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Underground Cable Installation

Manual

Horizon Power 1st Edition


March 2013

Prepared by
Asset & Works Capability
Operations Division

DOCUMENT CONTROL
Name:
Document Owner
(May also be the Process Owner)

Approved By *

Authorisation **
Process Owner is hereby vested
with authority and responsibility to
manage the process end to end.

Date Created/Last Updated

Shane Eeles

Position: Asset & Works Capability Manager


Date:

March 2013

Name:

Shane Eeles

Position: Asset & Works Capability Manager


Date:

March 2013

Name:

Ziggy Wilk

Position: General Manager Operations


Date:

March 2013

March 2013

Review Frequency ***

Every 3 years

Next Review Date ***

March 2016

Must be the Process Owner and is the person assigned authority and responsibility for managing the whole process, endto-end, which may extend across more than one division and/or functions, in order to deliver agreed business results.

**

This person will have the power to grant the process owner the authority and responsibility to manage the
process from end to end.

***

Frequency period is dependent upon circumstances maximum is 5 years from last issue, review, or revision
whichever is the latest. If left blank, the default will be 1 year unless otherwise specified.

STAKEHOLDERS

NOTIFICATION LIST

The following positions must be consulted if an


update or review is required:

The following positions must be notified of any


authorised change:

Work Delivery Coordinators

Regional Managers

Network Asset Management


Coordinators

Manager Asset & Works


Engineering & Projects

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
Horizon Power

Issue Date: Mach 2013


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Important Notice to Users

This Underground Cable Installation manual has been developed for use by Horizon
Power employees and Service Providers engaged to perform construction and
maintenance work on Horizon Powers underground electrical distribution networks.

This manual has been developed to provide guidelines for a minimum acceptable
standard of underground construction that is required by Horizon Power. To this end,
this manual provides the framework by which auditing of the underground electricity
distribution network may be undertaken.

It is issued by as a controlled document by Horizon Power to Horizon Power employees


and Service Providers on the condition that it will only be used whilst undertaking
Underground Cable Installation work on Horizon Power underground electrical
distribution networks.

Underground Cable Installation work will only be performed by individuals who are
appropriately trained and qualified in accordance with accepted standards within
Horizon Power. This Manual is not intended, and should not in any way be relied upon,
as a substitute for such training.

Copyright 2012
Copyright is owned by Horizon Power.

Horizon Power (ACN 57 955 011 697).

All rights reserved. No part of this work may be reproduced or copied in any form or by
any means (graphic, electronic, taping or information retrieval system) without the
written permission of the copyright owner.

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
Horizon Power

Issue Date: March 2013


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Table of Contents
Page i

Table of Contents

Section

Page Number

PURPOSE .............................................................................................................1-1

APPLICATION ......................................................................................................2-1

DEFINITIONS AND REFERENCES .....................................................................3-1

3.1
3.2

Definitions .................................................................................................................... 3-1


References .................................................................................................................. 3-3

GENERAL REQUIREMENTS ...............................................................................4-1

4.1
4.2
4.3
4.4
4.5
4.6

Training and Authorisation .......................................................................................... 4-1


Job Planning and Risk Assessments (Work Planning)................................................ 4-1
Personal Protective Equipment (PPE) ........................................................................ 4-2
Contractor Responsibilities .......................................................................................... 4-2
Traffic Management .................................................................................................... 4-2
Instructions, Procedures and Standards ..................................................................... 4-3

SURVEYING AND AS CONSTRUCTED RECORDS ........................................5-1

5.1
5.2

Survey Benchmarks and Datum Points ....................................................................... 5-1


As Constructed Records ............................................................................................. 5-1

CROSSINGS .........................................................................................................6-1

6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.2
6.3
6.4
6.5
6.6
6.7

7
7.1
7.2
7.3

8
8.1
8.2
8.3
8.4

Railway Crossings ....................................................................................................... 6-1


Planning Requirements ............................................................................................... 6-1
Installation of Cables and Conduits ............................................................................. 6-1
Installation of Cable Location Markers ........................................................................ 6-1
Installation of Power Cables under tracks and elsewhere on railway property ........... 6-2
Existing Pipes or Cables ............................................................................................. 6-4
Gas Mains ................................................................................................................... 6-5
Communications .......................................................................................................... 6-5
Existing Underground Electrical Cables ...................................................................... 6-5
Road and Vehicle Crossings ....................................................................................... 6-6
Horizontal Cable Clearance to other Services at Road Crossings .............................. 6-6

CABLE TUNNELS AND SUPPORT SYSTEMS ...................................................7-1


General ........................................................................................................................ 7-1
Access Pits .................................................................................................................. 7-1
Cable Support ............................................................................................................. 7-1

CABLE ON AND OFF NORMAL ALIGNMENT ................................................8-1


Standard Cable Alignment .......................................................................................... 8-1
Alternative Cable Alignment ........................................................................................ 8-1
Easements .................................................................................................................. 8-1
Retrospective Undergrounding .................................................................................... 8-1

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
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Table of Contents
Page i i

TRENCHING AND EXCAVATION ....................................................................... 9-1

9.1
9.2
9.3

General ........................................................................................................................9-1
Blasting ........................................................................................................................9-1
Excavated Materials .....................................................................................................9-1

10

DIRECTIONAL DRILLING .......................................................................... 10-1

10.1
10.2
10.3

Installation Principles .................................................................................................10-1


Drilling ........................................................................................................................10-1
Drilling Fluids Management Plan ...............................................................................10-2

11

PLOUGHING ............................................................................................... 11-1

12

CABLE LAYING.......................................................................................... 12-1

12.1
12.1.1
12.1.2
12.2
12.3
12.3.1
12.3.2
12.3.3
12.3.4
12.3.5
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
12.12

13
13.1
13.2
13.3
13.4
13.5
13.6

14
14.1
14.2
14.3
14.4
14.5
14.6

15

Drum Mounting and Inspection ..................................................................................12-1


Inspection prior to installation:....................................................................................12-1
Preparation for installation .........................................................................................12-1
Protection of Cables during Installation......................................................................12-2
Cable Installation methods .........................................................................................12-2
Stocking Pulling..........................................................................................................12-2
Installation using Pulling Eyes....................................................................................12-2
Bond Pulling ...............................................................................................................12-3
Armour Pulling............................................................................................................12-3
Mechanical Assisted Installation ................................................................................12-3
Cable Pulling Tensions ..............................................................................................12-3
Pulling Speed .............................................................................................................12-4
Cable Bending Radii ..................................................................................................12-4
Maximum Number of Cable Joints .............................................................................12-4
Installation of Cables on Poles ...................................................................................12-4
Bedding and Backfill ..................................................................................................12-4
Depth of Cover for Cables..........................................................................................12-4
Cable Protection Covers and Marker Tapes ..............................................................12-5
Sealing of Cables .......................................................................................................12-5

CONDUITS .................................................................................................. 13-1


Application .................................................................................................................13-1
Requirements for cables installed outside normal alignments ...................................13-1
Encased Conduits ......................................................................................................13-1
Sealing of Conduits ....................................................................................................13-1
Installation requirements for Conduits........................................................................13-2
Pulling Cables through Conduits ................................................................................13-2

CABLE JOINTING AND TERMINATIONS ................................................. 14-1


General ......................................................................................................................14-1
Cable Joint Excavations .............................................................................................14-1
Jointing .......................................................................................................................14-2
Termite Proofing ........................................................................................................14-3
Terminations ..............................................................................................................14-3
Working Ends .............................................................................................................14-3

TESTING AND COMMISSIONING ............................................................. 15-1

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
Horizon Power

Issue Date: March 2013


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Table of Contents
Page i i i

16
16.1
16.2
16.3
16.4

17
17.1

18
18.1

REINSTATEMENT .......................................................................................16-1
General ...................................................................................................................... 16-1
Compaction ............................................................................................................... 16-1
Levelling .................................................................................................................... 16-1
Restoration of Surface ............................................................................................... 16-1

DAMAGE TO PROPERTY ...........................................................................17-1


General ...................................................................................................................... 17-1

PILLARS AND PITS ....................................................................................18-1


General ...................................................................................................................... 18-1

APPENDIX A - SERVICE ALIGNMENT, DEPTH AND COLOURS FOR GREENFIELD


SITES .............................................................................................................................. 1
APPENDIX B CABLE INSTALLATION DATA ............................................................ 3
APPENDIX C - PILLAR LOCATION ............................................................................... 5
APPENDIX D - TYPICAL CABLE TRENCH ARRANGEMENTS ................................... 7
APPENDIX E - CONDUIT INSTALLATION AT ROAD CROSSINGS .......................... 13
APPENDIX F - DIAL BEFORE YOU DIG SERVICE ..................................................... 15

Document Title: Underground Cable Installation Manual


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SECTION 1
Page 1-1

PURPOSE

This manual specifies the technical requirements for the safe and efficient installation of
underground cables on Horizon Powers electrical distribution networks.
This document refers to other Horizon Power documents to provide reference standards
for underground cable installation work.

