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Underground Cable System

Design Manual

June 2012
Asset Management Department, TNB Distribution Division
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Underground Cable System Design Manual

June 2012

Asset Management Department


Distribution Division,
Tenaga Nasional Berhad
Wisma TNB
Jalan Timur, Petaling Jaya
Selangor

Disclaimer: This Underground Cable System Design Manual is a document providing


technicians, engineers, and managers of the Distribution Division of Tenaga Nasional
Berhad with an understanding of proper cable system design. The information in this
document has been prepared in good faith and represents the Asset Management
Departments intentions and opinions at the date of issue. The Asset Management
Department may change any information in this document at any time.

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Distribution Division Underground Cable System Design Manual

Acknowledgement
We would like to express our deepest gratitude to the management of the
Distribution Division, for giving us the opportunity to develop the TNB
Distribution Divisions Underground Cable System Design Manual.

Special thanks to Hj. Ismail Mohd Din, Mr. Md Zin Shamsuri, Ir. Tan Chow Heang
and Ir. Hairil Azli bin Abdul Satar all from Asset Management Department, for
their valuable contribution and assistance in developing this manual.

Our appreciation also goes to Dr. Ahmad Basri Abdul Ghani, Mr. Huzainie Shafi
Abdul Halim, Mdm Zairul Aida Abu Zarim and other TNB Research staff for their
help in determining the ampacity of cables under different circumstances.

The project team would also like to express its gratitude to Ir. Faisal Abood
Hareez, Ir. Noor Saleha binti Selamat, Mr. Nazli Bin Md Nusi and Mr. Abdulqahar
bin Idris from ILSAS, Bangi. Not forgetting Mr. Toh Kim Beng and Mr. Ammar
Alam Shah, Mr. Sangsaidi bin Omar, Mdm Masliza binti Md Noah and Mr. Mohd
Hisanudin Bin Hamzah, and the helpful staff of TNB (Pembahagian) Pulau Pinang.

Our appreciation also goes to the Uniten Team, comprising Ir. Ali Askar Sher
Mohamad, Mr. Mohd Zafri Baharuddin, Mdm Fareha binti Mohd Zainal, Mdm
Noor Miza binti Muhamad Razali, Ms Muaz Diyana binti Mohammad Murthadza,
Ms Nadhira binti Mat Nashim, Ms Nor Fazlin Faizol Ho, Mr. Shahrul Iznan,
Ms Nurul Aishah binti Mohd Rosdi, Ms Redia binti Mohd Redzuwan and
Ms Kamalambigai A/P Munusamy for their untiring efforts and patience towards
the successful completion of this manual.

Thank you.

Ir. Wan Nazmy Bin Wan Mahmood


General Manager,
Engineering Services,
Asset Management Department,
Distribution Division, TNB.

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Distribution Division Underground Cable System Design Manual

Foreword
VP Distribution Division, Datuk Ir. Baharin Din

As Malaysia progresses to achieve Vision 2020, the


volume of underground cables installed in the
distribution system has also increased in tandem with
the countrys rapid economic development. With
continuous expansion of the distribution underground
cable network and its ever challenging environment, it is
vital that the spirit of do it right the first time be
instilled among TNB personnel and appointed contractors. Properly designed and
correct installation of cable systems will ensure reliable and quality power supply
with longer underground cable system lifespan with improved system security.

Although various technical and engineering circulars and guidelines have been
issued from time to time, it is found that discrepancies in standard practices of
underground cable design and installation among states and areas are still
widespread, thus affecting the performance and lifespan of the cable system. In
view of this, it is timely that such a practical handbook on underground cable
design and installation is produced for easy reference throughout TNB
Distribution Division.

TNB Distribution Division through Distribution Asset Management Department,


in collaboration with ILSAS, TNB Research and Universiti Tenaga Nasional, have
taken a step forward to develop this manual which incorporates the latest
technological changes in underground cable and its accessories, existing relevant
instructions and circulars, as well as approved technical specifications.

Therefore, I would like to take this opportunity to congratulate the project team
from the Asset Management Department, as well as ILSAS, TNB Research and
Universiti Tenaga Nasional, for their impressive effort in developing this useful
manual for underground cable system design in distribution system.

Thank you.

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TABLE OF CONTENTS
Distribution Division Underground Cable System Design Manual

Table of Contents
Acknowledgement ................................................................................. ii
Foreword .............................................................................................. iii
Table of Contents .................................................................................. iv
1 Introduction .................................................................................. 1
1.1 Underground Cable Systems ............................................................... 1
1.2 Cable Installation in TNB Distribution Division .................................... 3
1.3 Cable Installation Practices ................................................................. 4
1.4 Reference Standards ........................................................................... 6
1.5 Outline of this Manual ........................................................................ 7
2 Basic Cable Theory ........................................................................ 8
2.1 Cable Design and Construction ........................................................... 8
2.1.1 Conductor ................................................................................ 12
2.1.2 Insulation ................................................................................. 13
2.1.3 Mechanical and Environmental Protection ............................. 18
2.2 Cable Types ....................................................................................... 19
2.2.1 33kV XLPE Single Core Cable ................................................... 20
2.2.2 11kV XLPE Single Core Cable ................................................... 21
2.2.3 11kV XLPE Three Core Cable .................................................... 22
2.2.4 11kV XLPE Triplex Cable........................................................... 23
2.2.5 11kV PILC Three Core Cable..................................................... 24
2.2.6 1kV PVC/PVC Single Core Cable ............................................... 25
2.2.7 1kV XLPE Four Core Cables ...................................................... 26
2.2.8 Summary ................................................................................. 27
2.3 Communication Cables ..................................................................... 28

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Underground Cable System Design Manual Distribution Division

2.4 Ampacity and Cable Damage Curve (CDC) ........................................ 30


2.4.1 Factors Affecting Cable Ampacity ........................................... 30
2.4.2 Cable Damage Curve (CDC) ..................................................... 31
2.5 Cable Laying Formation and Arrangement ....................................... 33
2.5.1 Three Core Cable Laying Arrangement ................................... 33
2.5.2 Single Core Cable Laying Arrangement ................................... 34
2.5.3 Communication Cable Laying Arrangement............................ 36
2.6 Sheath Bonding Methods ................................................................. 37
2.6.1 Three Core Cables Bonding Method ....................................... 37
2.6.2 Single Core Cables Bonding Methods ..................................... 37
2.7 Cable Accessories ............................................................................. 43
2.7.1 Joints and Joint Body Assembly .............................................. 43
2.7.2 Conductor Connectors ............................................................ 50
2.7.3 Conductor Connection Techniques ......................................... 52
2.7.4 Termination ............................................................................ 56
2.7.5 Earth Link Box ......................................................................... 62
2.8 Transformer Tail Cable ..................................................................... 66
2.8.1 11/0.4kV Transformer Tail Cable ............................................ 66
2.8.2 33/11kV Transformer Tail Cable ............................................. 67
3 Cable Laying Specification ........................................................... 69
3.1 Direct Buried in Trench ..................................................................... 69
3.1.1 Trench Dimensions.................................................................. 70
3.1.2 Direct Buried Cables ................................................................ 72
3.2 Laying Cables in Pipes / Ducts........................................................... 75
3.2.1 Types of Pipes ......................................................................... 76
3.2.2 Sizes and Usage of Pipe/Ducts ................................................ 79
3.2.3 Cable Arrangement in Ducts ................................................... 80
3.3 Joint Pit / Pulling Pit .......................................................................... 84
3.4 Cable Bridge ...................................................................................... 85

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TABLE OF CONTENTS
Distribution Division Underground Cable System Design Manual

4 Cable Laying Accessories ............................................................. 86


4.1 Cable Slab .......................................................................................... 86
4.1.1 uPVC Cable Slab ....................................................................... 86
4.1.2 nPVC Cable Slab ....................................................................... 88
4.1.3 Reinforced Concrete Slab ........................................................ 89
4.2 Cable Route Marker .......................................................................... 90
4.3 Cable Joint Marker ............................................................................ 92
5 Cable Laying Procedures.............................................................. 93
5.1 Safety Precautions Prior to Commencement of Work ...................... 93
5.2 Initial Preparation ............................................................................. 94
5.2.1 Site Visit and Route Survey ...................................................... 94
5.2.2 Utility Mapping ........................................................................ 94
5.2.3 Route Plan ............................................................................... 95
5.2.4 Route Plan Approval ................................................................ 96
5.2.5 Trial Holes ................................................................................ 97
5.3 Trench Excavation ............................................................................. 98
5.3.1 Safety of Site Works and Traffic Management ........................ 99
5.3.2 Removal of Top Surface ......................................................... 103
5.3.3 Trenching and Excavation of Soil ........................................... 104
5.3.4 Handling of Excavated Materials ........................................... 106
5.3.5 Sand Bedding ......................................................................... 107
5.3.6 Cable Support and Shoring Works ......................................... 107
5.4 Pipe/Duct Installation...................................................................... 110
5.4.1 Draw Ropes............................................................................ 110
5.4.2 Sealing Pipe or Duct Ends ...................................................... 110
5.4.3 Concrete Casting of Ducts ..................................................... 110
5.4.4 Work Specification................................................................. 111

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Underground Cable System Design Manual Distribution Division

5.5 Cable Pulling ................................................................................... 114


5.5.1 Cable Handling ...................................................................... 115
5.5.2 Installing Cable Rollers .......................................................... 120
5.5.3 Setting Cable Drum ............................................................... 122
5.5.4 Fitting Cable Stockings / Cable Grip ...................................... 125
5.5.5 Cable Pulling Methods .......................................................... 127
5.5.6 Cable Flaking & Unflaking ..................................................... 130
5.6 Laying-Off Cables ............................................................................ 132
5.6.1 Direct Buried in Trench ......................................................... 132
5.6.2 Cable Separation ................................................................... 133
5.6.3 Arrangement of Communication Cables ............................... 133
5.7 Alternative Cable Installation Methods .......................................... 134
5.7.1 Horizontal Directional Drilling (HDD) .................................... 134
5.7.2 Pipe Jacking ........................................................................... 137
5.7.3 Micro-tunnelling ................................................................... 138
5.7.4 Filling of Cement Sand Grout ................................................ 139
5.8 Cable Jointing ................................................................................. 140
5.8.1 Overview ............................................................................... 140
5.8.2 Safety in the Trench / Pit ...................................................... 141
5.9 Cable Termination .......................................................................... 141
5.10 Mechanical Protection, Backfill and Reinstatement ....................... 142
5.10.1 Washed River Sand ............................................................... 142
5.10.2 Mechanical Protection .......................................................... 142
5.10.3 Backfill Material .................................................................... 145
5.10.4 Reinstatement of Paved Surfaces ......................................... 146
5.11 Tidying Sites .................................................................................... 147

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Distribution Division Underground Cable System Design Manual

6 Cable Laying in Substations ....................................................... 148


6.1 Cable Arrangement in Cable Cellars ................................................ 148
6.1.1 Standard Guidelines .............................................................. 148
6.1.2 Cable Clamp with stand ......................................................... 149
6.1.3 Cable Tray/Cable Ladder........................................................ 150
6.1.4 Bracket and Cable Clamp ....................................................... 151
6.2 Cable Arrangement in Substation Trenches .................................... 152
6.2.1 Standard Guidelines .............................................................. 152
7 Cable Management ................................................................... 153
7.1 Overview ......................................................................................... 153
7.2 Cable Installations for 22kV and Below ........................................... 154
7.2.1 Planning ................................................................................. 156
7.2.2 Project Implementation......................................................... 156
7.2.3 Commissioning ...................................................................... 157
7.2.4 Project Closing/Handover ...................................................... 157
7.3 Cable Installations for 33kV............................................................. 158
7.3.1 33kV Planning ........................................................................ 159
7.3.2 33kV Project Implementation and Commissioning ............... 159
7.3.3 33kV Project Closing .............................................................. 159
Appendix ........................................................................................... 160
Graph 1: 11kV and 22kV PILC Aluminium Cable ............................................. 162
Graph 2: 33kV XLPE Aluminium Cable ............................................................ 163
Graph 3: 22kV XLPE Aluminium Cable ............................................................ 164
Graph 4: 11kV XLPE Aluminium Cable ............................................................ 165
List of Abbreviations .......................................................................... 166
Glossary ............................................................................................. 168

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CHAPTER 1 INTRODUCTION
Underground Cable System Design Manual Distribution Division

1 Introduction
1.1 Underground Cable Systems
Cable technology has progressed rapidly over the years since the
invention of electricity. The basic function of a cable is to transmit
electricity from one location to another. However, with increasing
voltages and higher power requirements, the cable has become more
and more sophisticated, requiring care during design, manufacturing and
installation with specific installation methods, as well as detailed
operations and maintenance guidelines. For example, Figure 1-1
illustrates how cable laying was conventionally done whereas Table 1-1
th
presents the chronology of the development of cables since the 19
century.

1
Figure 1-1: Cable laying in the 1950s was laborious

1
Image courtesy of TNB Corporate Communications Digital Archives

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CHAPTER 1 INTRODUCTION
Distribution Division Underground Cable System Design Manual

2
Table 1-1: Development of cable systems
Year Cable Development
1880s First gutta percha electric cable followed by rubber and vulcanised
bitumen insulation
1890 Ferranti 10 kV tubular cable and the introduction of paper
insulation
1914 Hochstadter development of screening which enabled distribution
voltage to be increased to 33 kV
1926 Emanueli provided the principle of pressurisation with fluid-filled
paper cables for voltages of 66 kV upwards
1930s Polyvinyl chloride (PVC) insulation first tried out in Germany
1949 Introduction of the mass-impregnated non-draining cable in the
United Kingdom to overcome the problems of drainage of oil-rosin
impregnated with cables installed on slopes
1950s Full commercial introduction of PVC and later thermoset insulation
for wiring cables. PVC for power cables followed at the end of the
decade
Successful development of aluminium sheaths, initially for pressure-
assisted cables, and gradual adoption of aluminium conductors for
power cables
1960s Significant distribution economies obtained by the use of combined
neutral and earth cables.
England/France 100 kV submarine d.c. link inaugurated in 1961.
First 400 kV fluid filled cable, operational in 1969
1970s Gradual extension of the use of thermoset insulation, mainly cross-
linked polyethylene (XLPE), as an alternative to paper insulation
1980s Introduction of optical fibre into overhead lines
Very widespread use of XLPE in the 11-33 kV range with significant
quantities installed for transmission voltages of 66-240 kV
Discovery of high temperature superconducting materials
Development and growing use of cables designed to alleviate the
effects when cables are involved in fires; properties include reduced
flame propagation, low smoke emission, reduced emission of
noxious fumes and corrosive gases and combinations of these
characteristics
1990s Widespread use of optical fibres in overhead lines
Extension of polymeric to extra high voltage (EHV) and the
commercialisation of polypropylene paper laminate (PPL)
Practical demonstrations of superconducting cables

2 rd
BICC Cables, Electric Cables Handbook 3 edition.

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CHAPTER 1 INTRODUCTION
Underground Cable System Design Manual Distribution Division

Electric cable consists essentially of a low resistance conductor to carry


the current and the insulation is to isolate the conductors from each
other and from their surroundings. In single-core wiring cables, the two
components form the finished cable, but generally as the voltage
increases the construction becomes much more complex.

Other main components may include screening to obtain a radial


electrostatic field, metallic sheath as a moisture barrier or to contain a
pressurising medium, armouring for mechanical protection, corrosion
protection for the metallic components and a variety of additions
extending, for example, to internal and external pipes to remove the
heat generated in the cable.

1.2 Cable Installation in TNB Distribution


Division
In the United States and countries under its influence, the vast majority
of the electricity supply networks, including transmission and
distribution, are overhead systems accompanied by pole-mounted
transformers. In Britain and Europe, the distribution system is mostly
underground. In Malaysia, TNBs medium voltage (MV) network is mainly
underground while the low voltage (LV) network is mainly overhead,
although MV aerial bundle cables (ABC) are increasingly being used
especially in the suburban and rural areas.

The underground networks obvious advantages are reduced outages,


especially those caused by climate conditions, as well as aesthetics since
it is hidden and cannot be seen. The main disadvantages are its high
initial cost, difficulty in locating a fault, and the time and costs involved in
repairs in case of damage to the cables.

Over the years, TNB Distribution Division has increased its inventory of
cables especially XLPE cables. To date, the total circuit length of its MV
cable network has reached about 380,000 km and continues to grow

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CHAPTER 1 INTRODUCTION
Distribution Division Underground Cable System Design Manual

daily in tandem with the rapid development of the country. In line with
cable design and construction development, different types of cable
joints and cable terminations had been introduced. TNB Distribution
Division issued different engineering instructions and circulars related to
cable installation/laying practices and jointing of cables.

1.3 Cable Installation Practices


As the distribution network expanded and becomes more complex, it is
critical to get things right the first time. Correct installation of cables will
ensure a reliable electrical system with a long operational lifetime and
improved system security. To ensure a reliable underground cable
network, care must be taken in the following stages of cable installation:

Cable network design


o Ensure the cable system is designed according to TNB
approved planning criteria for reliability, safe and ease of
operations and maintenance
o Derating factors need to be taken into account at the design
stage
Cable laying
o Cables should be laid in accordance to TNB laying practices
Ensure cable is not damaged during laying
Prevent additional derating of cables due to improper
cable laying practice, e.g. using the wrong backfilling
material
Avoid future damage to the cable by third parties
Cable jointing and termination
o Use of the correct jointing materials
o Installed by certified jointers
o Follow correct jointing and termination practices
Cable commissioning and record keeping
o Ensure correct tests are performed as recommended
o Produce as-built drawings and proper records of cable details

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CHAPTER 1 INTRODUCTION
Underground Cable System Design Manual Distribution Division

Cable installation procedures need to be followed strictly to achieve a


good underground cable installation. Faults that can be reduced or
avoided with proper installation practice include:

Open circuit faults


Short circuits faults
Failure due to overheating because of overloading, inadequate
ventilation or thermal dissipation
Mechanical failure due to insufficient mechanical restraint,
protection or support

This manual will make reference to all the existing engineering


instructions, circulars and other relevant material, and will provide a
detailed guide to cable installation practices.

Figure 1-2: Cable in trefoil formation laid in a trench

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CHAPTER 1 INTRODUCTION
Distribution Division Underground Cable System Design Manual

1.4 Reference Standards


Users of this manual are advised to refer to the following set of
reference standards to acquire more in-depth understanding of the
standards quoted in this manual:

a. IEC 60502-1 Power cables with extruded insulation and their


accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV
(Um = 36 kV), Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV)
and 3 kV (Um = 3,6 kV), 2009-11-25.

b. IEC 60502-2 Power cables with extruded insulation and their


accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV
(Um = 36 kV), Part 2: Cables for rated voltages from 6 kV (Um = 7,2
kV) up to 30 kV (Um = 36 kV), 2005-03-08.

c. IEC 60502-4 Power cables with extruded insulation and their


accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV
(Um = 36 kV), Part 4: Test requirements on accessories for cables
with rated voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV),
2010-12-15.

d. IEC 61238-1 for Compression and mechanical connectors for power


cables for rated voltages up to 30 kV (Um = 36 kV) - Part 1: Test
methods and requirements, 2003-05-09.

e. IEEE Guide for the Design and Installation of Cable Systems in


Substations, IEEE Std 525-1992, 1993.
doi: 10.1109/IEEESTD.1993.115135.

f. IEEE Guide for the Application of Sheath-Bonding Methods for Single-


Conductor Cables and the Calculation of Induced Voltages and
Currents in Cable Sheaths, ANSI/IEEE Std 575-1988, 1987
doi: 10.1109/IEEESTD.1987.122985.

g. IEEE Standard Power Cable Ampacity Cable, IEEE Std 835-1994, 1994
doi: 10.1109/IEEESTD.1994.85814.

