Professional Documents
Culture Documents
By
2015
UNDERGROUND ELECTRIFICATION
SYSTEM
APPROVED BY
Supervisor:
_______________________________
Engineer Hamid Raza
Lecturer (Preston University)
UNDERGROUND ELECTRIFICATION
SYSTEM
By
B. TECH (Honors)
Electrical
PRESTON UNIVERSITY
Islamabad
August, 2015
DEDICATION
I dedicate this report to my parents, teachers
and all my colleagues.
Page ii
ACKNOWLEDGEMENTS
I especially thank to Engineer Hamid Raza, Lecturer Preston University, who
guided me wherever I suffered from hurdles academically as well as morally. It was
he who under his kind supervision directed me towards successful accomplishment of
goals of thesis and to overcome any stumbling blocks faced. I also thank Mr. Tanvir
Asghar, Manager (Electrical), Habib Rafiq Ltd. (HRL), who gave me technical
support and provided access to the valuable technical data. He also shared with me his
practical expertise and knowledge especially related to cable laying, jointing and
termination. I am really grateful to and appreciate contribution of Mr. Mudassar
Hussain Hashmi, Senior Engineer, Pakistan Atomic Energy Commission (PAEC),
who guided me regarding technical report writing and provided me very useful tips
and trick. At the end I would like to thank all my colleagues and family members who
supported me morally, ethically and financially owing to which the successful
completion of the thesis was possible.
Page iii
ABSTRACT
Communication, electricity and transport lines often require the installation of
underground cables in order to obtain high-level performance and low impact on the
environment. Underground cables need stringing equipment capable of operating
under any condition, always providing good performance, high power and working
accuracy. This report specifies the methods and requirements for the safe and efficient
installation of underground cables in Pakistan.
With proper consideration of the many factors related to design, specification,
manufacturing, installation, and commissioning, underground cable systems can be a
viable alternative to overhead lines where the use of cable is warranted because of
rights-of-way constraints, sensitive areas along the planned route, specialized
obstacles (waterways, bridges, etc.) that must be crossed, concerns about weather
effects and reliability affecting overhead lines, or clearance limitations to get into a
congested substation. Though the material and installation costs of underground
power cables are higher than comparable capacity overhead lines, factors such as real
estate, permitting and constructability can often make underground the preferred
alternative as a complete underground system or portions of a hybrid underground and
overhead circuit.
This report provides an introduction to the cable system types and presents an
overview into considerations for using underground cable systems. The discussion is
focused on transmission cables but also has relevance for distribution cable
applications.
The report starts with standard methods and requirements of cable laying in
trenches. In subsequent section the details of cable preparation, termination, jointing,
and tools used for the purpose are detailed. At the end the methods for underground
cable fault detection and diagnosis are presented.
Page iv
TABLE OF CONTENTS
CHAPTER 1.
UNDERGROUND CABLES...........................................................1
1.1
INTRODUCTION..........................................................................................1
1.2
1.3
1.3.1
Construction of XLPE:...............................................................................2
1.3.2
1.3.3
Applications...............................................................................................5
1.4
1.5
1.5.1
Storage........................................................................................................6
1.5.2
Handling.....................................................................................................7
CHAPTER 2.
2.1
CABLE LAYING.............................................................................8
GENERAL.....................................................................................................8
2.1.1
Route..........................................................................................................8
2.1.2
2.1.3
Railway Crossing.......................................................................................9
2.1.4
Way Leave................................................................................................10
2.2
2.2.1
2.2.2
2.2.3
Cable Roller.............................................................................................12
2.3
2.3.1
General.....................................................................................................13
2.3.2
Trenching.................................................................................................13
2.3.3
2.3.4
Back Filling..............................................................................................20
2.3.5
Route Markers..........................................................................................21
2.3.6
CHAPTER 3.
Page v
3.1
CABLE JOINTING.....................................................................................23
3.1.1
Joints Pits.................................................................................................23
3.1.2
Safety Precaution.....................................................................................24
3.1.3
Jointer.......................................................................................................24
3.1.4
3.2
3.2.1
Cable Overlap...........................................................................................25
3.2.2
Cable Preparation.....................................................................................25
3.2.3
Core Preparation.......................................................................................26
3.2.4
3.3
3.3.1
3.4
3.4.1
CABLE TERMINATION............................................................................35
Characteristics of Termination Material...................................................35
PROCEDURE OF CABLE TERMINATION..............................................36
Cable Preparation for Termination...........................................................36
CHAPTER 4.
4.1
4.1.1
4.1.2
4.2
CONTINUITY TEST...................................................................................46
4.2.1
4.2.2
Test Procedure..........................................................................................47
CHAPTER 5.
5.1
BLAVIER TEST..........................................................................................48
5.2
5.3
5.4
CHAPTER 6.
6.1
SURGE GENERATOR................................................................................55
6.2
6.2.1
Surge Detector..........................................................................................56
Page vi
6.2.2
6.3
CHAPTER 7.
