attenuation constant per mile. For long junction cables and for trunk cables
88mH coils are used and spaced at 1840 mtrs(44mH with each conductor). Each (1840
Mtrs) of such a cable then appears as one section of a low pass filter in which Ll =
88mH(44mH in each limb of a pair) and the shunt capacitance is C x S (C = Capacity
per mile and S = spacing in miles)
Fig. 6.5 Attenuation Vs Frequency of one Loading section
A cable has an appreciable amount of resistance, so that the attenuation characteristic

of any one section loaded as above, would be as shown in Fig. 6.5
Please Note: Unloaded cable has an attenuation of approx. 1.04 dB per mile (0.65 dB/
Km.). This system of loading, therefore, applied to a 20 lb.cable increases the Zo from
520 ohms to approximately 1,100 ohms and reduces attenuation to 1/3 its unloaded
value i.e. 0.35 dB/mile (0.24dB/Km) and this is the practice being followed in R.E
cables.

6.4.2 Requirement of a Loading Coil:
The general requirements to be in selection of loading coils are
i) High insulation resistance in order of 1000 mega ohms. between windings.

ii) Low capacity between windings in order of .003 mfd.
iii) Magnetic stability with time and current.
iv) Non-interference between coils of neighbouring circuits.
v) Accurate inductive and resistance balance between windings.
vi) Economy of space.
6.5 V.F. BALANCING OF UNDER GROUND CABLES
6.5.1 The capacitance Unbalance Measuring SET [CUM SET]: -

The device is used to know the value of capacitance unbalances between the cables
Pairs.
The following cross talk measuring instruments and accessories as shown in

Table 6.3 are required to measure capacitance unbalance.
SL. No. Name of the instrument Quantity

1 Capacitance unbalance measuring (C.U.M.) SET 1 No
2 Oscillator, 800 Hz 1 No
3 Amplifier detector 1No
4 Quad to quad switching unit 1 No
5 Head Phone 1 No
6 Shielded connecting cords 2 Nos.
7 Multimeter 1No.
8 Magneto Telephones 5nos
Connecting wires and clips for making connections of
9 conductors to the cable sheath (as required depending on cable
size)
Identifying PVC/PE sleeves coloured White, Red, Green and
10
Blue, (As required depending on cable size).
Note: Any one or both of the items (ii) and (iii) may be incorporated in the C.U.M. Set
itself.
Table 6.3 List of measuring instruments required to measure Capacitance

unbalance.

6.5.2 Procedure of balancing the cable
Balancing is to be done for the paper insulated quads only. Before commencement of
cable balancing of a loading section of 1840mts. (half loading section of 915m) all the
transformer joints should be completed and the derivation cable ends should preferably
be terminated on their respective cable termination points. A loading section includes the
following joint positions.
Fig. Fig. 6.6 Shows the typical arrangement of joints in a loading coil section in RE
Cables.
L1 ----------- SJ1 ------------ CJ ------------ SJ2 -----------L2
Fig. 6.6 Typical arrangement of joints in LOADING section
a) Loading coil joint
b) Condenser joint
c) Straight through joint
d) Transformer Joint (Derivation Joint)
The cable is to be balanced loading section by loading section. The balancing comprises
the following distinct operations:
i) Measurement of earth couplings el and e2 and poling operation

for reduction of the earth couplings.
ii) Measurement and Balancing of cross-talk couplings K9 to K12 between adjacent

quads.
iii) Measurement and balancing of cross-talk coupling KI within a quad and reduction of
K2 & K3 to the extent possible while connecting the balancing condensers for KI.
iv) Measurement of residual capacitance unbalances.

The earth couplings are reduced by means of “poling” i.e., either straight-connecting or
cross-connection of the two conductors of a pair in adjacent cable lengths. The
cross-talk couplings are balanced mainly by adding balancing condensers to the cable
conductors. The detailed procedure for balancing of earth couplings and cross-talk
couplings is given below.

6.5.3 Balancing of earth couplings
For balancing of earth couplings
• Poling is carried out in two stages. The first stage involves poling at the straight
through joint SJI & SJ2 and the second stage involves poling at condenser joint CJ.
• Before making any permanent connections between the conductors of adjacent

cable lengths at straight through joints, SJI and SJ2, temporary connections,
between the conductors are made for the purpose of measuring the values of earth
couplings.
• The measurement of the earth couplings el and e2 for the adjacent length L1 and L2
or L3 and L4 are taken from the condenser joint position CJ.
• For the purpose of communication between the party at CJ and the parties at
position LI, SJ1, SJ2 and L2, a telephone communication should be established by
connecting magneto telephones to one of the pairs of polyethylene insulated quads.
• The conductor ends at positions LI and L2 should be kept insulated during the
course of measurement. The conductors of the adjacent cable lengths 11 and 12 at
position SJI and those of lengths 13 & 14 at position SJ2 should be temporarily
connected ‘straight’ i.e., the colour bands on conductor insulation in one length
correspond to those of the adjacent length.
• After the temporary connections at position SJ1 and SJ2 have been made, the
measurements for values of earth couplings el and e2 are to be taken first for one
side, say for lengths 11 and 12 and then for the other side i.e., for lengths 13 and 14.
• The conductors of the lengths 12 and 13 at position CJ should be fanned out to form
a circumferential array of quads for easy access of shielded connected cord to the
quads under measurement.
• The conductors of all other quads, excepting one under measurement, should be
connected together utilising the connecting wires and clips, to the cable sheath
before taking measurements of the values of el and e2.
• The sheath should then be connected to the measuring bridge centre (centre tap
terminal of the transformer) of the CUM Set through the screen of the shielded
connecting cord (See Figure)
• The shielded connecting cord should then be connected to the appropriate terminal
of the C.U.M.set. The oscillator, amplifier, detector and headphone should then be
connected to the respective terminals of the CUM set.

• The earth couplings effects of the shielded connecting cord on the measurement of
the values of el. and e2 are to be compensated first before taking the measurement.
• For this purpose, the relevant knobs (Lead Balancing Knobs) provided for the
purpose should be adjusted till the null point is obtained as observed in the
headphone.
• The positions of these knobs after adjustment should not be disturbed during the
course of measurement of cable unbalances.
• The other end of the shielded connecting cord should now be connected to the cable
quads starting with quad No.-l, great care should be taken to see that the 4 limbs of
the shielded connecting cords’ are connected correctly to the four conductors of the
quads under measurement.
• The switching knob of the CUM set should then be set to position el. for
measurement of earth couplings el and to position e2 for measurement of earth
coupling e2.
• The values of e1 and e2 of the quads should be measured one by one and recorded
in chart 1.
• After the measurement of el and e2 values for all the quads has been completed for
lengths 11 and 12, the party at position SJ1 should be asked to replace the “straight
connection” between the pairs of conductors of length 11 and 12 by temporary “cross
connections”.
• While the connections at position SJI are being replaced as stated above, the
measurement of values of el and e2, for the length 13 and 14, should be taken in a
similar manner and recorded in chart I.
• After this operation is completed the party at position SJ2 should be asked to replace
the “straight connections” between the pairs of conductors of lengths13 and 1 4 by
temporary “cross connections”.
• The measurements for the values of el, and e2 for the two sides should again be
taken with the pairs of conductors cross-connected at position SJI, for lengths 11 and
12 and at position SJ2 for lengths 13 and 14 and recorded in the appropriate
columns of chart 1.
• The final scheme of connections of pair of conductors at positions SJ1, SJ2 and CJ
is to be determined on the basis of values of el and e2 as recorded in chart I.
• The principle to be followed is that if the value of an earth coupling for a pair for the
cable length on one side of CJ is almost equal to the value for the cable length on

the other side of CJ so that by suitably poling, the pair of conductors at CJ, the two
values of the coupling can be made to balance each other.
• Therefore, the type of poling connections to be finally adopted for splicing at
positions SJ1 and SJ2 should be so chosen that the value of the earth coupling for a
pair for the combined length 11 + 12 and that for the combined length 13 + 14, are
as nearly equal to each other as possible, and they cancel each other. This has been
further illustrated vide example of earth coupling values indicated in chart I.
• The poling connections finally adopted for splicing of the conductors at joints SJI, CJ
and SJ2 should be marked by a ‘tick mark’ and the poling connections rejected
should be marked by a ‘X-mark’ as has been shown in chart 1.
Note: As the scheme of poling connections to be adopted at straight through joints
SJ1 and SJ2 has been finalised. It will now be possible to proceed with the
installation of straight through joints.
Balancing of cross-talk couplings
• The measurements of cross-talk coupling are to be taken from the loading coil joint
position L2 after completion of the straight through joints at SJ1 and SJ2.
• First of all, the pair conductors of cable length 12 and 13 are to be jointed straight at
position CJ through the coloured PVC/PE insulated 1ead wires for condenser
“Joints” of length 40 cm. each.
• The 4 lead wires for each quad should have four distinct colours, namely, White and
Red for limbs a and b of pair 1 and Green and Blue for limbs c and d of pair 2.
• After the conductors have been connected straight, the polling scheme finalised for
connections at CJ (As per chart 1) should be implemented carefully.
• As is seen from the above, some of the pairs of conductors have been
cross-connected at straight through joints/condenser joint.
• The conductor identification of pair by means of coloured bands on the paper

insulation may not be applicable.
• It is, therefore, necessary to identify the limbs of the pairs for the purpose of taking
further measurements and for ensuring that the balancing condensers are connected
to the correct limbs of the pairs.
• For this, identifying PVC/P.E. sleeves of four colours viz., Red, White, Green and
Blue, should be inserted on to the conductor ends at the loading coil joint position L2
by ascertaining the limbs by application of an earth to the conductors at position CJ
and utilising the Multimeter.

