Quality Policy Commitment

QUALITY POLICY
“We at RDSO, Lucknow are committed to maintain and update

transparent standards of services to develop safe, modern and cost
effective railway technology complying with statutory and regulatory
requirements, through excellence in research, designs and standards
by setting quality objectives, commitment to satisfy applicable
requirements and continual improvements of the quality management
system to cater to growing needs, demand and expectations of
passenger and freight traffic on the railways through periodic review
of quality management systems to achieve continual improvement
and customer appreciation. It is communicated and applied within the
organization and making it available to all the relevant interested
parties.”
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CONTENTS
CHAPTER 1 GENERAL DESCRIPTION OF CABLE ................................................................................ 1
1.1 Introduction .................................................................................................................... 1
1.2 Classification of Electrical Cables .................................................................................... 1
1.3 Classification of Power Cables ........................................................................................ 2
1.3.1 Classification as Per Designed Voltage ............................................................................ 2
1.3.2 Classification as Per Type of Insulation Used ................................................................... 2
CHAPTER 2 PVC , XLPE AND AB CABLE .......................................................................................... 3
2.1 PVC (Heavy Duty) & XLPE Insulated Electric Cables ........................................................ 3
2.1.1 Comparison between XLPE & PVC insulated cable .......................................................... 3
2.1.2 Core Identification of PVC & XLPE cables ........................................................................ 3
2.1.3 Features of PVC & XLPE cables....................................................................................... 4
2.2 Aerial Bundled (AB) Cables ............................................................................................. 5
2.2.1 Introduction .................................................................................................................... 5
2.2.2 Advantage & Disadvantage ............................................................................................. 5
2.2.3 Materials ........................................................................................................................ 6
2.2.4 Construction ................................................................................................................... 6
2.2.5 Code Identification .......................................................................................................... 6
CHAPTER 3 SELECTION OF CABLES ............................................................................................... 7
3.1 Selection of Type of Cable .............................................................................................. 7
3.2 Size of Cable .................................................................................................................. 8
3.2.1 Procedure for selection of size of cable are as below:- .................................................... 8
3.2.2 Take the rating of incoming MCCB of the system duly considering requirement of overload
protection factor. ............................................................................................................ 8
3.2.3 Identify the Method of Installation of Cable ...................................................................... 9
3.2.4 Applying reduction factor due to Thermal resistivity of soil (applicable only for
underground cables). .................................................................................................... 10
3.2.5 Applying reduction factor due to ambient temperature ................................................... 10
3.2.6 Applying reduction factor due to grouping ..................................................................... 11
3.2.7 Selection of Suitable size of cable after applying all reduction factor. .............................. 11
3.2.8 Check size of cable is suitable for short circuit fault conditions ...................................... 14
3.2.9 Check the voltage drop based on size & length of cable ................................................. 14
CHAPTER 4 INSPECTION, TESTING & STORAGE ............................................................................ 16
4.1 Classification of Tests ................................................................................................... 16
4.1.1 Type Tests:................................................................................................................... 16
4.1.2 Acceptance Tests: ........................................................................................................ 18
4.1.3 Routine Tests: .............................................................................................................. 20
4.1.4 Additional test at site ..................................................................................................... 20
4.2 Identification of XLPE, PVC & AB Cable ......................................................................... 21
4.3 Packing & Marking of XLPE,PVC & AB Cables ............................................................... 22
4.4 Handling (Unloading At Site) ......................................................................................... 22
4.5 Storage......................................................................................................................... 23
CHAPTER 5 LAYING AND INSTALLATION OF CABLES .................................................................... 24
5.1 Selection of the Cable Route ......................................................................................... 24
5.2 Minimum Permissible Bending Radii ............................................................................. 24
5.3 Methods of Cable Laying & Installation .......................................................................... 24
5.3.1 Laying Direct in Ground ................................................................................................ 25
5.3.2 Cable Laid Across Roads, Railway Tracks and Water Pipe Lines. ................................... 26
5.3.3 Cable Over Bridges ....................................................................................................... 27
5.4 Reinstatement............................................................................................................... 27
5.5 Cable Jointing ............................................................................................................... 27
5.5.1 Basic Types of Joints .................................................................................................... 28
5.5.2 Types of Cable Jointing Accessories ............................................................................. 28
5.5.3 One example is given below for making straight joint for better understanding ................ 28
5.6 Cable End Terminations ................................................................................................ 30

iv
5.6.1 One example is given below for making end termination for better understanding ........... 30
5.7 Earthing and Bonding of Cables..................................................................................... 32
5.8 Testing Of Cable Installation .......................................................................................... 32
5.8.1 Insulation Resistance Test on Newly Installed Cables Before Jointing. ............................ 32
5.8.2 Tests on Completed Cable Installation ........................................................................... 33
5.9 Cable Installation Plan ................................................................................................... 35
CHAPTER 6 FAULTS IN CABLE ...................................................................................................... 36
6.1 Types of Cable Faults.................................................................................................... 36
6.1.1 Open-Circuit Faults ....................................................................................................... 36
6.1.2 Short-circuit fault .......................................................................................................... 36
6.1.3 Earth faults ................................................................................................................... 36
6.1.4 Low insulation fault ....................................................................................................... 36
6.2 Causes of Cable Faults ................................................................................................. 37
6.3 Different Types of Tests to Locate Faults in Cables. ....................................................... 37
ANNEXURE – I: THICKNESS OF INSULATION FOR PVC & XLPE INSULATED CABLE ........................ 38
ANNEXURE - II : THICKNESS OF INNER SHEATH FOR PVC & XLPE INSULATED CABLE ................... 39
ANNEXURE – III : DIMENSIONS OF ARMOUR – ROUND WIRES AND STRIPS FOR PVC & XLPE
INSULATED CABLE ...................................................................................................... 40
ANNEXURE – IV: THICKNESS OF OUTER SHEATH FOR PVC & XLPE INSULATED CABLE .................. 41
ANNEXURE – V : SIZE AND REQUIREMENTS OF MESSENGER CONDUCTOR ...................................... 42
ANNEXURE – VI: RELATIVE MERITS/ DEMERITS OF DIFFERENT METHODS OF CABLE LAYING ....... 43
ANNEXURE - VII: EXAMPLES OF METHODS OF INSTALLATION PROVIDING INSTRUCTIONS FOR

OBTAINING CURRENT-CARRYING CAPACITY ........................................................... 45
ANNEXURE- VIII: DIFFERENT CORRECTION FACTOR TO BE APPLIED TO THE CURRENT-CARRYING

CAPACITIES FOR CABLES ........................................................................................... 52
ANNEXURE - IX: CURRENT CARRYING CAPACITY (IN AMPERES) IN DIFFERENT INSTALLATION .... 62
REFERENCES ...................................................................................................................................... 65
LIST OF FIGURES
Figure 1: Core Identification ............................................................................................................... 6

