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Design Manual
June 2012
Asset Management Department, TNB Distribution Division
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Underground Cable System Design Manual
June 2012
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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.
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Distribution Division Underground Cable System Design Manual
Foreword
VP Distribution Division, Datuk Ir. Baharin Din
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.
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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TABLE OF CONTENTS
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TABLE OF CONTENTS
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TABLE OF CONTENTS
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TABLE OF CONTENTS
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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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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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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.
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Underground Cable System Design Manual Distribution Division
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CHAPTER 1 INTRODUCTION
Distribution Division Underground Cable System Design Manual
g. IEEE Standard Power Cable Ampacity Cable, IEEE Std 835-1994, 1994
doi: 10.1109/IEEESTD.1994.85814.
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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
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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
(3) Insulation
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2.1.1 Conductor
CONDUCTOR
SOLID STRANDED
CIRCULAR SECTORIAL
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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)
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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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
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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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Typical sizes of PVC insulated, PVC jacketed LV cables in TNB are shown
in Table 2-5 below.
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2
33kV, XLPE, 1C, 630mm , Al, SCW, MDPE
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9 8 7 6 5 4 3 2 1
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8 7 6 5 4 3 2 1
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11 10 9 8 7 6 5 4 3 2 1
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3 2 1
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8 7 6 5 4 3 2 1
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
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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
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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
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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
4
FOC Specs For Tender Doc approved by Distribution TC
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o
Native soil thermal resistivity: 2 C.m/W
o
Sand thermal resistivity: 1.2 C.m/W
o
Ambient temperature: 30 C
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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.
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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.
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.
The detailed CDC graphs of typical 33kV, 22kV and 11kV XLPE Aluminium
cable sizes used in TNB can be found in the Appendix.
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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.
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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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
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(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.
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
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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
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Transformer Switchgear
Distribution
Open Earth
500m
Vmax
Voltage
Figure 2-18: Sheath voltage in both end-bonding for single core cables
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CHAPTER 2 BASIC CABLE THEORY
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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.
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
3 minor = 1 major
ST = straight-through joint
CB = cross-bond joint
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(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.
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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.
2.7.1.1 Overview
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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.
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.
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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)
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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.
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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.
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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.
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.
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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.
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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
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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.
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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.
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2.7.4 Termination
2.7.4.1 Overview
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.
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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.
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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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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.
Cross-bonds are made at 6+1 or 3+1 link boxes specified in the following
subchapters.
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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.
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
Joints
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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.
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
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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).
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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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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.
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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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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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
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Ground level
Earth backfilling
Cable slab
Washed river sand
Cable
Washed river sand
Road level
Wearing course
Binder course
Crusher run
Cable slab
Washed river sand
Cable
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Ground level
Earth backfilling
Road level
Wearing course
Binder course
Crusher run
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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.
8
Technical Specifications, Single & Double Wall High Density
Polyethylene (HDPE) Corrugated Pipe, 7 April 2000.
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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.
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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
9
Pekeliling Pengurus Besar Kanan (Kejuruteraan) Bil. A17/2008- Larangan Merentang
Kabel 1 Teras dalam Paip Besi GI
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10
P&PA Specifications
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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
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
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
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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.
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.
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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
The pits are also used as pulling pits to install cables in ducts.
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There are two basic cable bridge designs which are the I-beam (Type A)
and Truss (Type B) bridges.
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uPVC cable slab dimensions are 1000mm (L) x 250mm (W) x 2.0mm (T)
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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This cable slab uses a hook and lock interlocking mechanism to secure
the cable slabs together.
Hook Lock
Figure 4-2: Orange uPVC slab for 11kV and 22kV cable system
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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.
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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:
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Where cables are laid direct in ground, cable route markers shall be
provided at:
Two existing types of cable route markers are as shown in Figure 4-5 and
Figure 4-6.
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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
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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).
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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.
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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.
The route plan will consist of the proposed cable route location, jointing
pit, access road, obstructions, etc.
14
ENGR-750-90-WI-02, Arahan Kerja Pementaan Utiliti Bagi Laluan Kabel, 14
Oktober 2011.
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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.
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Where allowed, a bank of excavated materials not less than 0.5 metres
high may be regarded as a fence.
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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 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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Figure 5-1: Some safety signs and notifications used for roadside works
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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.
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Figure 5-2: Using the road cutter with diamond blade to cut through
the tarmac layer
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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
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.
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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.
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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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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:
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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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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7) The cable is pulled through the duct from the pulling pits/joint pit.
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The site plan should indicate the position of cable drum and pulling
winch (if used).
f) Cable drums, sand, tiles, rollers, etc., shall not be stored to block
access ways and roads.
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Connecting bolts
Spindle
Manufacturer info (used on site)
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
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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
Securing Wooden
cables/ropes wedges/chocks
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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.
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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.
Cable that is
being laid
15 x D
15 x D
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5.5.2.1 General
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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.
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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.
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.
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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.
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.
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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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.
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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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.
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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.
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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.
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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.
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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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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5.5.6.1 Flaking
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.
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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Remove roller equipment from the trench and place on the trench side
in a position convenient for collection.
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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.
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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HDD Machine
5.7.1.2 Pre-reaming
HDD Machine
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HDD Machine
Figure 5-22: Pull-back of the pipe and cable through the reamed hole
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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.
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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 joint body installation shall follow the jointing instruction provided
by the manufacturer together with the joint kits supplied.
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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.
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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 5-28: Use of uPVC slabs for 11kV and 22kV cable installations
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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.
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Distribution Division Underground Cable System Design Manual
15
Guidelines for Works Related to Public Utility Installations within the Road
Reserve, Road Engineering Association of Malaysia
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Underground Cable System Design Manual Distribution Division
Figure 5-31: The site must be cleaned and made safe for public use
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CHAPTER 6 CABLE LAYING IN SUBSTATIONS
Distribution Division Underground Cable System Design Manual
Placement on flooring:
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CHAPTER 6 CABLE LAYING IN SUBSTATIONS
Underground Cable System Design Manual Distribution Division
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CHAPTER 6 CABLE LAYING IN SUBSTATIONS
Distribution Division Underground Cable System Design Manual
Figure 6-4: Cable ladders should also bend according to the cable
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CHAPTER 6 CABLE LAYING IN SUBSTATIONS
Distribution Division Underground Cable System Design Manual
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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.
The aims of these PSIs and checklists is to achieve the objectives below:
Procedures are different for 33kV projects and projects that are
22kV and below.
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CHAPTER 7 CABLE MANAGEMENT
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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.
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7.2.3 Commissioning
ENGR-750-13 details out the steps that need to be taken for
commissioning projects that are 22kV and below.
ENGR-750-13 also includes the checklists and forms for testing of all
installations.
The information from the database will be used for system planning,
upgrading, replacement and addition of future projects.
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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)
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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.
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APPENDIX
Underground Cable System Design Manual Distribution Division
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APPENDIX
Distribution Division Underground Cable System Design Manual
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
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APPENDIX
Underground Cable System Design Manual Distribution Division
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
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APPENDIX
Distribution Division Underground Cable System Design Manual
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
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
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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
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LIST OF ABBREVIATIONS
Underground Cable System Design Manual Distribution Division
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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.
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Glossary
Underground Cable System Design Manual Distribution Division
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.
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GLOSSARY
Distribution Division Underground Cable System Design Manual
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Glossary
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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.