• White and Red PVC/PE sleeves should identify limbs a and b (pair 1) and green and
black PVC/PE sleeves should identify limbs c and d (pair 2) of the two pairs of a
quad.
• For measurement of quad-to-quad couplings, K9 to K12, quad-to-quad switching unit

is to be utilised. The set up of measuring chart is shown in Fig. 6.7
Fig. 6.7 Balancing chart

6.5.5 Measuring Quad to quad couplings - K9 to K12

• Three numbers of magneto telephones are to be connected at position LI, CJ and L2
by utilizing a pair of conductors.
• The two adjacent quads under measurement should then be connected by means of
two shielded connecting cords to the corresponding terminals of the C.U.M.set.
• The screens of the two shielded connecting cords should be connected to the
instrument earth terminal at one end and the cable sheath at the other end.
• The switching knob of the C.U.M. set should then be set to position K1.
• For balancing K9 to K12 couplings, both 2-wire and 4-wire condensers can be used.
In some cases, when the values of K9 to K12 are favourably disposed of, 4-wire
condensers can be utilised more conveniently.
• If the values of K9, K10, K11, and K12 do not differ by more than the permissible
residual capacitance unbalances, only one 4-wire condenser should suffice to
balance all the four couplings.
• The particular conductors of the two quads to which the four leads of the 4-wire
condensers are to be connected depends on the algebraic sign of the couplings K9
to K12.
Note: The conductor designations in brackets indicate the alternative scheme of
connecting the condensers.
Balancing of K9 to K12 individually by use of 2-wire condensers.
Sl.No. Cross talk conductors of quads to which condenser is to be

connected.
Quad 1 Quad 2
1. K9 + al (b 1) b2 (a2)
al (b 1) a2 (b2)
2. K10 + al (bl) d2 (c2)
al (b 1) c2 (d2)
3. K11 + c 1 (dl) b2 (a2)

c 1 (d1) a2 (b2)
4. K12 + c 1 (d1) d2 (c2)
c 1 (d1) c2 (d2)
Note: The conductor designations in brackets indicate the alternative scheme of

connecting the condensers.
4 Wire Condensers
The 4-wire condenser has the flexibility to provide capacitance value other than the rated
values by varying the combination of its terminals as shown below.
The capacitance values with different lead combinations are as below:
Between Leads Capacitance Value.

1) 1,2 (together) and Full Value - 4C
3,4 (together)
2) 1,3 (together) and Half Value - 2C
2,4 (together)
3) 1 and 2 or 3 and 4 Quarter Value C
4) 1 and 4 or 1 and 3 or 4/3C
2 and 3 or2 & 4
5) 1,3 (together) and 2 or 3C/2
1,3 (together) & 4
It would, therefore, be seen that a 4-wire condenser could be used as a 2-wire

condenser also giving a range of values depending upon the connections of its leads.
After the values of K9 to K12 for a pair of adjacent quads have been measured, the
balancing condensers are to be connected to the corresponding cable conductors. The
party at position CJ should be advised by the party at position L2 regarding the values,
type and the cable conductors to which the condensers are to be connected. The party
at position CJ should connect the balancing condensers correctly as per instructions
received from location L2 and report back as soon as the condensers have been
connected. The party at L2 should then verify by actual measurements that the
condensers have been connected correctly. The residual capacitance unbalances
should then be recorded in Chart II. As an example certain capacitance unbalance
figures have been indicated in Chart II. The measurements of K9 to K12 for the all-
adjacent quads are to be made and balancing condensers are connected; the values of
the residual capacitance unbalances are recorded. This process should be continued till
K9 to K12 couplings have been balanced and recorded in the Chart for all the pairs of
adjacent.

6.5.5 Capacitance unbalance with in a quad K1, K2 & K3:
The measuring set up for the couplings K1, K2 & K3 remains same as for K9 to K12
couplings except that the quad to quad switching unit is not used and only one shielded
connecting cord is required. These measurements are also made from position L2.
Before starting the measurements for KI, K2 and K3, the coupling effects of the shielded
connecting cord should be compensated by adjusting the relevant knobs on the C.U.M.
set. For measurements of values of K1, K2 and k3, the switching knob of the C.U.M. set
should be set to positions K1, K2 & K3 respectively. The readings should be recorded in
chart III in the first column shown against K1, K2 and K3 couplings. The next four
columns in chart III are for recording the values of the balancing condensers to be
connected to the conductors. Only blank spaces (unhatched) are to be utilized for this
purpose. The conductors of the quads to which the balancing condenser is to be
connected for balancing K1 are indicated by blank spaces (unhatched) in the chart
against K1. It will be seen that there are two alternative blank spaces for positive value
of K1 and two for the negative value of K1. Two examples are illustrated as below of Fig.
6.8
Fig. 6.8 Balancing chart for K1, K2, K3

Case I:
Measured values:
K1 = +120 pf
K2 = +200 pf
K3 = -320 pf
Here K1 should be balanced by connecting the condenser of 120 pf value across limbs a
and c, so that the residual capacitance unbalances will become as given below:
K1 = -120 + 120=0 pf
K2 = 200 + 120 = -80 pf
K3 = -320 + 120=-200 pf
Case II:
Measured values:
K1 = +300 pf
K2 = +50 pf
K3. = +600 pf
To balance K1, we should add one condenser of 300 pf value across the limbs a and b
so that the residual capacitance unbalances will become as given below:
K1 = +300-300 = 0 pf
K2 = +50 + 300 = 350 pf
K3 = +600 –300 =300 pf
The party engaged in taking measurements at position L2 should decide the value of the
condenser to be added and advise the party at position CJ about the value of the
condenser and the limbs across which it is to be connected.
The party at position CJ should inform the party at position L2, as soon as, the
condenser of the required value has been added to the correct limbs. The party at L2
should then verify by actual measurements that the condenser has been connected to
the correct limbs and should record the residual capacitance unbalance for the quad
under measurement in the column - (BAL) of chart III. The measurement for next quad
should then be made in a similar manner and recorded in the chart. This process should
be continued till all the quads-have been balanced.
The final measurement of the residual value of K1 should be taken just prior to the
plumbing of the lead sleeve to the cable sheath at condenser joint and recorded in the

column (TEST) in the chart. This is to ascertain the exact residual value of KI and to
ensure that the positioning of the balancing condensers and their lead wires have not
adversely affected the residual value. The capacitance unbalance meter is shown in Fig.
6.9
Fig. 6.9 Capacitance Unbalance Measuring (CUM) set
Fig. 6.10 Quad under test connectivity to CUM set

6.5.6 Review Questions:
1. What is the purpose of balancing the capacitance of R.E Cables? Why balancing is
not done in local cables?
2. What are the permissible unbalances within the quad and in adjacent quad
couplings?
3. What is poling? How earth unbalances are brought to minimum, explain it with an
example.
4. Indicate the condensers and their positions in the case of following unbalances in
quad 6
K1= +120 K2= -90 K3= +110

K9= +70 KI0=-30 K11 = -70
K12= -100.

JOINTING PROCEDURE OF POLTHENE INSULATED QUAD AND PAIRED CABLES
CHAPTER - 7
JOINTING PROCEDURE OF POLYTHENE INSULATED
QUAD AND PAIRED CABLES
7.1 Jointing of polythin insulated jelly filled paired cable
7.1.1 Normal joint:
The cable drum length of 20,50 and 100 pars is generally of 500mt. When two cable
lengths are joined together with the Thermo shrink filled closure type jointing kit, the
following sizes of jointing kit are selected. The jointing procedure of polythin insulated
paired cables is same as the polythin insulated quad cables.
Straight through jointing kits selection Table 7.1
Type of Cable size Heat Size of Maximum Wire

kit 0.4 0.5 0.63 0.9 shrink Aluminium sheath connection
sleeve canister opening
size L- (mm)
(Mm)
TSF-1 5p 5p 5p 5p 525 +or-15 155/42 225 45
10 10 10 10 42/8
20 20 20 20
TSF-2 50 50 50 20 700 +or – 305/42 350 A-45
15 B-110
42/15
TSF-3 100 100 100 50 700+or-15 305/62 350 A-110
62/22 B220
TSF-4 200 200 200 200 910+or-15 405/92 500 A-220
400 400 92/30 B-440
C-880
Table 7.1 Types of Jointing Kits

7.1.3 Branch Joint
The jointing kit that is specified above for normal joint, the same kit is used for Branch
Joint. When shrinking the heat shrink sleeve, the adhesive around the clip melts and

seals effectively the inter space between the branch cables. The Branch off clip of small
or medium size is available with the jointing kits.
7.2 JOINTING OF POLYTHIN INSULATED JELLYFILLED QUAD CABLE
A) Straight Through Joints

Thermo shrink filled closure type joint for jelly filled cables is used for straight joint.
TSF-1: - 4-Quad cable of 0.9 mm diameter.
TSF 2: - 6- Quad cable of 0.9 mm diameter
The items given bellow are common for all kits.
B) Derivation Joint.
Thermo shrink filled closure with matching transformer to connect derivation cable is
used.
The kit is used where derivation cable is connected with the Emergency Socket.
Jointing kits for quad cable as per new spec. No. IRS: TC-77/ 2000. (as shown in Table 7.2)
Incoming Type of joint Outgoing Sleeve Nomenclat