Figure 2: Illustration of equations 1 & 2 for Selection of Cable ............................................................. 9
Figure 3: Type of Installations........................................................................................................... 10
Figure 4: Group containing more than one circuit .............................................................................. 11
Figure 5: Heat shrinkable jointing kit ................................................................................................. 28
Figure 6: Heat shrink termination kit ................................................................................................. 30
LIST OF TABLES
Table 1: Rated voltage of cables ................................................................................................ 2
Table 2: Comparison between XLPE & PVC insulated cable ........................................................ 3
Table 3: Classification of XLPE & PVC insulated cable with improved fire performance ................ 3
Table 4: Core Identification of XLPE & PVC insulated cable ......................................................... 3
Table 5: Features of PVC & XLPE cables .................................................................................... 4
Table 6: Advantage & Disadvantage of AB Cables ...................................................................... 5
Table 7: Detail of Materials of AB Cables .................................................................................... 6
Table 8: Application of PVC/ XLPE Including AB cables............................................................... 7
Table 9: Application where improved fire performance for XLPE/PVC cable is required. ............... 7
Table 10: 1st Method for accessing the current carrying capacity of the particular cross-section of
the cable .................................................................................................................... 12
Table 11: 2nd Method for accessing the current carrying capacity of the particular cross-section of
the cable .................................................................................................................... 13
Table 12: Voltage Drop .............................................................................................................. 14
Table 13: List of Type Test for XLPE & PVC Cable ...................................................................... 16
Table 14: Additional Type Test for XLPE & PVC Cable with improved fire performance ................ 17
Table 15: List of Type Test for AB Cable..................................................................................... 17
Table 16: Number of Drums to Be Selected For Sampling and Permissible Number of Defectives 19
vi
Table 17: List of Acceptance Test for XLPE & PVC Cable............................................................ 19
Table 18: Additional Acceptance Test for XLPE & PVC Cable with improved fire performance ...... 19
Table 19: List of Acceptance Test for AB Cable .......................................................................... 20
Table 20: Cable Code ................................................................................................................ 21
Table 21: Minimum Permissible Bending Radii ........................................................................... 24
Table 22: Minimum depth of laying from ground surface to the top of the cable .......................... 25
Table 23: Desired Minimum Clearances ..................................................................................... 25
TABLE 24: Correction Factor for Ambient Air Temperatures Other Than 30 °C to be Applied to the
Current-Carrying Capacities for Cables In The Air ........................................................ 52
Table 25: Correction Factors for Ambient Ground Temperatures Other Than 20 °C to be applied to
the Current-Carrying Capacities for Cables in Ducts in the Ground ............................... 53
Table 26: Correction Factors for Cables Buried Direct in the Ground or in Buried Ducts for Soil
Thermal Resistivity Other Than 2.5 K·m/W to be Applied to the Current-Carrying
Capacities for Reference Method D ............................................................................. 53
Table 27: Reduction Factors for One Circuit or One Multi-core Cable or for a Group of more than
One Circuit, or more than one multi-core cable ........................................................... 54
TABLE 28: Reduction Factors for More Than One Circuit, Cables Laid Directly in the Ground –
Installation Method D2 .............................................................................................. 55
TABLE 29: Reduction Factors for More Than One Circuit, Cables Laid in Ducts in the Ground -
Installation Method D1 ................................................................................................ 56
TABLE 30: Reduction Factors for Group of More Than One Multi-Core in Free Air - Method of
Installation E............................................................................................................... 58
TABLE 31: Reduction Factors for Groups of One or More Circuits of Single-Core Cables in Free Air -
Method of Installation F .............................................................................................. 60
TABLE 32: Current Carrying Capacity in (A1/A2/B1/B2/C/E/F/G) Installation.................................. 62
TABLE 33: Current Carrying Capacity in D1/D2 Installation ........................................................... 63

ISSUE OF CORRECTION SLIP
The correction slips to be issued in future for this handbook will be numbered as follows:
CAMTECH/EL/2022-23/Vol.5/1.0/Conductor and Cables. # XX date---
Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).
Sr. No. Date of Issue Page no. & Item no. modified Remarks
viii
DISCLAIMER
It is clarified that the information given in this booklet does not supersede any
existing provisions of Indian Standards (IS) on the subject, related matters,
and other existing provisions laid down by the Railway Board, RDSO. This is
not a statuary document and instructions given are for the purpose of
guidance only. If at any point contradiction is observed, then Indian Standards,
regulations issued by Government bodies, Railway Board/RDSO guidelines
shall be referred.
OBJECTIVE OF PUBLICATION
To prepare guidelines which can educate the Indian Railway (IR) engineers and
technicians dealing with low voltage electrical installations and other IR officials about
various provisions given in IS standards pertaining to IS-1554 (Part-I) – 1988, IS-7098
(Part-I) – 1988, IS-1255 – 1983 & IS-14255 – 1995
जितेंद्र ज िंह आई आर ए एम ई
Jitendra Singh IRSME
प्रधान कार्यकारी जनदे शक
Principal Executive Director
FOREWORD
Our motto of preparing these documents under the series “Safety in Electrical Low
Voltage Installations” is to reduce damaging of equipment /fire cases due to electrical
faults and electrocution on Indian Railways. These publications are based on Indian
standards and codes in simplified and practically implementable manner.
This volume-5 on “Selection of Power cables in Electrical LV installations” has been

prepared by CAMTECH, Gwalior under this series of documents “Safety in Electrical Low
Voltage Installations”
Four volumes i.e. Vol-1: “Basics of LV Earthing System”, Vol-2: “Selection and application
of LV Protective Devices, Vol-3: “Inspection of Electrical LV Installations” and volume-4
on “Testing of Electrical LV Installations” have already been published under this
series.
To ensure safety of persons and apparatus against electrical faults, it is necessary to

follow the requirements for protection as dictated by various Indian Standards. And this
is also the requirement of the time that our electrical engineers and technicians shall be
familiar to correct practices.
I am sure that this volume-5 along with earlier volumes will be useful for electrical design
and maintenance engineers and technicians for updating their knowledge, improving the
reliability and safety of electrical LV installations as well as precious human lives. This will
be also helpful in reducing the accidents on account of electrical failures.
Date: 29.11.2022 (Jitendra Singh)

Place: CAMTECH/Gwalior Principal Executive Director
x
PREFACE
As per instructions of Railway Board, CAMTECH, Gwalior has done detail study on safety
in low voltage electrical installations by referring various Indian Standards on the subject
and with the help of experts in this domain.
On the basis of various Indian standards, CAMTECH, Gwalior has already prepared &
published four volumes under the series “Safety in Electrical Low Voltage Installations”.
These volumes give basic information about protective earthing, selection and application
of protective devices including inspection & testing of LV installations before being put
into service.
This volume-5 on “Selection of Power cables in Electrical LV installations” under the

document series “Safety in Electrical Low Voltage Installations” has been prepared, which
gives information on power cables based on Indian standard.
This booklet covers various topics on power cable like classification of power cables, basic
information of PVC & XLPE cable, Selection, Inspection, testing & laying of cables
including faults in cables etc. Basic information of Aerial Bunched (AB) cables & end
termination kit/straight through jointing kit are also cover in this booklet.
Selection of the type and size of cable with factors, which affects the size of the cable,
has been explained properly with suitable examples for better understanding of field staff.
All topics have been explained with photos/tables for better understanding of field staff.
This will help electrical engineers & technicians to understand the basic need & complete
procedure of testing for safe and reliable electrical LV installations.
Technological up-gradation & learning is a continuous process. Please feel free to write
to us for any addition/ modification in this booklet. We shall highly appreciate your
contribution in this direction.
Date: 25.11.2022 (Himanshu Maheshwari)

Place: CAMTECH/Gwalior Jt. Director /Electrical
SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS
CHAPTER 1 GENERAL DESCRIPTION OF CABLE
1.1 Introduction
Cables are used for transmission of electrical power. They are mostly used for low voltage distribution
in thickly populated area, in substations from transformers to main distribution panels and from main
distribution panels to different distribution panels. Low voltage cables are also used in industries,
workshops and maintenance shops/ sheds. Medium & high voltage transmission cables are also
used for crossing the roads, railway lines and in densely populated areas in big cities. Cables as
compared to overhead lines have the following advantages.
i. The cable transmission and distribution are not subjected to supply interruptions caused by
lightening or thunderstorms, birds and other severe weather conditions.
ii. It reduces accidents caused by the breaking of the conductors.
iii. Its use does not spoil the beauty of place, cities. But if a fault occurs due to any reason, it is
not easily located.
1.2 Classification of Electrical Cables
Electrical cables may be classified according to their application as follows:
Wiring cables
These cables are used for internal wiring of the buildings and other protected installations and have
two components viz. conductor and insulation. PVC as insulation material and annealed copper
(solid or stranded) as conductor are commonly used for wiring cables. Voltage grade of these cables
is upto 1100 Volts.
Control cables
These are designed for control purposes or measuring circuits for carrying signals of direct current
upto 220 Volts and alternating currents up to 440 volts. These cables are available with armour and
without armour. In these cables PVC, XLPE, EPR, Neoprene etc. are used as insulation. Control cables
are available in 0.5/0.75/1.00/ 1.5/2.5 mm2 size copper conductor (solid/stranded) from 2 cores to
61 cores.
Power Cables
Electrical power cables are used for distribution and transmission of electrical energy. These cables
either single core or multicore are particularly useful in power stations, substations, house service
connections, street lighting, etc. They can be installed indoors or outdoors, in air, in cable ducts or
under ground.
Special Application Cables
Cables are also classified based on special applications such as –
i. Fire performance and heat resistant cables.
ii. Pilot cables.
iii. Instrumentation cables.
iv. Submarine cables & ship board cables.
v. Airport lighting cables.
vi. Mining cables.
vii. Cables for lifts and hoisting gears.
viii. Welding cables.
ix. Cables for hazardous areas such as petro- chemical industries etc.
VOLUME 5: SELECTION OF POWER CABLES IN ELECTRICAL LV INSTALLATIONS 1

1.3 Classification of Power Cables

Electrical power cables are generally classified according to their designed (rated) voltages or the
type of insulation used.
1.3.1 Classification as Per Designed Voltage

Electrical power cables are generally classified according to their designed (rated) voltages as given
below:
i. Low voltage cables – up to and including 1100 volts.
ii. Medium voltage cables –from 3.3 kV up to and including 33 kV.
iii. High voltage cables – above 33 kV and up to and including 132 kV
iv. Extra high voltage cables – above 132 kV and up to and including 700 kV.
Medium voltage electrical power cables are usually available in following voltage ratings
Table 1: Rated voltage of cables

