OIA PROFESSIONAL GUIDELINES FOR LAYING OF CABLES © POLYCAGINDEX 1.1. Cable inspection 1.2. Cables Damages in Transit 1.3 Cable Handling & Storage 2.1. Unreeling of cable from drum. 2.2 Special precautions for unreeling and installation of Helogen free low smoke sheathed cables. 2.3 Laying Methods 2.4 Bonding Methods 2.5 Lugs and glands Recommended Procedure For Testing of Cables at Site After Laying and Commissioning.1 PRE INSTALLATION 1.1 Gableinspection + The cable marking orlabelshallbe checked against the sze/type of cable lo avold possible labellg/marking erors by the packers anc also the cable solectedis proper for designed application. + While opening the packing. a carefulwatch should bemadete eneure tools used in opening donat damage the lyersof cable, + Thecablehasnot been damaged intransitor unloading orstorage, 1.2Cable Damages in Transit Transit Damage is a common problem which occurs during unloading /shiting of cable drums or during transshipment by transporter. Damages in factory generally donot occur as drums are packed with wooden planks and handled using overnead cranes fois, To lentty any uchdamagetocabledhum andl cable: + Inspect visually every cablereelagansl transit damage such as packing, damage before accepting the shipment + Be paricutaly alr for cable derrage i: I) Areol's Wing flat on ts sce. Several oals ave stacked one over the other ih Other treightis: stacked onarclIV Gable drumsare without weodan planks or broken, + Acableene!sealis removed or damaged. + Machanicaldamages can cause: Tearing of Outer Sheath Il Bending /breakage of armour wires sts Damage ofinsulaton + IFthere are only smal sheath damages anc! armour is found intact the cable can be considered for use, after doing necessary repar on ‘Shoat and tostng the cable for High Pot tstorinsukatln tests (Moggar test) * the testresuts of insulation resistance is fourd very less (Phase concluctor to armour sho, the cable shale cut a that portion and the ‘woplecesare to be again tested, Cable lengtns wth good megger values can be taker fo jointing and charging. + Incase of doulttultest results or major damages please: the matterto Polycab Customer care | store re@polycab.com) 1.3 Cable Handling & Storage carols takeninthe manufacturing ofcable to ensure qualty at every stage. + Handing ofcableat damaged, tls the next important factor to ensure that by mishandling the cable, the outer shea andl insulation shall nt get ‘Thehandling is generally cari outby unskilled or somi-skilod men, strict supenision shouktbe maintained so tat the cable, which can ‘be vor easly damagod, ishandled with great care. Pra \When offloading ross from a truck, Never crop reels. reels lower reals caretuly using ‘must be rolled, lin a hydraulic gate, ‘opposite draction of the hoist o fort ruck cable weave to keep cable from loosening on the rea % la forklifts used for handing and shitting the cable | | Do not allow the It orks to contact t ‘drumathe forks shall approach the real tom the Care must be taken by the fori flange side, The forks all be ‘operator not to make eudden yt tums of rope. ppositoned such that the reals When using a hoist, installa mandrel This may lead to the bending of the ree! through the reel arbor holes and flanges and mashing the cable, aitach a sling. Use a spreader bar approximately 6 inches longer than the overall eal width placed between the sling ends just above the reel flanges. abe Iited with both reel fanges. s mH© aH EE eee Cea Its alvaye safer to use a stong and well-draines surface for storing crams. I possible, the orume ‘should be ra'sad fom the ground by the insertion of wooden plans, ec, below and on both sides o the drums : some check pieces should be placed s0 as not to alow the drums tobe role, bbosely and easily, Cable drums ‘should also be stored away trom the rect sun and rains. Reason : Direct suvays can ‘cause deterioration due to UV rays and rn can ‘cause damage to wooden cum, resuling dum ccolzose after few months. Muttole reels stacked on top of each other ("Pancake" storage is not recommended for cablo cums. The weight of the stack can total thousands of kgs. creatng an enormous load on the bottom real. Also, damage tothe reel andor cable wil ikely ‘occur when the reels tipped for transi. A concentration of stress fon the reel lange may cause it to break ang subsequent damage the cable Always use proper stoppers to prevent the drum from roling, When roling in the direction of the arrow, never rll for more than § metres COtremise the cable may become unfit for use, Ensure stoppers for every drum, to prevent mishaps during storage. Place the wedges by the ‘langas/tullwidt ofthe drum © ge I em ‘Allowthe drums to rollatany cost. Stack