Cable Cable Size ure Kit
name
4Q Straight through /normal joint for 4Q 4Q 42/8 RSJ (4Q)
cable
4Q Transformer joint/condenser Dir-1 4Q 75/15

joint/loading Coil jont/2T/ Dir-2 4Q
Emergency socket joint/
Termination Joint with VF
Transformer/derivation main/
Joints/LC Station cabins and pump
house Joints for 4Q
6Q Straight thru/Normal joint for Quad 6Q 75/15 RSJ (6Q)
cable
4Q/6Q Derivation joint (PIJF PAIR), Dir-1 75/15 RPIJF-D
for4Q/6QCab 4Q/6Q
Dir-2 PUJF 4/6
(5/10/20
6Q Transformer joint/condenser 92/30 R2TJ/RCJ

joint/loading (6Q)
Coiljont/2T/Emergencysocket joint/term Dir-1 6Q
joint with VF Transformer/derivation Dir-2
main/ 4Q/6Q
Joints/LC Station cabins and pump
house Joints for 6Q
Table 7.2 Specification IRS TC-77/2000

7.2.1 Description of contents in a jointing kit of Raychem RPG

Straight Through, Derivation, 2T, Loading coil or Condenser Joint for 6 quad cables
SL. No ITEM Quantity

Shrinkable sleeve with stainless steel channel
1 1
and retention clip
2 Aluminium canister- fingers coated 1
3 Filling compound (300gms pack). 2
4 Sealant Tape (400 x 35 x 3 mm strip. 1
5 Emery strip (600 x 25mm x 60mesh.). 2
6 Cleaning liquid kit size (A, B, C). 1
7 Cleaning Tissue. 2
8 Branch off clip (Small, medium). 1
9 Sheath connector assembly
10 Adhesive Aluminium strip 400 x 100 x 0.06mm 2
11 Transparent PE sheet (500 x 300,750 x 750,1000 x 750 mm) 1
12 Adhesive PVC Tape (25mm x 5mtrs). 4
13 Polyester Tape (25mm x 5mtrs). 1
Armour continuity wire 2mtrs of 0.9mm PVC insulated copper
14
wire.
15 Kit packing of plastic material or laminated paperboard. 1
16 Tinned copper braided shrunk with H.S. Tubing 1
17 Cleaning cloth. 1
18 Protective split Aluminium ring. 2
19 Spring steel roll. 2
20 PVC sleeve 35
21 Cotton waste
22 Packing slip 1
Table 7.3 Description of contents in a Jointing Kit

7.2.2 Cable preparation (Raychem RPG) (as shown in Table 7.4)
Straight Loading coil,

Procedure through Transformer,
Joint Derivation joint
Lay cable with an overlap of 225mm 225mm
Expose various sheaths/Armour as per details given bellow: -
225mm 225mm
Polyal sheath
Aluminium wire screen 40mm 40mm
Inner PE sheath 130mm 160mm
GI double tape armour 10mm 10mm
Table 7.4 Cable preparation procedure
7.2.3 Splicing:
In case of straight through joint/condenser joint, prepare splice as per conventional

procedure. Splice length must be maintained at225mm. As shown in the Fig. 7.1
M2 M1
C A B LE A
M1 M2
75 m m
C A B LE B
2 L 75 m m
L H E A T S H R IN K S LE E V E
Fig. 7.1 Splice

F IGpreparation
. 1 procedure
In case of loading coil joint splice the cable to the loading coil assembly lead wires at
both sides. Total splice length to be maintained at 225mm.
In case of transformer joint, splice the relevant quad of the lead wire of the transformer
assembly and the derivation cable as per conventional practice.

For the balance quads, take the wires over the transformer housing and make straight
joints with the corresponding quads of the other cable. Total splice length to be
maintained at 225mm.
Wrap tape over the two splices in case of straight through and condenser joint.
Wrap tape over the two splices at both sides of the loading coil/transformer assembly.
Also wrap the quads over the transformer assembly in case of transformer joint
Polyal sheath continuity assembly
Make a cut of 10mm on polyal sheath on both cables. Crimp crocodile clips on the polyal
sheath of both ends of cables. Put a layer of sealant tape over the crocodile clips to
avoid any sharp edge. As shown in Fig. 7.2
Fig. 7.2 Polyal sheath continuity assembly
Insert the protective split ring on Aluminium wire and push up to the end. Bend the
Aluminium wires over the ring. Wrap the tinned copper braid over the Aluminium wire
screen and tighten with spring steel roll.
Armour continuity wire

Clean the surface of the exposed GI tape armour using emery strip.

Wrap two layers of copper wire on the armour and solder at two places. Wrap two layers
of sealant tape on the armour. There should be no sharp edge of GI tap protruding as
shown in Fig. 7.3
Fig. 7.3 Armour continuity wire
Fill the splice with water proof compound and wrap the filled splice tightly with the PVC
tape as shown in the Fig. 7.4
PVC SHEET WRAPPED

TIGHTLY OVER FILLED SPLICE
FILLED SPLICE
PVC ADHESIVE TAPE FINISH
FILLING WATER - PROOF COMPOUND
Fig. 7.4 Wrapping the filled splice with PVC sheet
Installation of metal canister
Centre and install the metal canister over the splice bundle. The finger of the canister
should sit on the inner PE sheath. Using PVC tape, tape the fingers starting from the
canister body down to the inner PE sheath with50% overlap. Seal the parting line of the
canister with PVC tape. As shown in Fig. 7.5

Fig.4
Fig. 7.5 Installation of metal canister
Cleaning Abrasion and flame brushing of inner/outer PE sheath.
Degrease the exposed inner/outer PE sheath with cleaning tissue. Abrade the
inner/outer PE sheath circumferentially with emery strip. Remove abrasion dust with
clean dry cloth. Centre the heat shrink sleeve over the canister on the outer PE sheath
of the main cable and derivation cable. Wrap Aluminium foil 10mm inside from the above
mark on the main cable and derivation cable.
Wrap the heat shrinkable sleeve around the canister. Install the under clip. Pull the
flexible channel over the sleeve rails and channel should be positioned over the quad
cable. Install branch off clip in case of transformer/derivation joint between the main
cable and the derivation cable.
Start thermo shrinking from bottom of the sleeve towards the channel at the centre
circumferentially until the temperature indicator paint has changed from green to black.
When the paint has completely turned black, gradually move the flame towards the
channel area.
Continue shrinking as above moving progressively towards one end of the sleeve.
Ensure that at each heating place, the paint has completely changed to black. Adhesive
must flow from the ends of the properly shrunk sleeve and also adhesive of the BOC
should melt completely. White lines must appear in the channel area. Press the channel
with a blunt tool to follow the form of the canister at the transition area. Post heats the
transition area. Allow the joint to cool for half an hour before moving the joint. The
completed joint shown in Fig. 7.6

SPLICE
FLAME BRUSH FLAME BRUSH

HERE FLAME BRUSH HERE HERE
HEAT SHRINK SLEEVE
FIXING AL. FOIL AND FLAME BRUSHING
Fig. 7.6 Fixing Al foil and Flame brushing
7.2.4 6-QUAD TELECM.U/GCABLE JOINT LOCATED IN HALF LOCATION
Instead of putting the joints into the jointing pits, the joints are kept into a half location
box in the middle of the sections. The Fig. 7.7 shows the dimension of location box and
the assembling of joints in the box.
Fig. 7.7 6-Quad telecom U/G cable joint located in half location box

7.3 Termination of cable
Cable termination Boxes (Indoor) for Railway Electrified areas. Specification Sl. No.
TC18-75.The cable termination boxes are of sizes 5 pairs, 10 pairs, 20pairs, 30 pairs,
50pairs, and 100 pairs and above.
The cable termination box shall consist of the following components.
1. Case
a. Front cover
b. Back plate
c. Terminal plate
d. Terminal stud
e. Sleeve
f. Hinge pin.
The case front cover and back plate shall be made from alloy aluminium casting
conforming to IS: 317.Brass used for terminals shall conform to OS: 319.The terminals
block shall form one face of the C.T.Box. It shall have requisite pairs of brass terminals
so that the connections of the underground cable can be soldered on the inner side of
the block and external wires can be connected with nuts on the outer side. For outdoor
cable termination the Cast Iron C.T. Box or Alloy aluminium casting C.T. Box is used for
R.E or non-R. E area.
7.3.1 Cable termination at cabinets and pillar with CT box (Cable terminal box)
and crone
Cable terminal boxes are supplied in two sizes viz: 50 pairs and 100 pairs. They are
used for terminating the dry core cables or jelly filled cables entering the cabinet or pillar.
The boxes have inlets to allow the tail cable. The CC.T. Box may be provided with a
single cable inlet or two cable inlets. Single inlet C.T. boxes are used for type-A wiring,
while double inlet C.T. boxes are used for types B & C wiring. The cable entry holes are
sealed off by plumbing the lead sheath of the cable to the inlet or in the case of
polythene sheath the cable entry is sealed by some sealing agents like wax compound
or resin solution. One side of the box is provided with the requisite number of terminal
blocks, each with 10 pairs of terminals. These terminals extend through the insulating
faceplate to the back of the box and ends are soldering tags for the cable conductors.
The limbs of a pair are connected one below the other with the C.T. box mounted
vertically. The back portion of the box is closed by a separate metal cover which is seam

soldered to the box along its edges, after terminating the cable conductors on the
various tags.
TERMINAL NOS. TERMINALL No.

