CABLE LAYING AND CABLE JOINTING

CABLE LAYING
Methods :
1. In ducts or built in trenches
2. Directly buried in ground
3. Laying of cables on racks and cleats.
I Precautions In cable laying :
1.Cable route should be surveyed and shortest route should be selected based on the considerations
inside the plant like corrosive soil, communication cable nearby, future expansion etc.
2. The cables should not pass through storm water drain,drainage trenches and should not be taken
along the side of water mains.
3. Armoured cables alone can be laid directly in ground, in open areas or in built in trenches or ducts in
the factory. If unarmoured cables are used, these should be enclosed in suitable earthed
mechanically strong metal casing.
4. HV & MV cables should not be laid in the same trench. If it is unavoidable, suitable segregation
should be provided.
5. The cable trenches must be waterproofed, provided with water drains or water pumping units. Their
floors should be given a slope of atleast 0.1 % in the direction of water collecting pots or sumps.
6. The bottom of the cable trench should be leveled.
unavoidable should be gradual.

Gradients and changes of depth wherever

7. When pulling with a rope, care must be taken to prevent bending of the cable and see that it runs freely
over the cable rollers and will cross any underground obstacles in its path without rubbing against
them. Minimum bending rodings as per the table given in the Annexure I should be maintained. Another
important consideration is not to exceed the maximum allowable tensile strength of a cable when pulling.
Other-wise minor cracks may develop in the lead sheath which may result in failure within a few years.
Cable drums should be positioned in jacks so that it rotates freely. Suitable braking system should
also be provided.
8. Suitable tray bends & 'T's should be used in case of bends in trays.
9. Clamping of cables should be done at regular intervals and suitable M.S clamps shall be provided
to secure cable adopter boxes to walls or posts.

Method of pulling Cables to Ducts

10.Where the cable is installed on a vertical or a steeply inclined route, besides moving radially, due to the
heating of the cable, the impregnating compound will tend to migrate downward by gravity, both along the
interstices between the cores and along any gaps remaining between the insulation and the metal
sheath. This migration leaves voids in the upper end of the cable which becomes filled with the surplus
impregnating compound. As a consequence the electric strength of the cable in the upper end is reduced.
While the sheath at the bottom end is subjected to an interval hydro static pressure it expands the cable
and may even burst it. Therefore a normally impregnated paper insulated cable may be used for vertical
runs within certain shortlimits of height say upto 15 m in each of 11 kV cable. Owing to this vertical runs
are installed with special types of cables,with solid conductors, with predrained paper insulation and
with non draining compound impregnated insulation.
11. Where a cable crosses a drain or a road, it shall be laid at a depth of 1.5 m below ground level
and rotected by a stoneware or GI pipe of 4" dia.
12. Permanent cable route indicators should be provided at suitable intervals and at the points where the
cable changes its direction.
13.The route of the cable should be properly marked in a drawing and whenever there is any addition or
deletion it should be marked in it.
II Cable directly in ground :
For cable laying a trench of 1/2 m wide and 1 m deep is made throughout the route of the cable. The trench
must be of uniform depth free from stones and sharp edges of rock and the cable must rest on even and
solid ground. A bed of sand (preferably fine river sand) about 5 cm thick is made under the cable to avoid
the clay under the earth attacking it. Then the cable is covered with earth or more sand to a height of
about 15 cm, care being taken that no sharp stone should come in contact with the cable. Then a single
layer of bricks or tiles is laid to protect the cable from mechanical injury when somebody digs near about
the cable route. Whenever a pick-axe of the digger strikes against the brick he gets a warning of being
careful so as not to damage anything below.
If two or three cables are to follow the same route they may be put in the same trench but they must be
separated as far as possible to minimize the mutual heat-ing effect. They should not be allowed to cross
each other.
Depth of Trench as per IS 1255 :
(i) Upto 1.1 kV working pressure, 0.45 m plus radius of complete cable.
(ii) 3.3 kV to 11 kV working pressure, 0.75 m plus radius of complete cable.
(iii) 22 kV to 33 kV working pressure, 1 m plus radius of complete cable.