(Ref: Table 1 of IS 1255 – 1983)
UO (kV) U (kV) UM (kV)

0.65 1.1 1.21
1.9 3.3 3.63
3.3 3.3 3.63
3.8 6.6 7.26
6.6 6.6 7.26
6.35 11 12.1
11 11 12.1
12.7 22 24.2
19 33 36.3
Where,
UO = Rated power frequency voltage between conductor and earth or metallic screen.
U = Rated power frequency voltage between phase conductors.
UM = Maximum permissible continuous 3 phase system voltage.
1.3.2 Classification as Per Type of Insulation Used
Electrical power cables are generally classified according to the type of insulation used as given
below:
i. PVC (Poly Vinyl Chloride) cables.
iii. XLPE (Cross Linked Poly Ethylene) cables.
2 VOLUME 5: SELECTION OF POWER CABLES IN ELECTRICAL LV INSTALLATIONS

CHAPTER 2 PVC , XLPE AND AB CABLE
2.1 PVC (Heavy Duty) & XLPE Insulated Electric Cables

2.1.1 Comparison between XLPE & PVC insulated cable
Table 2: Comparison between XLPE & PVC insulated cable
Criteria XLPE Cable PVC Cable
Maximum working temperature of 90 Centigrade. 70 Centigrade
conductor
Maximum short (lasting less than 5 250 Centigrade. 160 Centigrade.
seconds) temperature
Current Rating Higher Lower
Service life Longer Less
Price Less Higher
Installation Slightly Tougher to Easy to Install
Install
Chemical Resistance Very Good Good
Toughness Good Poor Compare to PVC
Special category of cables with improved fire performance also comes in PVC & XLPE insulated
cable. Classification of these cables are as below
Table 3: Classification of XLPE & PVC insulated cable with improved fire performance
(Ref: Para 2.2 of IS 7098 (Part-I) – 1988 & IS 1554 (Part-I) – 1988)
Category Type Cable Definition

01 Flame retardant. Single cable self-extinguish being does not propagate flame
C1 FR Flame retardant. Does not propagate fire even when installed in groups in
vertical ducts
C2 FR-LSH Flame retardant cables with reduced Halogen evolution and smoke
2.1.2 Core Identification of PVC & XLPE cables

Different cores in a cable are identified by colours of PVC & XLPE insulation. Accepted colour codes
for both type cables are as under.
Table 4: Core Identification of XLPE & PVC insulated cable
S.N. No. of Core Identification

a. Single core Red, black, yellow, blue or black
b. Twin core Red and black
c. Three core Red, yellow and blue.
d. Four core Red, yellow, blue and black.
e. Five core red, yellow, blue, black and light grey.

2.1.3 Features of PVC & XLPE cables

Table 5: Features of PVC & XLPE cables
(Ref: Para 3 to 9 of IS 7098 (Part-I) – 1988 & IS 1554 (Part-I) – 1988)
S.N. Parts of PVC (HEAVY DUTY) CABLES XLPE INSULATED CABLES
Cable
1 Conductor The conductor shall be composed of plain copper or aluminium wires
complying with IS : 8130-1984.
2 Insulation a) General Purpose Insulation - The insulation The insulation shall be of

shall be of Type A PVC compound conforming cross linked poly-ethylene
to the requirements of IS : 5831-1984 conforming to the
requirements given in Table 1
b) Heat Resisting Insulation - The insulation
shall be of Type C PVC compound conforming of IS:7098 (Part-I) – 1988
to the requirements of IS : 5831-1984
.
The average thickness of insulation shall be not less than the nominal value
specified in Annexure-1
3 Filler and The filler and inner sheath shall be of the following:
Inner a) Unvulcanised rubber, or
Sheath b) Thermoplastic materiaIs, or
c) Proofed tape ( for inner sheath only ).
Vulcanized or unvulcanized rubber or thermoplastic material used for inner
sheath shall not be harder than XLPE and PVC used for insulation and outer
sheath respectively.
The materials shall be chosen to be compatible with temperature ratings of the
cable and shall have no deleterious effect on any other component of the cable.
4 Armouring Armouring shall be of the following:
a) Galvanized round steel wire,
b) Galvanized steel formed wire’, or
c) Any metallic non-magnetic wire/strip.
d) The galvanized steel wires/formed wires/tapes shall comply with the
requirements of IS 3975:1988, except that the provisions of 3.3.1 and 3.3.2 of
IS 3975 shall not apply.’
Armouring shall be applied over the insulation in case of single core cables and
over the inner sheath in case of multicore cables.
Where the calculated diameter below armouring does not exceed 13 mm, the
armour shall consist of galvanized round steel wires. Where the calculated
diameter below armouring is greater than 13 mm, the armour shall consist of
either galvanized round steel wires or galvanized steel strips
A binder tape may be provided on the armour.
5 Outer a. For Cables with General Purpose Insulation The outer sheath shall be of
Sheath - The outer sheath shall be of Type ST 1 Type ST 2 PVC compound
PVC compound conforming to the conforming to the
requirements of IS : 5831-1984*. requirements of IS : 5831-
b. For Cables with Heat Resisting Insulation - 1984*.
The outer sheath shall be of Type ST 2 PVC
compound conforming to the requirements
of IS : 5831-1984*.

S.N. Parts of PVC (HEAVY DUTY) CABLES XLPE INSULATED CABLES

Cable
c. For cables with improved fire performance,
the outer sheath shall, in addition, meet the
requirement of tests applicable for the
required category
2.2 Aerial Bundled (AB) Cables

2.2.1 Introduction
AB cable consists of three phase wire, one neutral wire of lower size and a messenger wire. The
messenger wire is used for earthing purpose. These heavy cables are used in LT line. Some time
additional wire is also used for the purpose of lighting streetlight
Aerial bundled cables are overhead power lines that use several insulated phase conductors bundled
tightly together, usually with a bare neutral conductor. This contrasts with the traditional practice of
using non-insulated conductors separated by air gaps.
In the ABC system, the insulated conductors (3 or 4 numbers as required) are twisted around a high
strength aluminium alloy bearer wire, which carries the main weight and also serves as the earth-
cum neutral wire. The bearer wire (messenger) may be bare or insulated. The phase conductors are
not under tension.
Since, the tension from the current carrying conductor is totally removed by introduction of
messenger wire the operating temperature of the conductor is 90.C as against 75.C of the bare
conductor of the same size.
2.2.2 Advantage & Disadvantage

Table 6: Advantage & Disadvantage of AB Cables
S.N. Advantages Disadvantages
1. Aerial bundled cables do not generate any spark These cables are costly as
when it touches the trees. compared to conductors.
2. Their appearance is good. Insulation of cables get weaker
due to heat of the sun.
3. They can be installed in narrow streets. Due to the weight of the cables
additional poles are required.
4. Insulators and cross arms are not required. It requires much longer time to
repair the cable and also requires
specialised equipment.
5. These cables are very safe as only neutral wire gets
damaged in case of any accident.
6. Electricity theft is merely possible.
7. Short circuit is only possible when insulation of a
cable is damaged.
8. Insulating bridging wires are needed to connect
non-insulated wires at either side at junction poles.

2.2.3 Materials
Table 7: Detail of Materials of AB Cables
(Ref: Para 4 & 5 of IS 14255 – 1995)
S.N. Type of Conductor/ Insulation Material
1 Phase/Street Lighting H2 or H4 grade Aluminium conductors conform to
conductor IS:8130(Class-II)
2 Messenger (Neutral Conductor The conductor shall be of heat treated Aluminium -
or Otherwise) magnesium -silicon alloy wires containing approximate
0.5% magnesium and approximately 0.5% silicon
confirming to IS 398 (Part 4) : 1979).
3 Insulation XLPE and HDPE insulation of power conductors specify
IS:7098 (Part – I & II) and IS:6474 respectively
2.2.4 Construction
(Ref: Para 6 of IS 14255 – 1995)
I. The power/outer insulated neutral/street lighting conductors shall conform to flexibility class 2
of IS 8130 : 1984.
II. The messenger (Neutral conductor) or otherwise shall be either stranded circular or compacted
circular type and shall have minimum 7 strands. The surface of the conductor shall be smooth.
III. A protective barrier may be applied between the conductor and insulation, if required. Such
barrier, when used, shall be compatible with insulating material and suitable for the operating
temperature of the cable.
IV. The size of street lighting conductor shall be 16 Sq.mm
V. There shall be no joints in any wire of the messenger conductor except those made in the base
rod or wires before final drawing. The direction of outer layer of wires in messenger conductor
shall be right hand.
VI. The size of messenger conductor and its breaking load shall be as per Annexure-5
2.2.5 Code Identification
(Ref: Para 8 of IS 14255 – 1995)
The single phase conductor shall be provided with 'One Ridge' and if neutral insulated conductor is
provided shall have 'Four Ridges' as shown in below Figure for quick identification. The Street Light
Conductor & Messenger Conductor (if insulated) shall not have any identification mark
Figure 1: Core Identification