Document Title: Underground Cable Installation Manual


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SECTION 2
Page 2-1

APPLICATION

This manual has been developed for use by Horizon Power employees and Service
Providers engaged in the installation of high and low voltage distribution cables on the
Horizon Power electrical networks.
Horizon Power employees and Service Providers shall comply with these requirements,
except as otherwise approved.
For subdivisional work managed by a developer where the subdivision does not require
equipment to be installed on public land, some items in this document may not be
applicable as they are specified in the Underground Distribution Scheme (UDS) Manual.
Note:

Public land is land that at the time of subdivision is freely available for public
use, e.g., existing road reserves, Public Access Way (PAW), Public Open
Space (POS) etc.

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SECTION 3
Page 3-1

DEFINITIONS AND REFERENCES

3.1

Definitions

Accredited
Service
Provider (ASP)

means a person or an entity who has been accredited through


the accreditation scheme of Horizon Power to undertake any
construction work on Horizon Power underground network.

Approved

means having appropriate organisation endorsement in writing


for a specific function.

Authorised
Person

means a person with technical knowledge or sufficient


experience who has been approved, or delegated authority to
act on behalf of Horizon Power to perform the duty concerned.

Cable

means a single cable core, or two or more cable cores laid up


together, either with or without fillings, reinforcements or
protective coverings.

Conductor

means a wire or other form of conducting material suitable for


carrying current, but not including wire or other metallic parts
directly employed in converting electrical energy into another
form.

means the officer appointed by Horizon Power as Horizon


Construction
Project Manager Powers representative to whom all site contractual and
technical matters are referred.
(CPM)
Earthed

means directly electrically connected to the general mass of


earth so as to ensure and maintain the effective dissipation of
electrical energy.

Energised

means connected to a source of electrical supply.

High voltage

means a nominal voltage exceeding 1,000 V ac or exceeding


1,500 V dc.

Insulated

means separated from adjacent conducting material by a nonconducting substance or airspace permanently providing
resistance to the passage of current, or to disruptive discharges
through or over the surface of the substance or space, to obviate
danger of shock or injurious leakage of current.

Live

means energised or subject to hazardous induced or capacitive


voltages.

Low voltage

means nominal voltage exceeding 50 V ac or 120 V dc but not


exceeding 1000 V ac or 1500 V dc.

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SECTION 3
Page 3-2

Safe

means not posing an unacceptable risk to life, health or


property.

Safety Observer

means a person competent for the task and specifically


assigned the duty of observing and warning against unsafe
approach to electrical apparatus, or other unsafe conditions.

Shall

means a requirement is "mandatory.

Should

means a requirement Is "advisory or discretionary.

Voltage

means a potential difference between conductors or between


conductors and earth.

HDPE

High Density Polyethylene

HV

High Voltage

LV

Low Voltage

MRWA

Main Roads Western Australia

PTA

Public Transport Authority

PAW

Public Access Way

POS

Public Open Space

UDS Manual

Underground Distribution Schemes Manual

WAGR

Western Australian Government Railway

WAPC

Western Australian Planning Commission

XLPE

Cross-linked Polyethylene

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SECTION 3
Page 3-3

3.2
References
Requirements and Information relating to this Standard may be found within the source
documents detailed below:

Utility Providers Code of Practice, Main Roads WA;

Restoration and Reinstatement Specification for Local Governments in Western


Australia published by the Institute of Public Works Engineering Australia (available
from Main Roads WAs web site);

Horizon Power Underground Distribution Schemes (UDS) Manual;

Horizon Power Network Standard: Testing & Commissioning Technical


Requirements;

Dial Before You Dig Service for lodging an enquiry and requesting a plan;

Traffic Management for Works on Roads - Code of Practice, Main Roads WA;

Occupational Safety and Health Act 1984 and Occupational Safety and Health
Regulations 1996.

WorkSafe Code of Practice: Excavation

Explosives and Dangerous Goods Act 1961 and Explosives and Dangerous Goods
(Explosives) Regulations 1963;

AS 1742 Manual of uniform traffic control devices, Australian Standards;

AS/NZS 3000 Australian/New Zealand Wiring Rules; and

AS 4799-2000 Installation of underground utility services and pipelines within railway


boundaries.

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SECTION 4
Page 4-1

GENERAL REQUIREMENTS

All Horizon Power underground cables shall be a termite protected type. Termite
protection is critical to achieve 40+ year cable life, as Horizon Power cables are often
installed in termite affected areas
Cables are termite protected using the following means:
a)
b)
c)

inclusion of a termicide in the outer sheath (Horizon Power method);


double brass tapes;
nylon sheaths

The cable sheath MUST NOT be scratched during installation. Scratch damage to the
outer sheath may allow termites mandibles (pincers) to bite into the cable outer
sheath.
4.1

Training and Authorisation

Underground Cable Installation work shall only be performed by individuals who are
appropriately trained, qualified and authorised in accordance with accepted standards
within Horizon Power.
Service Providers are responsible for ensuring all its employees and Sub-Contractor
employees have been authorised by Horizon Power. They must submit to Horizon
Powers site representative confirmation of authorisation for each employee, prior to the
commencement of the works.
Note:
4.2

This Manual is not intended, and should not in any way be relied upon, as a
substitute for training.
Job Planning and Risk Assessments (Work Planning)

Prior to the commencement of the work, an on-site job risk assessment must be
undertaken by all Horizon Power and Service Provider team members in accordance
with Horizon Powers Job Risk Assessment Process and Field Instruction FI 2.23
Job Hazard & Risk Assessment, to ensure all aspects of our work is carried out in a
safe manner.
The on-site job risk assessment shall include but not limited to:

Identify and discuss the job hazards;

Assess the risks that may result because of the hazard;

Agree on the tasks assigned to control or remove the hazards & risks; and

Implement the control measures

Document Title: Underground Cable Installation Manual


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SECTION 4
Page 4-2

4.3

Personal Protective Equipment (PPE)

Horizon Power and Service Provider employees engaged in the installation of high and
low voltage distribution cables on the Horizon Power electrical networks shall wear the
Personal Protective Equipment (PPE) as required in accordance with Horizon Powers
Minimum Personal Protective Clothing and Footwear Standard and relevant Field
Instructions.
This includes but not limited to:

Long sleeve overalls or long sleeve shirts and trousers with High Visibility properties
for day and night AS/NZS 1906.4:1997;

Have properties not inferior to 100% cotton drill;

Minimum material weight of 185gsm;

Safety footwear to comply with AS 2210 and Horizon Power Field Instruction 2.6 Worksite Clothing/PPE Requirements

Safety glasses must be worn in accordance with Horizon Powers Field Instruction
2.5 - Wearing of Eye Protection

Safety Helmets must be worn in accordance with Horizon Powers Field Instruction
2.2 - Wearing of Safety Helmets

4.4

Contractor Responsibilities

The Contractor is to provide competent, qualified and licensed Personnel to undertake


Underground Cable Installation.
All Contractor Personnel utilised to carry out work activities on or near Horizon Powers
electrical networks must have Horizon Power authorisation prior to the commencement
of the Services.
4.5

Traffic Management

Horizon Power and Service Providers shall ensure that where Services are sited
adjacent to existing roads, adequate precautions are taken at all times to protect
personnel, associated plant, and the general public.
Horizon Power and Service Providers shall comply with the Main Roads Department
Traffic Management for Road Works Code of Practice and Horizon Powers Field
Instruction FI 2.15 - Temporary Safety Barriers and/or Warning Signs (DM# 3136675)
The Local Government Authority shall be notified of any occasion it may be necessary
to obstruct a road or footpath to carry out the Services. The Contractor shall obtain the
written consent of the Main Roads Department and the relevant local authority before
creating such obstruction.
All vehicles shall be fitted with suitable warning lights.