1-5
O
1-5 O 1-5 1-5 O 1-5 6-10
6-10
O
6-10 O 6-10 6-10 O 11-15 16-20
11-15
O
11-15 O 11-15 11-15 O 21-25 26-30
16-20
O
16-20 O 16-20 16-20 O 31-35 36-40
21-25
O
21-25 O 21-25 21-25 O 41-45 46-50
26-30
O
26-30 O 26-30 26-30 O 51-55 56-60
31-35
O
31-35 O 31-35 31-35 O 61-65 66-70
36-40
O
36-40 O 36-40 36-40 O 71-75 76-80
41-45
O
41-45 O 41-45 41-45 O 81-85 86-90
46-50
O
46-50 O 46-50 46-50 O 91-95 96-100
50PR CT. BOX 100PR CT. BOX
Fig. 7.8 Termination in CT Box

Jumper wires are connected to the screw termination on the insulating faceplates Fig. 7.8
shows the termination of CT BOX.
The empty space inside the C.T Box should not be left vacant otherwise the terminals absorb
moisture. As the temperature changes during day and night the breathing action takes place
inside the vacant space of the D.P. The air becomes hot during day, and the moisture in the air
absorbs heat and evaporated from inside the C.T box. During nighttime the temperature falls
down, releasing the temperature of the water vapor in the air and accumulates inside the box as
droplet of water and terminal becomes oxidized. A thin film of copper oxide deposits on the
terminals and damage the terminal.
This type of C.T. BOX is used in cabinet, pillar or in D.P. The ebonite plate, on which terminals
are assembled, is fixed to the body from the front side. The cable is allowed to enter into the
Box through the ferrule of cable entry hole. The conductors are soldered on the terminals at the
back plate. After terminating the cable the ebonite plate is fixed to the C.I.box. as shown in Fig.9
bellow. The vacant space inside the Box is filled up with the wax compound of good quality
especially for jelly filled cable. The wax compound is poured in the Box through the hole on the
top of the Box. Precaution is taken to prevent leakage of compound before settle down. The
possible leakage is through the cable entry hole of the cable. The silent either as a solution or
M-seal can be used to prevent leakage.
Pocket for
Prs. Prs. dropping sealing
compound
1 41
2 42
3 43
49
9
50
10
Indoors tip
Cable entry port
Ferrule
Cable entry port
Fig. 7.9 CT box
To day the pairs of polythene-insulated jelly filled cables are terminated in crone. Generally one
block of crone can terminate 10 pairs of cable. Such type of crone can be used in cabinet, Pillar
or in DP for termination of primary, secondary or distribution cable. Each block of crone is
assembled in a frame, which may hold 10 such blocks (100 pairs termination) Fig. 7.8 shows
the crone
a1 1 b1 a2 2 b2 a3 3 b3 a4 4 b4 --------- a10 10 a 10
Row-1
Assembly
a1 1 b1 a2 2 b2 a3 3 b3 a4 4 b4 --------- a10 10 a 10
Row-10
Fig. 7.8 Crone & crone assembly

LOCAL LINE PLANT RECORDS
CHAPTER - 8
8.1 RECORDS
The records may be broadly classified as records of terminals and records of cables.
a) Records of terminals provide most of the information required for day-to-day

utilization and maintenance work.
b) The cable records give the information on cables required essentially for planning of
the network, and for fault localization on underground cables. These will be in the
form of maps and diagrams and will show the layout of the network, allocation of
cable pairs and so on.
8.1.1 Numbering of cabinets and pillars
The cabinets are given two digit numbers in the series 01 to 20. Pillars are also given
two digit numbers but in the series 21 to 99. It is not expected that the number of
cabinets in one exchange area will exceed 20 or the number of pillars exceed 79. Once
a cabinet or pillar is given a number it must not be normally changed unless the cabinet
or pillar is transferred to another exchange. The number of the cabinet or pillar must be
painted on the outside. In addition, in multi exchange areas the exchange name or code
may also be indicated, if necessary. The numbers of pillars controlled from a cabinet
must be indicated on the inside of the doors. In the case of pillars, the number of the
cabinet controlling it or if it is directly served from the exchange this fact must be
indicated on the inside of the door.
8.1.2 Numbering of D.Ps.
D.Ps, internal and external, are given four digit numbers. The first two digits correspond
to the number of the pillar from which the D.P. is fed. For D.P. in the inner one, the first
two digits will be 00. The third and fourth digits of the D.P. number denote the serial
number of the D.P. (01, 02, -------98, 99)
Within the pillar area (or the inner zone) it is not expected to have more than 99D.Ps. in
one pillar area or in the inner zone .The numbers must be painted on the D.Ps.

8.1.3 Coding of the terminals and cables
Each existing exchange area will have a separate series for coding (excepting for
junction cables which have a single series for the entire network). When a new
exchange area is formed or a part of an existing exchange area is transferred to another
exchange the items of plant falling within the new exchange area are recorded in the
new series.
Coding of terminals
The terminal code will indicate the exact position of a terminal at the point of termination,
that is, the MDF, the cabinet, the pillar or the D.P. Before coming to the conventions for
coding of terminals it will be necessary to lay down the principles for numbering of
cabinets, pillars and D.Ps, As these numbers form part of the terminal codes
Terminal code for exchange MDF
On the MDF, the terminals are arranged vertically and each vertical row is given a code
number starting from 01- 99(vertical row number-1, vertical row number-2 like way).
Each vertical row is installed with fuse strips and the fuse strips are numbered serially in
the single digit series 0, 1, 2, 3, -------9.The terminals or tags on the fuse strip are
numbered serially in two digit series 01 - 20.thus 148/ 06 refers to terminal 6 of the 8th
fuse strip on vertical 14. The code for a terminal on the exchange MDF will always
consist of a 3- digit number that denotes the position of the fuse strip on the MDF
followed by the terminal number on that strip.
Terminal code for cabinets and pillars
The position of a terminal in the cabinet or the pillar is fully specified by the number of
the cabinet or the pillar, the position of the CT box in any cabinet or the pillar, and the
terminal number on the CT box .In order to specify the position of a CT box in a cabinet
or a pillar each horizontal row on the panel is assigned a single letter code A, B, C etc.
connecting from the top most row and irrespective of whether a CT box has been
actually mounted in that row or not. Each horizontal row on the panel is divided into
sections corresponding to 50 pairs each. The 300, 500 and 700 pair shells will have two
sections per row and the 1400 pair shell will have 4 sections per row .The sections are
numbered 1, 2, 3, 4 connecting from the left hand side. A 50 pair CT box will occupy one
section and the number assigned to that section specifies its position in the particular
row. A 100 pair CT box occupies 2 sections and the number assigned to left hand

section specifies its position in that row. Thus terminal 38 of the 50 pairs CT box
occupying the second section on the third row on cabinet number 06 will be coded 06C2
/ 38. This is the full terminal code.
Terminal code for D.Ps.
The position of terminal on a D.P. is fully specified by the D.P. number and the terminal
number on the D.P. If D.P. consists of distribution frame as in large buildings the
terminal number is denoted by vertical numbers (1, 2 etc.) followed by pair number on
the vertical (01, 02, --99, 00) the verticals being of maximum 100 pairs each. Thus the
36th pair (from the top) on the second vertical of D.P.4813 will be coded 4813 / 236
8.1.4 Marking of terminal code
At the MDF
Local terminal code: Vertical numbers are painted on the guardrail or metal labels
attached to the guardrail of the MDF.
Distant end terminal codes: It will be readily available in the MDF cards, which are
maintained in the exchange.
At cabinets and pillars

Local terminal codes: only the CT box numbers (such as A1, B2, etc.) need be marked.
Labels are provided on the left hand and write hand sides of the mounting panels for
making this. The type and size of the CT box is also marked on this label.
Distant end terminal code

Designation strips are provided on the mounting panel above each C.T. Box for making
the distant end terminal code
At D.Ps
Local terminal code: There is no need to mark this
Distant end terminal codes: The method of marking the distant end terminal code
depends upon the type of DP. and arrangement of terminals.

8.2. Coding of cables:
Coding of cable is intended mainly to facilitate identification and tracing of cable pairs
from the originating point (MDF, Cabinet or pillar) to their termination at the other end. It
also helps to conveniently indicate the allocation of cable pairs.
Cable originating from the exchange:
Each cable given a single letter codes A, B, C, etc., the letters 1 and O being omitted. If
there are more than 24 cables two-letter codes, for example AA, AB, Ac, etc. is used for
the additional cables.
Cable originating from the cabinets or pillars:
Each cable is coded with the cabinet or pillar number followed by a single letter, A, B, C,
etc. (for example 12A, 12B, 12C etc., or 43A, 43B, 43C etc.) The letters A, B, C, etc, of
the cable code bear no relation whatever to the letters denoting the position of a C.T.
Box in the cabinet or pillar. The two are entirely independent. For example cable 43A
might connected to CT boxes say 43 BI and 43DI.
The cable between cabinets
These are assigned a code corresponding to one of the cabinets.
Junction cables between exchanges:
Unlike all the other items of plant, the junction cables do not have a separate numbering
series for each existing exchange area. The junction cables are coded as follows: -
Each exchange is assigned a letter, preferably the first letter of the exchange name. For
instance C for city, P for park etc. If there more than one exchange with the same first
letter in the name, one of them can be assigned the first letter and the others have to be
assigned different letters. For example for the exchanges City and central, the former
may be assigned C and the latter N. The junction cable code will consist of two letters
denoting the exchanges at which the cable is terminated and a digit denoting the serial
number among the cables terminated between these two exchanges. For instance
junction cables between city and park are coded CP1, CP2, CP3, etc.