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III Cable in built in trenches :
This is widely used within industries, on the grounds of powerstations and substations wherever the route
is of limited length.
A cable trench permits a new cable to be put in or an old cable to be replaced or repaired without any
need for excavation, permits the cables to be checked from time to time and also serves as a reliable
means of protection of the cables from mechanical damage.
Spacing between cables :
When more than one multicore cable or trefoil group of single core cables is laid in the same trench, a
horizontal inter axial spacing of 0.25 to 0.4 m is desirable in order to reduce the effects of mutual heating
and also to ensure that a fault occurring on one cable will not damage the adjacent cable.
Disadvantages :
In order to inspect cables, make a repair or lay a new cable, it is necessary to remove the covering of the
trench. The free movement of air and the dissipation of heat in the trench while the presence of several
cables laid close together gives rise to the danger of damage to all the adjacent cables whenever a
short circuit in one of them results in severe arcing.
Comparison :
----------------------------------------------------------------------------------------------------------------------------------------------Cable in ground

Cable in trays

----------------------------------------------------------------------------------------------------------------------------------------------1. Less cost

High cost

2. Easy method

Involves fabrication of trays, fixing of trays etc

3. No danger for human life

Dangerous if breakdown occurs

4. Fault locating is difficult

Easy

5. Life is more if thermal resistricting of

soil is minimum

Poor heat dissipation.

So poor at carrying capacity

.
---------------------------------------------------------------------------------------------------------------------------------------------Sealing the Ends of PILC Cable
The impregnated paper insulation over the conductors is very hygroscopic and will readily absorb moisture
if exposed. It is therefore of utmost importance that the cable ends are properly sealed in terminal boxes
using special insulating box compound. The ends should never be left exposed to the atmosphere
except for a very short period during jointing, as it will otherwise absorb moisture from the air and the
insulation will be adversely affected. If this happens it is necessary to cut off 10 to 15 ft of the damaged
portion of the cable and reseal the end in a
properly designed cable sealing box.

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SELECTION OF CABLES :

The following points should be considered for selection of cables :

1. System voltage and type of system i.e. earthed or unearthed.
In unearthed systems if one of the phase gets earthed, the other two phases will be in line for a
longtime till the fault is identified. This results in line to line voltage stress across the insulation of
two ungrounded conductors. Therefore such cable must have greater insulation thickness than a cable
used on a grounded system where it is impossi-ble to impose full line to line voltage on the other two
healthy phases for an extended period of time.
----------------------------------------------------------------------------------------------------------------Insulation Rating

Fault clearing time

-----------------------------------------------------------------------------------------------------------------Grounded system

100 %

Ungrounded system 133 %

173 %

Within 1 minute
No specific time but within 1 hr.
Time is indefinite.

---------------------------------------------------------------------------------------------------------------------Condition of Installation :
Selection of armoured cable or unarmoured cable based on the likelihood of mechanical damage.
3. Maximum continuous current.
4. Rating factors (Grouping of conductors, temperature etc)
5. Voltage drop in the cable.
6. Short circuit level.
7. Standardization, future expansion etc.
8. Economics - optimum size.
Current carrying capacity of cable depends on :
1. Depth of laying
If the depth increases,current carrying capacity decreases (Reference 75 cm)
2. Grouping and proximity of cables with each other (If the number of cables are more, then derating
should be done)
3. Ambient soil temperature. If it is more then, current rating will come down. (Reference 30 C)

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4. Thermal resistivity of soil. The reference value is 150 C cm/Watt. The current rating
should be multiplied by this value. If resistance is less then, current rating will increase.
5. Maximum permissible conductor temperature.
6. Thermal resistance of cable
(i)

from conductor to lead sheath

(ii) of bedding & serving

7. Load factor & load cycle
Daily Load Factor = Average Load
Max. Demand
Yearly Load Factor = No. of units in year
Max. load x No. of hrs in year.
Based on the considerations, we have standardized the size of conductors of different rating. Similarly the
size of earth conductors are also standardized as in Annexure. This has been calculated such that the
conductor should not get fused when carrying the fault current.
Minimum size of Aluminium to avoid fusing
A = 11.32 x 10 -3 x I x T
Where

I = Ground Fault Current in Amperes.

T = Fault Clearing time in seconds.