7.1
7.1.1
7.1.2
7.1.3
Interconnected System.............................................................................61
7.2
7.2.1
7.2.2
Padmount Transformer.............................................................................65
7.2.3
7.2.4
APPENDIX A:
Page vii
LIST OF TABLES
Table 3-1: Crimp Lug...................................................................................................38
Table 3-2: Mechanical Lug BLMT..............................................................................38
Table 4-1: Recommended test voltages for routine maintenance insulation-resistance
tests of equipment rated to 4,160V and above.............................................................42
Table 4-2: Listing of Conditions of Insulation as Indicated by Dielectric Absorption
Ratios............................................................................................................................45
Page viii
LIST OF FIGURES
Figure 1-1: Atypical XLPE Cable..................................................................................3
Figure 1-2: Cable Drum.................................................................................................6
Figure 2-1: Cable Laying Trailer..................................................................................10
Figure 2-2: Cable Pulling Winch..................................................................................11
Figure 2-3: A typical Heavy Duty Cable Roller...........................................................12
Figure 2-4: Cable Laying in Open Trench and Pulling................................................14
Figure 2-5: Excavation of Trenches.............................................................................15
Figure 2-6: Typical Direct Laid Configuration with Single Cable...............................21
Figure 2-7: CC Marker.................................................................................................22
Figure 3-1: A Typical Cable Joint................................................................................23
Figure 3-2: Joint Pits....................................................................................................23
Figure 3-3: Caution Board...........................................................................................24
Figure 3-4: Cable Overleap..........................................................................................25
Figure 3-5: Cable Preparation......................................................................................26
Figure 3-6: Folding Screen Wire..................................................................................26
Figure 3-7: Applying Mastic Tape...............................................................................27
Figure 3-8: Folding Screen Wires Back.......................................................................27
Figure 3-9: Applying Red Mastic Tape........................................................................27
Figure 3-10: Applying Black Tube...............................................................................28
Figure 3-11: Bending Screen Wires Back....................................................................28
Figure 3-12: Removal of Insulation Screen.................................................................28
Figure 3-13: Removal of Insulation.............................................................................29
Figure 3-14: Wrapping the Void Filler.........................................................................29
Figure 3-15: Sliding the Stress Control Tubing...........................................................29
Page ix
Page x
Page xi
INTRODUCTION
Where general appearance, economics, congestion, or maintenance conditions
1.2
Page 1
i.
ii.
ii.
iii.
ii.
Copper conductors may be used, only in special applications, where use of aluminum
conductor is not technically acceptable. Where paper insulated cables are used in
predominantly vertical situation, these shall be of non-draining type. Mostly use
XLPE cable in underground high voltage power system, so now we discuss about
XLPE cable.
1.3
Conductor:
The conductors made from electrical purity aluminum wires, are stranded
together and compacted. All sizes of conductors of single or three core cables are
circular in shape. Conductor construction and testing comply to IS 8130 - 1984.
Cables with copper conductor can also be offered.
Page 2
2)
Insulation:
High quality XLPE unfilled insulating compound of natural color is used for
Shielding
All XLPE cables rated above 3.3 kV are provided with both conductor
shielding and insulation shielding. Both conductor and insulation shielding consists of
extruded semi conducting compound. Additionally, insulation is provided with semiconducting tape and non-magnetic metallic tape screen over the extruded insulation.
Conductor shielding XLPE insulation and insulation shielding are all extruded in one
operation by a special process. This process ensures perfect bonding of inner and
outer shielding with insulation.
4)
hygroscopic fillers in the interstices and provided with common covering of plastic
Page 3
tape wrapping. As an alternative to wrapped inner sheath, extruded PVC inner sheath
can also be provided.
5)
Armouring
Armouring is applied over the inner sheath and normally comprises of flat
steel wires (strips) for multi core cables. Alternatively, round steel wire armouring can
also be offered. Single core armoured cables are provided with non-magnetic armour
consisting of hard drawn flat or round aluminum wires.
6)
Outer Sheath :
A tough outer sheath of heat resisting Tropodur (PVC) compound (Type ST2
as per IS 5831) is extruded over the armouring in case of armoured cables or over
non-magnetic metallic tape covering the insulation or over the non-magnetic metallic
part of insulation screening in case of un-armoured single core cables. This is always
black in color for best resistance to outdoor exposure. The outer sheath is embossed
with the voltage grade and the year of manufacture. The embossing repeats every
300/350 mm along the length of the cable.
Page 4
4. Low Dielectric Losses: XLPE cables have low dielectric loss angle. The
dielectric losses are quadratically dependent on the voltage. Moreover, these
losses occur continuously in every charged cable whether it carries load or not.
Hence use of XLPE cable at higher voltages would result in considerable
saving in costs.
5. Charging Currents: The charging currents are considerably lower permitting
close setting of protection relays.
6. Easy Laying and Installation: Low weight and small bending radii make
laying and installation of cable very easy. The cable requires less supports due
to low weight.
7. High Safety: High safety against mechanical damage and vibrations
1.3.3 Applications
Because of the excellent mechanical and electrical properties XLPE cables are
being used extensively in all power stations and in industrial plants. They are ideally
suited for chemical and fertilizer industries where cables are exposed to chemical
corrosion or in heavy industries where cables are exposed to chemical corrosion or in
heavy industries where severe load fluctuations occur and for systems where there are
frequent over voltages.
Cables can also be used at higher ambient temperature on account of their
higher operating temperature. There excellent installation properties permit the cable
to be used even under most difficult cable routing conditions and also in cramped
conditions e.g. City distribution network. Single core cables due to their excellent
installation properties are used in power stations, sub stations and industrial plants
with advantage.
1.4
Page 5
the period of its flow, especially in the case of HV cables. While deciding upon the
cable sizes, de-rating factors for the type of cable and depth of laying, grouping,
ambient temperature, ground temperature, and soil resistivity shall be taken into
account.
1.5
The cable drums shall be stored on a well drained, hard surface so that
the drums do not sink in the ground causing rot and damage to the cable
drums (see Figure 1 -2). Paved surface is preferred, particularly for long
term storage.
ii.