Coding of cable pairs:
In all the above cases the cable pairs are designated by the cable code followed by the
pair number within that cable. For example pair 86 of cable 50Awill be coded as 50A/86.
8.3 STANDARD LINE PLANT RECORDS
8.3.1 MAPS
a) The exchange area layout map

This shows the boundaries of existing exchange areas with the boundaries of future
exchange area super imposed. One map is required for each multi exchange telephone
area.
b) The cabinet and pillar area layout map

This shows the boundaries of the ultimate cabinet and pillar areas. One map is required
for each existing exchange area.
c) Large scale maps

Large-scale maps are useful for location of underground cable joints, relative positions
of the cables on each route, route distances of various points in the underground
network, boundaries of DP. Areas, location of loading points and so on.
8.4 DIAGRAM
8.4.1 The network development diagram:
It shows the proposed layout of the primary and secondary cables and how the existing
cables fit into it. One diagram has to be prepared for each existing exchange area. This
diagram also forms part of the basic plans.
8.4.2 The primary and secondary cable diagram
This shows the layout of the primary and secondary cable network as it exists. This
diagram has to be read in conjunction with the cabinet and pillar area layout map to get
an accurate picture of the geographical disposition of the cable plant. It is a straight-line
diagram and not in scale. This diagram must show the following details: -
a) The existing cabinet and pillars with number and capacity of each.

b) Existing primary and secondary cables on each route shown separately, each
route being shown distinct from the others.
c) Size and gauge of each cable and the length when it is known.
d) Cable codes and allocation of cable pairs at branching points and to cabinets
and pillars
e) Names of roads etc. Where necessary to identify the cable route.
f) Particular of joints
8.4.3 Distribution cable diagram

It is a straight-line diagram and must show the following details: -
a) The number and capacity of the pillar
b) Existing distribution cables
c) Size and gauge of each cable
d) Existing D.Ps
e) Number and capacity of each D.P. and the cable in which it is tapped.
f) Cable codes, and the allocation of pairs when the latter can be conveniently
indicated.
g) Names of roads etc., when necessary to identify the cable routes.
h) Additions and alternations to the distribution network must be incorporated in the
distribution cable diagram.
i) Location of joints
The entire network of primary, secondary and distribution cable diagram will have to be
shown in single straight-line diagrams that can be on more than one sheet if necessary.
8.4.4 The MDF Diagram

These diagrams show the position that each cable led into an exchange occupies on the
MDF. These are necessary to correlate the cable code with the terminal code.
8.4.5 The cabinet diagrams and pillar diagrams

These diagrams show the details of jointing of the cable tails from the CT. boxes to the
underground cabled and correlate the cable codes with the terminal codes. One cabinet
diagram is required for each cabinet and one pillar diagram for each pillar. It has to
prepare at the time of installation of cabinet or pillar.

8.4.6 Junction cable diagrams
This shows the junction cable network in multi-exchange areas. These are straight-line
diagrams and show the following particulars:
a) Existing exchange
b) Each existing junction cable shown separately.
c) Size and gauge and route length of each cable, and also the type of
cable.
d) Whether t6he cable is loaded. If the loading is not standard 88 mH at
2000 yards, the type of loading may also be indicated.
e) Cable code.
8.5 CARDS
8.5.1 The DP Cards
These cards as sown in Fig 8.1 show the number, size type (internal or external) and
location of DP and how each terminal of the DP is utilized. They also indicate the distant
end terminal code corresponding to each terminal of the DP. One card is required for
each 10 or 20 pairs DP. Larger than 20 pairs two or more cards have to be used.
Size 10 pairs Type-Internal/External Location position

IRISET Building/MW/Lab, Exchange Area Central
Terminal Distant end Circuit Name Address
No termination No
of cable
01 41C1 26 85670 M. Rammurty MW/Lab/IRISET
02 C1 27 85674 P. IMW-2/ IRISET
Bhattacharya
03 C1 28 85662 Y.V Prasad IEL-2/IRISET
04 C1 29
05 C1 30
06 C1 31
07 C1 32
08 C1 33
09 C1 34
10 C1 35
Fig. 8.1 DP-CARD

8.5.2 The cabinet cards and pillar cards
One set of cards is required for each cabinet or pillars. The set contains one card for
each 50 pair or 100pair C.T Box fitted on the cabinet or pillar.
Each card shows the following particulars. Number, size and type of the C.T.Box, size of
shell, location of the cabinet or pillar, circuit working on each terminal of the C.T.Box, the
terminal to which it is jumpered or strapped for setting up the circuit, the distant end
terminal code corresponding to each terminal of the C.T. Box and the codes of cable
pairs connected to the terminals.
8.5.3 MDF cards
It contains the distant end terminal code, which it works if the circuit working is a junction
or the circuit number and the subscriber’s address, if it is a miscellaneous circuit as
shown in Fig. 8.2
M.D.F-1 F.S No 20
Exch. – Central
Dist. Exc. For Jn. Cables M.D.F—Card
Terminal No Distance end Circuit No Address

Terminal code
01 01 A1 10 85827 P. Harikumar/Rly. Qr
02 01 A1 11 85823 SN .Pal/Rly. Qr
03 01 A1 12 85809 B. Gopi Singh/Rly. Qr
04 01 A1 13
05 01 A1 14
06 01 A1 15
07 01 A1 16
08 01 A1 17
09 01 A1 18
10 01 A1 19
Fig. 8.2 MDF Card

8.5.4 Subscriber’s index card
While in the DP, pillar, cabinet and MDF cards the circuit particulars are given terminal-
wise, the subscriber index cards show the terminal particulars circuit wise. Two types of
cards are necessary, one for direct exchange lines and other for the non-exchange lines.
These cards must be introduced along with the DP and MDF cards as shown in Tab-3
SUBS INDEX CARD
EXCHANGE CENTRAL
SUBS NO. SERIES ……………
Subs M.D.F CABINET PILLAR D.P. ADDRESS
No. F.S TERM NO E. D. NO E D NO TERM.
SIDE SIDE SIDE SIDE
0 1 06 1 3 IRISET
HOST/2
1 2 11 1 B1/23 B1/28 2 7 HOST/1
3 5 16 2 C1/15 C2/14 4 5 HOST/3
5 7 01 2 HOST/4
6 10 07 2 A1/12 A1/17 3 A1/17 A1/12 18 3 TYPE/4
QRT.
7 15 14 4 B1/14 C1/10 17 1 TYPE/3
QRT.
Fig 8.3 Subscriber Index card

EFFECTS OF ELECTRIFICATION ON TELECOM CIRCUITS
CHAPTER - 9
9.1 INTRODUCTION.
In the system of electric traction adopted by the Indian Railways, the catenary wire is fed
at 25,000 V, 50 c/s, and single phase. The rails is being employed as the return
conductor. Such an arrangement while resulting several advantages in respect of power
transmission and traction engineering, the power feed being inherently unbalanced,
produces certain undesirable effects on communication circuits in the neighbourhood of
the tracks, rendering them unsafe and unworkable.
9.1.1 Mechanism of Induction
The mechanism of induction from the AC traction system is due to capacitance coupling
and magnetic coupling.
Capacitance Coupling
• With the catenaries maintained at 25,000 V an electric field is created in the vicinity
of the tracks.
• An electric conductor, such as a communication wire insulated from earth and
situated within this field will get ‘charged’ to a certain potential with reference to earth
due to capacitance coupling.
• The magnitude of this potential depends on the voltage of the catenary and distance.
Magnetic Coupling
• The currents flowing in the catenary returns to the feeding point via the rails.
• The rails are not specifically insulated from the earth, which therefore, provides an
alternate path for the currents.
• Some portion of this current penetrates deeply into the earth, to find a path in other
rails, cable sheaths, metal pipes and similar conductors parallel to the track.
• Near the feeder points the whole of the current must return to the secondary
windings of supply transformer.
• The current in the catenary is the source of an alternating magnetic field.
• This field cuts any conductors parallel to the track and induces e.m.f.’s in them.