What will happen if the cables are operated at high temperature ?
Cables should not be operated too hot since
1. Expansion of the oil may cause the sheath to burst
2. The viscosity of the oil may decrease at a high tempera-ture and it may start draining off from a
higher level.
3. Due to unusual expansion voids may be created in the insulation and such a state of affairs will
lead to ioniza-tion.
4. Dielectric losses increase with temperature and will heat up the insulation causing breakdown.

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Voltage drop in Cables :
Here the manufacture's catalog is to be referred and the value of Resistance and Reactance per KM
should be converted into the actual value by multiplying it with the length of the cable and the receiving
end voltage should be calculated. For motors during starting itself the drop allowed is only 10 % (When
measured at the terminal box.)
Es = Sending End Voltage
Er = Receiving End Voltage
I = Current in Amps.
O = Phase angle (Load P.F Cos )
R = Total Resistance
IX = Wattless Component
Es = { (ER Cos + IR) 2 + (ER Sin + IX) 2 }
= ER + IR Cos + IX Sin
During starting up of a motor the starting current is 6 times of full load current and the power factor will be
low in the order of 0.3. This should be considered in calculating the voltage drop.
Precommissioning tests on laid cable :
Testing may be divided into three heads :
(a) Testing during laying and jointing operation
(b) Testing after laying and jointing is completed &
(c) Routine testing
(a) Testing During Laying :
(i) All new cables shall be megger-tested before laying. After laying and jointing all LV cables should
be megger tested and HV cables pressure tested before commissioning.
(ii) The cable cores should be tested for
1. Continuity
2. Absence of cross phasing (in case of joints)
3. Insulation resistance to earth &
4. Insulation resistance between conductors.

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(b) Testing after laying & jointing :
Immediately after the initial laying and jointing work is completed, a high voltage test should be applied to
all H.T cables to ensure that they have not been damaged during or after the laying operations and there
is no flow in the jointing.
Test Voltages for PILC cables as per IS 1255 - 1967
For 15 minutes
-------------------------------------------------------------------------------Voltage
Test volt for cables in Earthed System
designation
------------------------------------------------------------of cable
Between conductors Between conductors
& sheath
---------------------------------------------------------------------------------d.c
a.c
d.c
a.c
---------------------------------------------------------------------------------1.1 kV
3 kV
2 kV
3 kV
2 kV
3.3 kV

9 kV

6 kV

5 kV

3.5 kV

11 kV
30 kV 20 kV
17.5 kV
11.5 kV
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Voltage
Test volt for cables in Unearthed System
designation -------------------------------------------------------------------------------of the
Between conductors Between conductors
cable & sheath
-------------------------------------------------------------------------------------------------d.c
a.c
d.c
a.c
--------------------------------------------------------------------------------------------------3.3 kV
9 kV
6 kV
9 kV
6 kV
6.6 kV

18 kV

12 kV

18 kV

12 kV

11 kV
30 kV
20 kV
30 kV
20 kV
--------------------------------------------------------------------------------------------------Site test may be conducted either by a.c or d.c high voltage. The disadvantage of an a.c test is that when
the cable is long, heavy charging current will be drawn and the capacity of the transformer would be high,
whereas this is not the case in a d.c test. Therefore the d.c test is the more common.
Cables to be tested must have their ends disconnected from the equipment and away from the ground. All
conductors not under test must be grounded. Since equipment to which cable is customarily connected
may not withstand the test voltages allowable for cable, either the cable must be disconnected from
this equipment, or the test voltage must be limited to levels which the equipment can tolerate. The latter
constitutes a relatively mild test on the cable condition and the predominant leakage current measured
is likely to be that of the attached equipment. In essence, this tests the equipment, not the cable.
The test volt may be applied continuously or in steps and the current shown by the meter should be noted
for each minute. Using the test readings, the polarization index of the cable which nothing but the ratio of
current after 1 minute to the current after 5 minutes should be calculated.