The drums shall always be stored on their flanges, and not on their flat
sides.
iii.
iv.
Protection from rain and sun is preferable for long term storage for all
types of cables. There should also ventilation between cable drums.
Page 6
v.
vi.
1.5.2 Handling
i.
When the cable drums have to be moved over short distances, they
should be rolled in the direction of the arrow marked on the drum.
ii.
iii.
For loading into and unloading from vehicles, a crane or a suitable lifting
tackle should be used. Small sized cable drums can also be rolled down
carefully on a suitable ramp or rails, for unloading, provided no damage
is likely to be caused to the cable or to the drum.
Page 7
2.1
GENERAL
Following measures should be taken while cable laying.
i.
Cables with kinks, straightened kinks or any other apparent defects like
defective armouring etc. shall not be installed.
ii.
Cables shall not be bent sharp to a small radius either while handing or in
installation. The minimum safe bending radius for PVC/XLPE (MV)
cables shall be 12 times the overall diameter of the cable. The minimum
safe bending radius for PILCA/XLPE (HV) cables shall be as given in
Table-II. At joints and terminations, the bending radius of individual
cores of a multi core cable of any type shall not be less than 15 times its
overall diameter.
iii.
The ends of lead sheathed cables shall be sealed with solder immediately
after cutting the cables. In case of PVC cables, suitable sealing
compound/tape shall be used for this purpose, if likely exposed to rain in
transit storage. Suitable heat shrinkable caps may also be used for the
purpose.
2.1.1 Route
i.
Before the cable laying work is undertaken, the route of the cable shall
be decided by the Engineer-in-Charge considering the following.
ii.
While the shortest practicable route should be preferred, the cable route
shall generally follow fixed developments such as roads, foot paths etc.
with proper offsets so that future maintenance, identification etc. are
rendered easy. Cross country run merely to shorten the route length shall
not be adopted.
Page 8
iii.
Cable route shall be planned away from drains and near the property,
especially in the case of LV/MV cables, subject to any special local
requirements that may have to be necessarily complied with.
iv.
As far as possible, the alignment of the cable route shall be decided after
taking into consideration the present and likely future requirements of
other services including cables enroute, possibility of widening of
roads/lanes etc.
v.
vi.
b.
c.
Page 9
limits, pipes shall be laid up to a minimum distance of 3m from the center of the
nearest track on either side.
authorities,
such
as,
Municipal
authorities,
Department
of
2.2
Drum handling, cable drum move from one place to another very easy and safe. The
typical diagram of cable Trailer and its specification is given below.
2.2.1.1 Specification
Page 10
Page 11
This is our 3 tonne capacity single capstan winch and is a great asset to any
Multi Utility business. It is fitted with a free spooling payout system which makes it a
one man only operation. The unit is fitted with a pull load indicator with read out via
dial gauge.
2.2.2.1 Technical Specification
Power unit diesel engine, rated at 13kw, at 3600 rpm, main drive system single
capstan.
Rewind drum 400 mtrs. 10mm dia rope. (mounted under rewind drum)
Rope pull/speed 0.5 tonne 30 mtr/min 1.5 tonne 22mtr/min 3.0 tonne 7
mtr/min capacity (max)
Page 12
The main feature of the heavy duty cable roller (see Figure 2 -5) is the full
rounded edges of the frame that protect the cable in the event of the roller falling or
flipping over. This is why it is known as the 'SAFE' roller.
Weight: 3.5Kg
2.3
along roads/lanes, etc. and where no frequent excavations are likely to be encountered
and where re-excavation is easily possible without affecting other services. The
general method of cable laying in open trenches is show in .Figure 2 -6
2.3.2 Trenching
Method of trenching is discussed in following sections.
Page 13
i.
Width of Trench
The width of the trench shall first be determined on the following basis
a.
The minimum width of the trench for laying a single cable shall
be 35cm.
b.
c.
Page 14
Page 15
ii.
Excavation of Trenches
a. The trenches shall be excavated in reasonably straight lines.
Wherever there is a change in the direction, a suitable curvature
shall be adopted complying with the requirements of clause
2.6.1(ii).
b. Where gradients and changes in depth are unavoidable, these shall
be gradual.
c. The bottom of the trench shall be level and free from stones, brick
bats etc. (see Figure 2 -7)
Page 16
Sand cushioning
The trench shall then be provided with a layer of clean, dry sand cushion
of not less than 8cm in depth, before laying the cables therein. However,
sand cushioning need not be provided for MV cables, where there is no
possibility of any mechanical damage to the cables due to heavy or shock
loading on the soil above. Such stretches shall be clearly specified in the
tender documents. Sand cushioning shall however be invariably provided
in the case of HV cables.
ii.
iii.
iv.
The cable shall be pulled over on rollers in the trench steadily and
uniformly without jerks and strain. The entire cable length shall as far as
possible be laid off in one stretch. PVC/XLPE cables less than 120sq.mm.
Page 17
Size may be removed by Flaking i.e. by making one long loop in the
reverse direction.
Note:
For short runs and sizes upto 50sq.mm. of MV cables, any other suitable
method of direct handing and laying can be adopted without strain or
excess bending of the cables.
v.
After the cable has been so uncoiled, it shall be lifted slightly over the
rollers beginning from one and by helpers standing about 10m apart and
drawn straight. The cable shall then be lifted off the rollers and laid in a
reasonably straight line.
vi.
vii.
