Cables
Cable Drum Inspection
Underground Cables - Cable Trenching.
Cable laying.
Cable IR Test Prior to backfilling.
Trench backfilling.
Installation of cable Trays.
Above ground Cables laying.
Earthing and Bonding.
Conductor phase continuity test
Glanding, Tagging & Ferruling.
Cable termination
LV /HV Cable testing after glanding & termination.
Connectors
Ferrules
Cable Identification & Route markers.
Cable Drum Inspection
Verify cable size, number of cores,type,rating,colour code
Core marking, any physical damage,kinks on outer sheath/drum/batten etc.
Cable Drum inspection, continuity test &
Insulation Resistance test shall be carried prior to release to site for installation.
Cable shall exhibit continuity & comply with cable spec.
The IR test between core to core ,core to armour, shield to armour.
Test Voltage : - ( Duration 1 min )
1) 500V DC For LV Cables (50-1000 V)
2) 2500V DC FOR MV Cables (Up to 4.6 kv Cables)
3) 5000 V DC for MV/HV Cables (above 4.6 kv)
IR Value:10 x KV / KM
Both Cable end shall be sealed after drum test.
Underground Cables - Cable Trenching.
Cable Trench route & size as per AFC Drawing.
Trench Cleaning, sand quality and Sand layer (100mm both below and above cable ) as per specification.
Minimum depth of directly buried cable trench to be 750 mm for L.V. and 900 mm for H.V. cables. The depth
& width of the trench shall vary depending upon the number of layers of cables. These cables to be covered
with 150 mm of sand on top of the largest diameter cable and sand to be lightly compacted. A flat protective
covering of 75 mm thick second class red bricks or concrete tiles shall then be laid and the remainder of the
trench shall then be back-filled with soil, rammed and levelled.
Cable laying.
Cable jacks and cable rollers to be used during laying of cable.
Cable drum, cable size, voltage rating, type &
Correct cable route identified as per AFC drawings.
Color code shall be as per specification.
Cable shall be rotated in the indicated direction.
Cable drum are positioned on free rotation stand and aligned for cable pulling,
Cable pulling tension and bending radius shall meet manufacturers recommendation,
Single core cable shall be laid in trefoil formation, spacing bet'n cables and cable & pipe line as per AFC drgs.
Cable IR Test Prior to backfilling.
Insulation resistance test / continuity test and inspection of cable prior to backfilling the trench,
the IR test between core to core ,core to armour, shield to armour.
Test Voltage : - ( Duration 1 min )
1) 500V DC For LV Cables (50-1000 V)
2) 2500V DC FOR MV Cables (Up to 4.6 kv Cables)
3) 5000 V DC for MV/HV Cables (above 4.6 kv)
Open end of the cable shall be seal after the test.
Trench backfilling.
Cable segregation and spacing shall be done as per AFC drawing and specification.
Cable dressing/clamping shall be done as per specification.
Cable tagging shall be done as per AFC Drg.
Cable conduit and duct entries shall be sealed off as per approved material and procedure.
Sand quality shall meets specification requirement.
Warning tape and protection tiles shall be installed before final backfilling.
Verify soft sand bed is provided as per project spec requirement. Cable numbering should be provided in every
5m interval of underground cables. Cable route and joint
markers provided visibly above ground as per AFC Drawings
Installation of cable Trays
Tray size and type shall be ensure as per AFC drawing and specification
Spacing between tray, elevation and tray accessories as per specification
Tray bending radius as per specification
Expansion guides shall be at specified intervals.
Suitable nuts/bolts/washer & tightening as per approved specification
Exposed surface shall be cleaned, touch up with primer and finish paint.
All tray bonded and connected to earth grid as per AFC drawing
Proper kick guards/ stab ups should be provided where cable entering from below ground to above ground
Above ground Cables laying.
Cable drum, cable size, voltage rating, type & color code shall be as per AFC Drawing & spec.
Cable shall be rotated in the indicated direction.
Correct cable route identified.
Cable drum are positioned on free rotation stand and aligned for cable pulling.
Cable pulling tension and bending radius shall meet manufacturer’s recommendation.
Cable shall be laid in tray or racks as per layout drg.
Cable ties or clamp shall be provided every change in direction and interval.
Spare space available in the tray as per AFC Drg.
Properly arranged in correct compartment, i.e. power cable, communication cable etc., in
designated compartments.
Crossing of cables in multi-layer is per specification and drawing.HV cable shall be segregated from LV cable
Cables are properly identified.
Cables are tied with cable tray/ladder using appropriate cable ties.
Proper sealing shall be provided in wall crossings.
Earthing and Bonding.