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For good cables the polarization index will be between 1.25 to 2.00. Anything less than 1.0 should be
considered a failure and between 1.0 and 1.25 only a marginal pass.
The current shown by the meter consists of three components namely (i) leakage current, (ii) capacitance
component & (iii) absorption component which are illustrated in figures below :
The leakage component depends on the resistance of leakages path and the value of the driving voltage;
it is an ohm's law relationship. For good insulation, only a very small amount of leakage current occurs.
The capacitance component is a typical of the charging current of the capacitor. This component of test
current starts high but drops rapidly almost to zero.
The absorption component converts electric energy to stored energy in the form of a molecular strain in
the insulating material. Although each molecule is electrically neutral (the positive charge equals the
negative charge), it is positive and negative charges form a electric dipole. In the presence of an applied
voltage, the positive charges are pulled toward the negative terminal and negative charges towards
positive terminal. Thus each electric dipole not already aligned in the direction of applied voltage experiences a torque that tends to position it parallel to the line of action of applied voltage. This behaviour
called 'Dielectric Absorption' is a relatively slow process that may take many hours to complete. When
the applied voltage is removed and the wiring grounded the molecules return slowly to their equilibrium
position.
At completion of the maximum test voltage duration, the charge is drained off, the conductor grounded and
the test lead removed for connection to the next conductor. Grounds should be lefted on each tested
conductor for not less than 30 minutes. They may be touched only while the ground is connected to
them; otherwise the release of the absorption current by the dielectric may again raise their potential to a
dangerous level.
Note :
For cables which were already in service 1.5 times of the rated voltage may be applied.
(c)Routine Testing :
The life of PILC cables is considerably reduced through overloading. It is therefore essential to check the
loads as frequently as possible to ensure that the cables are not loaded beyond the safe current carrying
capacities. The derating factors due to grouping of several cables, higher ambient temperature and
higher thermal resistivity of should not be neglected.
Precautions in Cable Jointing :
Although the procedure of cable jointing varies slightly between the different types of cable jointing kits, the
precautions remains almost the same.
1. A tent should be used in all circumstances where jointing work is being carried out in the open. It
is a mistake to think that tents are only provided as a protection against rain. It is equally important
to prevent dust from being blown on to the exposed joint and jointing materials, especially on the
compound and tapes. It follows, therefore, that the tent should be erected in such a manner as to
reduce to a minimum the amount of dust or foreign matter likely to be blown in. This is generally
achieved by having only one entrance to the tent and the back facing the direction of the wind. The tent
and the back facing the direction of the wind. The tent cover should be weighted or tied down on the
three remaining,sides.

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2.
Each joint, whether of the straight-through or 'T' type or any termination, should be installed so that it
will not be subject to subsequent tension or external mechanical forces while in service.
3. The appropriate quantity and full reliability of a joint require that it should strictly conform with the
jointing instructions and that, once certain works processes have been started, they must never be
interrupted. For example, once the paper tape insulation has been applied in the correct manner, it must
be immediately sealed with hot compound, after the lead or aluminium sheath is stripped from the cable
there must be no interruption in the work. No other operations on the cable should be started until the
joint has been completed and the cable fully sealed.
4.
Care must be taken to observe all the safety rules, maintain the work place in tidy and orderly
condition, and keep the hands and work clothes clean.
5.

Crack test :-

Before jointing a paper insulated cable, the paper insulation should be tested for the presence of moisture
by immersion in hot compound or paraffin wax at a temperature between 120 to 140 C. The
presence of moisture is indicated by the formation of bubbles when a piece of the paper is immersed in
hot compound. Only a single strip of paper gripped by a pair of tweezers should be used for the test since
of several thicknesses of paper are immersed, the escape of occluded air between the layers may be
mistaken for the presence of moisture. Particular attention should be paid to the paper next to sheath and
to that next to the conductor, as it is in these positions that moisture is most likely to be found. The
samples of paper should be perspiration. In case moisture is present then 10 to 15 feet of the cable
should be cut and the test should be carried out. Only after confirming that there is no moisture the
jointing should be done.
6. Where heavy size cables are involved, it is desirable, except under unavoidable circumstances that
cables are always laid and jointed number to number or colour to colour as shown on the outer layer of
paper thus preventing cross joints. Generally, it will be found that the paper numbers or colours represent
the phases, but this should never be taken for granted.
7. The lead sheath or cable seals not be opened until all necessary precautions have been taken to
prevent the seasonal circumstances arising which might become uncontrollable. Special attention
should be paid to the selection of tools and to maintaining them in a fit working condition.
8.