Sand covering
Cables laid in trenches in a single tier formation shall have a covering of
dry sand of not less than 17cm above the base cushion of sand before the
protective cover is laid. In the case of vertical multi-tier formation, after
the first cable has been laid, a sand cushion of 30cm shall be provided over
the base cushion before the second tier is laid.
viii.
b.
Page 18
b.
c.
d.
Page 19
and painted with a single coat of Bitumastic paint. Steel pipes shall be of the same
internal diameter as the plastic ducts, normally used for the type of cable to be
installed. All steel plates and ducts shall be protected with a suitable cable protection
tape. Typical arrangements of cables in trenches are shown in Appendix A.
2.3.3.1 Cable Protection Tapes and Covers
All cables and ducts shall be protected by a cable protection tape or a
stokboard (heavy duty plastic tile). The tape used depends upon the highest voltage
to be protected, which are available from Power Networks Supply Chain:
Page 20
Page 21
Page 22
c. Inscription
The words BURIED-MV/HV CABLE as the case may be, shall be inscribed on the
marker.
2.3.6
Whenever more than one cable is laid / run side by side, marker tags as
approved, inscribed with cable identification details shall be permanently attached to
al the cables in the manholes / pull pits / joint pits / entry points in buildings / open
ducts etc. These shall also be attached to cables laid direct in ground at specified
intervals, before the trenches are backfilled.
Page 23
CABLE JOINTING
Before laying a cable, proper locations for the proposed cable joints, if any,
shall be decided, so that when the cable is actually laid, the joints are made in the
most suitable places. As far as possible, water logged locations, carriage ways,
pavements, proximity to telephone cables, gas or water mains, inaccessible places,
ducts, pipes, racks etc. shall be avoided for locating the cable joints. A typical cable
joint is shown in Figure 3 -10.
Page 24
ii.
3.1.3 Jointer
Jointing work shall be carried out by a licensed/ experienced (where there is
no licensing system for jointers) cable jointer.
Page 25
3.2
Page 26
i.
Remove the outer layer of the composite sheath for 215mm, from the
reference line. Remove the inner layer of the composite sheath to the
dimension as shown in Figure 3 -14.
ii.
Remove the water swellable tapes (if any) level with the inner layer of
composite sheath cut.
iii.
Abrade the outer layer of the composite sheath for a distance of 200 mm from
the outer layer composite sheath cut. Abrade the inner layer of the composite
sheath.
iv.
Clean and degrease the inner and outer layer of composite sheath using the
cleaning tissue provided in the kit.
Note:
On the side of the joint where the outer sealing sleeve is intended to be parked, clean
the outer layer of the composite sheath for a distance of 1 metre using the cleaning
tissue provided in the kit.
Page 27
Apply one layer of red mastic tape (20mm wide) over the insulation screen; 10
mm from the cable sheath cut (see Figure 3 -16).
Fold the screen wires back over the insulation screen (see Figure 3 -17).
Apply one layer of red mastic tape (20mm wide) over the screen wires, 10 mm from
the cable sheath cut (i.e. over the mastic applied in step 5).
Apply red mastic tape (50mm wide) to equally overlap the inner and outer
layers of the composite sheath (see Figure 3 -18).
Page 28
Slide the 150 mm long tube (black) over the cable, centered over the outer
sheath cutback. Shrink tube into position, applying additional heat over the area where
the red mastic tape was applied (see Figure 3 -19).
Bend the screen wires back over the tube and onto the cable sheath. Secure the
screen wires to the cable using PVC tape (see Figure 3 -20).
Cut the cables at 140mm as shown using a hacksaw or a suitable power driven
saw to prevent deformation of the conductor strands (see Figure 3 -21). Thoroughly
remove the insulation screen to the dimension shown, so that the insulation surface is
free from all traces of conductive material.
Page 29
Remove the insulation from the cables to for a length of 30mm (see I in
Figure 3 -22). Clean and degrease the insulation using the cleaning tissues provided
in the kit. Use a wiping action from the exposed conductor towards the insulation
screen. Do not use a cleaning tissue that has previously been in contact with the
insulation screen.
Remove the yellow void filling tape from the aluminum foil packet. Remove
the release papers from the yellow void filling tape with the pointed ends. Wrap the
void filler around the insulation screen starting 20 mm from the end of the insulation
screen and continuing onto the insulation for 10 mm (see Figure 3 -23). Stretch the
tape to half of its original width to achieve a fine, thin edge around the insulation.
Finish on the insulation screen.
Page 30
Slide the stress control tubing (black) over the cable level with the end of the
insulation cut. Start shrinking from the insulation cut towards the cable sheath (see
Figure 3 -24). Apply additional heat over the area where the void filling tape was
applied.
The connector is supplied with either half shell inserts or centralizing inserts
for use on smaller conductor cross sections. Check if each of the conductors will fit
with the respective half shell or centralizing insert installed. If the conductor fits,
leave the half shell or centralizing insert fitted. The centralizing insert is a tight fit in
the connector and requires complete insertion. If the conductor does not fit with the
half shell insert or centralizing insert installed, remove and discard the half shell or
centralizing insert from that side of the connector (see Figure 3 -26).
Page 31
Fit the conductors into the connector. There should be no gap left between the
connector and the insulation. Take up the tension equally on all shear bolts with a tee
bar spanner (do not shear the heads at this stage). Starting at the connector ends and
working towards the middle (following the number sequence indicated), tighten the
bolts until the heads shear off. If a proud edge remains after removal of the bolt heads,
this edge should be filed to obtain a smooth finish (see Figure 3 -27).