Document Title: Underground Cable Installation Manual


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SECTION 4
Page 4-3

4.6

Instructions, Procedures and Standards

Horizon Power and Service Providers shall comply with Horizon Power instructions,
procedures, standards and construction drawings when engaged in the installation of
high and low voltage distribution cables on the Horizon Power electrical networks.
This includes but not limited to the following Horizon Power documents:

Selected Horizon Power Field Instructions and Work Procedures

Electrical Safety Standards (ESS)

Fit for Work Policy

Minimum Personal Protective Clothing and Footwear Standard

Job Risk Assessment Procedure

Hazard Incident Reporting Notification and Investigation Procedure

Guidelines For Excavation Work Near Horizon Powers Underground And Overhead
Electrical Networks

Project Flow & Quality Assurance Procedure for All Work Types

Underground Distribution Schemes (UDS) Manual.

Underground Cable Installation Manual

Testing & Commissioning Standard

Substation Installation Manual

Distribution Equipment Labelling Standard

Construction Drawings

DFIS/DFMS Reference Guide As Constructed Drawing Requirements

Copies will be provided to Service Providers at pre-star meetings, prior to the


commencement of the works.

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SECTION 5
Page 5-1

SURVEYING AND AS CONSTRUCTED RECORDS

5.1

Survey Benchmarks and Datum Points

There may be official survey benchmarks installed in the project work area. Precautions
shall be taken to avoid disturbing these markers. Should any markers be disturbed, all
costs associated with restoring the benchmarks to their correct position shall be borne
by those responsible for such disturbance.
5.2

As Constructed Records

Upon completion of all work, the following As Constructed records shall be provided to
the Horizon Powers Construction Project Manager (CPM):
1.

Cable installation record. Where cables are installed using directional drilling, the
length and depth of cables shall be recorded.

2.

Electrical test schedules.

3.

HV cable joint schedule.

4.

Materials & equipment schedule.

The As Constructed records shall meet the requirements of Section 9.2.3.7 of the
Underground Distribution Schemes Manual.
Standard forms for Electrical Test Schedules, HV Cable Joint Schedules and Materials
& Equipment Schedule are available for download from Horizon Powers web site.

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SECTION 6
Page 6-1

CROSSINGS

6.1

Railway Crossings

6.1.1

Planning Requirements

Before commencing any works associated with railway property, it is essential that all
necessary applications are made and approvals obtained. Details of the applications
and approval process requirements are contained in the Utility Providers Code of
Practice for Western Australia (Appendix D- Utilities Located in Rail Reserves).
The approval process can take several months, so appropriate planning for the works is
recommended. In most cases, arrangements will be required to use a railway flagman
at the site for the duration of the works.
6.1.2

Installation of Cables and Conduits

Where site conditions permit, the installation shall be by boring or directional drilling for
the portion under the tracks and at least 3 m beyond the outer rails or 3 m beyond the
toe of embankment, whichever is the further.
In the case of boring, the diameter of the bored hole shall not exceed the outside
diameter of the pipe/conduit by more than 50 mm. If the diameter of the bored hole
exceeds the outside diameter of the pipe/conduit by 50 mm or the bored hole needs to
be abandoned, the hole shall be backfilled and remedial measures shall be taken to
provide support for the railway.
6.1.3

Installation of Cable Location Markers

Cable marker details are available in Horizon Powers Distribution Design Catalogue
(DDC) Section 7. Cable markers shall be installed to indicate the location of all
underground power cables.
1.

2.

The markers shall be located above or adjacent to the buried cable:


a)

At points of entering and leaving the Public Transport Authority (PTA)


property;

b)

At changes of direction;

c)

At a distance between consecutive markers of the lesser of 200 m or line of


sight; and

d)

Where specified, at the ends of the under track crossing (the end of the
under track crossing is taken as the point 3 m beyond the outer rail or toe of
the embankment).

The wording on the markers shall include the following:


a)

The owners name;

b)

A warning of the presence of a buried service;

c)

The nature of the buried service; and

d)

Contact details and advice in the event of an emergency.

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SECTION 6
Page 6-2

3.

4.

The markers shall comply with the following requirements:


a)

Stand at least 800 mm out of the ground, to the bottom of the marker plate;

b)

Be of non-combustible material for the marker plates and of at least fireresistant material for the pole; and

c)

Wording on the markers shall be legible, permanent, and formed in a noncombustible medium, or as otherwise approved by the PTA.

The descriptive wording and instructions shown on the markers shall face the
railway.

6.1.4

Installation of Power Cables under tracks and elsewhere on railway property

Power cables passing under the tracks shall be enclosed in an appropriate Category A
system. The top of the encasing pipe or conduit shall be at a depth of not less than
2000 mm below the top of rail and shall be maintained at this depth for not less
3000 mm beyond the outer rails, when measured at right angles to the track, unless
otherwise stated in the approved design.
A Category A system is an underground system where:
a)

Cables are enclosed in heavy duty insulating conduit without further


mechanical protection.

b)

Cables are enclosed in insulating wiring enclosures encased in concrete.

c)

Sheathed cables are enclosed in galvanised steel pipe without further


mechanical protection or

d)

Armoured sheathed cables or neutral screened cables are buried direct in


the ground without mechanical protection.

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SECTION 6
Page 6-3

Dimension

Description

Minimum depth (mm)

Depth between top of rail and


conduit, pipe or cable

1200/1500 (directly buried optic)


2000 (power)

Depth between top of rail and


encasing pipe

1200/2000 (power)

Figure 1 Section of conduit or pipe-carrying cable under tracks

Power cables passing elsewhere on the property of the PTA shall be laid at a depth of
not less than 1000 mm below ground level, or at the same depth below the level of
drain inverts they may cross unless, otherwise stated in the approved design.

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SECTION 6
Page 6-4

Where specified by the PTA, the cables shall also be enclosed in conduits or covered
by protective slabs.

Figure 2 Section of cable within and parallel to railway reserve

6.2

Existing Pipes or Cables

Whenever a crossing is made of an existing pipe or cable, such pipe or cable shall be
securely supported during the progress of the work.
The minimum spaces required between services are contained in the Utility providers
Code of Practice, summarised as follows.
1.

Electricity is to pass under gas and water at reticulation crossings.

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SECTION 6
Page 6-5

2.

The existing cable shall be protected by a split length of heavy duty conduit or
concrete slabs. If 150 mm clearances cannot be maintained then the cable shall
be sleeved with a conduit. The length of conduit shall be at least of 500 mm on
either side of the crossing.

3.

A minimum clearance of 300mm is required between gas and electricity services.


If 300mm clearance cannot be achieved, approval of the Gas Service Provider
shall be obtained.

4.

A minimum clearance of 150mm is required between the electricity services and


the sewer and water mains.

5.

All reticulation shall be laid within 100 mm of the indicated centre line and
secured against movement with initial backfill.