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CHAPTER 1 INTRODUCTION
Underground Cable System Design Manual Distribution Division

1.5 Outline of this Manual


The contents of this underground cable system design manual cover the
following area of interest:

Chapter 2 Basic Cable Theory


Introduction on theories and philosophies for cable design &
construction, available cable types, ampacity and cable damage
curve, cable laying formation and arrangement, sheath bonding
methods and cable accessories.

Chapter 3 Cable Laying Specification


Shows dimensions and details to install cables in trenches and in
pipes/ducts, including description of the joint/pulling pit and cable
bridges.

Chapter 4 Cable Laying Accessories


Description and use of different cable slabs, route markers and cable
joint marker.

Chapter 5 Cable Laying Procedures


Detailed procedures covering initial preparation, site safety, trench
excavation, duct installation, cable pulling, laying-off cables,
alternative cable installation methods (HDD, pipe jacking micro-
tunnelling), cable jointing, termination, backfill material and
protection of cables, road reinstatement and also tidying of sites.

Chapter 6 Cable Laying in Substations


Description of equipment used to install cables inside substations.

Chapter 7 Cable Management


Covers documentation for project planning, implementation,
commissioning and project closing/handover.

Any deviation from the designs provided here must first be


referred to the Asset Management Department (AMD) for
approval.

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2 Basic Cable Theory

2.1 Cable Design and Construction


Cable is a conductor which is insulated electrically and protected
mechanically. The cable design complexity increases with voltage level.
In LV cable design, the basic criteria are to provide insulation and
mechanical protection. For MV cable, beside insulation and mechanical
protection, electric field stress management must be considered
together with other parameters that may affect the safe operation of the
cable.

There are three main components for the LV cable: conductor, insulation
and outer sheath as shown in Figure 2-1. The function of each
component is described in Table 2-1.

(1) Conductor

(2) Insulation

(3) Outer Sheath / Jacket

Figure 2-1: Main components of an LV electrical power cable

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CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Table 2-1: LV cable main components, materials and functions

Component Material Function

1 Conductor Copper or aluminium. To carry the design rated


current.

2 Insulation XLPE To provide insulation


PVC between conductor and
Paper (oil earth to preclude
impregnated paper) dielectric failure.
PE (Polyethylene)

3 Outer Sheath / PVC To provide mechanical and


Jacket PE environmental protection.
MDPE (Medium To act as moisture barrier.
Density Polyethylene)

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

For MV power cable, there are six major components namely conductor,
conductor screen, insulation, insulation screen, metallic sheath and
outer sheath as shown in Figure 2-2. The functions of these components
are described in Table 2-2.

(1) Conductor

(2) Conductor Screen

(3) Insulation

(4) Insulation Screen

(5) Metallic Sheath

(6) Outer Sheath / Jacket

Figure 2-2: Major components of MV electrical power cable

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CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Table 2-2: MV cable components, materials and functions


Component Material Function

1 Conductor Copper To carry the design rated current.


Aluminium

2 Conductor Semiconducting To smooth out any irregularities


Screen material over the stranded conductors
contours
To reduce the probability of
protrusions into the insulating
layer in order to avoid localized
stress that may exceed
breakdown strength of the
insulation.
3 Insulation XLPE To provide insulation between
Paper conductors and earth to preclude
dielectric failure.
4 Insulation Semiconducting To provide a uniform earth
Screen material potential layer to enable
symmetrically spaced electrostatic
flux lines and concentric
equipotential lines in the
insulation.
5 Metallic Copper wire To provide return path for fault
Sheath Copper tape current.
Lead sheath To keep out moisture.
Laminated To contain a pressurising
aluminium foil medium.
To function as a reference
Ground for the whole length of
cable
6 Outer Sheath / PVC To provide mechanical and
Jacket MDPE environmental protection as well
as a moisture barrier.

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.1.1 Conductor

2.1.1.1 Conductor Shape

Cable conductors are shaped to reduce cable diameter and stranded to


provide flexibility.

Typical conductor shapes are illustrated in Figure 2-3.

TNB MV XLPE-insulated cable conductors are stranded compacted


circular design. LV insulated cable conductors are stranded compacted
shaped design.

CONDUCTOR

SOLID STRANDED

CIRCULAR SECTORIAL

UNCOMPACTED COMPACTED MILLIKEN

CIRCULAR SHAPED CIRCULAR SHAPED

Figure 2-3: Different types of conductor shapes

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CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.1.2 Insulation
Insulation of a cable is to provide insulation between conductors. The
insulating material must possess high dielectric strength. The following
are materials used as insulation in the cables:

Polyethylene (PE)
Cross-linked polyethylene (XLPE)
Paper (oil-impregnated)
Polyvinyl Chloride (PVC)

2.1.2.1 Polyethylene (PE)

Polyethylene is long-chain, thermoplastic hydrocarbon molecule that is


manufactured under pressure by the polymerization of ethylene gas.

PE does not have very good electrical tracking resistance (i.e. prone to
partial discharge erosion and corona cutting) and also prone to water
tree growth deterioration when exposed to electrical stress in a moist
environment. In its thermoplastic state, the maximum operating
temperature of PE is 75C. Consequently it could not match the rating of
fluid-impregnated paper-insulated cables, which have an operating
temperature in the range of 80C to 90C. This problem was solved with
the advent of XLPE that had the ability to match or exceed the thermal
rating of paper insulations.

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.1.2.2 Cross-linked Polyethylene (XLPE)

XLPE is a thermoset material produced by the compounding of Low


density polyethylene (LDPE) with a cross-linking agent such as dicumyl
peroxide. XLPE insulated cables have a rated maximum continuous
o o
operating temperature of 90 C and an emergency rating up to 140 C,
depending on the standard used to rate XLPE-insulated cables. Cables
o
insulated with XLPE also have a short-circuit rating of 250 C.

In general, as an insulation material, XLPE has the following superior


characteristics:

Tough and able to withstand higher temperature without


deformation;
Reduced insulation thickness hence the overall cable size; and
Superior resistant to thermal degradation and deformation due to
external mechanical pressure or conductor thrust at bends.

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CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Typical XLPE insulated cable conductor sizes used in TNB are listed in
Table 2-3.

Table 2-3: Voltages and cable conductor size for XLPE cables
Nominal cross-
Voltage Type 2
sectional area (mm )
33kV Single Core Aluminium 630
Single Core Copper 300
400
500
630
Three Core Copper 120
185
22kV Single Core Aluminium 70
150
240
500
11kV Single Core Aluminium 70
500
Three Core Aluminium 95
150
240
Low Four Core Aluminium 25
Voltage
70
120
185
300

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.1.2.3 Impregnated Paper

Impregnated paper insulation cables are often referred to as 'solid type'


as they are designed to operate without internal or external pressure.
The insulation consists of helically applied paper tapes with a small gap
between turns. The dielectric strength of the paper insulation is
enhanced by impregnate the paper with oil, wax and resin. They are two
types of impregnation i.e. draining and non-draining. Non-draining is
achieved by adding wax into the impregnation oil and resin.

Paper cables are no longer stocked but still exist throughout the TNB
distribution network. For reference, cable sizes that can be found in the
network are in Table 2-4.

Table 2-4: Voltages and cable conductor size for PILC cables
Nominal cross-
Voltage Type sectional area of
2
conductor (mm )
22kV Three Core Aluminium 70
185
400
11kV Three Core Aluminium 25
75
120
185
300
Low Four Core Aluminium 25
Voltage
70
120
185
300

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CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.1.2.4 Polyvinyl Chloride (PVC)

Polyvinyl chloride, commonly abbreviated PVC, is a thermoplastic


polymer. Properties of PVC insulation include:

Comparatively more permeable to water compared to polyethylene;


Up to 3kV, thickness largely dependent on mechanical
considerations;
A sustained maximum operating temperature of 70C, which is
determined by the thermal ageing characteristics of the material;
A temperature of the order of 120C which governs the maximum
degree of deformation permissible in the time/temperature range
required for the circuit protection to operate; and
A limit of 160C is used for the calculation of short-circuit ratings.

Typical sizes of PVC insulated, PVC jacketed LV cables in TNB are shown
in Table 2-5 below.

Table 2-5: Typical LV, PVC/PVC cable sizes in TNB


Nominal cross-sectional
Insulation Type 2
area of conductor (mm )
PVC/PVC Single Core Aluminium 300
500
Single Core Copper 500

Page | 17
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.1.3 Mechanical and Environmental Protection


Traditionally, underground cables are protected against mechanical and
environmental damage through jacket, metallic sheath reinforcement
and armouring. Some materials used for cable jacketing to provide
environmental and mechanical protection include:

Polyvinyl Chloride (PVC)


Polyethylene (PE)
o Low density polyethylene (LDPE)
o Medium Density Polyethylene (MDPE)
o High density polyethylene (HDPE)
Metallic sheath
o Lead sheath
o Aluminium sheath
o Copper tape/wire
Armour
o Common materials used as armour can be
Galvanised steel wire
Plain or galvanised steel tape
Plain or galvanised steel strip, and
Aluminium wire/strip

Aluminium wires/strips are used as armour for single core cables


because of the need to use non metallic materials.

However, TNB Distribution Division had adopted unarmoured cable


design for LV and MV cables since year 2000. It was found that the
traditional steel wire armour design could not prevent the cable from
external mechanical damage because most of the digging activities are
carried out by mechanical diggers/excavators.

Page | 18
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.2 Cable Types


Electrical cables are identified based on:

Nominal system voltage


Insulation material
Number of cores
Core sizes and
Conductor material

For example, the cable identification for a 33 kV XLPE insulated, single-


2
core cable with 630mm core cross-sectional area, Aluminium conductor,
copper wire screen and medium density Polyethylene sheath/jacket are
described as:

Cross-sectional surface area Outer Sheath / Jacket


Insulator
Core Material

2
33kV, XLPE, 1C, 630mm , Al, SCW, MDPE

No. of cores Metallic Sheath


Nominal Voltage

The following subchapters provide detailed cable constructions of some


typical cables used by TNB:

33kV XLPE Single Core Cable


11kV XLPE Single Core Cable
11kV XLPE Three Core Cable
11kV XLPE Triplex Cable
11kV PILC Three Core Cable
1kV PVC/PVC Single Core Cable
1kV XLPE Four Core Cables

Page | 19
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.2.1 33kV XLPE Single Core Cable


2
TNB Distribution Division uses the 33kV XLPE single core cable 630mm
Al cable with load capacity of approximately 30 MVA as interconnectors
between PPUs and/or SSUs. Typical construction of the single-core 33kV
XLPE cables is given in Figure 2-4.

9 8 7 6 5 4 3 2 1

Figure 2-4: Single Core 33kV XLPE Cable

1. Stranded circular compacted copper or aluminium conductor


2. Extruded conductor screen
3. XLPE insulation
4. Extruded insulation screen
5. Equipotential tape
6. Copper wire screen with equipotential copper tape
7. Semiconducting swellable tape
8. Laminated aluminium foil
9. MDPE outer sheath

Page | 20
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.2.2 11kV XLPE Single Core Cable


2
TNB Distribution Division uses the 11kV XLPE single core 500mm cables
with load capacity of approximately 10 MVA as interconnectors between
132/11 kV Transmission Main Intakes (PMU) to 11kV Main Switching
Stations (SSU) and between SSUs. Typical construction of single-core 11
kV XLPE cables is given in Figure 2-5

8 7 6 5 4 3 2 1

Figure 2-5: Single Core 11kV XLPE Cable

1. Stranded circular compacted copper or aluminium conductor


2. Extruded conductor screen
3. XLPE insulation
4. Insulation screen
5. Copper tape screen
6. MDPE Inner sheath
7. Separator tape
8. MDPE outer sheath

Page | 21
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.2.3 11kV XLPE Three Core Cable


TNB Distribution Division uses the 11kV XLPE three core cables of various
sizes to construct the 11kV underground distribution network. The size
of cable used depends on the design by system planners. Typical
construction of three-core 11 kV XLPE cables is given in Figure 2-6.

11 10 9 8 7 6 5 4 3 2 1

Figure 2-6: Three Core 11kV XLPE Cable

1. Stranded circular compacted aluminium conductors


2. Conductor screen
3. XLPE insulation
4. Insulation screen
5. Phase identification coloured strip
6. Copper tape screen
7. Non-hygroscopic polypropylene fillers
8. Binder tape
9. MDPE inner sheath
10. Separator tape
11. MDPE outer sheath

Page | 22
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.2.4 11kV XLPE Triplex Cable


Triplex cable is effectively three single core cables that are bundled
together. In TNB, the 11kV triplex cables are only used at Putrajaya and
Cyberjaya.

Figure 2-7: 11kV Triplex Cable

1. Stranded circular compacted aluminium conductors


2. Conductor screen
3. XLPE insulation
4. Insulation screen
5. Copper tape screen
6. Separator tape
7. MDPE sheath

Page | 23
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.2.5 11kV PILC Three Core Cable


TNB Distribution Division started introduction of XLPE insulated MV
cables since 1980s. Most of the 11kV PILC cables in TNB Distribution
Division underground cable network were installed before 1980s. The
11kV PILC three core cables in TNB Distribution system are belted design
based on BS standards.

Typical construction of three core 11kV PILC cables is shown below.

Figure 2-8: Three core 11kV PILC cable

1. Stranded sectorial compacted conductor (Alum/Cu)


2. Carbon paper conductor screen
3. Insulation Paper
4. Perforated Aluminium Foil Screen
5. Jute filler
6. Copper-woven fabric tape
7. Lead sheath
8. Bedding
9. Steel tape armour
10. Textile serving

Page | 24
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.2.6 1kV PVC/PVC Single Core Cable


The 1kV PVC/PVC single core cables are mainly used as the distribution
transformer LV tail cables connecting the transformer LV terminals to LV
distribution board (LVDB) / feeder pillar (FP) or customers main
switchboard (MSB).

Typical construction of the 1kV PVC/PVC single core cable is shown


below.

3 2 1

Figure 2-9: PVC/PVC single core cable

1. Stranded circular non-compacted conductor


2. PVC insulation
3. PVC sheath/jacket

Page | 25
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.2.7 1kV XLPE Four Core Cables


The 1kV XLPE four core cable is used as the LV underground reticulation
feeders to deliver electric power to its customers. It connects between
LV distribution board / feeder pillar in the distribution substations to the
customers or to the overhead poles as the source for the LV overhead
systems.

Typical construction of a 1kV XLPE four core cable is shown below.

8 7 6 5 4 3 2 1

Figure 2-10: Four-core cable

1. Non-hygroscopic filler
2. Stranded sectorial shaped compacted aluminium conductors
3. XLPE insulation
4. Binder tape
5. MDPE inner sheath
6. Copper tape
7. Separator tape
8. MDPE outer sheath

Page | 26
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.2.8 Summary
Common types of cables and sizes used in the distribution network are
as follows:

Table 2-6: Common cable type and sizes in the distribution network
Nominal cross-
Insulation Number of
Voltage Core material sectional area of
type Cores
conductor (mm2)
Aluminium 1 core 630
300
400
Copper 1 core
33kV XLPE 500
630
120
Copper 3 cores
185
185
PILC Aluminium 3 cores
400
22kV 150
XLPE Aluminium 1 core 240
500
25
70
PILC Aluminium 3 cores 120
185
300
11kV
70
Aluminium 1 core
500
XLPE 95
Aluminium 3 cores 150
240
300
Aluminium 1 core
PVC 500
Copper 1 core 500
25
70
XLPE Aluminium 4 cores 120
Low
185
Voltage
300
25
70
PILC Aluminium 4 cores 120
185
300

Page | 27
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.3 Communication Cables


Two types of communication cables are used in TNB, i.e. fibre optics and
pilot cables. They are both used for Supervisory Control and Data
Acquisition (SCADA) system, communication and protection system.

Typical pilot cable sizes currently being used according to distribution


network needs are summarised in Table 2-7.

3
Table 2-7: Typical pilot cables used in the distribution system
No. of pair used Number of pairs used for
Voltage
No. of pairs for unit SCADA to Regional Control
(kV)
protection Centre (RCC)
1-2 pairs per
12 pairs
communication loop
11 1 pair
8 pairs for telecontrol &
37 pairs
telecoms
17 pairs for telecontrol
33 37 pairs 1 pair
10 pairs for telecoms

3
Pekeliling Bil. A5/2004 - Use of pilot cable for unit protection in TNB distribution
network

Page | 28
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Fibre optic cables provide better performance compared to pilot cables.


The reasons behind the use of optical fibre cable as against pilot cables
are:

a) No signal degradation
b) Immune to electromagnetic interference
c) No electrical interferences
d) Higher speed and longer distance coverage
e) Support more RTUs in a communication loop
f) Less repeater needed to boost signal for long distance
g) Better dependability and security
h) Lower capital costs
4
Table 2-8: Underground fibre optic cable specification
Particulars Details
Cable sheath 1. UV resistant
material 2. Fungus resistant
3. Black colour
Construction 1. Slotted tube or loose tube construction
2. 24 single mode fibres compliant to ITU-T G.652
3. Resistant to water penetration
4. Non-armoured and non-metallic
Cable marking Adequate cable identification and marking

Figure 2-11: Cross-sectional view of pilot cable (left) and


an optical fibre cable (right)

4
FOC Specs For Tender Doc approved by Distribution TC

Page | 29
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.4 Ampacity and Cable Damage Curve (CDC)

2.4.1 Factors Affecting Cable Ampacity


Current carrying capacity or ampacity of power cables is affected by the
following factors:

Cable design and construction


Cable laying formation
Depths of installation
Method of installation
o Ducts
o Direct buried
o Cable tray
Depth of installation
Medium in which it is installed
o Soil thermal resistivity
o Backfilling material
Ambient temperature
Proximity effects from groups of cables

Table 2-9 shows sample variations in ampacity due to cable laid in


different surroundings based on typical TNB cable laying practice. The
calculations are based on the simulation parameters:


o
Native soil thermal resistivity: 2 C.m/W

o
Sand thermal resistivity: 1.2 C.m/W

o
Ambient temperature: 30 C

Page | 30
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Table 2-9: Variation of cable ampacity based on typical TNB cable laying
practice
Laying Cable Ampacity (Amps)
Voltage Cable
Depth Size 1 2 3
Level Type 2
(mm) (mm ) cable cables cables
95 200 155 135
XLPE (3C) 150 240 190 165
240 350 300 200
1200
11kV XLPE (1C) 500 550 460 400
120 200 160 130
PILC (3C) 185 250 200 170
300 330 265 220
150 250 200 170
XLPE (1C) 1200 240 340 260 230
22kV
185 275 230 200
PILC (3C)
400 420 345 300
33kV XLPE (1C) 1500 630 525 450 380

The above table, calculated by TNB Research, shows how depths of cable
laying and number of cables in the same trench affect the cable
ampacity.