Re-align the cables if necessary. The numbers indicate the bolt tightening
sequence. Clean and degrease the cable cores and connector using the cleaning
tissues provided in the kit (see Figure 3 -28). Using the clay pack supplied in the kit,
fill the hollows over the sheared off bolts in the connector to obtain a smooth finish.
Page 32
Remove the release paper from the stress grading patch (black). Position the
patch centrally over the connector area (see Figure 3 -29).
Figure 3-29: Removal of Release Paper from the Stress Grading Patch
The start of the patch should just cover the shear bolts to ensure two layers of
stress grading will be applied over the shear bolt area. Apply the long side of the patch
across the connector. Wrap the patch over the connector. Do not stretch the patch.
Position the screened insulating sleeve (black and red) centrally over the connector
area (see Figure 3 -30).
1. Start shrinking the sleeves in the centre (1).
2. Continue shrinking by working towards one side (2), stopping 50 mm from the
end.
3. Shrink the other half in the same way (3).
4. Shrink down the first end (4) and finally the second (5).
Page 33
Wrap one half-lapped layer of tinned copper mesh around the cable and across
the full length of the joint (see Figure 3 -31). Cover 80 mm of the 150mm long black
tube on the side of the joint with the short screen wires. Fix the screen wires with a
copper wire binder at the end of the tinned copper mesh.
For cable side with long screen wires bend the screen wires back over the joint
area. For cable side with short screen wires bend the screen wires back over the joint
area close to the tinned copper mesh. Gather the screen wires together and cut them
centrally above the 80 mm tinned copper mesh overlap on the cable sheath (see Figure
3 -32).
Page 34
Figure 3-32: Gathering the Screen Wires Together and Cutting Them Centrally
Insert the screen wires into the shear head connector supplied. Tighten the
shear heads until the heads shear off. Rotate the screen wire connector so that the
screws of the screen wire connector do not puncture the outer sealing sleeve or the
screened insulating sleeve (see Figure 3 -33).
Figure 3-33: Inserting the Screen Wires into the Shear Head Connector
Wrap a second layer of tinned copper mesh around the joint with a 50%
overlap. Cover the complete joint area including the mechanical screen wire connector
(see Figure 3 -34).
Abrade, clean and degrease the cable sheath for a distance of 150mm either
side of the tinned copper mesh (see Figure 3 -35).
Page 35
Wrap one layer of red sealant tape (50mm wide) around the composite sheath
sealing sleeve (Step 9) starting at 20mm from the ends of the mesh on both sides of
the joint (see Figure 3 -36).
Centre the outer sealing sleeve (black) over the copper mesh area. Start shrinking in
the centre, working towards the ends (see Figure 3 -37).
The joint is completed. Allow the joint to cool before applying any mechanical strain
(see Figure 3 -38).
Important Note: It must be ensured that a buried joint is surrounded with soft
bedding material up to a depth of 100mm above the joint.
Page 36
3.3
CABLE TERMINATION
3.3.1 Characteristics of Termination Material
A typical Medium Voltage Termination System is shown in Figure 3 -39.
Page 37
These results are borne out by the continuing performance of over a million
units installed in tropical, desert, arctic and industrially polluted climates, confirming
that Raychem terminations do not track even in severe service conditions and
verifying their exceptional erosion resistance and reliability.
3.3.1.4 Yellow void filler
The semi-conducting void filler is easily applied in form of a short adhesive
tape. It ensures that, independent of the type of semi-conductive screen or removal
method, no air voids can cause discharges in the high stress area of the screen end.
3.3.1.5 Earthing
Earthing wires or braids are imbedded in the sealing mastic to prevent any
corrosion by moisture ingress. For cables with tape screen or metal sheaths with
armour solder less earthing systems are either provided within the termination kit or
can be ordered separately.
3.4
1. Cut the cable and remove both the layers of composite sheath for 320mm
minimum. Remove the outer layer of composite sheath for 40mm. Leave
enough length to set the cores into their final position. Degrease and clean the
end of the oversheath for about 100 mm using the cleaning tissue provided in
the kit.
2. Wrap one layer of red sealant tape (50mm wide) with slight tension starting at
the end of the inner sheath cutback, downwards for 80 mm. Bend the shielding
wires from each core back onto the oversheath. Avoid crossing individual
wires. Temporarily fix the shielding wires to the oversheath.
Page 38
Figure 3-40: 1) Cutting of Cable & Sheath Removal; 2) Sealant Tape Wrapping
3. Remove any filler up to the end of the inner sheath cutback. Bend and shape
the cores into their final position. Cut the cores to the required length.
Thoroughly remove the core screen according to dimension a (see Error:
Reference source not found for crimp lugs. For mechanical lugs see Table 3
-2). The surface of the insulation should be free from all traces of conductive
material. Smooth out any irregularities.
4. Wrap one layer of red sealant tape (50mm wide) over the screen wires for
80mm. Mark the core screen 40 mm below the screen cut. Measure the
distance c of each individual core and cut the conductive tubing accordingly.
Page 39
95 to 24
a
95 to 240
BLMT
(range mm2)
[mm]
11kV indoor/outdoor
200
a
[mm]
11kV indoor/outdoor
200
5. Position the conductive tubing over the cores 40 mm below the end of the core
screen. Shrink each tubing into place by starting on top and continue shrinking
them down towards the cable crotch. Allow the tubing to cool before
continuing.