CHAPTER 3 SELECTION OF CABLES
There are two important criteria for selection of power cable in LV installation i.e type & size of power cable.
3.1 Selection of Type of Cable

Initially during the selection of type of cable type of load (Single or three-phase (system Voltage)
following information is required for selection of size of cable
Table 8: Application of PVC/ XLPE Including AB cables
S.N Type of Cable Application
1 PVC unarmoured single Mainly suitable for indoor conditions where chances of
core and multicore cables external damage is less ex House/Building wiring etc.
2 PVC armoured single core Mainly suitable for installations where rough operation
and multicore cables conditions and tensile stresses are required Generating
stations, substations, distribution systems, street lighting,
industrial installations, etc
3 XLPE cables a) On vertical runs of unlimited difference in level,

b) Locations having severe vibration problems,
c) Locations having higher ambient temperature up to
70°C,
d) Conditions demanding short time overload up to 120°C,
and
e) In systems having higher short circuit levels.
4 AB cable In areas with moderate climate, tree growth is significant

which causes a problem for overhead power lines. Aerial
bundled cables are suitable for these areas as they will not
arc over if touched by tree branches. These are mainly used
for LV distribution system.
Table 9:Application where improved fire performance for XLPE/PVC cable is required.
S.N. Environment Category Type (PVC & XLPE

Description with improved fire
performance)
1 Cables in open areas 01
2 Cables in constrained areas C1 FR
3 Cables in constrained areas with limited human C2 FR-LSH
activity and or presence of sophisticated systems

3.2 Size of Cable

(Ref: Para 4.2.3.3 of IS:1255 – 1983)
Selection of size of power cable is also important for safety in LV installation. The precise information
regarding actual load conditions helps in choosing correct cross-section of the cable. Load conditions
are as follows
a. Normal continuous load – It means that the given load current will be flowing continuously
through cable. Annexures may be referred for current ratings for PVC cables which are based
on the normal conditions of installation. If the actual conditions are not the same as the normal
conditions, the values for the normal current ratings should be multiplied by the relevant rating
factors given in the IS-3961.
b. Intermittent load – If the cable is switched on and off periodically, so that the time between
switching ‘off’ and then ‘on’ is not sufficient to cool the conductor to the ambient temperature
during the rest period, then such load is called intermittent load. A proper cross-section of
cable conductors for such load conditions may be decided in consultation with the cable
manufacturers.
c. Short time load – Under these load conditions, the conductor is allowed to cool down to
ambient temperature after the load period. Here again, the conductor cross-section may be
decided in consultation with the cable manufacturers.
d. Cyclic load – If the load is cycle, the maximum permissible current may be increased by an
amount depending on the shape of the load curve, type of cable, its heat capacity and
method of installation
3.2.1 Procedure for selection of size of cable are as below:-
 Take the rating of incoming MCCB of the system duly considering requirement of overload
protection factor.
 Identify the Method of Installation of cable
 Applying reduction factor due to Thermal resistivity of soil (applicable only for underground
cables).
 Applying reduction factor due to ambient temperature
 Applying reduction factor due to grouping
 Select the suitable size of cable after applying all reduction factor.
 Check size of cable is suitable for short circuit fault conditions.
 Check the voltage drop based on size & length of cable.
 Finally select the optimum size of cable for the installation.
3.2.2 Take the rating of incoming MCCB of the system duly considering requirement of overload
protection factor.
(Ref: Para 4.1.3.6 & 5.2.7 of IS 732:2019)
After deriving the capacity of incoming MCCB (rating of MCCB is selected based on load requirement
of installations). Now apply the overload factor to that rating current which is 1.3 times for normal
MCCB/ACB or as specified by manufacturers. The operating characteristics of a device protecting a
cable against overload shall satisfy the two following conditions:
IB ≤ I n ≤ I Z (Equation 1),
I2 ≤ 1.30x IZ (Equation 2)

Where;
IB The design current for that circuit
IZ The continuous current-carrying capacity of the cable/wire
In The rated current of Protective device
(NOTE: For adjustable protective devices, the rated current In is the current setting selected.
I2 The current ensuring effective operation in the conventional time of the protective device i.e.
1.30x In (As per table 6 of IS 60947 part-2)
Conventional time: -The conventional time is 1 h for circuit-breakers of rated current up to
and including 63 A, and 2 h for circuit-breakers of rated current above 63 A.
These equations can be also explain as per given diagram
Figure 2: Illustration of equations 1 & 2 for Selection of Cable
3.2.3 Identify the Method of Installation of Cable

(Ref: Para 4.1.3.6 & 5.2.7 of IS 732:2019)
Wiring/cabling is done in 73 different installation methods given in ANNEXURE-VII, these methods of

installation has been further classified under 10 groups (A1,A2,B1,B2,C,D1,D2,E,F & G) given in in
ANNEXURE-VII for obtaining current carrying capacity of different installations.
A1 A2 B1 B2 C D1 D2
E F G

Figure 3: Type of Installations

Based on above methods the current carrying capacity of different size/core/ PVC & XLPE insulation
type of cables are given in table 21 to table 24, table 29 to table 32 of IS 732:2019. Table 32 & 33
of ANNEX IX is a simplified version of above tables as shown below with reference ambient
temperatures.
a) For insulated conductors and cables in air, irrespective of the method of installation: 30 °C;
and
b) For buried cables, either directly in the soil or in ducts in the ground: 20 °C
3.2.4 Applying reduction factor due to Thermal resistivity of soil (applicable only for underground
cables).
The current-carrying capacities tabulated in Table 32 & 33 of ANNEX IX for cables in the ground
relate to a soil thermal resistivity of 2.5 K.m/W. This value is considered necessary as a precaution
for worldwide use when the soil type and geographical location are not specified.
In locations where the effective soil thermal resistivity is higher than 2.5 K.m/W, an appropriate
reduction in current-carrying capacity should be made. Such cases can usually be recognized by
very dry ground conditions. Correction factors for soil thermal resistivity other than 2.5 K.m/W are
given in table 26 of ANNEXURE VIII.
3.2.5 Applying reduction factor due to ambient temperature

(Ref: Para 5.2.5.1 of IS 732:2019)
The ambient temperature is the temperature of the surrounding medium when the cable(s) or
insulated conductor(s) under consideration are not loaded. Current carrying capacity of conductor
also depends on the ambient temperature.
While selecting the type of insulation of the conductor for a particular location, it should be ensured
that the ambient temperature in that area under normal operation and fault conditions should not
exceed the limiting temperature of the insulation, which is given Table 8 of IS 732:2019
Where the ambient temperature in the intended location of the insulated conductors or cables differs
from the reference ambient temperature (30 °C for Air & 20 °C for buried in ground), the appropriate
correction factor given in table-24 & 25 of ANNEXURE VIII shall be applied to the values of current-
carrying capacity set out in Table 32 & 33 of ANNEX IX
Ambient temperature for cables should be taken for particular location of the installation not the
ambient temperature of the environment.

3.2.6 Applying reduction factor due to grouping

(Ref: Para 5.2.6.5of IS 732:2019)
The group reduction factors (Table 27 to table 31 of ANNEX VIII ), are applicable to groups of
insulated conductors or cables having the same maximum operating temperature i.e. 70°C
The current-carrying capacities given in Table 32 & 33 of ANNEX IX related to single circuits for
single phase/three phase PVC/XLPE conductor in different installation (A1, A2, B1, B2, C, D1, D2, E
& F). Where more insulated conductors or cables, other than bare mineral insulated cables not
exposed to touch, are installed in the same group, the group reduction factors specified in tables 27
to table 31 of ANNEX VIII shall be applied.
For groups containing cables or insulated conductors having different maximum operating
temperatures, the current-carrying capacity of all the cables or insulated conductors in the group
shall be based on the lowest maximum operating temperature of any cable in the group, together with
the appropriate group reduction factor.
If, due to known operating conditions, a cable or insulated conductor is expected to carry a current
not greater than 30 percent of its grouped current-carrying capacity, it may be ignored for the
purpose of obtaining the reduction factor for the rest of the group.
Perforated cable tray Vertical perforated Perforated cable tray Vertical perforated
systems (vertical cable tray systems systems (for vertical cable tray systems
spacing between cable (for horizontal spacing between cable (for horizontal
trays of 300 mm and at spacing between trays of 300 mm and at spacing between
least 20 mm between cable trays of 225 least 20 mm between cable trays of 225
cable trays) mm) cable trays) mm)
Cable ladder Multi-core cables Single-core cables

systems, cleats(for
vertical spacing
between cable trays of
300 mm and at least
20 mm between cable
trays)
Figure 4: Group containing more than one circuit
3.2.7 Selection of Suitable size of cable after applying all reduction factor.
All above factors (para 3.2.2 to 3.2.6) affect the current carrying capacity of cabling system.
Following two methods are applicable for accessing the current carrying capacity of the particular

cross-section of the cable are as below. Above methods can be explain by taking an example as
given below:
Example: 125 A MCCB is installed for an installation. The outgoing XLPE insulated aluminium cable
is to be installed in underground with soil thermal resistivity of 2.5 K.m/m. Ambient temperature 40°C
is considered and two another cable is also to be installed along at a distance of 0.125m ( cable to
cable clearance) with this cable for other installation. What will be optimum size of cable for the
installation?
Table 10: 1st Method for accessing the current carrying capacity of the particular cross-section of
the cable
S.N. Procedure/Step Example Remarks