6.3

Gas Mains

Where work is required close to the gas transmission system such work shall be
performed in accordance with Horizon Powers Field Instruction FI 4.1 Work
Adjacent to Gas Mains.
6.4

Communications

The communications alignment is between 500-1300 mm from the property boundary


within the verge, and 450 mm deep. Whenever a cable crosses is a communications
cable, the cable shall be securely supported during the process of the work and the
power cable shall go under the communications cable, maintaining a 300 mm clearance
as per Utility Providers Code of Practice.
The space between the power cable and the communications cables shall be
maintained when the trench is backfilled.
Appendix A provides the diagram for the road reserve allocation for utility providers.
6.5

Existing Underground Electrical Cables

Prior to the commencement of excavation work, all efforts must be made to determine if
underground cables are present in the vicinity of the proposed excavation. This
includes but is not limited to using the One Call service.
Work on or near existing underground cables shall be in accordance with Horizon
Powers Guidelines for Excavation Work Near Horizon Powers Overhead and
Underground Network and Field Instruction FI 4.5 Working Near Underground
Cables.
If any unrecorded underground cables, conduits or bare earth wires are exposed, work
in the vicinity must cease and Horizon Powers CPM must be notified immediately.

Document Title: Underground Cable Installation Manual


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SECTION 6
Page 6-6

6.6

Road and Vehicle Crossings

All cables crossing roads and vehicle crossovers shall be installed in conduits. Road
crossings shall be installed:
a)

Perpendicular to the property street boundaries; and

b)

between readily recovered target points, e.g., common property boundaries


or intersections.

For service cables and streetlight cables, the conduits shall be installed from the edge
of the cable alignment to as close as practical to the termination point (e.g. street light
column, etc).
For cables with a large bending radius, road-crossing conduits shall extend a minimum
of 1000 mm beyond the kerb into the verge and as practically close to the termination
point. Cable covers shall be installed over cables in the gaps between the end of
conduits and the edge of cable alignment, to ensure that the cable is protected until it
enters the cable alignment.
Note:

Full details of the above requirements are shown on Drawing in


Appendix F.

Where roads and vehicle crossings are already constructed, thrust boring shall be used
to install the required conduits.
Conduit crossing locations shall be permanently identified on the road kerb-face.
Typical identification methods could include a:
a)

75 mm high letter E embedded or cut in,

b)

proprietary brass plate/letter E adhered to the face.

Where conduits are installed across roadways where no kerbs currently exist or will not
be installed when the conduits are installed, conduit location as-built drawings shall
show the conduit centreline end-point relative to surveyed property boundaries.
6.7

Horizontal Cable Clearance to other Services at Road Crossings

All cables and conduits crossing roads shall be installed with a minimum horizontal
clearance of 150 mm from other services.

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SECTION 7
Page 7-1

CABLE TUNNELS AND SUPPORT SYSTEMS

7.1

General

Where cable tunnels are to be used, the construction and installation requirements shall
be included on the design drawings.
Cables running through cable tunnels shall be supported on cleats with a maximum
spacing of 1500 mm or on cable ladders. Horizontal spacing of cable and circuits shall
be at least 100 mm between adjacent circuits.
7.2

Access Pits

In circumstances where there is a significant change in direction of the cables being


installed, the design may require the installation of an access pit to be large enough to:

7.3

a)

allow two people to work comfortably on the cable;

b)

install rollers; and

c)

accommodate the bending radii of the largest cable.


Cable Support

A cleat support system shall be installed in at a distance to ensure the cable is


maintained in a straight line and only minimal sagging occurs.
When using cleats, it is necessary to ensure the cable is rigidly held at the cleat
position.
Cleats for long vertical runs shall be designed to support the weight of the cable.
Cleats used on single core cable shall be of non-magnetic material, such as wood or
aluminium. Single core cables shall never be surrounded with a steel ring, as this will
cause local heating problems.
Care shall be taken to ensure the correct size cleat is used otherwise damage to the
cable may result. A tight cleat may pinch the cable whereas a loose cleat may allow
excessive cable movement.
Wooden cleats shall be used for paper/lead insulated cables.

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SECTION 7
Page 7-2

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SECTION 8
Page 8-1

CABLE ON AND OFF NORMAL ALIGNMENT

8.1

Standard Cable Alignment

Wherever practicable, cables shall be installed in Horizon Powers standard alignment


of 0 500 mm from the property boundary in accordance with the Utility Providers
Code of Practice for Western Australia and Drawing in Appendix E;
Other services shall not be installed in the power cable alignment without written
approval from Horizon Power.
All front boundary pegs shall be identified prior to the commencement of excavation.
8.2

Alternative Cable Alignment

Cables may be installed in the 2.7m alignment where there are installation and
maintenance issues adjacent to retaining walls and other structures in the standard 0
500 mm alignment. This is provided it is acceptable to the other Utility Service Providers
and it does not interfere with street trees.
In special circumstances if the 2.4 m to 3 m alignment is not available, a written request
to the other Utilities will be required to obtain approval to use their alignments.
8.3

Easements

Where HV and LV cables are installed outside the standard alignment or in locations
other than road reserves, including private property, public open space or public access
way, they shall be protected by surveyed and registered easements.
Two types of underground distribution easements exist.
a)

development areas controlled by the WAPC process: Easements are


arranged under Section 167 of the Planning and Development Act 2005.

b)

other developments areas: Easements are arranged under the Energy


Operators (Power) Act 1979.

The appropriate easement shall be selected and documented in the design file for each
particular location.
Note:
8.4

For subdivision developments, developers shall comply with the requirements


of the UDS Manual.
Retrospective Undergrounding

Where the standard cable alignment is not practically available for retrospective
underground areas, the cable centre line shall be relocated to a centreline of 2.7 m from
the property line (ie the standard pole and trees alignment). The correct property line
shall be identified by survey and where there is any doubt as to its correct location, the
required directions shall be obtained from the relevant authority.

Document Title: Underground Cable Installation Manual


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SECTION 8
Page 8-2

Where existing overhead electrical apparatus (poles) impedes the installation of


underground electrical apparatus (cables) in the 2.7 m alignment, approval may be
requested to install the cables on the opposite side of the road in the standard cable
alignment.
Where the poles and trees alignment is not available, special arrangements will need to
be determined and directed by Horizon Powers Asset & Works group.

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SECTION 9
Page 9-1

TRENCHING AND EXCAVATION

9.1

General

All excavation work shall be carried out in accordance with the requirements of
WorkSafe WA Code of Practice Excavation, Horizon Powers Field Instructions FI
4.4 Excavation Work and FI 4.5 Working On or Near Underground Electrical Networks.
Trenches shall be excavated to a width sufficient for satisfactory and safe working
conditions.
Excavations shall provide the specified minimum cover so as to avoid damage or loss
of support to, obstacles such as pipes, drains, cables and other utilities and services;
and
The excavated area shall be reinstated in accordance with section 16 of this manual.
Note:

9.2

The use of a dedicated safety observer will be required when excavating with
a machine in the vicinity of live or de-energised underground cables or ground
mounted electrical apparatus.
Blasting

On occasions blasting operations may be undertaken for excavation in rock, limestone


and clay.
Blasting is not permitted within 30 metres of other utilities and where the blasting will
affect their equipment
Handling and use of explosives for blasting operations shall be carried out by, or under
the direct supervision of, a licensed shot-firer.
Adequate warning signs shall be displayed and all precautions against flying material
taken by the use of pegged or weighted blasting mats or similar aids
Blasting shall be limited in built up areas and shall only take place when all nearby
building occupants have been notified in writing and all buildings have been thoroughly
inspected, photographed (where required) and their condition recorded.
Note:
9.3

Service Providers shall pay for any damage or injury caused by blasting.
Excavated Materials

In built up areas where permitted by the relevant authorities and where practicable,
reusable top layers of excavated material such as lawns, pavers, topsoil, etc shall be
neatly stacked on one side of the trench and the bottom layer of soil shall be stacked
separately on the opposite side of the trench.
Some Local Government Authorities require all excavated materials, including paving
materials to be removed temporarily or permanently from site to enable continued

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SECTION 9
Page 9-2

pedestrian access without having to walk on the road and reduce the potential for
vandalism. Unsuitable soil shall be disposed of and graded backfill brought in.
No excavated material shall be placed, or encroach, on private property without the
written approval of the owner.
In built up areas, excavated soil shall be covered with tarpaulins or similar protection if
weather conditions will cause soil to be washed or blown away.