the drums. ‘onnon-trangular/non-square wedges rae During transportation, fasten drums to the base through the central hole Fasten without taking a! Oe care. Always use support, and tie the drum from both the = ee ine Om Use a winch, forlit or makeshit ramp. Se ee ‘Allow one drum to strike another. Se 2% cen BN) ACO Ni Mirman Perea bending aca o cab() mt 2 INSTALLATION & LAYING 2.1 Unreeling (Cable Pulling) + For unreeling cable ‘tom a crum It should be mounted on cable jack. The drum should be lited above the ground with clearance of '50-100rmm gothatwhilaunreelng the drum flanges shouldnot ouch the ground and get damaged. + Tre cum should never be Kept flat on its side on the ground and the cable unroele in coll rom the same. This invariably leads to kinking andbia-caging + "Br-Caging'isadefect caused de to twist of cable during wrong unreeingtresuts ovtersheath crack or cuts andarmour sweling. Photograph ofbirdeaging, '+ The technique of puling cables is also an important, Sub-standlars and haphazard handling can cause damage to the cable which may ‘weaken the cable components, ancl cause a falue in due course. Care must be taken to select sultable poston forthe cable crum acs in ‘order lo ensure that the drum may be raised and rotated with full safely. The jacks should therefore be placed on a frm support of thick boards, * Care shoul be taken to ext a steady pull voicing ary jerks. Twisting or kinking or cable is vary dangerous as ths may cause damage to the smal size of cable conductor, insulion and sheath, shiting and knife-edging of the armouring and damage to te serving, etc. Care shouldbe taken toavord shortbends and coneequent staining of conductors + Properhancling of cables is ver/important both for safety as wellas longi ofthe instalation. + Themoet common causes of able faire are due to mshandling ofthe product installation etage ‘+ This canbe prevented by urinding the cabk by loading the crum on jacks pling the proper crection with stocking or puling eye + Ferpuling longo lengths and higher ameter of cables Puling Eyes canbe used. +n case of smaller lengths, pulling is carrac! out by manual labour and when the fangth is longer by means. of winches or other ‘mechanealmeans. + While puling with arope,careis necessary to avoid bending ofthe cable a close watch should be maintained to ensure the cable runs freely ‘over the cable rollers and passes smooth without ubbing against any surface. Recommended Minimum Bending Radius For HT Gables /LV Cables /Single Core Unsheathed. HT ables: Shgle Core:20xD Multicore: 15xD Lv Cables: Single Gore: 18xD Multicore: 12xD Shgle Core Unsreathod: SingleCore:8xD —__WhereD=Diameterofcablein mm) Recommended Safe oulling Fores With Stockings ‘a ForUnamoued Cable: P=5D2 Where b) FerArmouedCabk: — P=902 (Where! Recommended Safe Pulling Force When Pulled With Pulling Eye a) For Aluminium Conductors S0Nimm2 Puling force) Diameter ofcableinm) 1) ForCopper Conductor: SONmm2 Donot hammer metallic objects ke nailon the cable for fixing it. This leads to direct shorting and failure of cable.© ti 2.2 Special precautions for unreeling and installation of Helogen free law smoke sheathed cables. Cables having Low helogen polymer (SOM sheath needs tolsehandled with more cave duringinetallason, While special adkstives are used in formulation of LSOH compound to give the typical lame retardant charactertice of Zero halogen polmers some mechanical properties detrirate, The folowing basic precautions arenecessary + Cablee should net be exposed te sunight for considerable period before netalaion. the temperature of cable sheath shouts be below 400 celsius ‘+ Profeably installation shallbe done when the ambient temperatures +5 Dey C1030 Deg, + Urveating alow temperature below 5 eg.G andigh temperature above 40 Deg, C. can cause sheath crackat bends. + Wire/ Rope should not beusedrectl on the cable sheath or pling. + When pllecion cable rays/or any uneven surface, specialattentonis naeded o weking or unusually rough trans ‘Rollers ancibands shoukinot have any sharpness which may damage sheath 2.3 Laying Methods Formore details referIS 12 forlndian coneitons and detailed catalogue of manufacturer Single Core Cables — Installed in Parallel he Foloning rules mustbe observed ‘Cable shouldhave the same cross-sectonalarea, + Cables should nave the sametype & const + They shouldfollowthe same path + Theymustbectthe sams length substartialy. ‘+ They cannot bemadoto operate ndvidualy, + They mustnotinclude arybranch ccuits along theirroute. Cable pertaning to the same phase shouki bo as far as pra currents avoided For hvae single core cables per phase, thet blo altoratod with those cable ofthe othor phase so that unequal division of rect spositions are: FOR SINGLE CORE CABLES 2.4 Bonding Methods: Muticore cables + Alutcore cables shallbe boncied with both end bonding, as the phenomenon of culating curent ‘core cables only 1nd sheath votage related to single For Single core cables: Single point bonding + Screens connected and earthed atoneand. + Noclosedcruit, hence screen cxculating curentis elminates. + Normally used for lang outelengthslabove 1.2 kM), + Tremaximum allowable sheath voltage shallbe 65 volts, or cables wit single point bonding Both end bonding + Cable screen bonded and earthed at both end.