THE CLASSIFICATION OF UNDERGROUND CABLES

Place where it is used Insulation material used Mechanical protection Place of utilization System for which used Type of conductor

 Gauge of the conductor Pressurization of core

Sheath LSDC / PVC

Insulating material PVC / PAPER

C
2nd pair B Limb

O R E

1st pair A limb 1st pair B Limb

Annealed Copper Conductors

Filling material Dry air / Jelly

3rd pair A Limb

MECHANICAL PROTECTION 2 LAYERS OF GI STRIPS

CONDUCTOR Pairing and Overlay Unit Formation Core wrappings Filling compound SCREEN SHEATH ARMOURING

Pairing and Overlay

Two insulated conductors shall be twisted together with uniform lay to form a pair. The length of the lay of any pair shall be different from that of adjacent pairs. The lay of various pairs shall be so chosen as to satisfy the capacitance unbalance requirements and cross-task requirement.

SCREEN
An aluminum tape coated with polythene / copolymer on both sides shall be applied over the cable core with a minimum overlap of 6 mm for all sizes of cables

CODE FOR WIRE IDENTIFICATION

Primary colors For 1st wire in a pair White Red Black Yellow

 Blue

Secondary colors For 2nd wire in a pair and binder tape of unit in 50pr/100pr unit

Orange Green Brown

Slate/Gray

CODE FOR TAPE OR BINDER FOR UNIT IDENTIFICATION

Unit 1 2 3 4 5 Colour Blue Orange Green Brown Slate/Gray

Super Units
200 & 400 pair cable su of 50 paiirs Above 400 pairs su of 100 pairs

Identification of super units

Position of the layer First (Marker) Itermediate Last (Reference) Colour Red White Black

The numbering of the units will be clock wise

CABLE LAYING
Receipt, storage, handling and transport of cable Surveying and selection of routes, trenching and laying Jointing of cables and termination Preparation of cable plan, cable diagram and other relevant records Acceptance testing

SURVEYING THE SELECTION OF ROUTE :

The routes should be as short as practicable provided other requirements viz., future requirements and expansion of other services are take in to consideration. Normally the cable should be laid along road and railway tracks. (b) Corrosive soil should be avoided. If unavoidable measures like covering the cable with sand or drawing the cable through non-reactive duct should be adopted. (c) Opening of expensive pavements and roads should be avoided. (d) The consideration should be given to the existence, alternation and growth of other services. (e) While surveying along a new road under construction or newly developed area, proper coordination should be maintained with other underground services like water, electricity, sewage, gas etc.

 DEPENDING UPON THE ROUTE SELECTED, PERMISSION FOR DIGGING TRENCHES ARE TO BE TAKEN FROM THE RELEVANT AUTHORITIES

 AT THE TIME OF TRENCHING OPERATION CO-ORDINATION WITH THE FOLLOWING AUTHORITIES ARE TO BE MAINTAINED: (1)Electric supply. (2) Water supple. (3) Gas pipeline. (4) Sewage system.

TRENCHING :
Trenching should be such that the top of the cable should not be less than 60 cms. from the soil surface. (b) The alignment should be straight at least 50 m at a stretch. (c) It should be at least 0.3m away from the boundary walls. (d) The depth of the trench should be 1.2 m. (e) The width of the trench should be between 30 cm and 40 cm minimum

 (i) A separation of 0.6 m (relaxable upto 0.2m) should be maintained while cable laid parallel to electric cables. (ii) Parallelism exceeding 0.8 km with 11KV and above should be referred to PTCC (iii) At the crossing with electric cables, the telephone cable should be laid solid in between for 90 cm on either side. Cross-trenches (trial pits are to be made if records for existing services

 The min. bending diameter for armoured cables should be 15 times of the diameter of the cable

ROAD CROSSING
Cable should be laid through G.I. pipes of suitable sizes. (b) The depth of the pipe from the surface of the road should be 1m and with a slight slope to pass away water. (c) The number of pipes laid at a time should be sufficient to cater to the requirements for 20 years. (d) No jointing in the middle of the road

 Permission from the Chief Engineer PWD is to be taken. (b) The cables should be laid at distance not less than 457 cm from the Centerline of the road on formation.

GUIDELINES FOR LAYING OF CABLES ALONG NATIONAL HIGH WAYS

(c) The depth of the cable from the soil surface should not be less than 120 cm.
(d) While laying along grove or avenue, due consideration to save the cable from the clutches of the roots are envisaged

Along over bridges culverts & Fly over

A culvert should be paid by a concrete channel of 12 depth below the bed of the culvert to correspond to the footpath alignment so that all the cables can be drawn through this opening

 In order to lay the cable across small bridges with piers the piers should be extended beyond the width of the road so that pipe for cables may be securely clamped on the piers

 In case of long bridges and fly over in cities, liaison should be kept with proper authorities to ensure that suitable arrangements are provided for laying cables. the present practice is to have a concrete channel 20 to 30 cm in depth 90 cm in width along the footpath with removable covers

ALONG RAILWAYS
Side of the track will be selected by DET in consultation with proper Railway authority e.g. either Divisional Operating superintendent or district Engineer, if the alignment falls within 3 to 5.5 meters from the centre line of any Railway Track. Excavation and reinstatement for any underground cable within 3 meters of the centre of any Railway track or any attachment to any Railway structure should be attended by the Railway staff at the cost of DOT.