LV Cable amour is bonded to earth at both ends.
Copper screen of HV Cable bonded to earth at both ends.SP-1109 Appendix-1.
Cable gland earthing shall be done.
Connecting both side earths on S/C HV cable need to be consulted with company site representative
prior to connection
Conductor phase continuity test
To ensure the continuity and phasing of the cable conductor from terminal to terminal, the cable conductor shall
be tested by using a 500VDC megger
Cable Termination.
All cores of multi core cables shall be terminated All HV Cable termination shall be carried out
Suitable crimping type lugs for all terminations.
The double compression type cable glands to be used for indoor panels/ equipment (e.g. substation, control
room etc). The cable glands for outdoor terminations to be weather protected, double compression type. The
size of cable glands supplied to be appropriate to the size of cable so that frame proofness of glands is retained.
Entry thread of cable gland to be compatible to the entry thread provided in the equipment (BS, ET, NPT, PG
as applicable). If required, suitable reducers/ adopters to be used.
All XLPE cables up to 1100V grade to be terminated at the equipment by means of compression type cable
glands suitable for the cable size. The cables to be identified close to their termination points at both the ends
of cable and also along the route at recommended intervals, by cable tag numbers. All cable entries for outdoor
termination to be preferably through bottom.
All unused cable entries on equipment/ panels to be plugged/ sealed. The cable to be terminated at electrical
equipment/ switchboards through glands of proper size.
Crimping of lugs to cable leads to be done by hand crimping/ hydraulically operated tool Lugs shall enclose
all strands of cable core.
:
The number of joints to be restricted to minimize as far as possible.
The location of joints to be identified with permanent markers.
No joints to be allowed in hazardous areas without the approval of Engineer-in-charge.
No unauthorized repairs, modifications to be carried out on the hazardous area equipment terminal boxes and
junction boxes. After termination is complete, all the bolts, nuts, hard wares of terminal box to be properly
placed in its position and tightened. All power and control cables glands installed outdoor to be provided with
suitable sized shrouds
Connectors
Power cable terminations to be made with crimped type tinned copper solder less lugs which to be
suitable for the cable size mentioned in cable schedule.
Ferrules
Ferrules to be of approved type and of size to suit core size mentioned and to be employed to designate
the various cores of control cable by the terminal numbers to which the cores are connected, for ease
of identification. Ferrule to be printed type.
Glanding, Tagging & Ferruling.
Only Approved makes cable jointing glands and termination kit shall be used for Termination/
/jointing. Jointer Tool kit.
Adequate gland and accessories used for Glanding and termination of the cable.
Non-magnetic gland plate used for single core cable.
Tightening for gland, check nut & termination done.
Bolted connections are properly tighten by using torque wrench and ensured no loose connection exist.
Tagging and ferruling shall be as per project numbering procedure.
Glanding & termination process verified during work against manufacturer's instruction manual.
LV Cable testing after glanding & termination
Cable Continuity test for all core shall be done prior to IR test.
Insulation resistance test core to core & core to earth shall be done.
Test Voltage: 1)500 V DC @ 1 min. for LV Cables.
Phase sequence shall be checked during reconnection.
Termination tightening & torquing shall be done.
HV Cable Testing after glanding & termination
Continuity test & IR Test shall be done prior to Hi-pot test.
Earthing and safety requirements available.
Hi-pot test shall be carried and leakage current recorded at specified intervals.
IR test shall be done after hi-pot test.
Test Voltage for IR test: (Duration 1 Min)
1)2500 V DC for MV Cables (upto 4.6kV cables)
2)5000 V DC for MV/HV Cables (above 4.6kv)
Test Voltage for Hipot test: (Duration 3 Min)
Cable Voltage 1.8/3 (3.6) kV → Test Voltage - 10kV.
Cable Voltage 3.6/6 (7.2) kV → Test Voltage - 15kV.
Cable Voltage 6/10 (12) kV → Test Voltage - 25kV.
Cable Voltage 8.7/15 (17.5) kV → Test Voltage - 35kV.
Cable Voltge12/20 (24) kV → Test Voltage - 50kV.
Cable Voltge18/30 (36) kV → Test Voltage - 70kV.
Test voltage application shall be subject to manufacturer recommendation.
Cable grounding and discharge after each test.
Age of Cable - Test Voltage
0 to 2 years - 75 % and above
Cable Identification & Route markers.
Cable tag shall be provided at regular intervals as per AFC Drawing and approved material to be used
Cable tag shall be fastened by SS tie wire at outdoor installation
Cable tag numbering shall be done as per project spec.
Route marker shall be installed at specified interval/location.