The essential requirements of a good joint are :

(a) High electrical conductivity and

(b) Good mechanical strength.
A joint made between two conductors by means of a sleeve, or a joint made between the end of a
conductor and the connector or lug should not produce a drop in voltage greater than 9 mV at a rated
current carrying capacity of a conductor. Failure to meet this requirement leads to local overheating in the
cable line and may cause an interruption in supply.
It is considered necessary to have the breaking load of a joint to be atleast 60 % of the conductor. Failure
to satisfy this requirement may lead to breaks in the joints when the cable is subjected to tension.
9. The paper insulated cores should be looped with dry tape as soon as the cable is stripped, in order to
protect them from dirt. This should be removed before the joint is closed.
10.
The surface oxide film on aluminium, through very thin and quite brittle has a high electrical
resistance and therefore must be removed or penetrated to ensure a satisfactory electric joint. This
film can be removed by abrading with a wire brush, steel rod, emery cloth or similar abrasive tool or

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material. A plated surface whether on the connector or should never be abraded. It can be cleaned with
a solvent or other means which will not remove the plate. Corrosion inhibitor compounds must be used in
case of aluminium joints.
Corrosion is possible under some conditions because aluminium is anodic to other commonly used
metals including copper when electrolytes even from humid air are present. Also aluminium has a
coefficient of thermal expansion higher that of copper. The ultimate and the yield strength properties
and the resistance to creep of aluminium are different from corresponding properties of copper. Hence
bimetallic washers should be used if the joint is between aluminium and copper conductors.
11. After the armouring is properly clamped, the earth continuity conductor should be bolted in position.
12.
13.

IR values of both section of cables should be measured before jointing. After jointing, before
lining up the IR value of cable should be measured. Hypotest should be carried out if it is a H.T cable.
Suitable cable joint marks should be provided near the joint.

The recent method of cable jointing is done with Ray chem Joints. Here the main advantage is no curing
time and also the joint looks better.
I Minimum bending radius of cable as per IS 1255 - 1967
----------------------------------------------------------Single core
Multi core
----------------------------------------------------------Armoured Unarmoured
-------------------------------------Upto 11 kV
20 D
12 D
15 D
Upto 22 kV

25 D

15 D

20 D

Upto 33 kV
30 D
20 D
25 D
---------------------------------------------------------D - Overall diameter of the cable.
Whenever possible 25 % larger radius than that speci fied above should be used.
At joints and terminations, the individual cores of multicore cable should never be bent so that the radius
of the bend is less than 15 times the diameter over the insulation.
II SIZE OF CONDUCTORS FOR FEEDERS AND MOTORS
1. Upto
2. 2 to

1 kW 9 kW -

2.5 sq.mm. Copper

6 sq.mm. Al

Upto 2 A

2 to 13 A

3. 10 to 15 kW -

10 sq.mm. Al

- 14 to 21 A

4. 16 to 25 kW -

25 sq.mm. Al

- 22 to 35 A

5. 26 to 38 kW -

50 sq.mm. Al

- 36 to 50 A

6. 39 to 50 kW -

70 sq.mm. Al

- 51 to 65 A

7. 51 to 75 kW -

120 sq.mm. Al

- 66 to 100 A

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8. 76 to 100 kW -

185 sq.mm. Al

- 101 to 130 A

9. 101 to 130 kW -

300 sq.mm. Al

- 131 to 160 A

10. 131 to 160 kW -

400 sq.mm. Al

- 160 to 250 A

Feeders :
1. 250 to 500 A

---

2 runs 3 1/2 x 400 Al

2. 501 to 750 A

---

3 runs 3 1/2 x 400 Al

3. 751 to 1000 A

---

4 runs 3 1/2 x 400 Al

III Size of Earth Conductors :

(a) Motors :
1. Upto 15 kW

-- 6 sq.mm. Al

2. Upto 40 kW

-- 25 sq.mm. Al

3. 41 to 50 kW

-- 35 sq.mm. Al

4. 51 to 75 kW

-- 70 sq.mm. Al

5. 76 kW & above -- 120 sq.mm. Al

6. HT Motors

-- 300 sq.mm. Al

(b) Switch gears

-- 600 sq.mm. Al

(c) Light fittings, -- 6 sq.mm.

Control Gears etc.,
(d) Main Earth Strip

-- 750 sq.mm. when directly buried in ground.

-- 600 sq.mm. PVC sleaved when laid above ground.

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