RAILWAY CROSSING
Railway track should be crossed by G.I. pipes of 75 mm dia. Minimum depth of the GI pipe from below the rail level should be 1.25 meters. The length of the pipe should be sufficiently long so that work on telecom alignment can be carried out without any hindrance to the railway traffic. This should extend at least 4.5 meters from the center of the last track.

LAYING METHOD OF THE CABLE

Laying direct in the ground laying solid drawing through duct or duct laying

Digging the trench as per standard The digging may be done manually or be thrust boring or by other mechanical means. Preparation of a bedding 5 cm high of soft soil (sieved earth) free from stones and corrosive elements. Thorough checking of cable which is to be laid. Paying out the cable in the trench

LAYING METHOD OF THE CABLE

Laying direct in the ground laying solid drawing through duct or duct laying

As a protective measure a row of bricks (length wise or width wise depending upon the number of cables) or stone slabs are to be placed along with cable alignment. The modern practice is to lay a plastic tape with name of the Department printed on it at about 30 cms above and along with cable alignment

LAYING METHOD OF THE CABLE

Laying direct in the ground laying solid drawing through duct or duct laying

As a protective measure a row of bricks (length wise or width wise depending upon the number of cables) or stone slabs are to be placed along with cable alignment. The modern practice is to lay a plastic tape with name of the Department printed on it at about 30 cms above and along with cable alignment

DIRECT LAYING
Digging the trench as per standard The digging may be done manually or be thrust boring or by other mechanical means. Preparation of a bedding 5 cm high of soft soil (sieved earth) free from stones and corrosive elements. Thorough checking of cable which is to be laid. Paying out the cable in the trench

Precautions at the time of paying

There should not be any twist in the cable and there should not be heavy strain (specially in the case of un armoured cable) Laying should be as far as practicable straight and along one side of the bed of the trench . If more than one cable are to be laid at a time, there must not be any criss-cross of the cables.

Warning Bricks or tapes

As a protective measure a row of bricks (length wise or width wise depending upon the number of cables) or stone slabs are to be placed along with cable alignment. The modern practice is to lay a plastic tape with name of the Department printed on it at about 30 cms above and along with cable alignment

Preparation of diagrams & records

All the diagrams relating to the cable alignment viz. line diagram for primary secondary and distribution side, cable plan for primary secondary and distribution side, records for Pillars and DPs etc. are to be prepared.

JOINTING ACTIVITY

Some Common Wrong Practices and Their Remedies.

Crossing Water Pipes

Crossing Culverts

Crossing 11KV Electric Cables

In respect of parallelism, it is advisable to take the telecom cable with maximum horizontal clearance as far as practicable but not less than 0.6 meters Absence of sheath continuity and armour continuity in Telecom cable and its improper earthing in the vicinity of power cable will result in AC induction and consequent impairment of the telecom circuits

 When the power parallelism is more than 0.8 kms the cable route should be referred to Power Telecom Co-ordination Committee (PTCC) for recommendation of protection measures

 . In case of crossings, care should be taken see that telecom cable crosses at right angles and at a vertical clearance preferably of 0.6 meters but not less than 0.3 meters at any point. When the specified clearances cannot be maintained, it is preferable to lay the telecom cable through cement concrete pipes for a length of 1 meter on either side of power cable at the crossing and seal the mouths at both ends.

CABLE JOINTING
STRAIGHT JOINT BRANCH JOINT

 ARRANGEMENTS TO BE MADE BEFORE THE START OF JOINTING

CONDUCTOR JOINTING
CONVENTIONAL METHOD :-Twist Joint USING CONNECTORS

DIFFERENT JOINTING PROCEDURES IN TELECOM CABLES

LEAD SLEEVE JOINTS AUXILIARY LEAD SLEEVE SEAL (ALSS) JOINT. JOINTING OF JELLY FILLED CABLES USINGT THERMOSHRINKING TECHNIQUE

PROCEDURE FOR JOINTING J.F. CABLE USING XAGA TECHNIQUE

Cable Marking Armour removing Conductor Jointing Filling of Compound Metal Canister Cable Preparation Thermo shrinking Armour Continuity Completed

Kit Selection
TSF 1 TSF2 TSF3 TSF4 TSF5 TSF 6 10/6.5, 20/6.5 50/6.5 100/6.5 200,300, 400/6.5 600, 800/6.5 1000 ,1200/6.5

 When cables to be jointed are of same pair found on both sides, use the kit indicated in the kit selection chart

b)When one cable is larger in pair count than the other, the kit indicated against the smaller one is to be used, e.g. to join a 100 pair cable to a 20 pair cable, TST 1 is to be used.

 . The sum of the diameters of all the cables on the branch side plus the thickness of branch clips should not exceed the maximum splice bundle diameter indicated in the kit selection chart. Condition 2. If any side contains only one cable, the diameter of the single cable should not fall below the minimum cable diameter indicated in the kit selection chart.

Kit Selection
TSF 1 TSF2 TSF4 TSF5 TSF 6

Kit Selection
TSF 1 TSF2 TSF4 TSF5 TSF 6 10/6.5, 20/6.5

Kit Selection
TSF 1 TSF2 TSF4 TSF5 TSF 6

18/6.5, 28/6.5

Kit Selection
TSF 1 TSF2 TSF4 TSF5 TSF 6 10/6.5, 20/6.5

Kit Selection
TSF 1 TSF2 TSF4 TSF5 TSF 6 10/6.5, 20/6.5

Kit Selection
TSF 1 TSF2 TSF4 TSF5 TSF 6 10/6.5, 20/6.5