2.4.2 Cable Damage Curve (CDC)


The Cable Damage Curve (CDC) is a graph that describes the maximum
short circuit current that a cable can withstand within specific time
duration.

The CDC is important to assist the system planner in choosing a suitable


type and size of cable for specific use and system protection engineers to
determine the relay operating time to protect the cable from damage.

Page | 31
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

The following tables show the allowable short circuit current values for a
typical protection relay operating time (1 second for main protection and
3 seconds for back up protection) for typical cables in TNB supply system
network.

Table 2-10: Maximum fault current rating against fault duration


for 11 kV Aluminium XLPE cables
Fault Maximum Cable Fault Current Rating
Fault
Temperature (in Amps)
Duration o
( C ) Begin/End 2 2 2 2
95 mm 150 mm 240 mm 500 mm
1 Second 95 250 8 600 13 500 22 500 45 000
3 Second 95 250 4 965 7 794 12 990 25 981

Table 2-11: Maximum fault current rating against fault duration


for 11 kV Aluminium PILC cables
Fault Maximum Cable Fault Current Rating
Fault
Temperature (in Amps)
Duration o
( C ) Begin/End 2 2 2 2 2
25 mm 70 mm 120 mm 185 mm 300 mm
1 Second 70 160 1 860 4 640 8 500 13 333 21 852
3 Second 70 160 1 074 2 679 4 907 7 698 12 616

From the Table 2-10 and Table 2-11, it can be concluded that for 11kV
outgoing feeders from PMU/PPU with declared fault level of 20kA, only
2 2
cable size of minimum 240mm for XLPE and 300mm for PILC can be
used.

These practices complement current TNB Planning Guidelines which are:

50% cable loading capacity under normal operating condition to


facilitate full feedback capability during outages.
Reduce technical losses due to bigger conductor size.

The detailed CDC graphs of typical 33kV, 22kV and 11kV XLPE Aluminium
cable sizes used in TNB can be found in the Appendix.

Page | 32
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.5 Cable Laying Formation and Arrangement


When more than one cables are laid together, the cable formation
becomes very important. Cables in the same trench will affect each other
in the form of mutual heating. For single core (1C) cables, there will also
be induced voltages due to the neighbouring cables, different phases of
the same circuit, or cables of different circuits. 1C Cables are either laid
single layer flat-spaced or in trefoil formation, while three core (3C)
cables are always in single layer.

2.5.1 Three Core Cable Laying Arrangement


As standard practice in accordance to TNB Distribution cable laying
procedure:

Only single layer is allowed for 3C cables


A minimum distance of 2 times the diameter (2D) for any cable size
must be maintained between the cables as shown in Figure 2-12
There must also be a minimum 1 diameter (1D) clearance from
trench walls

3 core cable Trench wall

Figure 2-12: Cross-section view of three-core cables in a trench

Page | 33
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.5.2 Single Core Cable Laying Arrangement


There are two common single core cable laying formations: trefoil and
flat formation (flat equally spaced). TNB Distribution adopts trefoil
formation as standard practice. Flat formation is acceptable only in
areas where trefoil formation is not possible.

Trefoil Formation
All single core cables must be laid in compact trefoil formation
unless there are site constraints for which special permission must
be obtained.
The trefoil formation saves space so that more circuits can be laid in
the same trench.
The trefoil formation for 1C cables removes the necessity of
transposing the cores. However requirement for cross-bonding of
sheaths is still maintained.
Nylon cable ties are to be used at every one meter (1000 mm)
interval as shown in Figure 2-13. This is to ensure the trefoil
formation will always hold.

Nylon cable ties

1000mm

Figure 2-13: Trefoil formation of 3 single core cables held together with
nylon cable tie at every one meter interval

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CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Cable Arrangement
The distance between each circuit for the trefoil formation must be
maintained at 2 times of diameter (2D) as shown in Figure 2-14
There must also be a 1 diameter (1D) clearance from trench walls

Single core cables Trench wall


in trefoil formation

Figure 2-14: Cross-section view of single-core cables in a trench

Page | 35
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.5.3 Communication Cable Laying Arrangement


Communication cables are laid alongside the power cables in the trench.

(a) For direct-buried and ducted cables, the distance between the
communication cable and the power cable should be at least
0.5 metre apart to reduce electromagnetic disturbance on the
communication cable.
(b) Fibre cables in ducts can be in contact with power cable ducting.
5
(c) For cables installed in galvanised iron (GI) pipes , the GI pipes for the
communication and power cable can be in contact with each other.

0.5 metre 0.5 metre

(a-1) (a-2) (b) (c)


Direct buried Ducted Ducted power Cables in
comms cable comms cable and fibre cables GI pipes

Power cable Communication cable

Figure 2-15: Cross-section view of communication and power cables


6
laying arrangement

5
Pekeliling Pengurus Besar Kanan, Bil A44/2009
6
Pekeliling Pengurus Besar Kanan (Pengurusan Aset), Bil A29/2011,
Kaedah Pembaikan Kabel Pandu (Pilot Cable) di Bahagian Pembahagian

Page | 36
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.6 Sheath Bonding Methods


Current is induced into the sheaths of the cable. Over longer lengths of
cable this induced sheath current can be damaging to the cable through
increased temperature. To reduce this effect, sheaths of different phases
can be bonded.

2.6.1 Three Core Cables Bonding Method

2.6.1.1 Both End Bonding


Structurally, during cable core laid up in factory before application of
outer jacket, the metallic sheaths of three core cables are continuously
touching and effectively bonded. However both end bonding is made to
provide earth fault current return path back to source. Bonding must be
made at every termination for 3C cables.

2.6.2 Single Core Cables Bonding Methods


Detailed explanation of single point bonding at PPU and PMU can be
found in the circular Arahan Naib Presiden (Pembahagian) TNB
A06/2010: Amalan Single Point Bonding Pada Transformer Tail 11kV di
dalam PMU/PPU.

A guide for arrangement of bonding method can be referred to Edaran


2
Kejuruteraan Bil 60/95: Laying And Jointing of Single Core, 500mm
Aluminium 11kV and 22kV XLPE Cable.

Page | 37
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.6.2.1 Single Point Bonding

The simplest form of special bonding consists in arranging for the


sheaths of the three cables to be connected and earthed at one point
only along their length. At all other points, a voltage will appear from
sheath to ground that will be a maximum at the farthest point from the
earth bond. The sheaths must therefore be adequately insulated from
earth.

Since there is no closed sheath circuit, except through the sheath voltage
limiter (if any), current does not normally flow along the sheaths and no
sheath circulating current loss occurs (sheath eddy loss will still be
present).

In TNB, single point bonding is only allowed for short cables laid inside
the PMU/PPU compound only. Example of single point bonding practice
is the single core cable connections on the transformer tail are shown in
Figure 2-16 and Figure 2-17.

Transformer Switchgear

Transmission
Earth Open

Figure 2-16: Single point bonding at PMU


(transformer ground, switchgear open)

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CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Transformer Switchgear

Distribution
Open Earth

Figure 2-17: Single point bonding at PPU


(transformer open, switchgear ground)

2.6.2.2 Both End Bonding

Maximum voltage at mid point.


Not practiced for long cables with high loads (>500amps).
Circulating current exists in between the bonds.

500m
Vmax
Voltage

Distance 1000 metre = 1 minor

Figure 2-18: Sheath voltage in both end-bonding for single core cables

Page | 39
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.6.2.3 Cross-bonding

To limit the sheath voltage, the metallic screens of the XLPE cables shall
be cross-bonded at cross-bonding joints at every 1 kilometre (1 minor
section). Induced sheath voltage occurs due to induction across cables
carrying current. This only occurs in single core cables as in the three-
core cables the effect cancelled out due to the copper tape screen of
individual cores are internally bonded along the full length of the cable.

The diagram in Figure 2-19 shows an example of a 3 kilometres long


single core cable circuit with straight-through joints and cross-bonding
joints arrangement. The induced voltage is directly proportional to the
length of the cable and the maximum sheath induced voltage allowed by
TNB Distribution Division is 50V. A graph of this relationship is shown in
Figure 2-20.

To keep the sheath induced voltage below 50V, the metallic screens
must be cross-bonded at every 1 kilometre (1 minor section) and
connected to earth via a 6+1 way earthing link box at every 3 kilometres
(1 major section). Where this is not possible, the Engineers decision shall
prevail.

ST CB ST CB ST CB & earth

500m 500m 500m 500m 500m 500m

1000m = 1 minor 1000m = 1 minor 1000m = 1 minor

3 minor = 1 major
ST = straight-through joint
CB = cross-bond joint

Figure 2-19: Diagram of a major span


(3km, 3 minors, 1 cross-bond at each one km joint)

Page | 40
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

(1,000 m)
Sheath (1,000 m) (1,000 m) Cross bond joint
core Cross bond joint Cross bond joint with earthing

Sheath Major
Voltage Minor Minor Minor

Max
Voltage
= 50V

Distance

Figure 2-20: To keep the sheath induced voltage below 50V, the sheath
must be cross-bonded at every 1 kilometre (1 minor) and cross-bonded
with earthing at every 3 kilometres (1 major)

All cross bonding are made at 6+1 way earth link box shown in
Subchapter 2.7.5.1 according to technical specification number
KEJ09229:2007: Outdoor Earth Link Box (6+1) Ground Mounted for 33kV
single core underground cables and KEJ09222:2007: Outdoor Earth Link
Box (6+1) Ground Mounted for 11kV single core underground cables.

It has been designed such that it would be externally mounted and


therefore easily enable the disconnection of screen link for the isolation
of the different cable sections during testing and reconnection of screen
link of same phase during cable fault location.

Page | 41
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

Calculated values of sheath induced voltage and currents for a one


kilometre stretch are shown in Table 2-12.

Table 2-12: Sheath voltage and currents for trefoil formation


direct buried in backfill
Induced Induced
Ampacity
Cable Bonding Type Sheath Sheath Voltage
(A)
Current (A) (V/km)

Both end 485 28.4 -


11kV 1C
2
500 mm
Single end 493 - 28.6

Both end 488 278.6 -


33kV 1C
2 Single end 570 - 32.6
630 mm
Perfect
570 - 0
cross-bond
Note: Values calculated for a one kilometre cable at depth = 3.5ft (1m) and with thermal
resistivity of native soil = 1.5oC.m/W, backfill = 1.2 oC.m/W.

Page | 42
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.7 Cable Accessories


Joints and terminations are an integral part of a power cable distribution
system and must perform the same basic functions as the cable on which
they are installed. In addition to providing conductor connections
suitable for the full current rating of the cable and adequate insulation,
they must also provide stress control, mechanical protection, and
environmental protection.

Selection of joints and terminations are based on the installation skills


required together with the economic, technical and physical constraints
of the installation.

Joint designs must cater for straight-through joints, where two identical
cables are joined, and transition joints for connecting cables having
different types of insulation.

2.7.1 Joints and Joint Body Assembly

2.7.1.1 Overview

Joints must be able to reinstate the insulation between phases and


between phase to earth to that of the cables they are connecting.
Another important requirement is that the joint design must be capable
of providing mechanical protection against external damage and
prevents moisture entering the joint from the surroundings.

Type of joints used to connect cables according to insulation type:

Straight-through Joint is for connecting cable of same type of


insulation material, such as XLPE to XLPE or PILC to PILC.
Transition Cable Joint is for connecting cable of different types of
insulation material such as PILC to XLPE.

Page | 43
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

TNB Distribution Division uses three types of joint designs which are
heat-shrink, pre-moulded and tape resin joints which are further
elaborated in the following subchapters.

2.7.1.2 Heat Shrink Joint

Heat-shrink design is expanded tubes that are installed using a heat


source such as a torch or a hot air gun to shrink to its original shape. This
design is used for joints as well as terminations.

These joints are easy to install but require care to uniformly heat the
entire surface so that shrinkage is uniform across the cable substrate
without charring or burning of the polymeric materials. Sheds are
installed for outdoor or highly polluted environments to increase the
creepage path required. Sealant mastic is used at the jacket and the lug
end to prevent moisture ingress under the tubes.

Electric field stress at edge of semiconducting insulation screen are


managed by using stress relief mastic and stress relief tube of high-K
material (high dielectric constant).

Figure 2-21: Heat shrink joint

Page | 44
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

2.7.1.3 Pre-moulded with Outer Resin Joint

Pre-moulded with Outer Resin (PMOR) joints are made from Ethylene
Propylene Rubber (EPR), Ethylene Propylene Diene Monomer (EPDM) or
Silicone Rubber (SiR). The main components of the pre-moulded joints
are integrated in a joint body. Pre-moulded joints, being factory made
and tested, are of consistent quality and can be installed with minimum
skill required.

Figure 2-22: 11kV XLPE Premoulded Cable Joint with Outer Resin (REPL)

Page | 45
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

The typical construction of a pre-moulded cable joint is shown in


Figure 2-22. Its major components are:

Connector: Aluminium ferrule or mechanical connectors, depending


on conductor type.
Semi-conducting conductor shield (Faraday Cage): Same function as
conductor shield of cable.
Insulation: Usually Ethylene Propylene Rubber (EPR), Ethylene
Propylene Diene Monomer (EPDM) or Silicon Rubber (SiR).
Semi-conducting insulation shield: Same function as insulation
shield of cable.
Metallic shield: Braided Copper Strip or Copper stocking bonded
with the main cable copper tape at both ends.
Outer protection: Resin to protect joint body from mechanical
damage and water ingress.

Table 2-13: Pre-moulded with outer resin (PMOR) sizes


Voltage Cable size
Joint type Core 2
(kV) (mm )
Straight-through 11 Three core 95
150
240
Single core 70
500
22 Single core 150
240
500
Straight-through 11 Single core 500
with cross bonding 22 Single core 500
33 Single core 630

The joint body can be installed either by cold shrink or slip-on/push-on


method.

Page | 46
CHAPTER 2 BASIC CABLE THEORY
Underground Cable System Design Manual Distribution Division

Cold shrink (Pre-stretched)


The cold shrink joint body is pre-expanded in the factory onto a plastic
support tube. This tube is partially cut in a way to allow it to be removed
when positioned over the cable, allowing the joint body to shrink onto
the cable.

There are pre-stretched designs for terminations for indoor and outdoor
applications. Pre-stretched design for multi-core cable breakouts, sleeves
and end-caps are also available.

Figure 2-23: Cold shrink joint (TYCO Electronics)

Page | 47
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

Slip-on / Push-on
The slip-on joint is made entirely of high-grade silicon rubber with one
pre-moulded and pretested silicone rubber body. Silicone grease used in
push-on joints removes all air and fills all voids and interface gaps. The
stress control elements are cast into the stress cones and are likewise of
silicon rubber. They have an exactly calculated and optimised external
contour. This ensures that the field strength is within the permitted
range at every point in the joint and for every operating status.

The elasticity of the silicone rubber enables the joint to accept diameter
tolerances as well as changes in cable diameter caused by variations in
load. The low hardness of the silicone material prevents constriction of
the core insulation even under high alternating loads allowing it to adapt
to any unevenness in the stripped core insulation.

This joint system ensures high operating reliability and is also absolutely
maintenance-free even under extreme loading conditions. The slip-on
technique requires little assembly work and minimises the fitting risk.

Figure 2-24: Slip-on joint (REPL)

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CHAPTER 2 BASIC CABLE THEORY
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2.7.1.4 Tape Resin Transition Joint

There are small sized old PILC cables remaining in service in TNB
Distribution Division underground cable network. When fault occurs on
this small sized PILC cables, there is no standard transition joint kit
available for repair work. TNB Distribution Division has introduced the
tape resin type transition joints which have the capability of range taking
to overcome this difficulty. These joints are used especially for jointing
cables with conductor sizes not covered as TNB standard transition joint
sizes. These conductor sizes are shown in the table below.

Table 2-14: Cable conductor sizes for standard transition joints


2 2
Voltage (kV) PILC (mm ) XLPE (mm )
11 120 95
185 150
300 240
22 185 150 (1C)
400 240 (1C)

Table 2-15: Non-standard conductor size cables


2 2
Voltage (kV) PILC (mm ) XLPE (mm )
25 150
11 25 240
70 150
70 240
22 70 150
70 240

Self amalgamating stress control tapes are used to manage the electrical
stress at the conductor connectors and insulation screens cut back area.
High grade insulation tape is used to rebuild the insulation of the joint.

The epoxy resin compound acts as an electrical insulation, moisture


barrier and mechanical protection for the transition joint.

Page | 49
CHAPTER 2 BASIC CABLE THEORY
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Figure 2-25: Tape resin joint (Prysmian)

2.7.2 Conductor Connectors

2.7.2.1 Straight-through Ferrule

Designed for jointing same sized conductors, jointing ferrules are made
from high grade aluminium tube that conforms to American Standard
on Aluminium Standards and Data, 1986, Metric SI Alloy and Temper
Grade Specification 1050-0, as specified by TNB Technical Specification
for Crimping type Aluminium Straight-through Ferrules/Connectors for
Cable.

The inner bore of the straight through ferrules / connectors shall be filled
with electrically conductive oxide inhibiting grease to ensure good
conductor jointing, as specified by TNB Specifications for Oxide
Inhibiting Contact Grease and Wire Brush.

Table 2-16: Straight-through ferrule connector sizes


2
Material Cable Size (mm )

25, 70, 95, 120, 150,


Aluminium
185, 240, 300, 400, 500

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CHAPTER 2 BASIC CABLE THEORY
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2.7.2.2 Mechanical Connectors

Mechanical/bolted type connector is suitable for the connection of


Aluminium and Copper conductors. It is made from an alloy material
suitable for Aluminium and Copper conductor connection.

Among the benefits of mechanical / bolted connection is its range taking


where connectors of one size can be used to connect the conductors of
different sizes and it does not require special equipment such as a
hydraulic compressor and crimp head for making the connection.

Figure 2-26: Typical mechanical connector (Pfisterer)

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CHAPTER 2 BASIC CABLE THEORY
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2.7.2.3 Termination Lug

Termination lugs are used to connect the cable to the switchgear or


other devices such as transformer, LV distribution board (LVDB) or
feeder pillar.

Tinned copper lug (short barrel) use to connect the copper cable
conductor by soldering method.
Tinned copper lug (long barrel) use to connect the copper cable
conductor by compression crimping method.
Bi-metal lug use to connect the aluminium cable conductor by
indentation crimping method.
Bolted type mechanical connectors (alloy & bi-metal) Suitable for
connecting copper and aluminium conductors

Table 2-17: Termination lug sizes


2
Material Cable Size (mm )
25, 70, 95, 120, 150,
Bi-metal
185, 240, 300, 400, 500
Tinned copper 70, 500

2.7.3 Conductor Connection Techniques


The common conductor connection techniques adopted by TNB
Distribution Division are:

1. Compression / indentation crimping


2. Mechanical / bolted connection

A guideline for conductor connection techniques applicable in


Distribution is the Panduan Penyambungan Pengalir Kabel Bawah Tanah
(e-Doc > kabel > user manual > 2011).

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CHAPTER 2 BASIC CABLE THEORY
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2.7.3.1 Compression / Indentation Crimping

Hexagonal crimping
The hexagonal crimping connection method is used for connecting
copper conductors. It gives a very strong connection mechanically with
minimal risk of damage to the copper conductor. The hexagonal crimping
method expels air between the conductor strands and produces a good
connection between the conductor and connectors with minimal
movement of the conductors (minimum creep).