6. Pull the breakout down the crotch as far as possible. Shrink the breakout into
place starting at the centre. Work first towards the lower end and then shrink
the turrets onto the cores. The numbers in the drawing indicate the shrinking
sequence.
7. Cut back the insulation according to K = depth of cable lug barrel hole + 5 mm
for crimp lug. BLMT = depth of the cable lug + 0 mm. Install the cable lug.
Remove any sharp edges. Degrease and clean the lug and the insulation using
the cleaning tissue provided in the kit.
Figure 3-42: 5) Positioning the Conductive Tubing; 6) Pulling Breakout 7) Cutting Insulation
Page 40
Note: Do not use cable lugs with barrel holes deeper than 110 mm.
8. Remove the release paper and wrap the void filling strip (yellow) around the
end of the core screen. Stretch the strip to half of its original width to achieve a
fine, thin edge onto the insulation. Cover 20 mm of the core screen and
continue onto the insulation for 10 mm.
9. Apply one complete turn of red sealant mastic (20mm wide) around the barrel
of the lugs, at the tab end of the lug barrels as depicted covering the top
fastener of compressed area as applicable. Use the remaining sealant to fill in
the space between the core insulation and the cable lug to leave a smooth
transition.
10. Preheat the cable lug slightly before placing the tubing over the core so that
the top of the tubing covers the crimping area or the top fastener of the cable
lug. Shrink the tubing down starting at the screen cut using a soft yellow
flame. Heat the area well but avoid scorching of surface. Continue shrinking
towards the cable lug. Finally shrink down the bottom end of the tubing. The
numbers in the drawing indicate the shrinking sequence.
Figure 3-43: 8) Removing Release Paper; 9) Applying Sealant Mastic; 10) Preheating Cable Lug
Page 41
Page 42
Before Laying
Continuity Test
After Laying
Continuity test
DC pressure test
(For 15 minutes, if not possible than test for 01 minute with 1000 V Megger
for LT cable and with 2500/5000 V Megger for HT cable)
4.1
Page 43
Equipment AC Rating
DC Test Voltage
Up to 100V
440V to 550V
2,400V
Page 44
Page 45
During this interval, the resistance should drop or remain relatively steady. Larger
insulation systems will show a steady decrease, while smaller systems will remain
steady because the capacitive and absorption currents drop to zero faster on smaller
insulation systems. After one min, read and record the resistance value.
Note that IR is temperature sensitive. When the temperature goes up, IR goes
down, and vice versa. Therefore, to compare new readings with previous readings,
you need to correct the readings to some base temperature. Usually, 20C or 40C are
used as comparison temperatures; tables are available for any correction. However, a
common rule of thumb is that IR changes by a factor of two for each 10C change.
Page 46
Testing
Specifications
for
Electrical
Power
Distribution Equipment and Systems, provides much more realistic and useful values.
Test results should be compared with previous readings and with readings
taken for similar equipment. Any values below the NETA standard minimums or
sudden departures from previous values should be investigated.
4.1.2.2 Dielectric Absorption Ratio
This test recognizes the fact that "good" insulation will show a gradually
increasing IR after the test voltage is applied. After the connections are made, the test
voltage is applied, and the IR is read at two different times: Usually either 30 and 60
sec, or 60 sec and 10 min. The later reading is divided by the earlier reading, the result
being the dielectric absorption ratio. The 10 min./60 sec. ratio is called the
polarization index (PI).
For example, let's assume we apply the megohmmeter as described earlier
with the appropriate test voltage impressed. The one min. IR reading is 50 megohms,
and the 10 min. IR reading is 125 megohms. Thus, the PI is 125 megohms divided by
50 megohms, or 2.5. Various sources have tables of acceptable values of dielectric
absorption ratios (see Table 4 -4 below). The values must be considered tentative and
relative, subject to experience with the time-resistance method over a period of time.
Table 4-4: Listing of Conditions of Insulation as Indicated by Dielectric Absorption Ratios.
10/1-min Ratio
(Polarization Index)
Less than 1
Page 47
Questionable
1.0 to 1.25
1.0 to 2*
Good
1.4 to 1.6
2 to 4
Above 1.6**
Above 4**
Excellent
*These results would be satisfactory for equipment with very low capacitance,
such as short runs of house wiring.
**In some cases with motors, values approximately 20% higher than shown
here indicate a dry, brittle winding that may fail under shock conditions or during
starts. For preventative maintenance, the motor winding should be cleaned, treated,
and dried to restore winding flexibility.
4.1.2.3
4.2
CONTINUITY TEST
Page 48
1. Multimeter
2. Wire Nipper
3. Screw Driver Set
4. Box Spanner
Connect one probe of multimeter to earth and other probe to the end of the
cable conductor to be tested, as shown in above figure.
Instruct staff at the other end (at Location B) to connect earth to same
conductor of the cable.
If earth is light at both ends, connect earth to armour also at both the ends.
Deflection of multimeter needle shows that the conductor under test is OK;
otherwise there is a break in the conductor.
Then
test
continuity
of all
other
conductors
with
respect
to
this tested conductor. For example to test conductor 2, connect the one probe
of the multimeter to conductor 2 and other probe to the tested conductor (at
Location A). Instruct the staff at other end (at Location B) to short conductor 2
with the tested conductor. Test continuity of all other conductors as above.
Page 49
5.1
BLAVIER TEST
Blaviers test is used to find the earth fault location in an underground cable.
The two ends faulty cable are mentioned as sending end and far end respectively as
shown in Figure 5 -50. In this test, the sending end of the cable must be open and
isolated and the resistance between sending end and earth point is measured by
keeping the far end isolated from earth and then it measured keeping far end of the
faulty cable, shorted to the ground.