1 Decide type of cabling underground/ Underground Cabling direct in the ground
duct, shafts, voids, (where cable is to be laying
installed)
2 Based on the above installation method D-2 Installation S.N.73 of ANNEXURE VII
identify type of Installation from
ANNEXURE VII
3 Decide type of Insulation of conductor XLPE Type of insulation
PVC / XLPE/ EPR / Mineral as per table
8
4 Decide type of Core 4 Core Type of core
5 Check the rating of MCCB 125 Amp. Capacity of MCCB
6 Deriving the tripping current of MCCB 162.5 Amp. 125x1.3= 162.5
due to overload (Multiply overload factor
of MCCB (1.3) to this rated current)
7 Considering minimum Current carrying 162.5 Amp.
capacity of cable given above S.N.6
(tripping current of MCCB due to
overload )
8 Applying reduction factor (by current 162.5/1 Reduction factor=1 for
carrying capacity divided by reduction Thermal Resistivity 2.5
factor) for soil thermal resistivity from Km/W from tables 26 of
tables 26 of ANNEXURE VIII ANNEXURE VIII
9 Apply ambient temperature reduction 162.5/(1x0.85) Ambient temperature 40°C to
factor(by current carrying capacity be considered., Reduction
divided by reduction factor) from table- factor 0.85 from table 25 of
24 & 25 of ANNEXURE VIII ANNEXURE VIII
10 Apply reduction factor (by current 162.5/(1x0.85x 2 No. circuits with 4 core
carrying capacity divided by reduction 0.75) cable are also laid direct in
factor) depending on the number of the ground (D-2 installation
circuits (grouping) from table-27 to 31 ). Reduction factor 0.75
of ANNEXURE VIII (cable to cable clearance
0.125) from from table 28 of
ANNEXURE VIII
11 Deriving the final current (calculating 254.90 Amp. 162.5/(1x0.85x0.75)=254.
from S.N.10) 90

12 Checking of size of cable for particular 4 core 240 4 core 240 Sq.mm XLPE
size/core/insulation/installation from Sq.mm XLPE insulated aluminium cable
ANNEXURE IX which has minimum insulated is suitable for D-2
Current carrying capacity given in aluminium Installation as current
S.N.11 (final current after applying all cable carrying capacity is 272
reduction factor) Amp table 33 of
ANNEXURE-IX),which is
more than 254.90 Amp.
Table 11: 2nd Method for accessing the current carrying capacity of the particular cross-section of
the cable
S.N. Procedure/Step Example Remarks
1 Decide type of cabling underground/ duct, Underground Cabling direct in the
shafts, voids, (where cable is to be laying ground
installed)
2 Based on the above installation method D-2 Installation S.N.73 of ANNEXURE VII
identify type of Installation from
ANNEXURE VII
3 Decide type of Insulation of conductor XLPE Type of insulation
PVC / XLPE/ EPR / Mineral as per table 8
4 Decide type of Core 4 Core Type of core
5 Check the rating of MCCB 125 Amp. Capacity of MCCB
6 Deriving the tripping current of MCCB 162.5 Amp. 125x1.3= 162.5
due to overload (Multiply overload factor
of MCCB (1.3) to this rated current)
7 Selecting the size of cable for particular 272 Amp. 4 core 240 Sq.mm XLPE
size/core/insulation/installation from insulated aluminium cable
ANNEXURE IX , which has higher for D-2 Installation is being
(approx. 50 to 70%) Current carrying selected. Current carrying
capacity given above S.N.6 (tripping capacity is 272 Amp (table
current of MCCB due to overload ),as 33 of ANNEXURE-IX),
current carrying capacity will be reduced which is more tha 67.90%
due to reduction factor (as given below) from 162.5 Amp.
8 Applying reduction factor (by current 272x1= 272 Reduction factor=1 for
carrying capacity multiplied by reduction Thermal Resistivity 2.5
factor) for soil thermal resistivity from Km/W from table 26 of
tables 26 of ANNEXURE VIII ANNEXURE VIII
9 Apply ambient temperature reduction 272x1x0.85 Ambient temperature 40°C
factor(by current carrying capacity to be considered.,
multiplied by reduction factor) from Reduction factor 0.85 from
table-24 & 25 of ANNEXURE VIII table 25 of ANNEXURE VIII
10 Apply reduction factor (by current 272x1x0.85x0.75 2 No. circuits with 4 core
carrying capacity multiplied by reduction cable are also laid direct in
factor) depending on the number of the ground (D-2
circuits (grouping) from table-27 to 31 installation). Reduction
of ANNEXURE VIII factor 0.75 (cable to cable
clearance 0.125) from

from table 28 of
ANNEXURE VIII
11 Deriving the final current (calculating 173.40 Amp. 272x1x0.85x0.75=173.40
from S.N.9)
12 Check that Current carrying capacity 4 core 240 173.40 Amp. Is nearest
given in S.N.11 (final current capacity Sq.mm XLPE higher than 162.5 Amp.
after applying all reduction factor) is insulated
nearest higher than S.N.6 (tripping aluminium cable
current of MCCB due to overload ).If not is suitable
than upper size cable to be select
3.2.8 Check size of cable is suitable for short circuit fault conditions
(Ref: Para 4.4.5.5.2 of IS 732:2019)
The selected size of cable should be checked for short circuit withstand capability, the max short
circuit withstand current can be calculated by the formula given below or as given in manufacturers
manual. This current cable should hold without any thermal damage to it until such time the fault can
be removed by the protective device (circuit breaker or fuse).
Any cable’s short circuit withstand current can be calculated using the following formula:
𝑆×𝐾
𝐼=
√𝑡
Where,
I= Short Circuit Current, in Amperes,
t= Duration of Short Circuit, in seconds (This formula is applicable for short circuit duration up
to 5 Sec)
K = Adiabatic Constant (K = 115 for PVC /Copper, K = 143 for XLPE / Copper, K = 76 for
PVC / Aluminium and K = 94 for XLPE / Aluminium)
S= Size of cable in Sq mm.
3.2.9 Check the voltage drop based on size & length of cable
Voltage in an installation should be as per the standard supply voltage with permissible tolerance. To
ensure this, it is important to check that the cumulative voltage drop from the source up to any point
in the installation does not exceed the tolerance permitted. Due to increase length of wire, If value of
Voltage drop exceeds the specified value in the wiring system, then cross-section of the conductors
must be increased.
3.2.9.1 Permissible Voltage Drop in Consumer’s Installations

(Ref: Annex Y of IS 732:2019)
The percentage voltage drop with respect to the value of the nominal voltage from the source up to
any point in the installation shall not exceed the value given in below table.
Table 12: Voltage Drop
(Para 5.2.8 of IS 732:2019)
Type of Installation Lighting % Other Uses %
1 Low voltage installations supplied directly from a public low 3 5
voltage distribution system
2 Low voltage installation supplied from private LV supply 1 6 8

1
As far as possible, it is recommended that voltage drop within the final circuits do not exceed
those indicated in installation type 1.
When the main wiring systems of the installations are longer than 100 m, these voltage drops may
be increased by 0.005 percent per metre of wiring system beyond 100 m, without this supplement
being greater than 0.5 percent.
Voltage drop is determined from the demand by the current-using equipment, applying diversity
factors where applicable, or from the values of the design current of the circuits.
NOTES
1. A higher voltage drop may be acceptable in the following case:-
– for motor during starting periods,
– for other equipment with high inrush current,
It is also ensured that the voltage variations remain within the limits specified in the relevant
equipment standard.
2. The following temporary conditions are excluded:
– voltage transients;
–voltage variation due to abnormal operation.
3.2.9.2 Calculation of voltage drop
(Ref: Annex Y of IS 732:2019)
After selecting the size of cable voltage drop to be checked for particular length. It shall not
exceed the value given in table-12. Voltage drop chart are generally given by a manufactures in
their manuals further this can also be calculated using the following formula:
Where
u = Voltage drop in V
b = Coefficient equal to 1 for three phase circuit, and to 2 for single phase circuits.
= Resistivity of conductors in normal service, 0.0225 mm2/m for copper and
1
0.036 mm2/m for aluminium
L = The straight length of the wiring systems, in m
S = The cross-sectional area of conductors, in mm2
= The power factor, in the absence of precise details, the power factor is taken as
Cos 
equal to 0.8 (sin  =0.6)
 = The reactance per unit length of conductors
IB = Design current (in amps)
u
The relevant voltage drop in % is equal to : ∆𝑢 = 100 U , Where U0 = Voltage between line &
0
neutral, in V.