Indentation crimping
The indentation crimping method is used for connection of aluminium
conductors. This method is used because one of the important features
in the connection of aluminium conductors is to efficiently break the
aluminium oxide layers formed on the surface of the conductor. The
indentation crimping method is the most effective method to achieve
this goal.

Connection using the indentation crimping method should always be


done in the presence of an oxide inhibiting compound. The oxide
inhibiting compound has uniformly floating zinc oxide particles which will
penetrate the aluminium oxide on the surface of the conductor strand to
create a very good contact between the individual conductor strand and
the surface of the connector barrel to establish good contact.

The indenter compresses and breaks conductor strands coated with an


oxide inhibiting compound, producing a conductor connection that is
fused with the connector giving a very good electrical connection and
mechanical strength.

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CHAPTER 2 BASIC CABLE THEORY
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Deep Stepped Indentation Control Volume (DSICV)


The Deep Stepped Indentation Control Volume (DSICV) method is an
Indentation Crimp method that uses a Containing Die to control the
shape and size of the ferrule from being altered during indentation by
the Indenter.

Figure 2-27: Containing Die (left) and Stepped Indenter (right)

The Deep Stepped Indentation Control Volume (DSICV) method uses the
"two cone steps" type indenter. This method gives an indentation of
even thickness arch. All the conductor strands are compressed properly,
and air does not get trapped in between the conductor strands. This is as
illustrated in the diagram below.

Even thickness arch

All strands are


compressed

Figure 2-28: Cross-sectional view of cable conductor connection by


DSICV method

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CHAPTER 2 BASIC CABLE THEORY
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2.7.3.2 Mechanical/Bolted Connection

Connection is done by tightening of the shear bolt until it shears off at a


predetermined shear torque to produce a perfect conductor connection.

Figure 2-29: Installation of mechanical connectors.

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.7.4 Termination

2.7.4.1 Overview

Terminations are done when the cables are required to terminate or


connect to another piece of equipment such as switchgear or
transformer. They are either of outdoor or indoor type.

Outdoor termination design should be capable of withstanding the


effects of precipitation, pollution and ultraviolet radiation.
Indoor terminations are mostly fitted inside a metallic enclosure,
which provides an earth envelope around the termination. The only
exception to this are screened separable connectors which are
designed with the connector surface made of conductive material
and earthed when installed.

Outdoor Terminations
Outdoor terminations must be protected from environmental effect and
ultraviolet radiation along their entire length. Additional sheds are
provided to increase the creepage distance required for outdoor
application.

The outer surface layer of the termination must be designed to resist the
phenomenon of surface tracking. This occurs because the outer surface
has a voltage gradient along it; water and other pollutants reduce the
surface resistance, allowing leakage currents to flow. These leakage
currents quickly dry out areas or rings to form dry bands which are then
forced to withstand almost the entire voltage gradient. Arcs across these
dry bands can erode the outer protection or attack the surfaces leaving
carbonaceous tracks that can lead to failure.

Page | 56
CHAPTER 2 BASIC CABLE THEORY
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Figure 2-30: Pre-moulded outdoor termination


for 3C XLPE cables (REPL)

Page | 57
CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

Indoor Terminations
The indoor terminations normally are installed within the cable
compartment of the switchgear. This type of termination is not usually
exposed to harsh environmental effects.

Air insulation is achieved by adequate phase to phase and phase to earth


spacing for the system voltage. Using shrouds allows the clearances to be
reduced, whilst compound filling offers further reductions in clearances.

Terminations must be designed to withstand humidity, which is present


whenever air is either the sole or part dielectric medium.

Figure 2-31: Pre-moulded indoor termination


for 3C XLPE cables (REPL)

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CHAPTER 2 BASIC CABLE THEORY
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2.7.4.2 Heat Shrink Termination

For MV underground cables, current TNB Distribution Division practice


allows heat shrink joints and terminations to be used for PILC cables
only. These are the same technology as heat shrink for joints as
explained in Subchapter 2.7.1.2.

Table 2-17: Heat shrink joint and termination kit sizes for LV XLPE
cables
2
Voltage (kV) Core Cable size (mm )
1 Four core 25
70
120
185
300

Table 2-18: Heat shrink termination kit sizes for MV PILC cables
2
Voltage (kV) Core Cable size (mm )
11 Three core 120
185
300
22 Three Core 70
185
400

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

Figure 2-32: Heat shrink termination

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CHAPTER 2 BASIC CABLE THEORY
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2.7.4.3 Non-thermal Termination

There are two types of non-thermal termination designs: Slip-on/push-


on type, and Pre-stretched/cold shrink type.

The non thermal termination is suitable for indoor and outdoor


application and used for XLPE cables only.

Table 2-19: Non-thermal termination kit sizes for XLPE MV cables


2
Voltage (kV) Core Cable size (mm )
11 Three core 95
150
240
Single core 70
500
22 Single core 70
150
240
500
33 Single Core 500
630

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

2.7.5 Earth Link Box


The Earth Link Box is an important accessory in single core cable systems.
It is used to facilitate connection of single core cable metallic
screen/earth connection through suitable links for earthing and effective
neutralization of sheath induced voltages. Link boxes are used at every
cross-bond joint for single core cables.

Link boxes are required to perform the following functions:

To allow for sheath induced voltage and sheath current


measurements
To simplify the cross-bond connection
To isolate earth links and to reconnect cable sheaths of the same
phase for cable fault location and partial discharge (PD)
measurement

For easy access to link box, to do the necessary isolation of the cross-
bounding and earth links during fault location, it is recommended that
the link box is to be built above ground away from the road at a
convenient location close to the edge of the side table of the road below
which the cable is buried.

Earth link boxes should have the following features:

1) Clearly labelled with circuit number and feeder names.


2) Installed with suitable phase markers identification to facilitate
correct connection to ensure earth continuity.
3) Suitable for operation with safety features complying to IP Code 43
in accordance to IEC 60529:2001-02 to prevent vermin intrusion and
moisture ingress.

Cross-bonds are made at 6+1 or 3+1 link boxes specified in the following
subchapters.

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2.7.5.1 Ground Mounted (6+1) Earth Link Box

Ground Mounted Earth Link Boxes are used for cross-bonding cables that
are laid in trefoil or flat formation. They are typically mounted, stand-
alone, above ground level by approximately 760 mm or as allowed by
the local authority, and should provide easy access for connection of
6 bonding leads and 1 earthing lead.

The minimum cross-sectional area of sheath bonding leads, sheath


bonding links and earthing leads for various cable systems are as below:

2
11kV cable 1kV PVC/PVC 70 mm Cu cable

2
22kV cable 1kV PVC/PVC 120 mm Cu cable

2
33kV cable 1kV PVC/PVC 300 mm Cu cable

Connecting Link box


cable to link box

Joints

Figure 2-33: Typical link box location next to a reinforced concrete


trench

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

Figure 2-34: Typical example of 11kV, 6+1 Link box

Figure 2-35: Typical example of 33kV, 6+1 Link box

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CHAPTER 2 BASIC CABLE THEORY
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2.7.5.2 Wall Mounted (3+1) Earth Link Box

Wall mounted earth link boxes are used for connection of earthing lead
for single core cable termination in PMU, PPU and SSU. These link boxes
are typically mounted on a substation wall above ground level and
provide easy access for connection of three metallic screen/sheath
connection leads and one earthing lead.

The minimum cross-sectional area of sheath bonding leads, sheath


bonding links and earthing leads for various cable systems are as below:

2
11kV cable 1kV PVC/PVC 70 mm Cu cable

2
22kV cable 1kV PVC/PVC 120 mm Cu cable

2
33kV cable 1kV PVC/PVC 300 mm Cu cable

Figure 2-36: Link box for 3+1

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CHAPTER 2 BASIC CABLE THEORY
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2.8 Transformer Tail Cable


The transformer tail cable is the cable connecting either the MV or LV
side of the transformer to the switchgear. It can be divided into two
categories by voltage:

11/0.4kV Transformer tail cable


33/11kV Transformer tail cable

2.8.1 11/0.4kV Transformer Tail Cable


The LV supply from transformers is normally fed to customers through LV
Distribution Board (LVDB) / feeder pillars (FP). LV supply is also
sometimes fed directly to bulk customers installation.

Table 2-20 below indicates the standard cable sizes used to connect the
transformers MV bushing to the switchgear and LV bushing to LV
Distribution Board (LVDB) / feeder pillar (FP) or customers main
switchboard (MSB).

Table 2-20: Transformer tail cables for 11/0.4kV distribution


transformer
Transformer LV Tail
Rating HT Tail Phase Cable Neutral Cable
(kVA) (sq mm) (sq mm)
2
100 70 mm Al 1C XLPE 1x300 AI 1C PVC/PVC 1x300 AI 1C
2
300 70 mm Al 1C XLPE 1x500 AI 1C PVC/PVC 1x500 AI 1C
2
500 70 mm Al 1C XLPE 2x300 Al 1C PVC/PVC 1x300 Al 1C
2
750 70 mm Al 1C XLPE 2x500 AI 1C PVC/PVC 1x500 AI 1C
2
1000 70 mm Al 1C XLPE 2x500 Cu 1C PVC/PVC 1x500 Cu 1C

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CHAPTER 2 BASIC CABLE THEORY
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Table 2-21: Typical transformer tail cable ampacities


Ampacity
Types of cable
(Amp)
2
11kV 70 mm Al 1C XLPE 189
2
LV 300 mm AI 1C PVC/PVC 492
2
LV 500 mm AI 1C PVC/PVC 643
2
LV 500 mm Cu 1C PVC/PVC 706

2.8.2 33/11kV Transformer Tail Cable


The MV side transformer tail cables are normally terminated in the
terminal box attached to the MV side of the transformer. The terminal
arrangement of 11kV and 33kV sides of the cable boxes shall be suitable
for heat-shrinkable type and non-thermal termination system. This
termination which is partially insulated shall be enclosed in air-insulated
metal enclosures. The cable shall be terminated without any
modification made on the cable terminals and enclosures. The standard
practice with regards to types of cables, conductor sizes and material
(aluminium or copper), are shown in Table 2-22 and Table 2-23.

Table 2-22: Transformer tail cables for 33/11kV distribution


transformer
No. Cable Tx MVA Conductor Size, Material, & No. of Cables x
Type Rating No. of Cores No. of Cores
33kV Side
2
(i) XLPE 30 400 mm XLPE-Cu single core 3 x 1C
2
(ii) XLPE 15 400 mm XLPE-Cu single core 3 x 1C
2
(iii) XLPE 7.5 400 mm XLPE-Cu single core 3 x 1C
2
(iv) XLPE 5 150 mm XLPE-Al ABC 3 x 1C
11kV Side
2
(i) XLPE 30 400 mm XLPE-Cu single core 9 x 1C + neutral
2
(ii) XLPE 15 300 mm XLPE-Cu single core 6 x 1C + neutral
2
(iii) XLPE 7.5 300 mm XLPE-Cu single core 3 x 1C + neutral
2
(iv) XLPE 5 240 mm XLPE-Al three core 1 x 3C + neutral

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CHAPTER 2 BASIC CABLE THEORY
Distribution Division Underground Cable System Design Manual

Table 2-23: Typical transformer tail cable ampacities


Ampacity
Types of cable
(Amps)
2
33kV 400 mm Cu 1C XLPE 690
2
11kV 400 mm Cu 1C XLPE 680
2
11kV 300 mm Cu 1C XLPE 600
2
11kV 240mm Al 3C XLPE 350
2
33kV 150mm Al ABC XLPE 270

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3 Cable Laying Specification

3.1 Direct Buried in Trench


Direct buried is the preferred method of cable laying by TNB Distribution
Division.

For direct buried method of cable laying, the cable will be installed
in cable trenches excavated at site to the dimensions according to
the cable laying practice by TNB.
Trenches shall be sized appropriate to the number of cables to be
installed. Trenches shall provide adequate space and free from
foreign materials such as stones, glass, etc. which may harm the
cable.
When parallel circuits are to be installed in the same trench, a
minimum distance of at least two (2) cable diameters should be
maintained.
When a cable is to cross other cables it is required to leave a filling
layer of minimum 100 mm. Washed river sand is required between
that cable and other cables.
In order to avoid de-rating due to overheating of the cables caused
by proximity effect, the above mentioned spacing have to be
maintained at all times.

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3.1.1 Trench Dimensions

Depth and Width of Trench


The depth of all excavations for trench shall be measured from the
surface of the ground. The depth of cable laid is dependent on system
7
voltage .

The width shall be measured between the vertical sides of the trench.
The width of the cable trench is dependent on the number of cables to
be laid.

Table 3-1: Trench dimension of various cables installed on road verge,


underneath and across roads
Depth of Trench width* (mm)
Depth of
Cable Type trench
cable (mm) 1 circuit 2 circuits 3 circuits
(mm)
LV Cable
1200 1050 300 450 600
11/22 kV Cable
33 kV Cable 1500 1350 600 1200 1800
*cables are installed at least 2 cable diameters apart and
ideally 100 mm from the trench walls

Varying in Depth of Trench


Where trenches pass from footway to roadway, or vary in depth and a
change of level is necessary, the rise and fall must be gradual and adhere
to the cable bending radius limits.

7
Panduan Kej. A16/2008 Ulangkaji Penanaman Kedalaman Kabel-Kabel 0.415kV,
11kV Dan 22kV Dari 2.5 Kaki Kepada 3.5 Kaki

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CHAPTER 3 CABLE LAYING SPECIFICATIONS
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Trench Condition
Trenches shall be kept as straight as possible and shall have vertical
sides. Where a change of level is necessary, the rise or fall must be
gradual.
Precaution shall be taken to prevent breaking away of the sides or
surface of trenches.
The bottom of the trench shall be clean, firm and smooth and
without stones or hard lumps.
Every precaution shall be taken to prevent damage to roads or other
surface due to the breaking away of the sides of trenches etc., or
subsidence or by the movement of the Contractor's equipment.

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3.1.2 Direct Buried Cables


Figure 3-1 through Figure 3-4 illustrates typical cross-sectional view of
cable laying by direct buried method.

Ground level

Earth backfilling

Cable slab
Washed river sand
Cable
Washed river sand
Figure 3-1: Typical cross-section of direct buried LV, 11, 22kV
1C cable in trefoil formation under unpaved surfaces

Road level
Wearing course
Binder course
Crusher
run
Washed river sand

Cable slab
Washed river sand
Cable

Washed river sand

Figure 3-2: Typical cross-section of direct buried 11, 22kV


1C cable in trefoil formation under paved surfaces

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Ground level

Earth backfilling

Cable slab
Washed river sand
Cable
Washed river sand

Figure 3-3: Typical cross-section of direct buried LV, 11, 22kV


3C cable in flat formation under unpaved surfaces

Road level
Wearing course
Binder course
Crusher run

Washed river sand

Cable slab
Washed river sand
Cable

Washed river sand

Figure 3-4: Typical cross-section of direct buried LV, 11, 22kV


3C cable in flat formation under paved surfaces

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Figure 3-5 and Figure 3-6 illustrates the arrangement of communication


cable in the cable trench when laid using direct buried method.

Ground level

Earth backfilling

Concrete cable slab


Washed river sand
Cable
Communication cable
Earth
Washed river sand
Backfillin
Figure 3-5:g Typical cross-section of direct buried 33kV 1C cable and
communication cable in trefoil formation under unpaved surfaces

Road level
Wearing course
Binder course
Crusher run

Washed river sand

Concrete cable slab


Washed river sand
Cable
Communication cable
Washed river sand

Figure 3-6: Typical cross-section of direct buried 33kV 1C cable and


communication cable in trefoil formation under paved surfaces

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CHAPTER 3 CABLE LAYING SPECIFICATIONS
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3.2 Laying Cables in Pipes / Ducts


Although direct buried method is preferred by TNB but sometimes cable
needs to be laid in pipes or ducts especially in situation where direct
buried method is not suitable.

Situations where pipes/ducts are required:


a) Road crossing
b) Highway crossing
c) Railways crossing
d) Monsoon drain crossing
e) Culvert crossing
f) River crossing

The common methods used by TNB for crossings are:


a) Pipes or ducts installation via open cut
b) Horizontal Directional Drilling (HDD) / trenchless
c) Laid in G.I. pipe above ground
d) Cable bridge

When parallel circuits are to be installed in the same trench, a minimum


distance of at least two (2) cable diameters should be maintained.

Whenever pipe/ducts are installed at road crossings for cable laying,


additional pipes/ducts may be laid for future use. Where more than one
length of pipe is used, suitable pipe joints/adapters shall be used around
each joint.

The three types of pipes used by TNB are:


a) High Density Polyethylene (HDPE)
o Corrugated single wall and double wall
o Grade PN10
b) PVC Class B with SIRIM approved label
c) Galvanised Iron (G.I.) Pipes

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CHAPTER 3 CABLE LAYING SPECIFICATIONS
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A summary of specific applications for different pipes is shown in


Table 3-2.

3.2.1 Types of Pipes

3.2.1.1 High Density Polyethylene (HDPE)

Double Wall Corrugated HDPE


Where pipes/ducts are required for road crossing, Double Wall
Corrugated HDPE pipes may be used if encased in concrete.

Figure 3-7: Double Wall HDPE Corrugated Pipe

When cables are to be laid in HDPE pipes, one 150 mm diameter HDPE
Pipe/duct is required for each single core, three core and four core XLPE
cable and one 100 mm diameter HDPE pipe/duct for each pilot cable or
fibre optic cable.

The HDPE pipes shall be able to be connected by pipe connection means


of double connection sleeves or equivalent connection accessories
manufactured with the same material and shall be of sand proof or
water proof (special case). The HDPE pipe shall comply to TNB technical
8
specification for HDPE pipes .

8
Technical Specifications, Single & Double Wall High Density
Polyethylene (HDPE) Corrugated Pipe, 7 April 2000.

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CHAPTER 3 CABLE LAYING SPECIFICATIONS
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HDPE Grade PN10


HDPE pipe of grade PN10 is used as duct sleeve in HDD installations.

Figure 3-8: HDPE grade PN10

3.2.1.2 PVC Pipe Class B

PVC pipe Class B is used as protective sleeve for road crossings with
concrete encasement. It is also used as a protective sleeve for cables
installed on cable bridges. The Class B PVC pipe should have the SIRIM
approved label.

Figure 3-9: Class B PVC ducts

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CHAPTER 3 CABLE LAYING SPECIFICATIONS
Distribution Division Underground Cable System Design Manual

3.2.1.3 Galvanised Iron (G.I.) Pipes

G.I. pipes are used as a protective sleeve for all crossings.

Only used for 3 core and 4 core cables, and single core cables laid in
trefoil.
Cannot be used for single core cables laid singularly (alone) due to
9
induced and circulating eddy currents in the G.I. pipes .
Sizes:
o 150 mm diameter for power cables
o 100 mm diameter for communication cables

HDPE
pipes

G.I. pipes

Roadside
drain

Figure 3-10: Underground electrical ducts crossing a roadside drain

9
Pekeliling Pengurus Besar Kanan (Kejuruteraan) Bil. A17/2008- Larangan Merentang
Kabel 1 Teras dalam Paip Besi GI

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CHAPTER 3 CABLE LAYING SPECIFICATIONS
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3.2.2 Sizes and Usage of Pipe/Ducts


TNB uses various types of pipes/ducts for cable laying and crossing. The
standard size for pipes/ducts approved for each usage is as show in
Table 3-2.