Suppose, we get, resistance values R1 and R2 in these two said measurements
respectively. In the fault location, the conductor is shorted to ground, because of fault.
Thus, this short circuit may have some resistance that is mentioned as g. In Blaviers
test the total line resistance is supposed to be mentioned as L. The resistance
between the sending end to the fault end is mentioned as x and the resistance
between the fault end to the far end is denoted as y. So, the total resistance L is
equals to the addition of x and y resistances.
Now, the total resistance of the x and g loop is nothing but R1 the
conductor resistance between sending end and earth by keeping far end open,
The total resistance of the entire loop of the above circuit is nothing but R2 the
conductor resistance between sending end and earth by keeping far end earthed.
Page 50
This expression gives the resistance from the sending end to the fault location. The
corresponding distance is calculated by known resistance per unit length of the cable.
A practical difficulty in Blavier's test is that the resistance to ground g is variable,
being influenced by the amount of moisture present in the cable and the action of the
current at the fault condition. Also, the resistance g may be so high that it exerts very
little shunting action when y is placed in parallel with it by grounding the far end of
the line.
5.2
one Wheatstone bridge in it and by comparing the resistance we shall find out the
fault location. But we should use the known length of the cables in this experiment.
The necessary connection of the Murray loop test is shown in Figure 5 -51 & Figure
5 -52. The Figure 5 -51 shows that the circuit connection for finding the fault
location when the ground fault occurs and the Figure 5 -52 shows that the circuit
connections for finding the fault location when the short circuit fault occurs.
In this test, the faulty cable is connected with sound cable by a low resistance
wire, because that resistance should not affect the total resistance of the cable and it
should be able to circulate the loop current to the bridge circuits without loss.
The variable resistors R1 and R2 are forming the ratio arms. Balance of the
bridge is achieved by adjusting the variable resistors. G is the galvanometer to
Page 51
indicate the balance. [R3 + RX] is the total loop resistance formed by the sound cable
and the faulty cable.
Figure 5-51: Circuit Connection of Murray Loop Test for Ground Fault
Figure 5-52: Circuit Connection of Murray Loop Test for Short Circuit Fault
When the cross section area of the both sound cable and faulty cable are equal,
then the resistances of the conductors are directly proportional to their lengths. So, if
LX represents the length between test end to the fault end of the faulty cable and if L
represents the total length of the both cables, then the expression for LX is as follows;
Page 52
The above test is only valid when the lengths of the cables are known. In
Murray Loop Test, the fault resistance is fixed and it may not be varied. Also it is
difficult to set the bridge as balance. Thus, the determination of the fault position is
not accurate. Then the current circulation through the cable would cause temperature
rises due to high voltage or high current. If the resistance varies according to the
temperature, then the balance collapses. So, we need to apply less voltage or less
current to this circuit.
5.3
one Wheatstone bridge in it and by comparing the resistance we shall find out the fault
location instead of calculating it from the known lengths of the cable. The necessary
connection of the Varley loop test is shown in Figure 5 -53 & Figure 5 -54. The
Figure 5 -53 shows that the circuit connection for finding the fault location when the
ground fault occurs and the Figure 5 -54 shows that the circuit connections for
finding the fault location when the short circuit fault occurs.
In this test, the faulty cable is connected with sound cable by a low resistance
wire, because that resistance should not affect the total resistance of the cable and it
should be able to circulate the loop current to the bridge circuits without loss. A single
pole double through switch S is used in this circuit. There would be a variable
resistor R which is used to balance the bridge circuit during the working period.
If the switch S is in position 1, then we need to adjust the variable resistance R to
balance the circuit. Let us assume that the present R value as RS1. At this position,
the expressions are as follows;
This expression gives the value of [R3 + RX], if the value of R1, R2 and RS1
are known. If the switch S is in position 2, then again we need to adjust the variable
Page 53
resistance R to balance the bridge circuit. Let us assume that the new R value as
RS2. At this position, the expressions are as follows;
Figure 5-53: Circuit Connection of Varley Loop Test for Ground Fault
Page 54
Figure 5-54: Circuit Connection of Varley Loop Test for Short Circuit Fault
Varley Loop Test is valid only when the cable sections are uniform throughout
the loop. The current flowing through the cable would cause the temperature effect.
Due to this temperature effect, the resistance of the cable would change. Thus, we
need to apply less current to this circuit to carry out the experiment.
5.4
In this Fisher Loop Test, there must be two healthy sound cables which must have the
same length and same cross sectional area as the faulty cable. As per the Figure 5 -55
& Figure 5 -56 circuit diagram, all the three cables are connected by a low resistance
wire.
Figure 5-55: Circuit Connection (A) for Fisher Loop Test to Locate the Cable Fault
Page 55
Figure 5-56: Circuit Connection (B) for Fisher Loop Test to Locate the Cable Fault
In this two circuits, if the bridge arm resistors are equal (or) if [(RA + RB) =
(RA' + RB')], then the expression (3) can be modified as,
Page 56
So, when the resistance per unit length of the conductor is uniform in all
conditions, then the fault location LX is as follows;
Here L if the total length of the faulty cable. But practically, this is not
possible. There would be fractional changes in the bridge arms. Thus, the fault
location LX is as follows;
CHAPTER 6. CABLE
FAULT
LOCATING
INSTRUMENTS
Following instruments are used for location of cable faults.