CHAPTER 4 INSPECTION, TESTING & STORAGE
After giving order of cable by purchaser the supplier submits the test reports with Material. There are different
classification of Test i.e Type Test, Acceptance Test and Routine test which are done on cables that are
based on Indian Standard IS 7098:1988, IS1540:1988 and 15250 with amendments for XLPE, PVC & AB
Cable respectively.
4.1 Classification of Tests

4.1.1 Type Tests:
4.1.1.1 Definition
A. Tests required to be made before supply on a general commercial basis a type of cable in
order to demonstrate satisfactory performance characteristics to meet the intended
application.
B. These tests are of such a nature that after they have been made, they need not be repeated
unless changes are made in the cable materials or design which might change the
performance characteristics.
C. When type tests have been successfully performed on a particular type of cable with a
specific conductor cross-sectional area and rated voltage, type approval shall be accepted
as valid for cables of the same type with other conductor cross sectional areas and/or rated
voltages provided the following two conditions are satisfied:
a. The same material of insulation and manufacturing process are used.
b. The conductor cross-sectional area is not larger than that of the tested cable. Approval
shall be independent of the conductor material.’
4.1.1.2 List of Type Test for XLPE & PVC Cable
Table 13: List of Type Test for XLPE & PVC Cable
S.N. Name of Test For Test Method Refer Part
Number of IS : 10810
a) Tests on conductor
i) Annealing Test (for Copper) 1
ii) Tensile Test (for Aluminium) 2
iii) Wrapping Test (for Aluminium) 3
iv) Resistance Test 5
b) Test for Armouring Wires/Strips 36 to 42
c) Test for thickness of Insulation & Sheath 6
d) Physical tests for insulation
i) Tensile Strength and elongation at break. 7

ii) Ageing in air even. 11

iii) Hot Set Test. 30
iv) Shrinkage Test. 12
v) Water Absorption (Gavimetric) 33
e) Physical tests for outer sheath
iii) Loss of mass in air oven 10
v) Hot deformation Test 15
vi) Hot Shock Test. 14
vii) Thermal stability
h) Insulation Resistance Test 43
i) High Voltage Test 45
j) Flammability Test 53
The following shall constitute additional type tests for cables with improved fire performance as
per the categories given below:
Table 14: Additional Type Test for XLPE & PVC Cable with improved fire performance
Category Name of Test For Test Method Refer Part
01 No additional tests
C1 Oxygen index test 58 (under preparation)
Flame retardance test on single cable 61
Flame retardance test bunched cables 62
Temperature index Under Consideration
Flame retardance test bunched cables 62
Test for specific optical Under Consideration
density of smoke 63
Smoke density 59
Temperature index Under Consideration
4.1.1.3 Type Test List for AB Cable
Table 15: List of Type Test for AB Cable

(Ref: Para 10.1 of IS 14255 – 1995)
S.N. Name of Test For Test Method Refer Part

a) Tests on Phase/Street Light Conductor
i) Tensile Test (for Aluminium) 2
ii) Wrapping Test (for Aluminium) 3
iii) Resistance Test 5
b) Test on Messenger Conductor
i) Breaking Load. 2
ii) Elongation Test. 11.3
iii) Resistance Test 5
c) Physical tests for insulation
iii) Hot Set Test. 30
v) Water Absorption (Gravimetric) 33
vi) Carbon black:
1) Content
2) Dispersion
d) Physical test for PE insulation
ii) Melt flow index 23
iii) Carbon black:
1) Content
2) Dispersion
iv) Vicat softening point 22
v) Environmental stress cracking 29
e) Test for thickness insulation. 8
f) Insulation performance (Volume resistivity) Test. 43
g) High Voltage Test. 45
4.1.2 Acceptance Tests:

4.1.2.1 Definition
These tests are done for the purpose of acceptance of the lot and carried out on samples taken
from that lot. Details of size of sample is given in below table.
Table 16: Number of Drums to Be Selected For Sampling and Permissible Number of Defectives
(Ref: Appendix B of IS 7098 (Part-I) – 1988 & IS 1554 (Part-I) – 1988 & Annex A of 14255 – 1995)
Number of drums In The Lot Number Of Drums To Be Permissible

Taken As Sample Number Of Defectives
Up to 50 2 0
50 to 100 5 0
101 to 300 13 0
301 to 500 20 1
501 and above 32 2
Suitable length of test sample shall be taken from each of the drums selected. These test samples
shall be subjected to each of the acceptance test. A test sample is called defective if it fail in any of
the acceptance tests
4.1.2.2 List of Acceptance Test for XLPE & PVC Insulated Cable
The following shall constitute acceptance tests for XLPE & PVC Insulated Cable:
Table 17: List of Acceptance Test for XLPE & PVC Cable
S.N Name of Test

a) Tensile Test (For Aluminium Conductor)
b) Wrapping Test (For Aluminium Conductor)
c) Annealing Test (For Copper Conductor)
d) Conductor Resistance Test
e) Test for thickness of Insulation & Sheath
f) High Voltage Test
g) Insulation Resistance Test
h) Tensile Strength & Elongation at break test
for Insulation and Sheath
I) Hot Set Test for Insulation
Table 18: Additional Acceptance Test for XLPE & PVC Cable with improved fire performance
(Ref: Para 15.2.1 of IS 7098 (Part-I) – 1988 & IS 1554 (Part-I) – 1988)
Category Name of Test For Test Method Refer Part Number
of IS : 10810
01 No additional tests


Test for specific optical density of smoke Under Consideration
Test for halogen acid gas evolution'
4.1.2.3 Acceptance Test List for AB Cable
The following shall constitute acceptance tests for AB cables:
Table 19: List of Acceptance Test for AB Cable

(Ref: Para 10.2 of IS 14255 – 1995)
1. Tensile test (for phase/street light conductor),
2. Wrapping test (for phase/street light conductor),
3. Breaking load test for messenger conductor,
4. Elongation test for messenger conductor,
5. Conductor resistance test,
6. Test for thickness of insulation,
7. Tensile strength and Elongation at break test,
8. Hot set test for XLPE insulation,
9. Insulation resistance test, and
10. High voltage test.
4.1.3 Routine Tests:
4.1.3.1 Definition
Tests made are carried out by the manufacturer on all finished cable lengths to demonstrate the
integrity of the cable.
4.1.3.2 Routine Test List for XLPE & PVC Cable
a) Conductor Resistance Test
b) High Voltage Test
4.1.3.3 Routine Test List for AB Cable
a) Conductor Resistance Test
b) High Voltage Test
4.1.4 Additional test at site
There are some addition tests which may be used by purchaser for quality of cable
a) Measurement of size of XLPE/PVC cable
After receiving the cable on site ,size of cable may be checked by following procedure:-
I. Cable may be 1/2/3/3.5/4 core. Each core has number of conductors i.e. called strands
II. First of all counting the number of total strands in each core
III. Next step to measure diameter of each
conductor/ strand through screw gauge.
Procedure for measure diameter of each
conductor using screw gauge:-

a. Find the value of one linear scale division (L.S.D).