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SECTION 10
Page 10-1

10

DIRECTIONAL DRILLING

10.1

Installation Principles

Directional drilling is becoming the preferred method of installation for underground


works due to improvements in technology and minimum installation disruption.
Conduits and cables shall be installed in accordance with the approved construction
drawings.
In general, the following principles shall apply:
a)

each cable shall be installed in a single way conduit.

b)

cable and conduit installations shall be installed between 900 mm minimum


depth and 1500 mm maximum depth unless other requirements of this
document (eg rail crossings) or local site conditions apply.

c)

cable spacings shall meet the requirements of Drawing No. UDS-6-2 in the
Underground Distribution Scheme (UDS) Manual or as designed for
alternative installations.

d)

Conduits installed by directional drilling shall not require additional cable


protection covers or cable marker tapes.
A maximum of two LV cables of 185mm, including streetlight cables can be
installed in a common directional drilling bore if there will be no tee or
service joints along the cables.
One 35mm HV transformer cable and one LV cable of 185mm or less can
be installed in a common directional drilling bore if there will be no tee or
service joints along the LV cable.
Multiple high voltage feeder cables (185mm, 240mm or 400mm) shall not
be combined into a single directional drilling bore.
Separate directional drilling bores shall be used between 900mm
minimum depth and 1500mm maximum depth. Cable spacing shall meet the
requirements of Drawing No. UDS-6-2 in Appendix 22 of the UDS Manual

10.2

Drilling

During construction, continuous monitoring and plotting of the pilot drill and back
reamer progress shall be recorded to ensure compliance with the required alignment
and installation depth. The monitoring may be accomplished either by manual plotting
based on the location and depth readings provided by the tracking system or by
computer-generated track logs fed by this information. The tracking system shall
provide information on:
a)

Clock and pitch.

b)

Alignment and Depth.

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SECTION 10
Page 10-2

c)

Position (x-y).

d)

Azimuth - is defined as the direction of cable where a walkover is not


possible.

The bore logs shall show a depth and bore position from a known boundary every 3m
along the bore line. These records shall be made available to Horizon Power
electronically as a permanent record.
To prevent collapse of the borehole, drilling mud or similar material rather than just
water shall be used for both drilling and back reaming operations.
Drilling, back-reaming speeds and fluid flow shall be set to ensure spoil is removed
without putting unacceptable pressure on the surrounding soil (e.g. surface humping).
During conduit and/or cable installation, pull-back tension shall be set so as to not
exceed conduit/cable manufacturers maximum pulling tensions.
Note:
10.3

See Appendix B or Manufacturers recommendations for maximum pulling


tension for various cable types and sizes.
Drilling Fluids Management Plan

A drilling fluids management plan shall be completed prior to the commencement of


directional drilling work. The plan shall contain the following:
a)

Method of slurry containment.

b)

Method of recycling drilling fluids and spoil if applicable.

c)

Method of transporting drilling fluids and spoil off site.

d)

Drilling fluid pressures.

e)

Measures to contain and clean the affected area for inadvertent return of
drilling or hydraulic fluids.

f)

Measures to adequately clean up of surface seepage of drilling fluids and


spoils.

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SECTION 11
Page 11-1

11

PLOUGHING

Ploughing installation of cables is not a current approved method at this stage.


Proposals to use this technology should be discussed with Horizon Power prior to
committing to the technology.

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SECTION 11
Page 11-2

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SECTION 12
Page 12-1

12

CABLE LAYING

12.1

Drum Mounting and Inspection

Prior to installation of cables, the following shall be carried out:


12.1.1

Inspection prior to installation:

Following removal of the drum battens or transport protective covering and prior to
commencing cable installation, check:
a)

each drum for transport damage;

b)

integrity of manufacturers seals on inner and outer cable ends;

c)

condition of armouring, serving and sheath, particularly damage from drum


batten nails;

d)

Mechanical damage, corrosion and/or leakage of impregnating oil (where


applicable).

If the cable is found to be defective, it shall not be installed and arrangements made for
it to be returned to the supplier for replacement.
12.1.2

Preparation for installation

Each drum should be mounted on jacks, cable trailer or cable stands so


the cable is preferably pulled from the top and always in the direction
opposite to that indicated by the arrow on the drum;
Lighter cables may be laid by mounting the cable drum on its side on a
truck-mounted turntable and laying the cable directly into the trench;
Prior to removing the cable drum battens, ensure the drum-spindle is level and that the
drum turns freely;
If it is necessary to roll a drum into position prior to mounting, ensure the drum is rolled
in the direction indicated by the arrow on the drum;
Cable drums should be positioned in line with the direction of cable pull;
As an alternate to a fixed mounting for the cable drum, cables may be rolled directly into
a trench from the drum mounted on mobile plant (e.g. excavator) moving along the
trench.

WARNING

Sealed cables may contain methane (a flammable gas)


The cable manufacturing process produces methane inside the
cable.
Where a cable has fitted with a heat shrink end cap & pressure
relief valve before the cable is cut, any pressure build up shall be
bled by inserting a pin into the valve until no further gas is heard to
be escaping.

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
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Cable end cap


with pressure
relief valve

Issue Date: March 2013


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SECTION 12
Page 12-2

12.2

Protection of Cables during Installation

Cable should be fed from the top of the drum to prevent cable
slack.
When pulling from large drums, the cable should be supported
between the drum and the trench with a suitable ramp or
rollers to prevent stressing the cable;
Cables shall be kept clear of abrasive surfaces by suitable means, e.g.
rollers, etc to prevent any damage to the cable sheath. The cable shall
be placed in the trench without sustaining abrasion damage and without
allowing rocks or debris to fall into the trench that could also damage the
sheath integrity (allowing termite attack);
Precautions should be taken to prevent the drum from over-rotating and allowing cable
slack. A suitable braking mechanism should be installed, either in the form of a drum
flange drive or an effective friction brake, eg plank brake shoe. Where brake shoes are
utilised, care shall be taken to ensure no damage occurs to the cable Z (inner) end
that protrudes through the drum flange;
On long cable runs or where a cable has significant direction changes (both horizontal
and/or vertical), rollers shall be used to ensure minimum pulling or bending of radii are
maintained to ensure a smooth pull and avoid damage to the cable;
Cables which are pulled into position by a winch, shall use suitable
cable stockings and swivels to prevent damage; and
When installing cable by directional drilling, it is essential the cable sheath is not
damaged, since damage to the outer jacket may cause sheath faults or compromise the
integrity of the cable termite protection.
12.3

Cable Installation methods

There are numerous methods by which the cable can be pulled into the final installed
position. Generally, the most economical methods employ power winches.
If considering only those pulling methods using mechanical winches, then there are four
distinct methods:
12.3.1

Stocking Pulling

Cable pulling using a steel mesh cable stocking is probably the most common form of
installation for cables up to and including 33 kV. The cable stocking is slipped on to the
end of the cable and the winch rope attached.
Application of pulling tension locks the stocking onto the cable sheath. Care shall be
taken to ensure the manufacturers recommended pulling tensions are nor exceeded as
cable damage will result.
12.3.2

Installation using Pulling Eyes

The strength of the cable sheath limits the length and size of the cable that can be
pulled by stocking pulling. For long and large cross section cables, pulling-eyes can be
fixed directly to cable conductors for pulling the cable.

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SECTION 12
Page 12-3

12.3.3

Bond Pulling

When likely pulling tensions may exceed the tension limit of the cable, straight end pulls
may have to be replaced by bond pulls. In this method, the cable is lashed to the pulling
rope at close intervals (eg every half metre for a distance of 20 metres or more) to
distribute the strain of the pulling.
Mechanical padding is required to protect the cable sheath from damage at the lashing
points.
12.3.4

Armour Pulling

This system uses the armour wires of a cable as the pulling medium. The armour wires,
left extended past the end of the cable, are formed into a pulling eye and the winch rope
attached to it.
Caution: This method shall not be used for XLPE cables.
12.3.5

Mechanical Assisted Installation

For long or difficult cable installation or large cable sizes, mechanical


assistance can be used to insist installation. Typical methods include:

12.4

a)

One or more cable caterpillars installed mid or multi-point


along the cable route to provide intermediate cable thrust;

b)

Power assisted driven cable drums.