6.1
SURGE GENERATOR
The surge generator is a lightweight and compact unit that impulses at 3, 6, 9,
12, or 15-kV. It offers benefits that ensure efficient and effective fault locating. Figure
6 -57 shows a simple surge generator.
Features:
Page 57
6.2
by detecting both the electromagnetic and acoustic pulses emitted from an arcing fault
when it is surged. Either single or dual detector configurations are available. A typical
surge detector (Model SD-3000) is shown in Figure 6 -58 (A).
Features:
Page 58
6.3
efficiently pinpoint the fault. The working principle of Model SD-3000 Surge
Detector is shown in Figure 6 -59. A pickup in the receiver detects the magnetic field
produced by the current impulse and also displays its magnitude on a bar graph
display every time the thumper discharges. The indicated magnitude of the impulse
will decrease if the fault has been passed or if the receiver is no longer over the cable
route. After detecting an impulse, an acoustic pickup placed on the ground listens for a
thump as a result of the discharge. The detected impulse starts a timer in the receiver
and when an audible thump is sensed, the timer is stopped. This measurement is the
time it takes the sound wave produced at the fault to travel to the acoustic pickup and
is displayed in milliseconds.
As the fault is approached, this time interval decreases to a minimum directly
over the fault and increases again as the fault is passed. The time never goes to zero
because there is always the depth of the cable between the pickup and the fault. This
technique relies on the elapsed time between the two events, not simply the loudness
Page 59
of the sound and thereby eliminates the problems of accurate pinpointing even under
difficult conditions.
If two acoustic pickups are used, the receiver makes dual measurements and
indicates with an arrow on the display which direction to move toward the fault. As
the fault is approached, the tail on the arrow becomes shorter until the fault is passed
when the direction of the arrow reverses. At this point, small movements of the
pickups are made. When they actually straddle the fault, two arrowheads appear
pointed toward each other. Once the instrument hears the thump, headphones are no
longer necessary and the measurements will lead the operator directly to the fault. The
receiver also measures and displays a digital value of the sound level, which typically
increases as the fault is approached. By using the Save function in the unit, two sets of
time and sound level values can be saved and displayed while observing the current
values which confirm that the direction being taken is correct.
The SD-3000 provides information on its liquid crystal display, which will efficiently
and quickly guide the operator to within inches of the exact fault location:
Page 60
Features:
Page 61
Page 62
Less copper is required as each part of the ring carries less current than that
in radial system.
ii.
iii.
It is more reliable. In the event of fault on any one section the continuity of
supply to all consumers can be maintained by isolating the faulty section
iv.
v.
vi.
Page 63
Page 64
ii.
Any area fed from one generating station during peak load hours can be
fed from the other generating station. This reduces reserve power capacity
and increases efficiency of the system.
7.2
SWITCHGEARS
USE
IN
UNDERGROUND
DISTRIBUTION SYSTEM
7.2.1 Ring Main Unit (RMU)
Ring Main Unit as an important part of Secondary Distribution Substations
(Figure 7 -64) A Ring Main Unit (RMU) is a totally sealed, gas-insulated compact
switchgear unit. The primary switching devices can be either switch disconnectors or
fused switch disconnectors or circuit breakers.
Page 65
Different combinations of these primary switching devices within the unit are
commonly used. In case a circuit breaker is the switching device, it is also equipped
with protective relaying, either with a very basic self-powered type or a more
advanced one with communication capabilities. A single-line representation of a
typical RMU configuration is show in Figure 7 -65.
Page 66
The rated voltage and current ranges for RMUs typically reach up to 24
kV and 630 Arespectively. With many of the manufacturers of RMUs, the basic
construction of the unit remains the same for the whole of the voltage range. An
example of distribution network with Ring Main Units is shown in Figure 7 -66.
Page 67
Page 68
7.2.3.1 Features/Specifications
i.
ii.
iii.
iv.
NEMA 3R rated
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
Page 69
7.2.4.1 Features
i.
ii.
NEMA 3R rated
iii.
iv.
Branch circuits
v.
vi.
section
vii.
Pole mount
viii.
Test switch
ix.
Pad-lockable cover
x.
xi.
Page 70
CONCLUSION
With proper consideration of the many factors related to design, specification,
manufacturing, installation, and commissioning, underground cable systems can be a
viable alternative to overhead lines where the use of cable is warranted because of
rights-of-way constraints, sensitive areas along the planned route, specialized
obstacles (waterways, bridges, etc.) that must be crossed, concerns about weather
effects and reliability affecting overhead lines, or clearance limitations to get into a
congested substation. Though the material and installation costs of underground
power cables are higher than comparable capacity overhead lines, factors such as real
estate, permitting and constructability can often make underground the preferred
alternative as a complete underground system or portions of a hybrid underground and
overhead circuit.
Page 71
Page 72
Page 73
Page 74
Page 75
BIBLIOGRAPHY
[1]
Page 76
VITA
The author of the thesis is currently an employee of Habib
Rafiq (Pvt.) Ltd., HRL a multinational construction company
since 2004. He is resident of Mandi Bahauddin, Punjab, Pakistan.
He completed his technical education in 2004 and started his
career in Speciallists Group Incorporated (SGI) as a technician.
Then he joined Habib Rafiq (Pvt.) Ltd. as an electrical technician
and was promoted to electrical supervisor due to his meritorious performance in the
said field. After completion of B. Tech (Pass), he was given the charge of assistant
electrical engineer in 2009. Since then he is working in the aforementioned
organization and has solved many practical problem in the field of underground cable
laying, jointing and termination.
Page 77