b. Determine and record the pitch and least count of the screw gauge.
c. To find the zero error, bring the plane face B and A near. Repeat and record this for three
times. Record zero error as nil if there is no error.
d. Move face B away from face A. using a ratchet head R, move the face A towards face B
lengthwise and stop when R turns without moving the screw.
e. Linear scale reading (L.S.R) is recorded by noting down the no.of visible and uncovered
divisions of linear scale.
f. Let n be the no.of divisions of the circular scale lying on the reference line.
g. To measure diameter in a perpendicular direction, repeat steps (e) and (f ) by rotating the
wire to 90°.
h. For the entire length of wire, repeat steps (d),(e),(f) and (g) for five different positions and
record the observations.
i. Find the total reading and also zero correction.
j. Take the mean of different values of diameter.
k. Using a half-meter scale, measure the length of the wire. Repeat this step three times and
record the readings.
IV. Multiply the diameter of each conductor/ strand to number of conductor/ strand for
calculating the size of conductor.
b) Measurement of Insulation resistance test:- Detail given in para 5.8.1 of this booklet
4.2 Identification of XLPE, PVC & AB Cable
I. The manufacturer shall be identified throughout the length of the cable by means of a tape bearing,
the manufacturer's name or trade-mark, or by manufacturer's name or trade-mark being, indented,
printed or embossed on the cable. In case none of those methods can be employed, or if the
purchaser so desires, colour identification threads in accordance with a scheme to be approved
by the Bureau of Indian Standards (BIS} shall be employed. The indication, printing, or embossing
shall be done only on the outer sheath.
II. In order to distinguish these electric cables from telephone cables the word ‘electric' shall be
indented, printed or embossed throughout the length of the table
III. The code shall be used for designating the cable as per below table
Table 20: Cable Code

Aluminium conductor A
PVC insulation Y
XLPE insulation 2X
Steel round wire armour W
Non-magnetic round wire armour Wa
Steel strip armour F
Non-magnetic strip armour Fa
Double steel strip armour FF
Double steel round wire armour WW
PVC outer sheath Y
NOTE - No code letter for conductor is required when the conductor material is copper.

4.3 Packing & Marking of XLPE,PVC & AB Cables

A. The cable shall be wound on a drum (see IS : 10418.1982) and packed.
B. The ends of the cable shall be sealed by non-hygroscopic material
C. The following information be stenciled on the drum with either water proof ink or oil paint:
i. Reference of IS / IEC standard.
ii. Manufacturer’s name or trademark.
iii. Type of cable and voltage grade.
iv. No. of cores.
v. Nominal cross-sectional area of conductor
vi. Cable code.
vii. Length of cable on the drum
viii. Number of Lengths on drum (if more than one);
ix. Gross weight
x. Direction of rotation of drum (by means of an arrow)
xi. Country of Manufacture
xii. Year of manufacture
4.4 Handling (Unloading At Site)
(Ref: Para 7 of IS: 1255 – 1983)
I. On receipt of cable drums visual inspection of drums should be made ensuring drum packing is
original. While unloading the cables certain precautions are to be taken to ensure the safety of
the cables.
II. The cable drums should not be dropped or thrown from railway wagons or trucks during
unloading operations as the shock may cause serious damage to cable layers.
III. A crane should be used for unloading cable drums. When lifting drums with the crane, it is
recommended that the lagging should be kept in place to prevent the flanges from crushing on
to the cable.
IV. If the crane is not available, a ramp should be prepared with approximate inclination of 1:3 or 1:4.
The cable drum should be rolled over the ramp by means of ropes and winches. Additionally a
sand bed at the foot of the ramp may be prepared to brake the rolling the cable drum.
V. Cable should not be dragged along the earth surface.
VI. Cable ends should always be sealed by means of suitable end sealing materials to prevent
moisturisation of cores and armour.
VII. Drums should be rolled in direction of arrow marked on the drum.

4.5 Storage
(Ref: Para 7 of IS: 1255 – 1983)
I. Cables should be stored in a dry covered place to prevent exposure to climatic conditions and
wear and tear of wooden drums
II. It should preferably stored on a concrete surface/firm surface which will not cause the drums to
sink and thus lead to flange rot and extreme difficulty in moving the drums.
III. Whenever the storage time is very long then rotate the drum at 90 degree after every 3 months.
The direction of drum rotation should match the direction of arrow marked on the flat side.
IV. All drums should be stored in such a manner as to leave sufficient space between them for air
circulation.
V. It is desirable for drums to stand on battens placed directly under the flanges.
VI. In no case should the drums be stored, “On the Flat”, i.e., with flange horizontal as shown below.

CHAPTER 5 LAYING AND INSTALLATION OF CABLES
5.1 SELECTION OF THE CABLE ROUTE

Prior to start excavation of cable trench, conduct a preliminary survey of the cable route and prepare
a plan drawing and obtain approval from all concerned authorities if necessary. Following points may
be considered while selecting cable route.
a. Select the shortest but the easiest route to reduce the overall cost.
b. Due consideration shall be given for access/transportation of cable drums. Check the road
conditions, turns and width.
c. As far as possible avoid paved roads and follow the footpaths.
d. The route should be as far as possible, away from parallel running gas, water pipes and
telephone/ telecommunication cables.
e. Suitable locations for cable joints and terminations should be selected as required.
f. Take due consideration of future expansion or upgrading the system.
5.2 Minimum Permissible Bending Radii
The cable should not be bent to a sharp radius. Minimum permissible bending radii
for cables are given below:
Table 21: Minimum Permissible Bending Radii

(Ref: Table-5 of IS 1255 – 1983)
Voltage PVC and XLPE cables
rating(kV) Single core Multi core
Up to 1.1 15 D 12 D
Above 1.1 to 11 15 D 15 D
Above 11 20 D 15 D
Note: D is outer diameter of cable. At joints and terminations bending radius for the individual cores
should be above 12 times the diameter over the insulation.
5.3 Methods of Cable Laying & Installation
(Ref: Para 6.1 of IS: 1255 – 1983)
The conventional methods of cable laying and installation are:
 Laying direct in ground.
 Drawing in ducts.
 Laying on racks in air.
 Laying on racks inside a cable tunnel.
 Laying along buildings or structures.
Relative Merits/ Demerits of Different Methods of Cable Laying is given in Annexure-6

5.3.1 Laying Direct in Ground

(Ref: Para 6.3 of IS: 1255 – 1983)
This method involves digging a trench in the ground and
laying cables on a bedding of minimum 75mm riddled
soil or sand at the bottom of the trench, and covering it
with additional riddled soil or sand of minimum 75mm
and protecting it by means of bricks, tiles or slabs.
Cable Trench Layout
5.3.1.1 Depth
The desired minimum depth of laying from ground surface to the top of the cable should be as
below
Table 22: Minimum depth of laying from ground surface to the top of the cable
(Ref: Para 6.3.2 of IS: 1255 – 1983)
3.3 KV to 11 kV Voltage rating 0.9m
22 kV, 33 kV Voltage rating 1.05 m
Low voltage and control cables 0.75 m
Cables at road crossings 1.00 m
Cables at railway level crossings 1.0m
(Measured from bottom of sleepers to the top of pipe) 2.0m
5.3.1.2 Clearances
Table 23: Desired Minimum Clearances
(Ref: Para 6.3.3 of IS: 1255 – 1983)
Power cable to power cable Clearance not necessary. However larger the
clearance, better would be current carrying capacity.
Power cable to control cables 0.2m
Power cable to communication cable 0.3m
Power cable to gas/ water main 0.3m
5.3.1.3 Trenching
Following are the known methods of trenching.
i. Manual excavation
ii. Excavation with mechanical force.
iii. Thrust bore
iv. Trench ploughing
Manual excavation method is generally in practice. Trenches shall be excavated according to the
line and level shown on the cable route plan. It possible the cable trench shall be of straight lines.
All curves must be smooth and suitable for laying the cable. The excavated trench sides and trench
floor should be trimmed to remove the sharp projections, if any, which might damage cables.
During excavation take adequate measures to protect all existing structures and existing services
such as electrical cables, telecom cables, gas line, water pipe etc.

5.3.1.4 Cable Laying (By hand)

Before laying the cable, it should be examined for any exterior damage. Mount the cable drum on a
cable jack with a strong spindle. Drum is to be jacked high enough to fit in braking plank. Weak
shaft should not be used otherwise drum would revolve unevenly.
The drum should never be kept flat on its side on the ground and the cable taken away from the
same. This invariably leads to kinking and bird caging.
The pay in rollers, corner rollers and properly aligned and smooth running cable rollers should be
placed every 3 to 4 m in the cable trench. At least three solid plates for guiding the cable around
the bend should be used for maintaining minimum bending radius.
Raise the drum slowly equally from both the ends by using both the jacks. Now the cable is to be
paid out from the top of the drum by rolling the drum in the direction of arrow marked on the drum.
A cable grip may be provided at the end of the cable or men may also directly grip the cable,
positioning themselves near the cable rollers and pull after a sufficient length about 50m has been
pulled.
The gangman (Mucadam) should stand in a commanding position and make evenly timed calls.
This enables the men positioned at each roller to pull the cable evenly, simultaneously and without
jerks. The number of man required for pulling largely depends on the size and weight of the cable
being laid. The men at rollers should also apply graphite grease in the course of pulling, as and
when required. When pulling round a bend, corner rollers should be used so as to minimise
abrasion.
During the preliminary stages of laying the
cable, consideration should be given to proper
location of the joint position so that when the
cable is actually laid the joints are made in
most suitable places.
Cable Joint Pit and Overlapping of Cable Ends
There should be sufficient overlap of cables to allow for the removal of cable ends which may have
been damaged. This point is extremely important as otherwise it may result in a short piece of the
cable having to be included. The joint should not be near pipe end or at the bend.
5.3.2 Cable Laid Across Roads, Railway Tracks and Water Pipe Lines.
(Ref: Para 6.3.4 of IS: 1255 – 1983)
 Hume pipe/ ‘B’ grade GI pipe of suitable size shall be used where cable cross roads, railway
tracks. Spare ducts for future extensions shall also be provided.
 The duct/ pipe joints shall be covered by collars to prevent settlement in between pipes.
 The diameter of the cable conduit or pipe/duct shall be at least 1.5 times the outer diameter of
cable. The ducts/pipes shall be mechanically strong to withstand forces due to heavy traffic
when they are laid across the road/ railway tracks.
 The cable entry and exit shall be through bell mouth or padding.
 The bending radii of steel or plastics ducts shall not be less then 1.5m.
 Single core cables shall not be laid individually in steel ducts but instead, all three cables of the
same system shall be laid in one duct.