Table 3-2: Summary of pipes/ducts usage and sizes


Type of Pipe/Ducts Diameter (mm) Usage
HDPE double wall 100, 150 Paved and unpaved roads not to
corrugated be used for bridge crossing
HDPE double wall 50 Communication cable ducting
corrugated
HDPE PN10 100, 150 HDD for crossings
G.I. pipes 100, 150 All crossings
450 Crossings culverts for one circuit
1C cable in HDPE pipes
914 Crossings culverts for two circuits
1C cable in HDPE pipes
PVC Class B 100, 150 Bridge Crossing
Paved and unpaved roads

Monsoon Drain & Culvert Crossings


For single core XLPE cable crossing on top of monsoon drain and culvert,
G.I. pipes of 450 mm/914 mm diameter shall be used for each circuit,
enclosing three 150mm diameter Double Wall HDPE Corrugated Pipe
duct for every three single core XLPE cables and one 100 mm diameter
Single or Double Wall HDPE Corrugated Pipe duct for pilot cable or fibre
optic cable. Similarly for two circuits and above, two and more 450 mm
10
diameter G.I. pipes shall be used .

10
P&PA Specifications

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CHAPTER 3 CABLE LAYING SPECIFICATIONS
Distribution Division Underground Cable System Design Manual

3.2.3 Cable Arrangement in Ducts

3.2.3.1 Cables Laid in Pipes/Ducts

Figure 3-11 through Figure 3-16 illustrate typical cross-sectional view of


cables laid in ducts.

Ground level

Earth backfilling

Cable slab
Washed river sand
Cable in HDPE pipe
Washed river sand
Figure 3-11: Typical cross-section in pipe LV, 11, 22kV 1C cable in trefoil
formation under unpaved surfaces

Road level
Wearing course
Binder course
Crusher run
Washed river sand

Cable slab
Washed river sand
Cable in HDPE pipe
Washed river sand

Figure 3-12: Typical cross-section in pipe LV, 11, 22kV 1C cable in trefoil
formation under paved surfaces

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Ground level

Earth backfilling

Cable slab
Washed river sand
HDPE pipe in cable
Washed river sand

Figure 3-13: Typical cross-section in pipe LV, 11, 22kV 3C cable in flat
formation under unpaved surfaces

Road level
Wearing course
Binder course
Crusher run
Washed river sand
Cable slab

HDPE pipe in cable

Washed river sand

Figure 3-14: Typical cross-section in pipe LV, 11, 22kV 3C cable in flat
formation under paved surfaces

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Ground level

Earth backfilling

Concrete cable slab


Washed river sand
Cable in HDPE pipe
Communication
cable in HDPE pipe
Washed river sand
Figure 3-15: Typical cross-section in pipe 33kV 1C cable in trefoil
formation under unpaved surfaces

Road level
Wearing course
Binder course
Crusher run
Washed river sand
Concrete cable slab
Washed river sand
Cable in HDPE pipe
Communication cable
in HDPE pipe
Washed river sand

Figure 3-16: Typical cross-section in pipe 33kV 1C cable in trefoil


formation under paved surfaces

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3.2.3.2 Split Pipes or Ducts

Split G.I. pipes may be used for fitting over existing cables as mechanical
protection. It shall not be used over single core cable. A suitable means
should be provided to secure the two halves in position.

3.2.3.3 Duct Banks

In areas whereby digging is not possible or allowed after initial


installation or local authority enforces no-dig policy, then duct bank
method can be considered.

The main advantage of using cable ducts is the ease of access for
replacement or extension of the installation without extensive workings.
Especially, where there are many circuits, the cables installed in ducts
can be subjected to higher loading than when laid in the ground.

A disadvantage is the high cost of supply and installation of the ducts.


For this reason installation in ducts is normally restricted to buildings and
around substations.

General specifications for duct banks are:

Duct banks shall use 150 mm diameter Class B polyvinyl chloride


(PVC) encased in concrete.

Detailed specifications for Duct Banks can be found in the Cable


Trenching Manual Special Requirements for Areas with Dedicated
Utility Trench and No Digging Policy.

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Figure 3-17: A 4 x 3 duct bank with one circuit of single-core cables, six
three-core cables, and a fibre/pilot cable

3.3 Joint Pit / Pulling Pit


Joint pit or joint bay as it is sometimes called must be prepared
beforehand. This will normally be based on the length of the cable and
the suitability of the location.

The pits are also used as pulling pits to install cables in ducts.

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3.4 Cable Bridge


Cable bridges are used for supporting cables crossing small rivers, big
monsoon drains, and sometimes for railway crossings.

There are two basic cable bridge designs which are the I-beam (Type A)
and Truss (Type B) bridges.

The cable bridge is normally constructed by contractors with designs


sourced from external civil engineering consultants.

Figure 3-18: Type A: I- beam type cable bridge design

Figure 3-19: Type B: truss type cable bridge design

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4 Cable Laying Accessories


4.1 Cable Slab
Cable slabs are used as visual warning indicators, while at the same time
providing mechanical protection for underground cables. The cable slabs
are buried below the ground level and above the underground cables as
specified in the cable laying guideline.

There are three types of cable slabs:


11
1) uPVC Cable Slab
12
2) nPVC Cable Slab
13
3) Concrete Slab

4.1.1 uPVC Cable Slab


Unplasticised Polyvinyl Chloride (uPVC) cable slab is made from
polyvinylchloride without plasticizer with a specific gravity of 1.32 to
1.58. The cable slab provides visual warning and mechanical protection
for underground cables during subsequent excavation work.

uPVC cable slab dimensions are 1000mm (L) x 250mm (W) x 2.0mm (T)

It is indelibly embossed with lettering to provide a warning on the


voltage level of the cable it protects.

11
Specification for PVC cable slab (16 Feb 1994)
12
Technical Specification nPVC cable slab (KEJ09436:2010)
13
P&PA, Article 6.15.6, Cable Protective Reinforced Concrete, Cable Laying
Tender Technical Specifications.

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The uPVC cable slab is colour-coded according to the voltage levels as


follows:

Green (BS381C No. 262) for LV cable system


Orange (BS381C No. 557) for 11kV and 22kV cable system

This cable slab uses a hook and lock interlocking mechanism to secure
the cable slabs together.

Hook Lock

Figure 4-1: Green uPVC slab for LV cable system

Figure 4-2: Orange uPVC slab for 11kV and 22kV cable system

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4.1.2 nPVC Cable Slab


The nPVC cable slab is red in colour according to BS 381C No. 557 for
high voltage. The nPVC cable slab dimensions are 1000 mm (L) x 250 mm
(W) x 4.5 mm (T).

This slab is used only under these two conditions:

i. For areas where the depth of the cable laying is less than 1050
mm (3.5 feet) due to site constraints.
ii. For all new 11kV and 22kV cable laying at fast developing areas
where a lot of future excavation works may be carried out.

Figure 4-3: The standard nPVC cable slab

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Nylon cable ties are used to lock/tie together a string of nPVC cable
slabs. The material and dimensional specifications are as follows:

Table 4-1: Material and dimensions of nylon cable ties


Material Thickness Length Width

Nylon 6.6 black 2.0mm 240mm 8.15mm

Figure 4-4: Locking nPVC slabs using cable ties

4.1.3 Reinforced Concrete Slab


All 33kV cables are to be installed with reinforced concrete slabs as an
indicator and mechanical protection.

Reinforced concrete slabs of Grade 20 in accordance to BS 8110 (1997) is


laid to cover the full width of the trench on top of the first sand filling.
The reinforced concrete slab should follow the following dimensions:

For each power cable circuit:


o 1000 mm long x 300 mm wide x 50 mm thick
For optical fibre/alarm cables:
o 1000 mm long x 150 mm wide x 50 mm thick

They are arranged successively one with the other.

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4.2 Cable Route Marker


All power cable and communication cable routes shall be marked with
identification markers of an approved type, so as to indicate the
locations of cables and joints.

Where cables are laid direct in ground, cable route markers shall be
provided at:

intermediate points along the route, 50 meters apart; and


at all points where trench changes direction or branch-off.

Two existing types of cable route markers are as shown in Figure 4-5 and
Figure 4-6.

Side view Front view

Figure 4-5: Cable route marker, circular type

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Side view Front view

Figure 4-6: Cable route marker, rectangular type

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4.3 Cable Joint Marker


Joint markers are installed to mark the location of cable joints.

Joint identification markers shall be made of a permanent material


typically as shown in Figure 4-7. The marker should have details of the
joint as follows:

No. Sambungan:
Voltan:
Saiz Kabel
Dari:
Ke:

Where the installation of cable route / joint markers is not feasible e.g.
cables installed on the road, other means of marking the cable route and
joint positions shall be employed.

Joint details

Side view Front view

Figure 4-7: Cable joint marker

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5 Cable Laying Procedures


5.1 Safety Precautions Prior to Commencement
of Work
Before commencement of work on underground cable installations,
please ensure that the following safety precautions and work
instructions are adhered to.

1. Perform all appropriate initial preparation such as route survey and


utility mapping.

2. Conduct Safety Briefing at the workplace and on-site.


Refer: Panduan Kejuruteraan Bil 9/2002.

3. Use appropriate Personal Protection Equipment (PPE).


Refer: Arahan Naib Presiden: Bil L3/2009 Pemakaian Peralatan
Perlindungan Diri (PPD) di Semua Tapak Kerja Bahagian
Pembahagian TNB.

4. Inspect all tools and equipment to ensure they are properly


functioning.

5. For work done by contractors, Site Supervisor must ensure all the
contractor staffs have the NTSP certification.
Refer: Surat Naib Presiden ( Sumber Manusia) : Penguatkuasaan
Niosh TNB Safety Passport (NTSP).

6. Works involving existing substations must follow the Kejuruteraan


Bil A7/2008: Tatacara Kerja Selamat di Pencawang Bahagian
Pembahagian guideline.

7. Other circulars / instructions / guidelines issued by the Engineering


Department.

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5.2 Initial Preparation

5.2.1 Site Visit and Route Survey


The functions of site visits and route surveys are:

to ascertain requirement of manpower, equipment and installation


methods
to identify geographical constrains, obstructions and potential
hazards
to establish that the proposed route is practical as decided by the
planner and cater for cable bending radius

Before cable laying, it is advised to inspect and survey the cable routes
and take into consideration the surfacing materials of both paved and
unpaved surfaces, roadways and other obstacles along the routes.

5.2.2 Utility Mapping


In areas where the local authority enforces the requirement of utility
mapping as the pre-requisite for cable route approval, then the utility
mapping contractor appointed by TNB shall be engaged. The contractor
is required to determine, locate and map all existing underground
utilities or services within the proposed cable routes. They must also
produce coordinated plans or utility mapping plans for submission to the
local authority.

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The main scope of work for the Utility Mapping shall comprise of the
14
following :
a) Details of plan / topography & underground utility mapping.
b) Location and depth determination of all underground utilities by
radio detection, ultrasonic method or any other techniques.
c) Mapping of the located utilities in relation to surface features
including construction of survey grids and survey of reference lines
e.g. road edge, culverts, fences, etc.
d) Construction of survey grids and survey of reference lines. All
acquired survey information is to be stored into computerised
information database.

5.2.3 Route Plan


Cables should always be laid within the routes approved by the relevant
authorities alongside roads wherever possible in order to avoid
unnecessary expense in excavating and backfilling.

The route plan will consist of the proposed cable route location, jointing
pit, access road, obstructions, etc.

Before making the route plan, these factors should be considered:

Requirements and guidelines by local authorities


Location of jointing pit
Site accessibility
System design
Existing utility as determined by utility mapping (if any)

14
ENGR-750-90-WI-02, Arahan Kerja Pementaan Utiliti Bagi Laluan Kabel, 14
Oktober 2011.

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5.2.4 Route Plan Approval


When a proposed cable route has been decided upon, general route
plans should be submitted for approval from relevant parties. Excavation
of trenches should only commence after the relevant approvals have
been obtained.

Typical authorities where approval may be required such as:

Majlis Daerah, Perbandaran / Local Council


Jabatan Kerja Raya (JKR) / Public Works Department (PWD)
Lembaga Lebuhraya Malaysia (LLM) / Malaysian Highway Authority
Railway Authority
Jabatan Pengairan dan Saliran / Department of Irrigation and
Drainage (DID)

Other utility owners may also need to be consulted to avoid damaging


their property, for example gas, water and telecommunication utility
companies.

In the absence of any specifications or instructions on clearances from


other utilities the following clearances may be used as a guide.

Table 5-1: Measurement of clearance for TNBs cables from those of


other service authorities
Other Service
Tenagas cable Clearance
Authority
Telekom Cables 3 Core MV Normal: 30cm (12)
Difficult situations: 15cm (6)
1 Core MV Without exception: 45cm (18)
Multicore LV Normal: More than 5cm (2)
Water Mains All Cables All Cases: 15cm (6)minimum
Railway cables, Single Core Normal: 45cm (18)
signal, metalwork
Multicore Normal: 30cm (12)
*Special arrangement must be made for reduced clearances

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5.2.5 Trial Holes


A series of small traversing cuts (perpendicular to the cable route) will be
done along the cable route at appropriate intervals to determine exact
location for trenching and to locate possible interference (i.e. other
services) to avoid any damage to them during excavation and in order to
achieve the minimum clearance. These small cuts are called trial holes.

The trial holes serve to confirm the proposed plan for cable routing for
that specific location. With this information, the actual line of excavation
can now be marked on the ground. Trial holes are made manually.

Normally before excavation of trial hole, utility tracing equipment is used


to detect presence of live cables or other utility installations.

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5.3 Trench Excavation


As a general rule, mechanical excavators shall be used to carry out mass
excavation. Manual excavation is restricted to those parts of the job
where the existence of other services render the use of a mechanical
tools impractical.

The trench excavation works consist of:

1) Safety precautions of the site.


2) Removal of top surface.
a) Paved surfaces streets, roads, highways and other paved
carriageways.
b) Unpaved surfaces rural roads, pedestrian walkways, road
kerb, turf and other unpaved areas.
3) Trenching and excavation of soil.
4) Reinforcing the trench strength with cable supports and shoring the
trench walls.
5) Handling of the excavated material.

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5.3.1 Safety of Site Works and Traffic Management


Malaysia Standard MS 981 shall be applied wherever applicable. Safety
signs with symbols shall be used to ensure that the requirement for
safety signs and notices are met e.g. notices or labelling of hazardous
substances, personal protective equipment (PPE), traffic signs, live
conductors, etc.

5.3.1.1 Traffic Safety Code for Road Works

The term traffic includes pedestrian traffic. In view of the absence of a


traffic safety code, the following measures as detailed below would
provide guidance on measures to be carried out during roadwork.

5.3.1.2 Guarding of Excavation

Excavation must be adequately fenced for safety purposes. Fencing pins


and ropes can be employed for this purpose but barriers may be
required at trench ends or intermediate entrances.

Where allowed, a bank of excavated materials not less than 0.5 metres
high may be regarded as a fence.

Footpath boards will be fitted across the trench at appropriate


entrances. Where the trench is being crossed by vehicular traffic, steel
roadway plates will be fitted.

Barriers provide a more suitable method of fencing small excavations,


i.e. joint pits and trial holes, since these are more easily detectable by
blind persons stick.

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5.3.1.3 Advance Warning Signs

Where trench excavations and installation of cables are being carried out
on the carriageway, side tables and footpaths, the Contractor shall erect
and maintain suitably approved Danger Notice Boards as a warning to
the public that dangerous conditions prevail.

The general arrangement and locations of these signs at works in


progress shall be strictly in accordance with the latest drawing as in the
Jabatan Kerja Raya (JKR) Manual on Traffic Control Devices and Traffic
Signs, which is obtainable from the JKR Head Office. All the signs
displayed shall be legible to road users and must include the word
TENAGA NASIONAL BERHAD and the name of the Contractor.

Road Works Ahead or Kerja di Hadapan signs must be placed


sufficiently ahead of the obstruction for vehicle drivers to take necessary
action.

The said sign boards shall be maintained for such periods until the
installation of cables has been completed and the disturbed surfaces
have been permanently reinstated.

Table 5-2: Speed of traffic and the distance from sign to obstruction
Distance from sign to
Speed of Traffic (km/h)
obstruction (meters)
50 50
60 100
80 200
90 250
110 300

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Proper non-conductive barriers shall be used to separate live zone and


construction area.

The following signs shall be placed where appropriate:

Figure 5-1: Some safety signs and notifications used for roadside works

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5.3.1.4 Traffic Guidance Cones and Temporary Traffic Control

When a portion of a roadway has to be closed to traffic, traffic guidance


cones shall be used to guide traffic smoothly from the wide section to
the narrower section in which portion of the roadway has been closed to
traffic.

Cones or lamps at night must be arranged to guide drivers around an


obstruction. Flashing amber beacons may be sparingly used to indicate
the obstruction ahead.

Manually operated Stop/Go signs or Traffic Signals must be used to


control traffic, the use of red and green flags are not permitted. It is
preferable to employ signals if the situations require two mentor control
duties.

5.3.1.5 Safety of Personnel

Suitable coloured high visibility vest must be worn by men working on or


near the carriageway.

5.3.1.6 Free Flow of Traffic

Where trenches follow or cross roads and footpaths, the work shall be
carried out in such a manner that the interference to the public and
traffic is kept to a minimum. It will normally be expected that in crossing
roads, only one lane of traffic can be cut off at a time.

In some areas, it will be necessary to restrict work to periods when the


volume of traffic is low and to bridge over all openings with skid-proof
steel decking of adequate thickness and dimensions during busy periods.

5.3.1.7 Temporary Crossings

Temporary crossings shall be provided across trenches to give pedestrian


and vehicular access continuously to all properties and roads affected by
the excavation.

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5.3.2 Removal of Top Surface

5.3.2.1 Paved Surfaces

As a general rule, work on one half of the carriageway should be


completed with at least temporary reinstatement made before work on
the second half of the carriageway commences. With the determination
of the actual of excavation by trial holes, the route can now be marked
on the road, usually done using paint or spray paint.

A road cutter using diamond blade is then employed to do the cutting of


the road surface (tarmac layer). Both sides of the trench dimensions
have to be cut in order to achieve a clean straight separation. A jagged
edge would contribute unnecessary chipping and early failure of the
reinstatement/resurfacing material.

Mechanical equipment, i.e. a backhoe, can then be deployed for removal


of the top surface materials after the cut has been made. Excavated
material should be removed from worksite to an approved dumping site.

Figure 5-2: Using the road cutter with diamond blade to cut through
the tarmac layer

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5.3.2.2 Unpaved Surfaces

Turf within the trench dimensions should be cut into suitable sizes that
are capable of being handled without breaking. Removal of turf is made
by applying a horizontal cut below the root level after which, the sod is
carefully lifted. Where situation allows, the sod should be placed turf
down, on one side of trench, while excavated soil is placed on the other
side. In restricted condition, the sods should be transported by
wheelbarrow and stacked in suitable positions

5.3.2.3 Other Surfaces

Paving Stones
Paving stones and/or interlocking tiles should be lifted and laid to one
side in correct sequence. The associated bedding is then put aside in a
pile.