Cable Pulling Tensions

Cable pulling tensions shall not exceed the manufacturers recommendations.


The maximum recommended pulling tensions when using stocking grips to install unarmoured XLPE cables are shown in Appendix B.
The trench or conduit line should be set out so that any necessary deviations from a
straight line occur over the largest possible radius. When pulling cable into conduits
incorporating bends or pulling rope rollers, lower maximum pulling tensions may be
necessary to avoid the wire pulling rope cutting into the side of the conduit.
Any winch used to pull cables shall have either a facility to automatically limit the pulling
tension applied to a cable (a tension fuse) or a continuous reading dynamometer
incorporated in the pulling arrangement to enable the actual pulling tension to be
monitored.
In special circumstances, cable pulling pits may be required at significant changes in
cable route direction. Required pits shall be indicated on the design drawing.
On long or complicated cable installations, intermediate cable feeder equipment (or
caterpillars) may be required to limit pulling tensions.

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SECTION 12
Page 12-4

12.5

Pulling Speed

To avoid damage due to overruns, the cable should be pulled just fast enough to keep
the drum rotating smoothly.
Higher speeds are possible when pulling small cables into straight trenches or conduits
with good conditions at the feeding and pulling ends;
Drums with long lengths of cable should not be rotated rapidly as overrun can cause
cable damage if pulling is slowed or stopped suddenly.
12.6

Cable Bending Radii

The permissible bending radii of all cables are given in Appendix B. No twists, knots or
kinks are permitted.
Where a 3x1 core HV cable is to be laid to transformers or switchgear, the three twisted
cores can be separated at termination location (e.g. Triplex style) into three individual
cores to reduce the minimum bending radius required.
12.7

Maximum Number of Cable Joints

Underground cable joints between terminal points shall be kept to a minimum. For
information on the maximum numbers of through joints that may be installed in any
section of cable, refer to the Underground Distribution Scheme (UDS) Manual,
Section 9.2.8.7.
12.8

Installation of Cables on Poles

Where cables are installed onto termination poles, the cable shall be
installed as directly as possible from the cable trench to the pole. No
spare loop of cable is required to be installed at the base of the pole,
as it is better to joint in a new section of cable if a termination failure
occurs. The section of cable off the standard alignment shall be
protected by cable slabs and marker tape.
12.9

ty
per
Proundary
Bo

Bedding and Backfill

To protect the cable sheath, all cables shall be firmly and uniformly bedded on sand
free from rocks or other hard formation. The cable shall be surrounded with a thickness
of sand prior to backfilling, bottom by 150 mm and two sides by 100 mm, top by
300 mm as shown in drawing in Appendix D. The upper 300 mm of the backfill to final
ground level shall also meet the local government authoritys requirements.
12.10

Depth of Cover for Cables

The depth of cover over cables shall not be less than 850 mm. The depth of cover shall
be increased as required to ensure that cable joints will have the required depth of
cover.

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SECTION 12
Page 12-5

12.11

Cable Protection Covers and Marker Tapes

The cable covers shall comply with the requirements of clauses 3.11.3.3 of AS/NZS
3000:2000 and if required, cable covers and PVC marker tape shall be laid at the
required levels, as shown in drawing UDS-6-1 in Appendix E.
Where more than one cable is installed, the PVC maker tape or cable cover must be
wide enough to fully cover the cables, otherwise additional maker tapes and covers
shall be installed.
Additional cable protection shall:
1.

be placed maximum 75 mm above the wiring system

2.

be not less than 150 mm wide

3.

overlap the wiring system by at least 40 mm on each side

4.

consist of one or a combination of the following:


a)

precast concrete slabs with a minimum thickness of 40 mm and a


classification of not less than grade 20 degrees in accordance with AS 3600

b)

a continuous concrete pour having a thickness of not less than 75 mm

c)

fibrous cement slabs having a thickness of not less than 12 mm

d)

bricks (slabs) manufactured specifically for the protection of electric cables

e)

polymeric cable cover strip (complying with AS 4702)

f)

other materials that offer the same degree of protection as the materials in
items (a) to (e) above.

Note:
12.12

Conduits installed by directional drilling shall not require cable protection


covers and marker tapes.
Sealing of Cables

To ensure water cannot penetrate into the cable conductors or insulation, ends of
cables shall be kept sealed. On completion of the cable pulling, any damaged or nonwaterproof pulling eyes or sealing end caps should be removed and the cable resealed,
unless it is to be terminated immediately.
Where cables have been cut following installation, both the installed and drum ends
shall be sealed immediately, except where the cable is to be jointed immediately.

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SECTION 12
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SECTION 13
Page 13-1

13

CONDUITS

13.1

Application

Conduits complying with Australian Standard AS 2053 shall be used to protect cables
where they are installed in the following situations:

13.2

a)

in easements;

b)

exit cables from a distribution substation that is set back from road or
property boundary;

c)

near retaining walls where there is a danger of cable installation damage due
to foundation subsidence;

d)

crossing roads;

e)

crossing water courses and drains;

f)

crossing high pressure gas pipelines;

g)

crossing under railway lines or restricted access areas such as airports; and

h)

within bridge crossings.


Requirements for cables installed outside normal alignments

Where cables are installed outside the 0-500 mm standard alignment or the 2400
3000 mm alignment as approved by Horizon Power for street installation, conduits are
NOT required. The cables shall be direct buried, laid in accordance with Section 14.9
and protected with cable slabs as shown in Drawing in Appendix E.
13.3

Encased Conduits

In some locations PVC conduits may be encased in concrete pipes, steel pipes or
concrete encased steel pipes. Unless approved by Horizon Power, cables shall not be
installed directly in concrete conduits due to potential damage to sheaths during
installation.
13.4

Sealing of Conduits

All conduits, including spare conduits, shall be effectively sealed at the ends and at
couplings;
Sealing of conduits is required to prevent the ingress of water and any foreign material
that may cause blockage or flooding of cable pits, basement-type substations and
switch rooms;
Wherever possible, suitable conduit plugs or covers should be used for sealing of
conduits in lieu of taping or other makeshift arrangements.
Conduit joints and couplings shall be installed and sealed in accordance with the
manufacturers instructions.

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SECTION 13
Page 13-2

13.5

Installation requirements for Conduits

Where conduits are installed in excavations, they shall be installed:


a)

with a minimum cover of 850 mm to the top of the conduit;

b)

not more than 1100 mm cover as approved by Horizon Power;

c)

where all cables in the trench are all installed in conduits, excavated soil may
be used for bedding and backfill, provided it is free of organic matter and
rocks of 50 mm diameter or larger;

d)

normally in flat, horizontal formation for up to four cables, thereafter in tier


formation;

e)

for road crossings, in accordance with Section 6.6 Road and Vehicle
Crossings;

f)

sealed with suitable end caps;

g)

with approved draw wires provided in every conduit;

h)

when installed prior to the main cable trenching, installed with marker tape
300 mm above the conduit. The marker tape shall be brought out to ground
level at each end, with the conduit end position also being marked with a
peg; and

The most economical method shall be used to install conduits across roads. Subject to
cost, boring is preferred for single or double conduit crossings, where conduits of
100 mm size or larger are required.
For locations where more than two conduits are to be installed together, open
excavation methods may be used for crossing roads.
13.6

Pulling Cables through Conduits

Care shall be taken to avoid damaging the outer sheath of the cable where it enters and
leaves the duct. Single core bundled XLPE high voltage cables are particularly
susceptible due to their uneven shape and thin outer sheath.
To prevent future cable failure a suitable lubricant should be used to reduce the friction
between the cable and the duct.
A tapered or belled entry shall be used at the entry end of ducts during pulling to
prevent damage to cable.