• The catenary system acts like a primary winding and each other parallel conductor
acts like the secondary winding of a transformer.
Therefore, from the above, it should be evident that the inductive interference constitutes a
hazard to personnel using or working on the lines as also to the connected equipment. The
induced voltages also seriously interfere with the signalling arrangements on the
telecommunication circuits causing them to be unworkable. Apart from the induction at the
fundamental frequency 50 c/s another source of trouble is on account of the harmonic
components of the catenary currents.
9.2 Screening factor
The reduction in induced voltages that is effected by the various conductors parallel to
the catenary system is expressed by saying that each such conductor has a screening
factor. This is defined as follows: -
Screening factor K = Voltage induced to the conductors of the cable core in the
presence of the metallic sheath of the cable to which the screening factor refers / voltage
that would be induced to the conductor of the cable core if the metallic sheath of the
cable to which the screening factor refers, is absent.
• It follows from this definition that the screening factor is normally less than unity.
• Generally this value is as low as possible.
• The screening effect of current is the consequence of the magnetic field produced by
current in that conductor (sheath).
• This conductor (sheath) can only provide a screening factor when it is carrying current.
To achieve, it must be a part of complete circuit.
• By considering the screening effect of a cable sheath, clear distinction should be made
between "the voltage of the core to the sheath," and the voltage of the core to earth".
• If the sheath is insulated from earth identical voltages are induced in sheath and core,
the voltage between them is zero.
• At the same time the sheath does nothing to reduce the voltage between core and earth.
• To do this the sheath must carry a return current, the field of which opposes the field
induced by the current in the catenary.
• To carry such current the both ends of the sheath have to be earthen.
• According to the phenomenon above mentioned, it is very clear that, an induced voltage
developed due to the difference of primary & secondary magnetic fluxes in the cable
conductors as shown in fig. Shown bellow
In Fig. 9.1 below, the magnetic flux 1 arises in the direction of arrow by means of the
current I1 which flows along the power line and then the induced voltages E12 and E13 due
to the primary magnetic flux 1 are induced respectively along the screen and the
conductors of the telephone or control cable installed not far from the power line. When
the both ends of the cable screen are grounded to the earth the induced current I2 flows
along the screen and the secondary magnetic flux 2 arises by means of current I2 in the
opposite direction to the primary magnetic flux 1. As the magnetic flux 2 as well as 1
interlinks the conductors of cable, there arises an induced voltage E23 due to the flux 2
along the conductors. According to the phenomenon above mentioned, we come to the
conclusion that there arises an induced voltage due to the difference of primary magnetic
flux 1 and secondarily magnetic flux 2 along the conductors.
• In practice the sheath is usually earthen at finite intervals of about 1 Km.
• Each earthing point has a resistance of 4 ohms.
• The screening factor that a cable sheath would have if its resistance to the earth
through out its length were zeroed is called the “intrinsic screening factor".
• The higher screening factor of the imperfectly earthen sheath is called the “ cable
system-screening factor”.
• The ratio of cable system to intrinsic screening factor is called the “earthling penalty”.
• By increasing the permeability of the sheath, compensating induced current in it is

more effective.
Fig. 9.1 Induction of Voltage

• For ensuring safe and satisfactory performance of the communication circuits in

electrified railway sections, obviously it is necessary to adopt measures for minimising
the extent of induction.
• Such measures can be adopted either on the traction system, the communication-
system or on both.
• On the traction system the method usually consists in ensuring that very little of the
catenary current returns via the earth.
• This is achieved by means of a device known as booster transformers installed at
frequent intervals between the catenary rails or better still, between the catenary and a
separate return conductor specially provided for this purpose and suitably bonded to the
rails.
• Shifting of aerial lines to a safe distance from the track.
• Provision of protective devices such as gas discharge tubes relay protectors, drainage
coils etc. These methods cannot mitigate noise induction.
• Replacing the aerial lines by metal sheathed under ground cables.
• The metal sheath, suitably earthen, acts as an almost perfect screen against induction
due to capacitance coupling.
• It also reduces the extent of magnetic induction.
Suppression at source
• Screening by means of cable sheaths does not always reduce induced voltages to a
sufficiently low value.
• Moreover, UN-screened circuits that are installed prior to electrification have also to be
protected.
• This is affected by the provision of booster transformers with a 1.1 ratio.
• Their primary windings are introduced into the catenary system and the traction current
passes through these windings.
• The secondary windings are connected either in series with the rails or in series with a
return conductor
• The effect of such an arrangement is greatly to reduce the amount of return current that
flows through the earth.
• The rail connected to booster transformers nearly the whole of the return current is
confined to the rails.
• The return conductor connected to booster transformers to flow the return current into
rails up to the nearest point, at where the return conductor is bonded to the rails.
• From there it flows through the return conductor back to the feeder point.
• In the case of rail connected booster transformers there will be problem of efficient
maintenance of the insulation of rail joints and they are likely high potentials of those
joints. Therefore, return conductor booster transformer system has been adopted.
• Also with the return conductor booster system the improvement obtained in the
screening factor is considerable especially when the spacing between adjacent booster
transformers is low commensurate with economics and technical requirements.
• Therefore, where heavily built up areas with multi-exchange telecommunication systems
are encountered; it would be necessary to provide booster installation at close intervals.
• Normally the spacing adopted will be 2.66 Km or 4 Km as required.
9.4 I.T.U.T. Recommendations
• Recommendations on permissible voltages, calculating method and protective measures

have been issued by the I.T.U.T.
• Accordingly the following voltages may not be exceeded in, the circuit formed by cable
conductors and ground.
• As regards electrostatic induction, the critical figure recommended by the I.T.U.T a
current of 15 ma amperes.
• When a person is in contact with both the earth and with the conductor of a
telecommunication line. During the normal functioning of the power line, or electric
traction system, the longitudinally induced voltage in the telecommunication circuits
should not exceed 60V.
• As regards interference to speech transmission, the psophometric voltage in the
communication circuits should not exceed 2mV.
• For telecommunication cables induced longitudinal electric force should not exceed a
r.m.s value of 60% of the lowest voltage used for factory tests.
• The breakdown voltage strength between conductors verses sheath, or between the
equipment verses the cable sheath or earth, unless there is reason to fear that the laying
and jointing operations have caused any appreciable reduction in the breakdown point.
• In such an event, a special study should be made to select the method for determining
the permissible limit.
• In certain situations longitudinal induced voltage at 50 c/s of a lower value for an
example 5 volts or even less is sufficient to cause non-function of the signalling
equipment on telecommunication ccts. With these limitations of induced voltages under
service conditions and short circuit conditions, special protective measures are
necessary.

• By the way of sectionalising all the communication circuits to break the metallic
continuity of the conductors to prevent cumulative build up of induced voltages with the
introduction of isolating transformers in between cable and working equipment at all
access points and adoption of special maintenance precautions.
• The booster installations are not uneconomical, with the limitations as explained above,
it was considered that the following measures would meet the requirements of I.T.U.T.
• The cables to be laid along the tracks should have aluminium sheath and steel tape
armouring so as to have a screening factor of less than 0.1 in the anticipated range of
magnetic field intensity.
• Aluminium sheath was preferred to the conventional sheath, since the degree of
screening obtainable with the former is about 3 times that of the latter for an equivalent
size of cable.
• This was also expected to offer sufficient protection against noise due to harmonic
frequency induction.
• In order to further minimise the effects of induction the cable conductors should be
sectionalised at appropriate points.

CABLE TETSING AND FAULT LOCALISATION
CHAPTER - 10
CABLE TESTING AND FAULT LOCALISATION
10.1 Types of tests
Thorough testing of the cable is the correct way to localize the faults. Tests of
underground cables may be classified into four heads.
i) Tests during laying of cables

ii) Testing after completion of cable laying
iii) Routine tests.
iv) Fault localisation tests.
Tests during laying of cables

i) Test the cable for proper end sealing.
ii) Check for proper end sealing in case of jelly filled cables.
iii) Check up the cable through-out the length for any physical/ mechanical damages
during transportation and handling of cables. Also check for manufacturing
defects, if any.
10.1.1 Tests before joining the cables
Continuity
Absence of crosses
Absence of contacts.
Insulation
To test a cable for continuity, absence of cross connection and absence of contacts,
proceed as follows:
At one end every wire is twisted with its mate wire to form a loop in each pair, the twists
being insulated from each other by means of paper sleeves or PVC sleeves and make
the end moisture proof.
At the other end or testing end layers of cable should be bound with twine to keep the
wires in their proper place so that if a fault is detected, the position of the faulty wire is
known. Then all the wires should be earthed with a piece of soft bare copper wire, which
is also connected to the cable sheath and to the positive terminal of the A.V.O meter.
Disconnect one mate wire from earth and connect to the negative terminal of the
Avometer, there should be a deflection indicating continuity. Disconnect the mate wire
from earth; the deflection should disappear proving absence of crosses of contacts. If
the tested wires are found O.K., they should be set-aside without earthing them again. If
however any of the wires show a cross or contact, they should be earthed again so that
when the wire with which they are crossed or in contact come to be tested they also will
show faulty. Each pair of wires must be tested in turn in the above manner.
10.1.2 Testing Insulation of Local Cables After Laying
To test cables for insulation connect all the "A" wires together and connect all the "B"
wires together. First connect the 'B' wires to earth and measures the insulation of the 'A'
wires with 250 V Megger. Then earth the 'A' wires and measures the insulation of 'B'
wires. Take the mean and calculate the insulation resistance per KM or mile. Insulation
resistance per KM = measures insulation X length of cable X number of wires (in KM).
The insulation resistance per KM at 270 C should not be less than 500 Meg ohms.
Routine Tests of Insulation:

Routine tests of insulation should be made with a Megger of 250 V for new cables and
100 V for old cables. In the case of routine insulation 'tests there is no necessity to earth
all the wires other than those under test, but it is preferable to earth any spare wires.
With cables other than dry core, each wire should be tested separately. With dry core
cables 10 percent of the wires should be tested. 500 V Megger should be used for
cables in RE area.
10.1.3 Nature of cable faults
The faults that can occur in a cable can be one or more of the following type.
i) Earth Fault
ii) Contact or short fault
iii) Low insulation fault
iv) Break fault

Earth Fault
This may be due to water penetration because of faulty joints owing to faulty
workmanship, or mechanical damage of joint. This may also due to physical damage of
cable while digging operation.
Contact or Short Fault Contacts pure and simple are sometimes caused by lightening
and will usually be close to that end of the cable that is
connected to bare aerial wires, adjacent tree roots, and earth electrodes. It may be due
to manufacturing defects such as broken or defective paper insulation. Also faulty
workman-ship during splicing or worn out insulation results in such faults.
Low Insulation Faults