+ Results circulating curentin cable whichis clroctlyproportionaltocurent cariedlby consucto. + NoSheathvottage + Losses canbe minimized by ying cable in TREFOIL formation. 2.5 Lugs & Glands. + tis sean as a practice of fow ofthe users that they insert the conductor inthe lugs or the cable inside a gland and if found loose they ‘complain that he conductor/cableis undersized + Cablee of same ve has so many types of conductor conelructons with which the OD can vary to great extent Le, cables with round stranded conductors, bunched concluctors, compact and shaped conductors et, + Soctor shaped conductors and compact round conductors ae the types which have minimum possible conductor ameter. When cables are madewith ths conductors the OD willberinimum, + When such Conductors ao used for making XLPE insulated cablos, tho OD will be further reduced as te thickness of XLPE insulation is {urtherless than thal of PVC. + Insuchcases tmay experienced thatlugs and glands etc are much boseto the conductors cables, + This practice is not the method to asses the size ofthe conductor or cable. Capacity ofthe conductors can be confemed by measuring ‘conclvcterresistance ofthe cable, 3. SITETESTING Recommended procedure for testing cables at site after laying and commissioning, 1. Thecables shall visually checked forany hanling damages. 2. Afterunreeting the cables from drum and|ayingitto the desired locaton, prepare both the ends ofcablesfortestng 8. Remove approx 300 - 400 mm length of outer covering PVC Sheath Armour, Bedding et, separate the cores and remove conductor insulation forapphying the voltage. 4 For cables up to 1000 vols rating, hsulation resistance ehall be measured with 1000 vols magger and values of each core shall be recorded. These values shall not fer rom each other more than 10% to 15%, 5. For cables 86 KV and above - DC High voltage testing shall be cartlod out before making torminations in exder to find any laying / hanaling damages. ‘8. Forscreonad cables, the copper seroon, somi-conducting layers shallbo removed approximately 150mm, rom both ends ofthe cabo ‘Thedemoisas below Lv Cable HV screened cableFollowing Test / Test Voltages shall be apple: “Test requirements ater installation (Before Crergingh"* Sr.No | Voltage Grade | Insulation Resistance | Observation WV test * Remarks ofcable | Test (Megger Test) (iv DC Test) 1 | weiaw 1000 vats Ves ofeach coe | NotRecarmerded | coe o amour IRvabes ‘amour care ce shal be geval same fr ‘sal b ee, Mores esta othe cable Chum elena 2 | sawn 25K Vues eteacieueto | skort | Coe esceevamour vals 8/660 vom aramau'and | and 05k | shale gerry sare te at retnce sal | or BOK Gabe, | cae eas rb cal un erected. | Duan 18 ines | erent, rsa ‘wand Veh 3 | easnw sky Vales each sore tek ‘ore sreeveraur taseren or ameur and | Duaton 15 Virtes | Rvalie shale geeraly oxo ove sal sae er a oes esto be rece ‘he cable cum reg sha estan HV et 4 ww 5h Vales teach cre sow ore screeveraur ‘ascren er amour and | Dualon 5 Vues | Rai shale general ‘etocue sane for a cores ste or shal ree ‘he cble um leg shal westand HV test s | rareew sk us of each cee a5 caret sreierour soem arama 2nd | Dual 5 Vrtes | vas sabe geval ue sae a aes este or shat eae. th cab du or nah, salt Vel 6 sa sky \atus a each coe sony core sreearaur twscren or amu and | Dyaton 15 Vrtes | vais sabe geal fone ve al sae fe a aes eo or ered tha cable du rng ha tad Vt ~ OCHY Tes vag sper 1255 “or Cals above 3 kt Pave eer mauactrer Datasheet or peo gules. “The cables shouldbe preferably tested before charging to avoid any damages inte intenaloflaying & charging, Insome cases VLF Testing (AC. HV Testng)is alsorecommended ‘+ After DC test, the conductor of cable halle earthed for 2 minutes o for a auitable tne In order to remove any residual charge fortheXLPE Insulation. © POLYCAG ‘CORPORATE OFFICE POLYCAB WIRES PVTLID. Polyab House, 771, Pant Sawaletar Mag, Mahim (W), Mumbai 40 06. Te 91-22-2492 7070 4 6795 1400+ Fax: 91-22-2432 7075, Weoste wir-poheab.com » Eall: nauny@poweab com Follow us on: KE] wwefacebook com/Palyeablnd G wotwtterconvPoycabindia { ninkesn comicompanyPoyead