Tarmac and Concrete Footpaths


It is generally advisable to use diamond cutter to cut through the hard
top surface marking the trench to be excavated. Mechanical excavating
equipment may then be deployed for surface removal once the cuts are
completed.

5.3.3 Trenching and Excavation of Soil


Trenches shall be kept as straight as possible with vertical sides. The
bottom of the trench shall be firm with a smooth contour. Where a
change of level is necessary as in where trenches pass from a footway to
a roadway or at other positions, the level or bottom of the trench shall
rise or fall gradually.

Mechanical excavation is usually done by backhoes and excavators.


When excavation by this means is deployed, an assistant is usually
available in the excavation part of the trench directly in front of the
excavator to guide the bucket and smoothen the trench bottom at the

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same time. This is an added safety feature as the assistant is providing an


extra pair of eyes to prevent unnecessary damage to existing services
which may not be detectable earlier.

Where mechanical excavation methods are not possible or not allowed,


manual excavation needs to be employed.

Figure 5-3: Mechanical excavation using backhoe

For direct buried cables, the excavation of any section of the trench shall
only commence when the cables to be laid in the section are available
and can be made ready for laying as soon as the excavation of the trench
is completed.

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For situation where long trench openings are not possible for direct
buried cables, pipes/ducts will be installed in stages where cable will be
pulled through later. Excavation of the trench for installing pipes/ducts
can only commence once the pipes/ducts and its accessories are
available on site.

Refer details on depth and width of the trench on Chapter 3.

Figure 5-4: A typical trench for underground cable laying

5.3.4 Handling of Excavated Materials


In general, the material excavated from the trench shall be placed so as
to prevent nuisance or damage to adjacent hedges, trees, ditches,
drains, gateways and others properties. These materials shall be stacked
on the far side of the trench from the roadway so as to avoid undue
interference to the traffic and to create as minimum disturbance as
possible to pedestrians and other road users.

Whenever practical, surface material, foundation material and subsoil


shall be separated in order to facilitate the re-use of excavated material.

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In situations where local authorities do not allow excavated material to


be placed around the worksite, the excavated material should be
transported immediately to an approved dumpsite.

5.3.5 Sand Bedding


To provide consistent ampacity and good arc quenching capability, a
150mm thick sand bed needs to be prepared in all trenches. Once the
sand bed is prepared, installation of the cables or ducting may
commence.

Figure 5-7: Preparation of sand bed

5.3.6 Cable Support and Shoring Works

5.3.6.1 Cable Support

In the event of soil being too soft to support the cable and there is a
possibility the cable can sink after laying, it is then required the cables be
supported by bakau timber or precast concrete slab all along the portion
of the cable route.

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5.3.6.2 Shoring of Excavations

Trenches shall be shored where necessary for the safety of personnel,


works, adjacent buildings, pavements, etc. Sheet piling shall be carried
out when it is necessary for the security of the works and cables.

Requirements for Shoring


Shoring must be used to support the side of any excavations where there
is the possibility of collapse. Most common causes of collapse are:

a) Mechanical failure of the soil because it cannot support its own


weight.
b) Breakdown of strength of soil by moisture from heavy rain.
c) Failure caused by vibration from movement of vehicles.
d) Failure due to loads placed near the edge of the excavation.
e) Failure due to excavation on or near the site of a previous
excavation.
f) Failure due to the side of the excavation being struck by heavy
loads.

Erection of Shoring
Shoring will be first erected at one end of the excavation so that men are
protected while installing the next section.

Having decided the length of the wall, poling boards are erected
vertically; sufficient earth carefully removed to permit the boards to bear
against the trench wall. Both sides of the trench are poled in this
manner.

The walling boards are then fitted on temporary props and the struts cut
to length and the assembly tightened by wedging. Instead of timber
struts, screw jacks may be used.

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Maintenance of Shoring
Maintenance is necessary for the following reasons:

a) The timber may dry and cause shrinkage.


b) The ground may dry out and shrink, loosening the timber.
c) The ground may absorb moisture, swell and displace the
timbering.
d) Soil may leak into an excavation from behind the timber which
will become loose.
e) The timber may rot.

Shoring must be inspected daily before work into the excavation


commences.

Shoring Removal
Shoring is removed as back filling is being carried out; poling boards
being lifted as successive layers of back fill are stuffed and compacted.
Spaces left by withdrawal of timber shall be immediately filled, the
degree of compaction being sufficient to support the trench sides.

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5.4 Pipe/Duct Installation


In area where long open cut trench is not permitted during cable laying,
pipes/ducts are installed and trench is backfilled.

Pulling pits are provided at suitable intervals, covered with anchored


steel plates to allow normal movement of traffic.

5.4.1 Draw Ropes


Approved type heavy-duty draw rope for cable installation shall be
provided in all ducts. The breaking strength of the draw rope shall be 1.5
times the cable pulling force.

5.4.2 Sealing Pipe or Duct Ends


After the construction of cable duct banks, the ends of the pipes/ducts
shall be effectively sealed to prevent the entry of sand etc. into the
pipes. Appropriate/suitable bungs should be fitted to the ends of
pipes/ducts or where back filling of the trench ends is required before
the cables are laid.

5.4.3 Concrete Casting of Ducts


For pipes/ducts installed for crossings, concrete encasement is required
to provide additional mechanical strength.

The concrete used to cover the pipes is 1:2:4 (cement: sand: stone) mix
using 9.525 mm 12.7 mm aggregate. The mix should be semi dry with a
water content not exceeding 0.5 (approximately 22.73 litres of water to
1 cwt cement).

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5.4.4 Work Specification


Typical workflow for installation of pipes/ducts and pulling of cables is as
listed below:

1) Excavation of trench to required length, width and depth according


to the size mentioned in Subchapter 3.2.

2) Fill the trench with washed river sand 150mm.

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3) Lay the pipes and ducts according to proper formation.

4) Backfill with washed river sand.

5) Place cable slabs at the slab level.

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6) Backfill and reinstate the top surface.

7) The cable is pulled through the duct from the pulling pits/joint pit.

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5.5 Cable Pulling


Pulling of cables can be done either by hand or with mechanical auxiliary
equipment.

The site plan should indicate the position of cable drum and pulling
winch (if used).

The following considerations shall apply for cable pulling operations:

a) In all cases sufficient manpower shall be available near the cable


drum to drive and stop it in time

b) Sufficient use must be made of rollers particularly where it


involves changing of direction and long runs.

c) Cables are to be laid on sand bedding as specified.

d) Manufacturers maximum recommended cable pulling tensions


and bending radii shall not be exceeded.

e) Cable stockings/cable grips shall be used for pulling cables.

f) Cable drums, sand, tiles, rollers, etc., shall not be stored to block
access ways and roads.

g) Drum reeling position shall be selected to give minimum


interference with traffic.

h) In the case of trench being filled with water, it shall be pumped


out to a discharge point approved by the site supervisor.

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5.5.1 Cable Handling

5.5.1.1 Checking Cable Condition

Upon receiving cables from the store, a physical inspection needs to be


performed and recorded in the form ENGR-2014-PSI Borang Ujian
Terima Barang-barang Stor.

Wooden battens Electrical cable


Directional arrow
Flange

Connecting bolts
Spindle
Manufacturer info (used on site)

Figure 5-5: Parts of the cable drum

5.5.1.2 Drum Handling

The most important point to observe in handling cable is that great care
must be exercised at all times and every precaution should be taken to
avoid dropping the cable drum.

When lifting the drum using spindles, the sling wire size must be the
appropriate to the cable size. As shown in Figure 5-6 the cable drum can
be damaged if lifted using the wrong method.

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Stress on
drums
Spindle

Figure 5-6: Lifting the drum using a crane and properly sized sling wire

Figure 5-7: Lifting the cable correctly

5.5.1.3 Storage of Drums

To store the cable drums, the following points must be observed:


Flange to flange method, ensure to provide safety and accessibility
Ensure coiled cable are well protected and its ends are properly
sealed
Stand firm on well drained hard surface and secured from rolling, do
not lay flat
Wooden drum to be rotated 90 periodically to prevent rotting of
the flanges

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Figure 5-8: Cable should not be laid flat on flanges when storing the
cable drum

5.5.1.4 Transportation

Cable drums are typically transported on trucks and should be properly


secured. Prior to transporting the cable drums:
Check drum condition and connecting bolts
Use correct sized and well maintained sling and spindle
Ensure that the truck is appropriate to the drum weight and do not
overload the truck
Secure drum well to the truck to prevent rolling or sliding with
chocks and chains
Load/Unload gently onto firm and level surface, do not drop

Securing Wooden
cables/ropes wedges/chocks

Figure 5-9: Drums secured adequately during transportation

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5.5.1.5 Cable Pulling Tension

Cables are usually pulled into position during laying in the trench or duct.
However if the cable is handled with a pulling tension above its
maximum permissible pulling force, this can damage the electrical and
physical properties of the cable. The suggested cable pulling tension
using different pulling tools are as below.

Table 5-3: Cable pulling method base on the pulling tension


Pulling Method Maximum Pulling Tension, T

Pulling Eye attached to the conductor T=KxS

Pulling Grip over the cable sheath T= 500 kg


2 2
K = 7kg/mm for Copper Conductor; 4kg/mm for Aluminium Conductor
2
S = Total Cross-sectional Area of Conductors (mm )

Table 5-4: Typical values for maximum cable pulling tension


Voltage Core Size Pulling Tension
2
33 kV 1C Aluminium 630 mm 2500 kg
2
1C Aluminium 500 mm 2000 kg
11 kV 2
3C Aluminium 240 mm 2900 kg

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5.5.1.6 Bending Radius

The cables may be bent during installation within limits of the bending
radius.

The minimum bending radii specified shall refer to the inner surface of
the cable and not to the axis of the cable as shown in Figure 5-10.

Table 5-5: Minimum bending radius during installation


Type of Cable Single Core Multi Core

Unarmoured 20 x Diameter 15 x Diameter

Cable that is
being laid
15 x D

15 x D

Figure 5-10: Bending Radius for Multi Core Cable

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5.5.2 Installing Cable Rollers

5.5.2.1 General

Roller is a free-running cylinder or set of cylinders, suitably shaped to


support and to assist in conveying the cable during laying.

The purpose of cable rollers and skid plates are:

a) To protect the cable servings from damage due to abrasion. This is


particularly important in the case of unarmoured cables with PVC
sheaths.
b) To reduce the effort required to pull the cable by reducing friction.
c) To guide the cable around bends and obstacles.

Figure 5-11: Cable roller

5.5.2.2 Laying Out Rollers

Where practicable the rollers should be distributed on site by off-loading


direct from the delivery vehicle.

When rollers are located at a site store the buckets of excavators or


wheelbarrows can be used for moving purposes. The rollers must be

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placed on the side of the trench in such a position that they may be
readily handled by a person working in the trench.

5.5.2.3 Positioning of Roller

Points to bear in mind are:-

a) Straight line rollers must be spaced to prevent cable touching


trench bottom. In practice 3 metres (9 feet) spacing will be
satisfactory, but spacing may be increased for larger or more
rigid cables.
b) Corner rollers are being used for right angle bends, particularly
in pulling tensions are high. Closed rollers should be placed at
each end of the plate to prevent the cable lifting
c) Where the presences of existing services prevent the driving of
pins corner rollers may be secured by struts.
d) Where the cable passes beneath obstacle, a rollers secured in
the inverted position can reduce friction and damage to serving,
together with dispensing the need to posting a man.

Figure 5-12: Straight line roller

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5.5.2.4 Maintenance of Equipment

Rollers should be cleaned after use and kept well oiled. Wooden bases to
be occasionally treated with an approved preservative. Aluminium rollers
must be inspected for surface wear.

5.5.3 Setting Cable Drum

5.5.3.1 Positioning and Jacking Up Drum

Where possible arrange the equipment to allow the cable to be drawn


off the drum whilst it is still mounted on the cable trailer or vehicle.

If it is necessary to move the drum manually on site, the drum should be


rolled with the cable end at the top of the drum, pointing away from the
direction of rolling. This prevents the cable from unwinding on the drum.
A slewing bar must be used to change the direction of rolling.

When rolling the drum into position it is essential that the drum rolls
smoothly in the direction of the arrow painted on the side of the drum. If
this instruction is not observed, slack cable will tend to accumulate
towards the inner turns and may possibly result in damage to the cable.

Figure 5-13: Drums must be rolled according to the directional arrow

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When the drum is in place it should be mounted on jacks and positioned


so that the cable is pulled off from the bottom and not over the top.

The safe working load of each of the drum jacks used should not be less
than half the gross weight marked on the drum. Use the largest size of
drum spindle acceptable by drum.

Jacks must be placed on a firm base. On soft ground, timber balks or


steel plates under the jacks spread the weight. Packing may be weight
required on rough or uneven ground.

When jacking up drums, the weight of the drum must first be taken and
the jacking assembly must be inspected. If satisfactory, the drum may be
raised clear of the ground, with care being taken to ensure that the drum
remains level whilst this is being done.

Figure 5-14: Cable drum jack and spindle

It is preferable to mount the drum at one end of the cable run as close as
possible to the edge of the trench so that the cable can be pulled off in a
continuous manner on roller in the trench and is in its final position
when the last turn leaves the drum. This procedure is not always possible
because of excessive length and weight of cable run or because of
obstructions of pipes under which the cable have to be threaded.

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In such cases it may be necessary to position the drum at some other


point along the cable run and lay off the cable on the ground near the
drum in a series of loops, one above the other in the form of a figure of
eight, crossing the cable back and forth on itself.

When the whole length has been removed from the drum, the inside end
of the cable will be on top and can be pulled along toward its final
position on rollers in the same manner as if the cable was coming off the
drum itself.

Whichever procedure is adopted, great care must be taken at all times to


ensure that the cable is not twisted and that the turns are well above the
minimum bending radii of the cable.

5.5.3.2 Removing Drum Battens

Wooden battens around the cable drum should be very carefully


removed. Hoes or shovels should not be used for this purpose. This is to
ensure the cable outer sheath is not damaged.

Lift battens using a crowbar. Nails should be knocked down and the
battens stacked. Gloves are to be worn when handling battens and steel
retaining bands.

Inspect the rims and the inside faces of drum flags for nails and sharp
edges.

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5.5.4 Fitting Cable Stockings / Cable Grip


Pull the running end of the cable off the drum to a position
approximately 1 meter over the cable entry roller. Inspect the end cap of
the cable for damage; if satisfactory the appropriate sized cable stocking
should be fitted over the cable end. Gloves must be worn when handling
cable stockings.

Figure 5-15 shows types of cable stockings with single and double pulling
eyes. Double eyes are preferred because there is less damage to the cap
on the cable end if the pulling load is high.

Figure 5-15: Cable stocking / grip with single and double pulling eyes

After use, inspect the cable stocking for damage. If excessive needling
has occurred, the stocking should be discarded.

If it is considered that the cable will be subjected to excessive pulling


tension, the Field Engineer should be consulted on the advisability of
fitting a pulling eye or other approved means.

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A swivel must always be interposed between the wire or rope and the
cable stocking or pulling eye, D shackles used for the eye connections
and swivels should be inspected for abrasion and cleaned and oiled after
use.

Figure 5-16: Swivel

A swivel is a connection, a link or pivot that allows the connected object


to rotate horizontally and/or vertically. A common design for a swivel is a
cylindrical rod that can turn freely within a support structure. The rod is
usually prevented from slipping out by a nut, washer or thickening of the
rod. The device can be attached to the ends of the rod or the centre and
another common design is a sphere that is able to rotate within a
support structure.

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5.5.5 Cable Pulling Methods


Cables are either pulled manually or mechanically with a winch. The
latter is most frequently used these days as it cut down on the
requirements of labour and can get the job done faster. However, when
pulling by mechanical means is rendered impracticable, manual pulling is
deployed. Manual pulling is normally done when pulling cable inside the
substation building.

5.5.5.1 Manual Cable Pulling

Thread the pulling rope round through ducts and check to ensure that
when pulling, the rope will bear on a roller. For short clear pulls the rope
may be laid along the trench side.

The cable laying supervisor should be in a position where he can best


observe the job and team. Members of the team must understand the
signal used to commence and stop pulling. Two men should be posted at
the drum to cause the drum to rotate as cable is pulled and to prevent
over-run. The remainder of the team is to be placed at short intervals
apart from the pulling rope. Gloves shall be worn by all men. The pull
must be made by all men in unison at the supervisors command. Check
that the cable rollers have not been displaced and the cable is riding
freely on them.

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5.5.5.2 Mechanical Cable Pulling

Install the winch at the position indicated in the site plan and ensure
that ground anchors and pins are secure. Cable winch is a
mechanical device that is used to pull out the cable from the cable
drum during process of cable laying. The cable winch consists of a
spool (winch drum) and a winch motor.

Figure 5-17: Cable winch for mechanical pulling of cable

Start winch motor and run for approximately one minute. The winch
wire can be run along the trench route and shackled to the cable
stocking eye. Check that the winch wire is laid on the cable rollers.
If required, a lead-in roller placed at the trench head will support the
winch wire to clear the snatch block. Installation time can be used
more efficiently if the cable team is divided when preparing the
cable for pulling and for running out the winch rope.
All members of the team must understand the signals used to
commence and stop pulling. The cable laying supervisor must place
himself in a position where he can be seen and where he can see
any difficulties which may arise. Members of the team should be
arranged as follows:

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Table 5-6: Number of persons required per task


Task No of person
Operating pulling winch 1 man
Controlling Cable Drum 1-2 men
Lifting Cable Ends on Rollers 1 man
Checking & Re-aligning Rollers 1 man
Obstructions 1-2 men

Operate the winch to tension the cable and check that the winch
wire remains on the rollers. Adjust rollers if necessary. Members of
the team should not enter the trench while cable is being pulled.
Those members of the team instructed to lift the cable end on
rollers and to straighten rollers shall be equipped with lifting hooks
and operate from the top of the trench.
When a dynamometer is fitted to the winch or inserted in the pull,
readings must be taken to ensure that the following tensions are not
exceeded.

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5.5.6 Cable Flaking & Unflaking

5.5.6.1 Flaking

Flaking is carried out when:

a) Only half the cable trench can be excavated at one time and the
drum has been placed at the mid position.
b) Where bad access requires the drum to be placed at an inconvenient
position.
c) Where obstructions or a number of ducts runs are encountered and
pulling tensions becomes excessive.

The aim when flaking cable is to ensure that the cable is taken from the
drum and laid out in a manner that will prevent damage by kinking or
twisting. The cable is laid out in a figure of eight and minimum bending
radius must not be less than the values shown in Table 5-7.

Table 5-7: Sample of cable type/sizes and


minimum bending radius allowed for cable flaking
Minimum Bending
Cable
Radius (mm)
Service Cable 400
LV 4 Core Cables
2
70 mm 500
2
95 mm 600
2
120 mm 800
2
185 mm 800
2
300 mm 900
11kV Cables All size 800

For 33kV cable, the minimum bending radius for cables shall be 15 times
but for lead sheathed single core and minimum sheathed paper
insulated cables 25 times the cable diameter. Fixed bends at terminal
boxes may have a radius of 70% of the above-mentioned figures,
provided that they are made by skilled labour.