Commonly occur due of moisture penetration in to the joints due to faulty workmanship,
physical damage of joints, cables, etc., (faults is not well formed). Low insulation faults
are always associated with foreign potential that comes through leakage from the
working pairs. The foreign potential on a faulty pair is directly proportional to the value of
its insulation with respect to the earth. That is, higher the value of fault resistance, the
higher would be the foreign potential.
Break Faults.
These are associated with

i) Faulty workmanship
ii) Physical damages while digging operation
iii) Theft
v) Corrosion of conductor.
10.2 Fault localization tests: (conventional methods)
Various fault localisation techniques are available from the classical Varley loop test to
the sophisticated microprocessor based pulse echo tests. The nature of the fault
determines the techniques most suitable. It may also be noted that no single technique
can localized all types of faults.
Earth Faults:
Should invariably be tested by means of Varley loop test either with a wheat-stone
bridge or bridge Megger. For arranging good pair for testing, Connect 17 HZ, 75 V
ringing current from the MDF on a good wire in the affected or some other cable. Catch
the same wire at the other end. You will get current on the right wire/tag. Similarly
identify the other limb of the pair. You can use Megger also for this purpose.
In most cases there will not be a good pair available in the cable in such case run a drop
wire to use as good pair.
The bridge Megger is used for 'loop' and fault 'Localisation' tests. There are different
models of bridge Meggers as per make (manufacturer).
10.2.1 Use of bridge Megger for localizing earth and contact faults.
a) Loop Test: Make connections for loop test as follows:

a) Turn the 'test switch' on RX or bridge position
b) Set ratio switch at 1. Turn each resistance in 'Resistance box' to zero. Turn the
handle increasing resistance step by step. First fix the thousands digits, then
the hundreds, tens and units respectively until the pointer show a null point by
resting at infinity or '0' in the Galvo scale.
c) Crank the handle generator at full speed and get the null point by choosing the
required value of resistance in the resistance box. Note down the 'loop test' readings
call it R1 (this is the corrected value of the observed reading as per the ratio switch).
Varley Test
a) Make the connections for Varley test as shown in Fig. 10.1

b) Set the 'test switch' at Varley Position.
c) Crank the generator at full speed and get the null.
d) Record Varley reading call it R2 (this is the corrected value of the observed
reading as per the ratio switch).
Calculation of Distance to the Fault

i) Find the gauge of the conductor of the cable from cable diagram.
ii) Calculate the distance to-fault using the formula Resistance to fault:
(R1 - R2)/(1+N)
Where N is 1, 10,100,1/10 and 1/100 (position of ratio switch). Having found resistance
to the fault, divide by the resistance per meter of the cable to get the distance to the fault
in meters.

DISTANCE TO FAULT = (R1 - R2) X1000/[(1+N) x (Loop resistance of faulty cable per
KM.)
Fig. 10.1 Varely Test
10.3 Inspection of cable route to identify the spots of Recent Digging:
Follow the route correctly especially the length of overlap. If there is any sign indicating
any recent digging the same can be suspected to contain the fault. Excavate the trench
and expose the cable. Identify if this is the Cable concerned. Extend the trench for about
10 ft. length or up to the length covered by the recent digging. Expose the cable. Inspect
for any damage on the cable. If there is any damage, operate the cable. Verify if this is
the fault. If so, repair and close the case. If not proceed as follows.

Identification of Faulty Cable:
If there is more than one cable looking similar in diameter to the one under detection of
fault, identification of the right cable is a must before you proceed further. Quite likely
you have not exposed the right cable and so you do not find any damage.
10.3 1 How to identify the Right Cable:

a) Take a cross trench, a trench perpendicular to the route. This will expose all the
cables in the route. Tone detector may be used to locate the cable. For this tone
detection, the instruments required are as follows.
1. Audio frequency generator.

2. Universal receiver with headphones.
3. Cable identification coil. (Same as universal search coil but small and handy one)
Feed tone from the MDF to the testing cable and move the search coil on the exposed
cables. If search coil is put on a cable which is parallel to the search coil, minimum e.m.f.
is induced in the search coils because there is no longitudinal component of field.
But when the coil is put on the right angle to the cable, longitudinal field appears and get
maximum signal. In this way you get the right cable.
b) In case this method to get the right cable also fails, the next alternative is to expose
the nearest joint. Operate it and verify if this is 'our' cable. From this point excavate
the trench and go up to the point of localisation.
c) The next alternative or rather last resort when the nearest joint is more than 100
meters from point of localisation is to take a cut on the cable to verify the right
cable.
Operating the joint nearest to the point of localization
a) Find out from the cable diagram the joint nearest to the point of localisation. Locate
it (Joint J1 in figure). Expose the joint. Inspect for any damage. If the joint is
damaged, verify if this was the fault. If so, repair and close the case.

b) If the fault is not found in this joint, expose the joint on the other side of point of
localisation. Call it joint J2 Repeat the above operation of testing.
Spot localizations
1. Test from joint J1 to determine if the fault is towards the point of localisation or on
the other side i.e., towards joint J3.
Jtl ------L------ Jt2 -----L-------Jt3-----L-----Jt4
2. If the fault is towards joint J2. take the test from J2. If the fault is towards J1 from
here, proceed for spot localisation and determine the length of the over lap
between joints J1 and J2. Use Jumper wire as good wire.
3. If fault is towards J3, tested from J1, operate J3 and repeat the spot localisation
and determine the length of overlap between J1 and J3.
4. If the fault is towards J4 when tested from J2, operate A and repeat for spot
localisation and determine the length of the over lap between J2 and A. Thus try
to sectionalise the fault between two joints and proceed for the spot localisation.
For spot localisation a jumper wire can be used as good wire.
5. If fault goes beyond the length of overlap as indicated by testing from B and A
'Localization test' taken from the exchange will have to be repeated. Perhaps it
was wrong. This time at least be sure that you take some good and faulty wire at
the two ends.
6. If you find fault on either side of a joint, it indicates multiple faults. Clear faults
one by one.
Exposing the overlap after the spot localisation:
1. Excavate 5ft trench from either side of the point of localisation and inspect for
any damage on the cable. If fault is not found go on extending the trench in steps
of 5ft on either side.

2. The trench may have to be extended up to the nearest joint. Sometimes this may
have to be done to ensure we are inspecting the right cable. Operating the joint
can check this.
10.3.2 Fault localizations by pulse echo technique
Cable repair work, localisation of faults must be simple and accurate. In most of the
techniques adopted for cable fault localisation, the procedure adopted is very much
laborious. Varley loop test for example, is time consuming. It is essentially a D.C. test
whose accuracy can be altered with the presence of a foreign potential in the cable pair
under test.
For accurate and speedy fault localisation, the techniques using pulse reflection method
is found to be quite useful. It is essentially a high frequency AC test signal generator and
useful for localizing those faults that do not upset any DC condition but affect the
propagation of the A.C. high frequency energy. The nature of faults that include open
circuits, open sheaths, high resistance joints, and water logged cable section etc.
Testing Procedure
There is no need for a good pair or limb for conducting the tests. However if a good pair
is available in the same cable it can be used as a reference pair. It is advisable that the
cable pair to be tested is free from voltage. The reflection of pulse will depend on the
impedance irregularity of the pair under test.
In the case of open or break fault the reflection pulse will be indicated by upward kink or
positive reflection. For short or low resistance faults the reflection pulse will be indicated
by downward kink or negative reflection. Whatever energy reaches the dead short is
totally reflected back because the dead short appears as a mere impedance irregularity
and we can see a big reflected pulse corresponding to the dead short. Poorer the
insulation at the fault greater is the magnitude of the impedance irregularity and bigger
the reflected pulse. The presence of water in a particular section alters transmission
characteristics of that section. It is essential to connect the instrument to one end of the
circuit under test and shift it to the other end and carryout the same test so as to find out
the length of overlap.
The accuracy of distance to fault depends upon the accuracy of V/2 values.

D = V/2 X T where T is the time taken for the reflected pulse energy to arrive back at the
instrument, V is the velocity of propagation in a circuit and D is the distance to fault
For Knowing V/2 value, connect the cable pair to the instrument the reflected pulse
should be aligned accurately with the incident pulse and the thumb wheel switch should
be set such that the display on the digital readout corresponds to the V/2 value for that
pair. The V/2 for a typical paper core and PIJF cables are 103 to 105 and 88
respectively.
It should be remembered that alignment of incident and reflected pulses should be done
with reference to the commencement of their leading edges (align the foot of the
reflected pulse with the foot of incident pulse).
10.3.3 Types of Faults and their respective Reflection Pulses
1. Conductor break fault (one limb or both):A positive reflection Will be shown at the
point of break.
2. Contact Fault (Limb to Limb). A negative reflection will be shown at the point of
contact.
3. Earth Fault (Limb to Sheath). It is a very low resistance fault. When pulse is
applied between the conductor (limb) and sheath a negative reflection similar in
the above case is observed.