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SECTION 14
Page 14-1

14

CABLE JOINTING AND TERMINATIONS

14.1

General

Underground cable jointing is based on the following Principles of Good Cable


Jointing:
1.

Safety shall never be compromised;

2.

Jointing pits should be large enough to allow jointers to work freely;

3.

Before joining any cable it must be positively identified by approved testing


methods and marked at both ends of the cable;

4.

Water barrier within the cables to checked prior to joining the cables:

5.

The correct kit for joint and cable size shall be selected;

6.

Manufacturers jointing instructions shall be followed unless practicalities suggest


a variation. Where fixture torque are recommended, apply those with torque
wrench;

7.

Accurate measuring, cutting, stripping and torque settings and workmanship shall
be in accordance with the manufacturers instructions;

8.

Ground covers shall be used to keep tools & equipment and jointing components
clean throughout the job . (Ensure joints dont get contaminated with surrounding
soil, sand, or moisture);

9.

Ensuring enough spare cable so that the cable stripping distances are suitable for
lay of cable (after cable is manipulated to correct position) to complete the joint(s)
in accordance with the manufacturers requirements;

10. All cable ends are to be sealed after cutting. Where they are not sealed they are to
be considered suspicious and checked for water ingress prior to use.
11. Housekeeping keep the work environment clean by placing used packaging in
box as work progresses.
14.2

Cable Joint Excavations

There is no standard size for a jointing pit, however joint sizes vary and therefore the
size of the pit in which to carry out the jointing will vary.
To facilitate the joining of Cables and to reduce the impacts on the health and safety of
the employee/contractor completing the joints, as a minimum, a pit in the trench should
be excavated to the following dimensions:
a)

2 meters wide;

b)

2 meters in either direction (4 meters long) of the joint; and

c)

at the same depth as the trench.

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
Horizon Power

Issue Date: March 2013


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SECTION 14
Page 14-2

Depending upon the depth of the trench / lay of cable; an additional step should be to
excavate in the pit to either side of the cable joint to allow for ease of access and
facilitate the joiner working on the joint. Fig 1 illustrates the concept.

Figure 3 Cable joint pit dimensions

The sides of the pits should be covered with tarpaulins or similar to prevent soil from
being dislodged while working in the pit.
14.3

Jointing

Before joining any cable it must be positively identified by approved testing methods
and marked at both ends of the cable.
Water barrier within the cables must be checked prior to joining the cables to ensure no
moisture has penetrated into the cable. (Moisture barrier turns green when water is
present) If moisture is detected, the cable must be strip the cable back to the point
where no moisture is present.
All jointing equipment shall be installed in accordance with the manufacturers
instructions supplied with the equipment kit to which they relate.
The use by date of the jointing equipment shall be checked prior to use. Where the
used by date has expired, the jointing equipment shall be removed from service and
returned to the depots store for disposal.
Ensure no conductive material is left on the XLPE cable. If necessary remove any
remaining semi-con material with abrasive paper (sandpaper) then clean with a solvent
wipe.
Note:

Never use a knife to cut the semi-con. This can create a void and could result
in the delaminating of the XLPE screen below the ring cut. When stripping the
semi-con screen and you score the XLPE insulation, sandpaper the damaged
area to smooth out the void/irregularities

Document Title: Underground Cable Installation Manual


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SECTION 14
Page 14-3

The installer identification tags are required on all joints. They shall be marked and
fitted adjacent to the joint or termination equipment as per drawing R39 in the
Reference section of the Distribution Construction Standards Manual.
All 11KV rated cable requiring transition joints shall use FJ0310 and FJ0405 joint
assemblies. All 22KV rated cables requiring transition joints shall use FJ0403 joint
assembly.
Shear bolts ends shall be filed back to prevent the sharp edges creating a stress point
within the cable joint.
14.4

Termite Proofing

Termite proofing shall be installed over all XLPE to XLPE HV straight joints.
The preferred method of termite proofing shall be of the stocking type, which is fitted
over the cable prior to joining. Where the stocking type is not available, termite sheeting
may be used in conjunction with heat shrink outer seal of the entire termite protection
area. Full heat shrink sleeve as provided in kit or zip shrink if jointing area is restricted
On completion of the joint, the termite stocking can be moved over the joint with a
minimum cable overlap of 200mm. The ends of the termite stocking shall be sealed with
brass roll springs as provided within termite protection kit TPKIT 80920.
Where termite sheeting is used, it shall be wrapped around the cable twice and have a
minimum cable overlap of 200mm. The ends of the termite sheeting shall be sealed
with brass roll springs as provided within termite protection kit TPKIT 80920. These
may be sourced individually from the supplier.
The remaining overlap of termite sheeting over the joint body should be secured evenly
in intervals every 150mm to 200mm with the use of 5mm stainless steel cable ties
14.5

Terminations

All Low Voltage terminations shall be completed in accordance with Part 5 - Low
Voltage Underground of the Distribution Construction Standards Manual.
Where no termination drawing exists, all equipment shall be installed in accordance
with the manufacturers instructions supplied with the equipment kit to which they relate.
14.6

Working Ends

If a cable for a future scheme/connection is laid from a universal pillar, kiosk or a low
voltage frame unit in an existing scheme, then the remote end of this cable must not be
left on a cable drum.
The cable must be made off, insulated to approved methods and placed in a mini pillar
with its top painted white.
In areas where it is not possible to install a pillar, then the remote end of this cable must
be made off in a joint/shell located in Horizon Powers cable alignment. When this

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
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SECTION 14
Page 14-4

method is utilised, the location of the joint/shell (e.g. distance from closest property
boundary) must be recorded accurately in GIS.

Document Title: Underground Cable Installation Manual


Document Number: DM #3597930v3
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SECTION 15
Page 15-1

15

TESTING AND COMMISSIONING

Testing and commissioning shall only be carried out by qualified and Horizon Power
authorised personnel and in accordance with Horizon Powers Network Testing &
Commissioning Standards. (DM# 3127547) and the VLF Testing of HV Cables manual
(DM# 3651308)
The Tester-in-Charge shall be responsible for carrying out tests in accordance with
these standards and recording all test results and additional comments where relevant.

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SECTION 15
Page 15-2

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SECTION 16
Page 16-1

16

REINSTATEMENT

16.1

General

The excavated or disturbed land shall be restored to its original condition. Backfilling
and reinstatement of road verges and vehicle crossings as necessary shall be
completed within three working days from the time the cables are laid and jointed.
Road reserves and all work sites shall be levelled and left clean and tidy. Debris, trees,
stumps and excess soil dug from the excavation shall be removed from site when
trench backfilling has been finished.
All materials, stakes, plant and equipment used during installation shall be removed and
all work sites left in a safe condition.
All material off cuts, waste materials and general rubbish shall be removed from site
and disposed of in accordance with the Local Government Authoritys requirements.
The initial backfill over the bedded cables shall be carried out in accordance with
Section 12.9 Bedding and Backfill of this manual.
Trenches shall be backfilled, reinstated and compacted to their original level and/or in
accordance with the requirements for footpaths by the Local Government Authority.
16.2

Compaction

Spoil or other approved filling shall be carefully placed in layers into the trench. Stones,
rocks and paving material shall be removed from site and not used as backfill.
All backfilling shall be compacted to a minimum 90% of the density as the surrounding
soil in accordance with Horizon Powers Work Procedure WP21 Soil Compaction
Testing Requirements (DM# 3561676), to prevent future subsidence.
All results shall be compiled on the Compaction Test Certificate DM# 3483983
16.3

Levelling

Backfilled excavations shall be levelled so as not to constitute a hazard and shall be to


the same as the original unexcavated land.
16.4

Restoration of Surface

On completion of any operations affecting pavements or constructed surfaces, except


Greenfield subdivision the pavements or constructed surfaces shall be restored in
accordance with the Restoration and Reinstatement Specification for Local
Governments in Australia Published by the Institute of Public Works Engineering
Australia, which is available at Traffic/Road-works/Working on main roads from Main
Roads WAs web site or through the Institute of Public Works Engineering Australia
(WA Division) on the IPWEA website.