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Figure 5-18: Cable flaking and unflaking

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5.6 Laying-Off Cables


Lift the cable from the roller and lay on the floor of the trench. Using
wooden battens, straighten out and ease the cable at bends. Work out
slack cable to the ends.

Remove roller equipment from the trench and place on the trench side
in a position convenient for collection.

5.6.1 Direct Buried in Trench


Lay the cable in flat or trefoil formation, according to site requirements.
The cables need to be laid on top of 150 mm thick sand bedding.

Figure 5-19: Cable placed on sand bedding in the trench

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5.6.2 Cable Separation


An absolute distance of 2 times of diameter (2D) for any cable size must
be maintained between the cables as mentioned and shown in
Subchapter 2.5 for Cable Laying Formation and Arrangement.

5.6.3 Arrangement of Communication Cables


When communication cables are laid with MV Cables, the
communication cables are to be laid in the same manner as an LV cable
as shown in Subchapter 3.1 for Direct Buried in Trench.

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5.7 Alternative Cable Installation Methods


For cable paths and crossings that do not allow for excavation of open
trenches, some other method of installing the cables have to be
employed. The following methods of horizontal directional drilling (HDD),
pipe jacking and micro-tunnelling have been used to install cables for
underground crossings of highways, railroads, runways, rivers, and
environmentally sensitive areas for a variety of utilities.

These methods avoid the need to have long stretches of open trench for
pipe laying, which causes extreme disruption to the community.
However some drawbacks of these methods are that they are expensive
and that the installation might enter the path of other utilities.

5.7.1 Horizontal Directional Drilling (HDD)


Essentially, installing utility tunnels using the HDD technique comprises
of three stages, pilot hole drilling, pre-reaming, pipe and cable pulling.

The following are applied in current TNB practice for HDD installations:

Only HDPE grade PN10 rated pipes are to be used as duct sleeve for
HDD.
Calculate a route or bore path for the pipe along a shallow
underground arc.
Selection of appropriate pipe size and estimation of load to be
applied to the pipe during pullback.

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5.7.1.1 Pilot Hole Drilling

A small diameter pilot hole is drilled to a pre-determined path using a jet


bit on the end of the pilot string and drilling operations take place until
the exit point is reached.

HDD Machine

Figure 5-20: Pilot hole drilling

5.7.1.2 Pre-reaming

Pre-reaming operations are carried out to enlarge the drilled hole to a


size suitable for accepting the product pipe. Pull-back pipe is added
behind the reamer. Depending upon the pipe diameter to be installed
several pre-reaming operations may be necessary, each progressively
enlarging the hole.

HDD Machine

Figure 5-21: Pre-reaming process

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5.7.1.3 Pipe Installation

The pull-back pipe is connected to a cleaning reamer which in turn


connects to a swivel joint, (to prevent pipe rotation) that is attached to
the pipeline towhead. The drill rig is then used to pull the product pipe
into the preformed hole.

HDD Machine

Figure 5-22: Pull-back of the pipe and cable through the reamed hole

Figure 5-23: A Horizontal Directional Drilling (HDD) machine

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5.7.2 Pipe Jacking


Pipe jacking consists of mechanically forcing specially designed pipes
through the ground behind a jacking shield with powerful hydraulic jacks.
The method provides a flexible and structurally sound finished pipeline
as the tunnel is excavated.

There is no theoretical limit to the length of individual pipes to be jacked


although practical engineering consideration and economic will impose
restrictions. A number of excavation systems are available including
manual, mechanical and remote control. Jacking of pipes of any diameter
can be installed by employing the appropriate system. Construction
tolerances are compatible with other tunnelling methods.

Pipe jacking is an economic alternative to open trench work as well as to


other forms of tunnelling and is particularly useful in limiting the risk of
surface settlement.

The system is designed for tunnelling without the use of ground


improvement process such as compressed air. Owing to the small size of
the launch and reception shaft required by the system and the
containerised design of the equipment it is ideal for use in urban areas.

Figure 5-24: Pipe jacking process forces pipes through the ground

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5.7.3 Micro-tunnelling
Micro-tunnelling is a process that uses a remotely controlled Micro-
tunnel Boring Machine (MTBM) combined with the pipe jacking
technique to directly install pipelines underground in a single pass. This
process avoids the need to have long stretches of open trench for pipe
laying, which causes extreme disruption to the community.

It is a tunnelling process where the workforce does not routinely work in


the tunnel and currently the most accurate pipeline installation method.
Line and grade tolerances of one inch are the micro-tunnelling industry
standard. This can be extremely important when trying to install a new
pipeline in an area where a maze of underground utility lines already
exists.

A typical micro-tunnel equipment spread consists of:

a MTBM matched to the expected subsurface conditions and the


pipe diameter to be installed;
a hydraulic jacking system to pipejack the pipeline;
a closed loop slurry system to remove the excavated tunnel spoil;
a slurry cleaning system to remove the spoil from the slurry water;
a lubrication system to lubricate the exterior of the pipeline during
installation;
a guidance system to provide installation accuracy;
an electrical supply and distribution system to power all of the
above equipment

Top side equipment used to support the tunnelling operation usually


includes a crane; pile driving and dewatering equipment for shaft
construction; backhoe and front end loader for shaft excavation; and
truck transport for equipment moving.

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Figure 5-25: Micro-tunnelling uses Micro-tunnel Boring Machine


(MTBM)

5.7.4 Filling of Cement Sand Grout


If more than one pipe is installed in a bore hole exceeding the outside
diameter of the pipe by more than 25 mm, the voids shall be pressure-
filled with cement sand grout.

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5.8 Cable Jointing

5.8.1 Overview
When a cable circuit length longer than the cable drum length is
required, multiple spans of cables have to be laid to meet the required
length. To do so, these spans of cables have to be connected to complete
the circuit, hence cable jointing.

Cable jointing consists of two parts:

1) Cable conductor jointing


2) Cable joint body installation

Cable conductor jointing techniques shall follow TNB approved jointing


techniques which was described in Subchapter 2.7:

1) Aluminium conductor Deep Stepped Indentation Control


Volume (DSICV)
2) Copper conductor Hexagonal Compression Crimp

Cable joint body installation shall follow the jointing instruction provided
by the manufacturer together with the joint kits supplied.

Figure 5-26: Cable Jointing

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5.8.2 Safety in the Trench / Pit


Even though the cables to be jointed are not energized, safety measures
should still be taken to prevent unnecessary mishap during the course of
jointing the cables.

a) Make sure the pit walls are smooth, stable and firm to prevent
caving in during the jointing process.
b) If the pit walls are not stable, install timber shuttering or
equivalent with adequate support.
c) If such pit is located where there is vehicular traffic flow, make
sure that all arrangement for traffic management is met. This
means having all necessary road signs placed at appropriate
positions to warn motorists of the obstruction.
d) All sharp tools must be visible to all in the pit and positioned in
such a way that the sharp point not pointing upwards.
e) Blow torch and any other flaring instrument must be switched
off when not in use. Be careful where you point these
instruments when they are being used.
f) Maintain cleanliness as best as possible during the whole course
of the jointing process. Rubbish e.g. papers can easily obscure
sharp objects.

5.9 Cable Termination


To complete the installation, the cables must be terminated at
switchgears or transformers with the appropriate termination kits
matching the equipment where it is to be terminated.

As each equipment termination differs in technique and methodology,


care must be taken to follow the relevant instruction manual of each
type and make.

Please refer to Subchapter 2.7.4 for theory on Cable Termination.

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5.10 Mechanical Protection, Backfill and


Reinstatement

5.10.1 Washed River Sand


Cables must be covered and protected immediately after they have been
installed. Washed river sand is used for bedding and covering off the
cable. The sand used must be free from large or sharp stones. In cases
where no suitable sands are available on site, arrangement must be
made to import the sand which should be dumped at chosen positions at
the side of the trench.

Should there be presence of stones or hard lumps of earth or clay, the


sand should be put through a sieve having a mesh not greater than
2
4mm . Excavators, wheelbarrow; or buckets should be used to convey
and tip the imported material into the trench. The sand must be on site
before the cable is laid. The cable is covered with a layer of sand with
thickness of 150mm and then compacted manually.

5.10.2 Mechanical Protection

5.10.2.1 Cable End Caps

To protect the cable from the environment, immediately after cutting, all
cable ends for both of the installed cables and of the cable part
remaining on the drum shall be protected by sealing and capping with
heat shrinkable end cap.

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Figure 5-27: Cable end cap of various sizes

5.10.2.2 Cable Slabs

For LV cable up to 22 kV cable, cable slabs are used for mechanical


protection and visual warning indicator. While for 33kV cable, concrete
slabs are used for mechanical protection and visual warning indicator.
Details of the cable slab are discussed in Subchapter 4.1 and a summary
is provided in the table below.

Table 5-8: Cable slabs and their use


Cable Slab
Cable uPVC uPVC nPVC
Concrete
Green Orange Red
415kV (4C)
11kV / 22kV (3C)
11kV (1C)
33kV (1C)
For areas where the depth of the cable laying is less than 1050 mm (3.5 feet)
due to site constraints

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Figure 5-28: Use of uPVC slabs for 11kV and 22kV cable installations

Figure 5-29: Use of concrete slab for 33kV cable installations

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5.10.3 Backfill Material


After the cables have been laid, covered with sand according to the
requirement and protective slabs have been laid on top of the sand, the
trench shall then be backfilled. A summary of materials used for unpaved
and paved surfaces is shown in Table 5-9.

Table 5-9: Allowed backfill material for cable installations


Excavated
Surface Sand New Soil
Soil
Unpaved
Paved
* Refer chapter 3 for detailed soil layer arrangement.

The backfilling of trenches and joint bays shall be done as soon as


possible after the cable laying and/or cable jointing is completed.
Excavations shall not be left open other than for actual work to be done.

5.10.3.1 Unpaved Surfaces

Backfilling and spreading will be done using back pushers and backhoes.
Compaction is to be carried out with an appropriate mechanical
compactor. Where turfing had been removed, these have to be
reinstated.

5.10.3.2 Paved Surfaces

In case of excavation on tarmac, the trench shall be backfilled with sand,


crusher run and finally resurfaced with tarmac. To avoid soil subsidence,
compaction is to be carried out before resurfacing. All surplus earth and
other material remaining after backfilling shall be moved to a designated
disposal area approved by the local authorities.

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5.10.4 Reinstatement of Paved Surfaces


The surfaces of backfilled trenches are to be reinstated and maintained
in a thoroughly safe condition until complete consolidation of the trench
is achieved.
15
General guidelines for reinstatement of paved surfaces are as follows :

1. Backfilling material for the trench after completion of installation of


utility service shall be granular material of approved grading.

2. The Controlling Authority reserves the right to carry out tests on


material quality and workmanship any time during the work.

3. Unless the reinstatement of road pavement is done immediately


after backfilling, the trench shall be temporarily covered with steel
plates of suitable thickness securely spiked to facilitate temporary
opening to traffic. Such steel plates shall be maintained until
permanent pavement reinstatement is done.

4. The road pavement shall be reinstated to the same structure as that


of the existing pavement at the least. The Applicant shall submit his
proposal (drawings and specifications) to the Controlling Authority
for approval. When in doubt, the Controlling Authority shall decide
on the pavement structure and material specifications for
reinstatement, and his decision on this matter shall be final.

5. Pavement reinstatement shall be completed within 3 days after


backfilling for trenches along the road; within 24 hours for cross
trenches; and immediately for pilot pits.

6. The reinstated pavement shall be finished flush with the surface of


the adjoining existing pavement.

15
Guidelines for Works Related to Public Utility Installations within the Road
Reserve, Road Engineering Association of Malaysia

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Figure 5-30: Compaction of temporary reinstatement using mechanical


compactor

5.11 Tidying Sites


The site shall be left in tidy and safe condition after the completion of
work. The contractor shall be responsible disposing all the empty cable
drums from the work site immediately after the completion of work.

Figure 5-31: The site must be cleaned and made safe for public use

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6 Cable Laying in Substations


6.1 Cable Arrangement in Cable Cellars

6.1.1 Standard Guidelines


For cables laid in cable cellars of PMU or PPU, the cables are either laid
out in cable trays / ladders or on the cable cellar floor. During the
planning stage the space requirement (taking account of ampacity,
number of cables/circuits and permissible bending radii) as well as the
strength of supporting structures and other component parts are to be
considered.

The following are some standard guidelines when installing MV electrical


cables inside PPU and PMU:

Minimum cable bending radius must be observed

No joints is allowed inside a substation cable cellar

Power cable and control cable should be physically separated

Single core cables should be laid in trefoil formation and


clamped/tied at 1 meter intervals

Placement on flooring:

o Should be arranged neatly to avoid overlapping

o For cables where overlapping one another cannot be avoided,


proper structure such as mini cable bridge/cable support should
be used

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Figure 6-1: Cables laid inside substations must be neatly arranged

The following diagrams show typical cable supports in the substation


cellar.

6.1.2 Cable Clamp with stand


The cable clamp with stand is used to support cables to avoid any
touching of crossing cables.

Figure 6-2: Cable clamps with stand

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CHAPTER 6 CABLE LAYING IN SUBSTATIONS
Distribution Division Underground Cable System Design Manual

6.1.3 Cable Tray/Cable Ladder


Cable trays for the installation of electric power and communication
cables are usually specified as perforated hot-dipped galvanized sheet
steel. The perforation (usually defined as holes to the sheet of the trays)
allows a more natural flow of air circulation around the electric cables.
This air movement can effectively help cool the cables on the tray.

Figure 6-3: Perforated cable tray

The construction of the cable ladders is better suited to handle the


weight and stresses imposed by larger cables.

Figure 6-4: Cable ladders should also bend according to the cable

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CHAPTER 6 CABLE LAYING IN SUBSTATIONS
Underground Cable System Design Manual Distribution Division

6.1.4 Bracket and Cable Clamp


To keep cables in place and maintain its formation, cable brackets and
clamps can be used. These are useful to support and secure cables rising
from the cable cellar floor to terminate into the switchgear cable box. It
is also used to support and secure cables onto the cable ladder when
transiting cables between floors.

Figure 6-5: Cables laid along cable shaft wall

Page | 151
CHAPTER 6 CABLE LAYING IN SUBSTATIONS
Distribution Division Underground Cable System Design Manual

6.2 Cable Arrangement in Substation Trenches

6.2.1 Standard Guidelines


The following are some standard guidelines when installing MV electrical
cables inside substation cable trenches:

1) Minimum cable bending radius must be observed

2) No joints is allowed inside a substation cable cellar

3) Power cable and control cable should be physically separated

4) Single core cables should be laid in trefoil formation and


clamped/tied at 1 meter intervals

5) Cables should be neatly arranged

6) Substations trenches must be filled with river sand, covered with a


thin layer of cement render.

Page | 152
CHAPTER 7 CABLE MANAGEMENT
Underground Cable System Design Manual Distribution Division

7 Cable Management
7.1 Overview
Underground cables are one of TNBs most important assets. A
comprehensive management system is required to ensure every step in
the cable system life cycle is managed in accordance to TNBs policies,
procedures and practices.

Every step of cable management is outlined in the TNB Distribution


Division list of PSI and it is accessible via the e-Docs portal. These
documents cover project planning, implementation, commissioning and
project closing,handover for operation & maintenance and asset
replacement / retirement.

The complete life cycle management of the cables also consider


maintenance plans, mitigation of breakdowns, replacement and finally
retirement / disposal of the aged cables. The list of relevant PSI is also
accessible via the e-Docs portal.

In the installation stage of the underground cable system, the use of


checklists have been implemented to maintain installation standards and
to ensure installation quality and hence reduce cable breakdowns due to
poor installation work.

The aims of these PSIs and checklists is to achieve the objectives below:

i. All the workers follow standard work procedures, adopting the


work principle Do It Right The First Time.
ii. To standardize management control procedure and improve
monitoring and control of the quality of work.
iii. To make sure the standard work procedures are strictly adhered
to at the worksite.
iv. To assist in improving the competency of workers.

Procedures are different for 33kV projects and projects that are
22kV and below.

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CHAPTER 7 CABLE MANAGEMENT
Distribution Division Underground Cable System Design Manual

7.2 Cable Installations for 22kV and Below


Underground cable systems of 22kV and below are normally planned,
implemented and maintained by respective TNB Regional Offices
(Pengurus Kawasan).

For managing of 22kV, 11kV and LV cables projects, refer to the latest
editions of the PSI documents listed in Table 7-1.

Table 7-1: Related PSI for managing of cable projects that are
22kV and below
Planning
ENGR-750-11 Project Planning & Implementation Procedure for 22kV
and below
Prosedur Perancangan Perlaksanaan Projek 22kV dan Ke
Bawah
Project Implementation
ENGR-750-12 Project Implementation Procedure for 22kV & Below
Prosedur Perlaksanaan Projek 22kV dan Ke Bawah
ENGR-750-12-WI-02 Work Instruction for Installation of Underground
Cables
Arahan Kerja Pemasangan Kabel Bawah Tanah
ENGR-750-12-WI-06 Work Instruction for Underground Cable Jointing &
Overhead Lines
Arahan Kerja Sambungan Kabel Bawah Tanah Dan
Sesalur Atas
ENGR-750-12-WI-07 Work Instruction for Underground Cables PMOR
Straight Through Joints.
Arahan Kerja Sambungan Terus PMOR Kabel Bawah
Tanah
ENGR-750-12-WI-08 Work Instruction for Underground Cable (XLPE/PILC)
Transition Joint
Arahan Kerja Sambungan Peralihan (Transition) Kabel
Bawah Tanah (XLPE/PILC)
ENGR-750-12-WI-09 Work Instruction for Medium Voltage (MV)
Underground Cables Termination
Arahan Kerja Tamatan Kabel Bawah Tanah Voltan
Sederhana

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CHAPTER 7 CABLE MANAGEMENT
Underground Cable System Design Manual Distribution Division

Commissioning
ENGR-750-13 Project Commissioning Procedure for 22kV and Below
Prosedur Mulatugas Projek 22kV Ke Bawah
ENGR-750-13-WI-01 Work Instruction for Shutdown & Commissioning
Arahan Kerja Hentitugas dan Mulatugas
ENGR-750-13-WI-02 Work Instruction for Testing
Arahan Kerja Pengujian
ENGR-750-13-WI-03 Work Instruction for Registration of New MV Asset into
CGIS
Pendaftaran Aset Voltan Sederhana Baru Dalam CGIS
ENGR-750-13-WI-04 Work Instruction for Update existing and Registration
of new LV asset into CGIS
Arahan Kerja Kemaskini Aset Dan Pendaftaran Aset
Voltan Rendah Baru Dalam CGIS
Project Closing/Handover
ENGR-750-14 Project Closing Procedure for 22kV and Below
Prosedur Penutupan Projek 22kV Ke Bawah
ENGR-750-14-WI-01 Work Instruction for TECO WBS
Arahan Kerja TECO WBS

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CHAPTER 7 CABLE MANAGEMENT
Distribution Division Underground Cable System Design Manual

7.2.1 Planning
Planners in underground cable installations have to prepare Borang
Kebenaran Kerja Modal (BKKM) and determine the cable route suitable
for the project. Approval from relevant authorities must be obtained
before implementing the project.