MAINTENANCE AND INSPECTION OF CABLES
CHAPTER - 11
11.1 Maintenance
a) Underground cable installations when laid strictly in accordance with the

recommended practice will hardly need any maintenance throughout their
anticipated span of life. As far as the buried portion of the cable is concerned, no
repairs are generally possible except in cases where moisture or water has
entered the cable and is detected before it has damaged the insulation.
b) All cable termination devices, pillar-boxes, cable heads and glands shall be kept
clean and dry.
c) All cables shall be tested periodically to enable timely action being taken and
prevent breakdowns.
d) No digging operations by other departments shall be carried out close to the
cable route without prior notice to the telecommunication Inspector who will take
necessary precautions to protect the cable from damage.
11.2 Special requirements in 25 KV AC electrified areas
a) A notice board prohibiting the entry of unauthorised person in the S & T repeater stations
shall be displayed at a prominent place of the repeater premises.
b) Test-speaker local and test-speaker through circuits as well as a pair of polyethylene-

insulated conductors have been specially provided in the telecommunication cables for
this purpose.
c) The cable maintenance staff shall ensure that the markings on OHE masts concerning
the location of cable joints are kept well painted.
d) The protective works provided for the cables at places like track crossings, culverts,
bridges, etc., shall regularly inspected by the cable maintenance staff, special attention
being paid to these protective works soon after the monsoon.

11.3 Fault Tracing:
(a) Whenever a fault is detected, the faulty wire or pair in the cable shall be cut off
from the circuit and isolated.
(b) The circuit Should be restored through a spare pair, if available.
(c) The fault shall then be localized in the faulty pair or wire.
Types - Cable faults may be generally divided into the following two groups:
(a) Faults in the end or termination portion.

(b) Faults in the buried portion.
11.4 Rectification
(a) When a fault is suspected to be at the end, affected conductors should be

disconnected and retested for the continuity and insulation to ascertain whether the
fault is in the conductor.
(b) The terminal and leading wires should then be separately tested to ensure that the
fault is not in the terminal or leading wires.
(c) The di-electric of the conductor of the cables, which are not part of the main cable
like cable - headed or pot-headed is likely to deteriorate by moisture causing
leakage, to the earth. In such cases, the ends shall be cut off and re-made
(d) If the cable is terminated with a switch-board cable, the end of the switch-board
cable can be cut off and re-made, in case low insulation is detected.
(e) In case of cable terminated by cable heading, the fault may be due to leakage from
the conductor terminal to the body of the cable head.
(c) Insulators should be examined and if found cracked or chipped should be

replaced by new ones.
(d) Dust, cobwebs or rust around insulators shall be removed.

11.5 Causes of faults:
(a) The most common causes for faults in the buried portion are due to damages
caused to sheathing by working parties engaged in excavation and due to
electrolytic action.
(b) Damage to sheathing allows moisture to enter and thus results in breakdown.
(c) A few other rare causes of leakage to lead sheathing are lightning, excessive
currents, subsidence of soil and crushing due to heavy vehicular traffic.
(d) Where a single conductor or only a few conductors are faulty, the fault may be due
to defective joints. Insulation of a single conductor may also deteriorate due to
sparking. In such cases, immediate necessary action should be taken to remove
the cause.
11.6 Localizing the fault

(a) Where the faulty cable is divided into sections by means of testing loops in pillar-
boxes or has been tapped off at intervals, the faulty section should be traced first.
(b) The fault should then be localized by one of the regular localisation tests.
(c) A Varley loop test using a bridge Megger is recommended for this purpose.
(d) The surface of the earth near the point of localisation shall be inspected to find out
whether the damage could have been caused by recent excavation.
(e) The ground should then be opened and the cable is exposed for careful
examination.
(f) If the cable is found to be defective due to penetration of moisture, the wet portion
should be cut off immediately and replaced by new one to avoid damage to the
entire cable, as the moisture will gradually spread to the entire length of the cable.
Fault due to moisture:
(a) If moisture or water has entered the cable and is detected before it has damaged
the insulation, desiccating process (Exhaust of moisture) is adopted to dry the
cables, by forcing dry air or anhydrous gas through the cables.
(b) The rate of improvement of insulation during desiccation depends upon the size of
cable, the degree of dampness and spacing between wires. The improvement in
insulation is slow in the beginning, but becomes rapid later.
(c) The insulation resistance should not be less than 625 Meg-ohms/Km of conductor
0
at 16 after desiccation

Route tests
(a) Underground cables shall be tested once a year with a Megger for insulation only
and the results of tests shall be submitted to DSTE/ASTE.
(c) Apart from the testing to be performed during laying and after laying the cables,
routine tests shall also be conducted on the cables to ensure that the cable is in
good condition. This will provide data to decide as to when a cable has served its
life and to replace the same in time, to avoid complete breakdown.
(c) All spare pairs in a cable shall be tested periodically once a year to ensure that they
are in good condition. This will help in using the same pairs whenever a working
pair has been faulty and the circuit carried by it has to be transferred to one of the
spare pairs.
11.7 Periodical tests on under ground cables.
The following tests as shown in Table 11.1 are performed periodically.
SL Name of the Instrumen Standard value Probability of

No test t Used cable fault
1 Insulation Megger 1500 Ohms (PJ filled) 10000 Ohms (RE Water
500 V cable Paper) Penetration
Megger into cable
100V
2 Conduction Bridge 1) 0.63 mm.dia. - 109.65 Ohms/loop Km. Break of
Megger 2) 0.9 mm. dia. - 54.83 Ohms/loop Km. insulation
3) 1.2 mm. dia.- 27.41 Ohms/loop Km. and not a
proper contact
3 Transmission TMS Kit or 1) 0.63 mm dia.- 0.973dB/loop Km 1) Bad joint.
loss dB meter unloaded. 2) Partial
2) 0.9 mm. dia - 0.619dB/loop Km unloaded break in
0.25dB/loop Km loaded conductor
3) 1.2 mm. dia - 0.434dB/loop Km.
4 Cross talk Cross talk 1) Far end X talk = -65dB 1)Power
test meter 2) Near end X talk= -60dB parallelism
2)Earth
leakages
3)Unbalance
in the pars
of cable
5 Psophometr- Psophomet 2mv Do
ic er
Noise test
Table 11.1 Periodic tests on Underground cable
11.8 Review question
1. Indicate step by step how you will proceed to localize a cable fault?
2. What are all the periodical tests to be conducted on R.E cable?


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INDIAN RAILWAYS INSTITUTE OF

SIGNAL ENGINEERING & TELECOMMUNICATIONS

Issued in October 2008

2 Constructional details and Utilities of paper 9

PREPARED BY P.BHATTACHARYA IMW2

INTRODUCTION OF UNDERGROUND CABLES

1. Core: Everything inside the sheath of the cable.

IRISET 2 TELECOMMUNICATION CABLES

inside the sheath. As an alternative, this may a moisture-resistant

1.3 Formation of a Cable (Refer to Fig 1.1)

Fig.1.1 Stranding of Layers (Twin cable)

IRISET 3 TELECOMMUNICATION CABLES

1.4 Special Features of Telecom Cables

1.5 Electrical characteristics of Telecom Cables

The four primary constants

Z (Impedance)= R + jωL, and

IRISET 4 TELECOMMUNICATION CABLES

Zo = (Z/Y) 1/2 = [(R + j ω L) / (G + j ωC)] ½

Propagation constant γ = (ZY) 1/2 = [(R + jωL) (G+ jωC)] ½

The real part is known as the attenuation constant = α

and imaginary part is known as the phase constant = β

V = ω/ β, will be different for different frequency components.

At carrier frequencies, values of ωL and ωC are large compared to those of R and G

So the expressions of Z0, β, α and v are simplified to,

Z0 = (L/C) 1/2, β = ω. (LC) 1 /2, α =R/ 2Z0 and v = 1/(LC)! /2.

IRISET 5 TELECOMMUNICATION CABLES

Thus at carrier frequency, characteristic impedance, attenuation constant and velocity of

1.5.1 Distortionless condition

If there is to be no phase distortion, the velocity of propagation must be same for

The expression γ = (ZY) 1/2 = [(R + jωL) (G+ jωC)] ½ is simplified

Velocity constant, v = 1/(LC) 1/2 and characteristic impedance,

1.5.2 Distiortionless condition in telephone cables

1.5.3 Loading of underground cable

IRISET 6 TELECOMMUNICATION CABLES

1.5.4 V.F balancing of underground cable

(I) Earth Couplings:

(II) Cross-talk Couplings within a quad.

K1 = The capacitance unbalance of a side-circuit of a quad with respect to

K2 = The capacitance unbalance of phantom circuit with respect

K3 = The capacitance unbalance of phantom circuit with respect to pair- 2 of a

(III) Between adjacent quads:

K9 = The capacitance unbalance of side-circuit- 1 of quad- 1 with respect to

Capacitance unbalance For full loading For half loading

Table 1.1 Capacitance unbalance permissible limits

Note: While balancing by connecting balancing condensers the attempt should be to

Fig.1.2 Capacitance Network of Telephone quad

IRISET 8 TELECOMMUNICATION CABLES

1.6 Classification of telecom cable Cables

I. PCUT - Paper Core Unit twist Cables.

IRISET 9 TELECOMMUNICATION CABLES

C Conductor (dia. in mm) 0.4 0.51 0.63 0.90 1.2

Maxim. Loop Resistance/Km 288Ω 182Ω 109.6Ω 54.83Ω 27.41Ω

Transmission loss/ loop Km .973dB .619dB .434dB

Table 2.1 Electrical Parameters of Underground cables

2.1.1 Advantage and disadvantage of paper insulation

Table 2.2 Advantages and disadvantages of paper insulation cables

2.2 Paper core unit twin cable (PCUT)

2.3 Paper core guard twist cable (PCQT)

Formation of a quad in paper insulated quad cable.

IRISET 11 TELECOMMUNICATION CABLES

Fig. 2.1 QUAD MARKING

Identification of pairs in a quad (Finland cable)

IRISET 12 TELECOMMUNICATION CABLES