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Document Number: DM #3597930v3
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SECTION 16
Page 16-2

Restoration of surface includes restoration of all type of footpath materials, e.g.


bitumen, brick paving, liquid limestone, etc.
Where cement footpath slabs have been removed to allow cable trench excavation,
they shall be replaced and reinstated in accordance with the Local Government
Authoritys requirements unless otherwise directed by the Horizon Power.

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SECTION 17
Page 17-1

17

DAMAGE TO PROPERTY

17.1

General

In all areas where cable installation work has been carried out, except as approved by
Horizon Power, property or services damaged shall be repaired or replaced as soon as
possible after making safe.
Fences around areas holding livestock shall be secured at all times and if damaged
during construction shall be repaired or made safe immediately to prevent the stock
from straying.
Damage to reticulation systems and underground services that are disturbed or
damaged shall be restored to working order.
Trees planted in the road verge shall be protected as far as possible. Tree limbs
interfering with the construction shall be removed appropriately by pruning and sealing
and the trees left in a reasonable condition.
Inspection shall be done of any structures located along the cable trench route prior to
the commencement of works and arrangements shall be made to protect these
structures if there is a possibility of damage or hazards occurring.
Horizon Powers CPM shall be notified in all cases of such damage or hazards
occurring.

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SECTION 17
Page 17-2

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SECTION 18
Page 18-1

18

PILLARS AND PITS

18.1

General

Where approved by Horizon Power, service pillars shall be located within the lot
boundaries at the corner, adjacent to common boundaries where possible, as shown on
Drawing in Appendix D.
Pits shall only be used where it is impractical to install a pillar, such as on a traffic island
or beside a narrow driveway where there is a high probability of impact damage.
Where there is a change in level between the service tee and the pillar, the cable shall
be protected in conduit where it traverses the slope.

Figure 4 - Service pit installation

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APPENDIX A - Service Alignment, Depth And Colours For Greenfield Sites


Page 1

APPENDIX A - SERVICE ALIGNMENT, DEPTH AND COLOURS FOR GREENFIELD


SITES

850mm

Source: Figure B2 Utility Provider Code of Practice (1 Feb 2010)

Note: The minimum depth of cover required for Horizon Powers cables is 850 mm.
However, the depth of cover of cables in nominal cable alignment shall be increased as required
so that cables joints will have the necessary depth of cover.

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APPENDIX A - Service Alignment, Depth And Colours For Greenfield Sites


Page 2

Standard Service and Pipe Colours:


Utility
Gas

Service and Pipe Colours


Yellow pipe or Yellow Striped pipe

Electrical

Orange pipe or Orange Striped black pipe or Orange


electrical tape for directly buried black sheathed cable

MRWA
a) Traffic Signals
b) Roadside Lighting
c) ITS
Telecommunications

a) Orange pipe
b) Orange pipe
c) Orange pipe (power) and White pipe (communications)
White pipe or black pipe with White Stripe

Water

Blue pipe or Blue Striped pipe

Sewerage

Cream pipe or Grey pipe or Cream/Grey Striped pipe

Third Pipe/Effluent
Reuse

Purple pipe

Note: Colours of pipe relate only to PVC and polyethylene pipe and other materials could be used,
particularly in older established areas unless otherwise stated. Some services can be buried
directly in the ground and not in conduits.

WARNING

In existing areas, pipes and conduits of other Utilities may not


conform to these standards

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APPENDIX B Cable Installation Data


Page 3

APPENDIX B CABLE INSTALLATION DATA


Typical cable reference data, including data relating to cable installation, is shown below.
Type of
Cable

Transformer
cable
HV Feeder
Cable
HV Feeder
Cable
HV Feeder
Cable
HV Feeder
Cable
Transformer
cable
HV Feeder
cable
HV Feeder
cable
HV Feeder
cable
LV Feeder
cable
LV Feeder
cable
LV Feeder
cable
Service

Volts
(kV)

33

No of
Cores

33

3x1c
Triplex
3x1c
Triplex
3x1c
Triplex
3x1

33
12.7/22

33
33

12.7/22
12.7/22
12.7/22
0.6/1

Cable
Size
(mm 2)

Condr
Material

Drum
Length
(m)

Nominal
Cable
core
Dia
(mm)

Nominal
Overall
Cable
Dia
(mm)

Maximum Pulling Tension (kN)

Minimum Bending
Radii
(Bundle/One Cable)

1 x Sheath
stocking
over all cores

3 x Sheath
stockings
one on each
core
(per core)

Conductor
grip
(per core)

Pulling
(mm)

Set
(mm)

50

Al

250

34.4

80 (3c)

7.5

7.5

2.5

1120/860

740/520

95

Al

250

37.9

94 (3c)

9.8

13.5

4.7

1220/950

820/570

185

Al

250

42.8

97 (3c)

11.1

15.3

9.2

1390/1070

920/640

630

Cu

500

30.9

65.4(1c)

7.95

1640

980

3x1

1000

Al

500

39.7

72.2(1c)

8.86

1805

1085

3x1c
Triplex
3x1c
Triplex
3x1c
Triplex
3x1c
Triplex
1x3c

35

Al

250

27

69 (3c)

5.2

5.2

1.75

870/680

580/410

185

Al

250

36.4

87 (3c)

9.4

4.4

9.25

1210/930

810/560

240

Cu

250

38.7

95 (3c)

10

4.6

16.8

1310/1010

870/610

400

Al

250

48.8

105 (3c)

12.6

5.9

20

1480/1140

980/690

120+

Al

250

NA

38.7

5.2

NA

NA

565

375

Al

250

NA

46

7.7

NA

NA

880

590

Al

250

NA

51

10

NA

NA

970

650

Cu

250

NA

26

2.2

NA

NA

220

220

Cu

1000

NA

13

1.0

NA

NA

100

100

Cu

1000

NA

14

1.5

NA

NA

120

120

Wave N

0.6/1

1x3c

185+
Wave N

0.6/1

1x3c

240+
Wave N

0.6/1

1x3c

25+
Wave N

Street
Lighting
Street
Lighting

0.6/1

10+
Wave N

0.6/1

16+
Wave N

Note: The ASP shall obtain and verify the cable installation data from the manufacturer for the particular cable to be installed at site

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APPENDIX B Cable Installation Data


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APPENDIX C - Pillar Location


Page 5

APPENDIX C - PILLAR LOCATION

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APPENDIX C - Pillar Location


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APPENDIX D - Typical Cable Trench Arrangements


Page 7

APPENDIX D - TYPICAL CABLE TRENCH ARRANGEMENTS

850

850

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APPENDIX D - Typical Cable Trench Arrangements


Page 8

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APPENDIX D - Typical Cable Trench Arrangements


Page 9

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APPENDIX D - Typical Cable Trench Arrangements


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APPENDIX D - Typical Cable Trench Arrangements


Page 11

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APPENDIX D - Typical Cable Trench Arrangements


Page 12

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APPENDIX E - Conduit Installation At Road Crossings


Page 13

APPENDIX E - CONDUIT INSTALLATION AT ROAD CROSSINGS

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APPENDIX E - Conduit Installation At Road Crossings


Page 14

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APPENDIX F - Dial Before You Dig Service


Page 15

APPENDIX F - DIAL BEFORE YOU DIG SERVICE

C1

General

Dial Before You Dig Service (sometimes referred as One Call


System) provides a single National point of contact between
excavators and utilities that own assets including buried pipes and
cables, as well as the owners of other buried services.
This free service makes it safer and easier for people undertaking excavation activities.
C2

Further information

For further information on Dial Before You Dig, telephone (08) 9424 8116 or (08) 9424
8117 during office hours (Perth). Further information on Telstra assets can be obtained
directly by telephoning 1800 806 246.

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APPENDIX F - Dial Before You Dig Service


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