The approved BKKM is then handed over to Project Unit for


implementation.

7.2.2 Project Implementation


The scope of Project Unit starts from receiving planning documents
(BKKM) from Planning Unit until the issuing of work order to contractors
to begin installation works.

ENGR-750-12 contains the set of procedures for installation of


equipment that are 22kV and below.

Additionally, Pekeliling Pengurus Besar Kanan A19/2011 introduces the


checklists for:

Effective Supervision of Cable Laying


Effective Supervision of Cable Jointing
Testing and Commissioning of Cables

These checklists are a useful tool to ensure installation quality and


reduce cable breakdowns.

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CHAPTER 7 CABLE MANAGEMENT
Underground Cable System Design Manual Distribution Division

7.2.3 Commissioning
ENGR-750-13 details out the steps that need to be taken for
commissioning projects that are 22kV and below.

The procedures cover shutdown application, until submission of the


System Commissioning Form (Borang Maklumat Mulatugas Sistem
Voltan Tinggi) and updating of the CGIS database.

ENGR-750-13 also includes the checklists and forms for testing of all
installations.

It is important to update project details into the CGIS and ERMS


database, as highlighted in ENGR-750-13-WI-03 and ENGR-750-13-WI-04.
Among the details required are date of project completion, equipment
commissioning date, equipment ratings, test output, geo-location data
and as-built drawings which will include information such as location for
joint and route markers.

The information from the database will be used for system planning,
upgrading, replacement and addition of future projects.

7.2.4 Project Closing/Handover


These set of procedures covers the submission of the following
documents to the Planning Unit for project closing/handover.

Commissioning Data (Maklumat Mulatugas Voltan Tinggi)


Project Closing Documents (Dokumen Penutupan Projek)
Technically Complete (TECO)

Page | 157
CHAPTER 7 CABLE MANAGEMENT
Distribution Division Underground Cable System Design Manual

7.3 Cable Installations for 33kV


33kV underground cables are the primary distribution network. The
planning and implementation of 33kV project is handled by a dedicated
department in TNB Distribution Division.

For managing of 33kV underground cable projects, refer to the latest


editions of the PSI documents listed in Table 7-2.

Table 7-2: Related PSI for managing 33kV cable projects


Planning
ENGR-750-56 Planning procedure for 33kV Supply & System Projects
Prosedur Perancangan Projek Bekalan dan Sistem 33kV
ENGR-750-57 Planning Procedure for 33kV Primary Distribution
Substation (PPU) System Projects
Prosedur Perancangan Projek Sistem 33kV Bagi Pencawang
Pembahagian Utama(PPU)
ENGR-750-90 Procedure for Aquiring of Right of Way (ROW) for Cable
Route and Overhead Lines
Prosedur Perolehan Izinlalu Bagi Laluan Kabel dan Talian
Project Implementation and commissioning
APDV-750-50 Procedure for 33kV Project Construction
Pembinaan Projek 33kV
APDV-750-50-WI-01 Work Instruction for Preparation of Project Work
Implementation Report
Arahan Kerja Penyediaan Project Implementation Report
(PIR)
APDV-750-50-WI-02 Work Instruction for 33kV Project Tendering Process
Prosedur Proses Tender Projek 33kV
APDV-750-50-WI-03 Work Instruction for Kick Off Meeting
Prosidur Proses Mesyuarat kick off
APDV-750-50-WI-04 Work Instruction for Getting for Drawing & Permit to
Start Work Approval
Prosedur mendapatkan Kelulusan Lukisan & Permit Mula
Kerja
APDV-750-50-WI-05 Work Instruction for Factory Acceptance Test (FAT).
Prosedur Proses 'Factory Acceptance Test (FAT)'
APDV-750-50-WI-07 Work Instruction for 33kV instalation at work site
Prosedur Proses Kerja Di Tapak - Pepasangan 33kV

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CHAPTER 7 CABLE MANAGEMENT
Underground Cable System Design Manual Distribution Division

Project Closing
APDV-750-50-WI-08 Work Instruction for Clearance Certificate
Prosidur Sijil Pelepasan Pepasangan (Clerance Certificate)
APDV-750-50-WI-10 Work Instruction for Take Over Certificate (TOC).
Prosedur Pengeluaran 'Take Over Certificate' (TOC)

7.3.1 33kV Planning


Planning for 33kV projects begin from the Distribution Network Master
Plan (DNMP) where distribution system requirements for the next 5
years are studied. These plans will determine additional network
infrastructure required to enhance system reliability in each supply zone.

7.3.2 33kV Project Implementation and Commissioning


The main 33kV Project Construction document is the APDV-750-50. It
contains procedures and guidelines for preparing technical proposals,
budgeting, preparation and approval of BKKM, memorandum of
agreement (MOA), tendering, management of construction works,
equipment installation, testing, commissioning and closing of the project.

It is important to ensure the guidelines are adhered to, which includes


obtaining approved project drawings, and permission from the local
authorities.

Documents APDV-750-50-WI-06 and APDV-750-50-WI-07 outline the


procedures that cover all new installations for 33kV equipment in PPUs
and on site, respectively.

7.3.3 33kV Project Closing


These documents detail out procedures for obtaining the Clearance
Certificate and Taking Over Certificate (TOC), prior to commissioning.

Page | 159
APPENDIX
Distribution Division Underground Cable System Design Manual

Appendix
The Cable Damage Curve (CDC) describes the maximum short circuit
current that a cable can withstand within specific time duration. The CDC
is used to determine the relay operating time to protect the cable from
damage. The CDC graphs for typical 33kV, 22kV and 11kV XLPE
Aluminium cable sizes used in TNB.

Table A-1: Maximum fault duration before cable breakdown


for PILC Aluminium cables
Fault Adiabatic Short
Voltage Cable Size
Duration Circuit Current (A)
0.8sec 23362
2 1.0 sec 20896
300 mm
1.2 sec 19075
1.6 sec 16519
0.8sec 14407
2 1.0 sec 12886
11kV 185 mm
1.2 sec 11763
1.6 sec 10187
0.8sec 9345
2 1.0 sec 8358
120 mm
1.2 sec 7630
1.6 sec 6608
0.8sec 14407
2 1.0 sec 12886
185 mm
1.2 sec 11763
1.6 sec 10187
22kV
0.8sec 31149
2 1.0 sec 27861
400 mm
1.2 sec 25433
1.6 sec 22026
o o
PILC Fault Temperature Begin: 75 C, Fault Temperature End: 150 C

Page | 160
APPENDIX
Underground Cable System Design Manual Distribution Division

Table A-2: Maximum fault duration before cable breakdown


for XLPE Aluminium cables
Fault Adiabatic Short
Voltage Cable Size
Duration Circuit Current (A)
0.8sec 66,599
2 1.0 sec 59568
33kV 630 mm
1.2 sec 54378
1.6 sec 47093
0.8sec 25371
2 1.0 sec 22693
240 mm
1.2 sec 20715
1.6 sec 17940
22kV
0.8sec 15857
2 1.0 sec 14183
150 mm
1.2 sec 12947
1.6 sec 11213
0.8sec 25371
2 1.0 sec 22693
240 mm
1.2 sec 20715
1.6 sec 17940
0.8sec 15857
2 1.0 sec 14183
11kV 150 mm
1.2 sec 12947
1.6 sec 11213
0.8sec 10043
2 1.0 sec 8983
95 mm
1.2 sec 8200
1.6 sec 7101
o o
XLPE Fault Temperature Begin: 90 C, Fault Temperature End: 250 C

Page | 161
APPENDIX
Distribution Division Underground Cable System Design Manual

Graph 1: 11kV and 22kV PILC Aluminium Cable


100
90
80
70

60

50

40

30

20

400 mm2
Fault current in Kilo-Amps

300 mm2

10
9
8
185 mm2
7

5
120 mm2

1
0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.0 2.0 3.0
Duration of short-circuit in seconds

Page | 162
APPENDIX
Underground Cable System Design Manual Distribution Division

Graph 2: 33kV XLPE Aluminium Cable


100
90
80
70

60

50

40

630 mm2
30

20
Fault current in Kilo-Amps

10
9
8
7

1
0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.0 2.0 3.0
Duration of short-circuit in seconds

Page | 163
APPENDIX
Distribution Division Underground Cable System Design Manual

Graph 3: 22kV XLPE Aluminium Cable


100
90
80
70

60

50

40

30

500 mm2

20
Fault current in Kilo-Amps

240 mm2

10
9
8
150mm2
7

4
70 mm2

1
0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.0 2.0 3.0
Duration of short-circuit in seconds

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APPENDIX
Underground Cable System Design Manual Distribution Division

Graph 4: 11kV XLPE Aluminium Cable


100
90
80
70

60

50

40

30

500 mm2

20
Fault current in Kilo-Amps

240 mm2

10
9
8
150 mm2
7

5
95 mm2

1
0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.0 2.0 3.0
Duration of short-circuit in seconds

Page | 165
LIST OF ABBREVIATIONS
Distribution Division Underground Cable System Design Manual

List of Abbreviations
1C Single core
3C Three core
A Amperes
ABC Aerial bundled cables
Al Aluminium
AMD Asset Management Department
BKKM Borang Kebenaran Kerja Modal
BS British Standard
CDC Cable Damage Curve
CGIS Corporate Geospatial Information Management
System
Cu Copper
DSICV Deep Stepped Indentation Control Volume
EHV Extra high voltage
EPDM Ethylene Propylene Diene Monomer
EPR Ethylene Propylene Rubber
ERMS Enterprise Resource Management System
FAT Factory Acceptance Test
FP Feeder pillar
GI Galvanised iron
HDD Horizontal Directional Drilling
HDPE High Density Polyethylene
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
ITU International Telecommunication Union
LDPE Low density polyethylene
LV Low voltage
LVDB Low voltage distribution board
MDPE Medium Density Polyethylene
MOA Memorandum of Agreement
MSB Main Switchboard

Page | 166
LIST OF ABBREVIATIONS
Underground Cable System Design Manual Distribution Division

MTBM Micro-tunnel Boring Machine


MV Medium voltage
PE Polyethylene
PILC Paper Insulated Lead Covered
PMOR Pre-moulded with Outer Resin
PMU Transmission Main Intakes / Pencawang Masuk Utama
PN Pressure Nominal (bar)
PPE Personal Protection Equipment
PPL Polypropylene Paper Laminate
PPU Primary Distribution Substation / Pencawang
Pembahagian Utama
PSI Process System Improvement
PVC Polyvinyl chloride
RCC Regional Control Centre
ROW Right of Way
RTU Remote Terminal Unit
SCADA Supervisory Control and Data Acquisition
SiR Silicone Rubber
SSU Main Switching Stations / Stesen Suis Utama
TNB Tenaga Nasional Berhad
TOC Take Over Certificate
uPVC Unplasticised Polyvinyl Chloride Pipes
UV Ultraviolet
V Volts
XLPE Cross-linked Polyethylene
TECO Complete (Technically)
WBS Work Breakdown Structure

Page | 167
GLOSSARY
Distribution Division Underground Cable System Design Manual

Glossary
Ageing The irreversible change of material properties after exposure
to an environment for an interval of time.
Ampacity The current carrying capacity of a cable, expressed in
amperes. The current that a cable can carry under stated
thermal conditions without degradation.
Ampere (Amp) The basic SI unit of the quantity of electric current. That
constant current that is maintained in two straight parallel
conductors of infinite length, or negligible cross section, and
place one meter apart in vacuum, would produce a force
equal to 2x10-7 Newton per meter of length.
Backfill The materials used to fill an excavation, such as sand in a
trench.
Bedding A layer of material that acts as a cushion or inter-connection
between two elements of device, such as the jute o
polypropylene layer between the sheath and wire armour in
a submarine cable.
Bending Radius The inner radius of a cable, such as when it is trained or being
installed.
Bimetallic Lug Lug formed by two different metals metallurgically bonded,
used to connect conducting parts consisting of these same
metals.
Braid An interwoven cylindrical covering usually of fibre or wire.

Cable Assembly consisting of:


one or more cores,
their individual covering(s) (if any),
assembly protection (if any),
protective covering(s) (if any).
Cable Drum Cylinder with flanges on to which cable is wound during
manufacture, for storage, transportation and installation.
Cable Slab Visual warning indicators and as a mechanical protection for
underground laid cables in the event of excavation/digging
work.
Cable Tray A rigid structure to support cables. A type of raceway
normally having the appearance of a ladder. May be open at
the top (or side) to facilitate changes, or be covered with a
ventilated or solid cover.
Cable, Aerial Bundle An assembly of one or more insulated conductors that are
lashed or otherwise fastened to a supporting messenger.

Page | 168
Glossary
Underground Cable System Design Manual Distribution Division

Cable, Belted A multi-conductor cable having a layer of insulation over the


assembled insulated conductors.
Concrete Slab A flat, reinforced-concrete structural member.

Core, Assembly comprising a conductor with its own insulation


Insulated Conductor (and screens if any).

Corrosion The deterioration of a substance (usually a metal) as a result


of a chemical reaction with its environment.
Cross-bonding Special bonding in which the cable shields in consecutive
elementary sections are cross connected so that each
continuous shield circuit surrounds the three-phase
conductors consecutively.
Cross-linked Insulation made of a thermoplastic material or a copolymer
Insulation or a compound based on one of these materials, the internal
molecular structure of which is changed when cured by
chemical reaction, such as, cross-linking or vulcanization
and/or physical process, such as irradiation.
Current, Induced Current in a conductor due to the application of a time-
varying electromagnetic field.
Current, Leakage That small amount of current that flows through insulation
whenever a voltage is present. The leakage current is in
phase with the voltage and its power loss.
Dielectric Strength The maximum voltage that an insulation can withstand
without breaking down, usually expressed as a gradient
volts per mil or kilovolts per millimetre.
Duct Class B polyvinyl chloride (PVC) pipe.

Duct Bank Method to have covered trenches with cables via ducts may
be employed.
Eddy Current Circulating currents induced in conducting materials by
varying magnetic fields, usually considered undesirable
because they are represent loss of energy and create heat.
Fibre/Pilot Cable Control cable laid in parallel with a power cable and intended
for transmitting signals related to the operation of that cable.
Filler A relatively inert and low-cost material used to a compound
to improve physical properties and make it less costly.
Flat Formation Formation of a number of cables laid in a plane, usually with
equal spacing between adjacent cables.
Hardness Resistance to plastic deformation; stiffness or temper;
resistance to scratching, abrasion or cutting.

Page | 169
GLOSSARY
Distribution Division Underground Cable System Design Manual

Insulated Separated from other surfaces by a substance permanently


offering a high resistance to the passage of energy through
that substance.
Joint Accessory making a connection between two cables to form a
continuous circuit.
Joint Ferrule Metallic device for connecting two consecutive lengths of
conductor.
Link Box Box in which bonding and/or earthing connections are made
through removable links and which may also contain shield
voltage limiters.
Mass-Impregnated Impregnated paper insulation in which the paper tapes are
(Paper) Insulation impregnated after lapping.

mm Millimetre. Unit of measure equal to 0.001 meter.

Monometer A term denoting a single property or ingredient. A molecule


of low molecular weight used as a starting material to
produce molecules of larger molecular weight called
polymers.
Nominal A term used to describe functional behaviour as being within
expected norms or as designed.
Ohm The SI unit of electrical resistance; one ohm equals one volts
per ampere.
Permeability (1) The passage or diffusion of a vapour, liquid or solid
through a barrier without physically or chemically
affecting either,
(2) The rate of such passage.
Plasticizers Chemical agents added during compounding of plastics to
make them more flexible and pliable.
Polymer A high molecular weight compound whose structure can
usually be represented by a repetition of small units of that
compound.
Pulling Eye A device attached to the end of a cable to facilitate field
connection of the pulling ropes.
Reinforced Concrete Concrete in which reinforcement bars (rebars),
reinforcement grids, plates or fibres incorporated to
strengthen the concrete in tension.
Sand Bedding Cushioning layer or layers applied to a cable immediately
beneath a metallic layer such as the armour or the
reinforcement.

Page | 170
Glossary
Underground Cable System Design Manual Distribution Division

Semiconducting A conducting medium where conducting is by electrons. The


resistance of these materials is generally in the range
between that of conductors and insulators.
Service Pit Service pits are used for pulling, bending, duct bank tee-offs
and jointing of cables.
Sheath/Jacket uniform and continuous tubular covering of metallic or non-
metallic material, generally extruded.
Shoring Bracing of the walls of a trench in order to prevent collapse.

Strand, Sector A stranded conductor formed into sectors of a circle to


reduce the overall diameter of the cable.
Strand, Segmental A stranded conductor formed into sectors that are insulated
from one another to reduce the ac resistance of the
conductor.
Terminal/Lug Metallic device to connect a cable conductor to other
electrical equipment.
Termination Device fitted to the end of a cable to ensure electrical
connection with other parts of the system and to maintain
the insulation up to the point of connection.
Thermal Resistivity The materials ability to resist heat transfer.

Thermoplastic (1) A plastic that is thermoplastic in behaviour.


(2) Having the quality of softening when heated and of
returning to its original state when cooled below that
range.
Thermosetting Materials that upon curing undergo an irreversible chemical
and physical property change so that subsequent heating
does not return them to their original state.
Topsoil The upper, outermost layer of soil, usually the top 2 inches
(5.1cm) to 8 inches (20cm).
Trefoil Formation Formation of three cables so laid as to be mutually
equidistant.
Trench A type of excavation or depression in the ground where
cables are installed.
Triplexed Three conductors or cables that are twisted together.

Voltage Rating The designated maximum permissible phase-to-phase ac (or


direct current) voltage at which a cable is designated to
operate.
Washed River Sand Premium grade clean river sand.

Page | 171
Cable Laying Design Manual
Version June 2012
Asset Management Department
TNB Distribution Division

Cable technology has progressed rapidly over the years since the
invention of electricity. With increasing voltages and higher power
requirements, cable technology has become very sophisticated,
requiring care during design, manufacturing and installation with
specific installation methods, as well as detailed operations and
maintenance guidelines.

Asset Management Department (AMD), in collaboration with ILSAS,


TNB Research and Uniten, have developed this manual which
incorporates all existing relevant circulars and standardizes
underground cable installation in TNB under all circumstances.

The contents of this manual cover the following points of interest:

Chapter 2 Basic Cable Theory


Introduction on theories and philosophies for cable design &
construction, available cable types, ampacity and cable damage curve,
cable laying formation and arrangement, sheath bonding methods
and cable accessories.

Chapter 3 Cable Laying Specification


Shows dimensions and details to install cables in trenches and in
pipes/ducts, including description of the joint/pulling pit and cable
bridges.

Chapter 4 Cable Laying Accessories


Description and use of different cable slabs, route markers and cable
joint marker.

Chapter 5 Cable Laying Procedures


Detailed procedures covering initial preparation, site safety, trench
excavation, duct installation, cable pulling, laying-off cables,
alternative cable installation methods (HDD, pipe jacking micro-
tunnelling), cable jointing, termination, backfill material and
protection of cables, road reinstatement and also tidying of sites.

Chapter 6 - Cable Laying in Substations


Description of equipment used to install cables inside substations.

Chapter 7 Cable Management


Covers documentation for project planning, implementation,
commissioning and project closing/handover.

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