5.3.3 Cable Over Bridges

(Ref: Para 6.3.5 of IS: 1255 – 1983)
On bridges, the cables are generally supported on steel cable hooks or clamped on steel supports
at regular intervals. It is advisable that cables laid in bridges are provided with sun shields to protect
the cable from direct heating by sun’s rays.
5.4 Reinstatement
(Ref: Para 11 of IS: 1255 – 1983)
 After laying the cable it should be checked again for ensuring that the all cable ends are
undamaged and sealed.
 If trench is partially filled with water, cable ends should kept clear off water as far as possible.
 If cable has to be cut, reseal both the cable ends immediately. Lead cap for paper cable and
plastic cap for PVC/XLPE cable should be used. As a temporary measure, end can be sealed by
inserting them in an empty tin which is filled with hot bitumen based compound.
 Each cable length should be aligned immediately after it is laid starting from one end. When
aligning the cable, it should be ensured that there is no external damage.
 If the joints are not to be made immediately after laying the cable, the cable ends should be
covered. The position of cable joint should be marked with markers.
 The trench at the duct mouth at road or railway crossing should be deepened to prevent the
stone or the gravel from being drawn into duct and clogging it.
 Before the trench is filled in, all joints and cable positions should be carefully plotted.
 The requisite protective covering should then be provided, the excavated soil replaced after
removing large stones and well rammed in successive layers of not more than 0.3m in depth.
Where necessary, the trenches should be watered to improve consolidation.
 It is advisable to leave a crown of earth not less than 50mm in the center and tapering towards
the sides of the trench to allow for settlement.
 After the subsidence has ceased, the trench may be permanently reinstated and the surface
restored to its original conditions.
 Cable route markers are to be installed on either sides of the cable trench at every 200m interval
on straight runs, and turning points. Joint markers should be installed at all the four corners of
the joint pit.
5.5 Cable Jointing
(Ref: Para 12 of IS: 1255 – 1983)
Cable joint is a device used to join two or more cables together for extension of lengths or to branch.
These joints are made to perform at the same voltage class and ratings of the intended cables and are
able to withstand the normal and emergency loading conditions. Selection of proper cable accessories,
proper jointing techniques, skill and workmanship is important. The quality of joint should be such that
it does not add any resistance to the circuit. All underground cable joints must be mechanically and
electrically sound and it is protected against moisture and mechanical damage. The joint should further
be resistant to corrosion and chemical effects.

5.5.1 Basic Types of Joints

(Ref: Para 12.1.2 of IS: 1255 – 1983)
The basic types of cable joints are
i. Straight through joints
This type of joint is used to connect two cables lengths together. This joint is further divided
in two categories.
a. Simple straight through joints.
For jointing same type of cables such as PVC to PVC, XLPE to XLPE.
b. Transition straight through joints.
For jointing two different type cables such as XLPE to PILC.
ii. Tee/branch joint
These joints are normally used for jointing a service cable to the main distribution cable in
distribution network. These joints should be restricted to 1.1kV grade cables. Tee joints on
HT cables upto and including 11kV may be done only in exceptional cases.
These joints are made either using cast resin kits or C.I. boxes with or without sleeves for
PILC cables and cast resin kits for PVC and XLPE cables.
iii. Termination or sealing end
This is generally used to connect a cable to switch gear terminal in switch boards, distribution
pillars, transformer box, motor terminal box and to overhead lines.
5.5.2 Types of Cable Jointing Accessories
Following types of jointing accessories are mainly used for jointing all types of low voltage & medium
voltage power cables. Every jointing kit is provided with an instruction manual supplied by the
manufacturer. Joints shall be made according to the guidelines given in instruction manual.
i. Heat shrinkable jointing kit. (Preferred)
Figure 5: Heat shrinkable jointing kit
ii. Cold shrinkable jointing kit.
iii. Tapex tape type jointing kit.
iv. Push on type jointing kit.
v. Cast resin jointing kit.
Measurement of Insulation Resistance
Before jointing is commenced, it is advisable that the insulation resistance of both sections of the
cable to be jointed, be checked by insulation resistance testing instruments like megger.
5.5.3 One example is given below for making straight joint for better understanding
(M-seal tapex type joint for 12 kV to 36 kV XLPE cables)
Cable jointing is basically a technique of rebuilding the cable construction in the same formation as
the original cables to be jointed. Jointing of XLPE power cables is based on following components.
i. Crimping type jointing ferrule.
ii. Self amalgamating insulating tapes.
iii. Self amalgamating semiconducting tapes.

iv. Non-linear stress grading pads.

v. Earthing connector and clamps.
vi. Plastic mould and jointing compound etc.
The important steps in the cable jointing of medium voltage XLPE insulated screened armoured cable
is given below.
a. Strip the jointing ends of both the cables to be done i.e. stripping of outer sheath, armour, inner
sheath, insulation screen, core insulation and conductor screen.
b. Joint all the conductor cores shall be joint with the help of jointing ferrule and its crimping by
suitable crimping tool.
c. Fill up the space between the ferrule and
the core insulation and the crimped
portion in ferrule with semi conducting
tape, so that it forms a smooth and round
profile with 2 mm. Overlap on the
insulation on each side of the ferrule as
shown in figure.
d. Measure a distance of 20 mm on both sides

of the semi-conducting tape. Apply stress
grading pad of 30mm width over the core
covering 10mm of the semi conducting tape
as shown in figure.
e. Keeping a gap of 5mm from the semi

conducting layer of core, wrap the self
alamgamating insulating tape so that the
required insulation thickness is built up.
Ensure a tapered profile of the tape towards
the semi conducting layer of the insulation, the self-amalgamating tape should be stretched to 2/3
rds of its original width while applying as shown in figure.
f. Fill up the gap 5mm between self

amalgamating insulating tape and semi
conducting layer of core by stress grading
pad of 30mm width as shown in figure.
g. Apply semi conducting tape one layer half over

lapped about 10mm on one side of metallic
shielding to the other end in the same manner
as shown in figure.

h. Wrap 2 layers of self amalgamating insulating

tape, each half overlapped to cover the semi
conducting tape. Stretch the tape 2/3rds of
width while applying as shown in figure.
i. Wrap one layer of copper wire mesh on the core

to connect the copper tape from end to another
over the tapes as shown in figure.
j. After earthing place the mould & fill it with cable

jointing compound as shown in figure.
5.6 Cable End Terminations

Termination kits are designed for terminating cable ends at an indoor type equipment with an indoor
termination kit or on pole tops/ outdoor transformer with an out door type termination. Both type of
terminations are designed to operate at optimum level during normal loading and emergency
condition of the cables. Following types of termination kits are mainly used for terminating all types
of PVC/XLPE power cables upto medium voltage.
i. Heat shrink termination kit.
Figure 6: Heat shrink termination kit
ii. Cold shrink termination kit.

iii. Premoulded push o termination kit.
iv. Cast resin termination kit.
v. Brass glands (for low voltage indoor terminations in dry and non corrosive atmosphere.)
Every terminating kit is provided with an instruction manual supplied by the manufacturer.
Terminations shall be made according to the guidelines given in instruction manual.
5.6.1 One example is given below for making end termination for better understanding
(M-seal push-on type pre moulded terminations for XLPE/ EPR/ PVC cables upto 36 kV)
M-seal push on type termination kit comprises of intricately engineered and moulded EPDM (Ethylene
Propylene Diene Monomer) rubber components and these are available up to 1000 sq. mm for cables
from 3.3 kV to 22 kV and up to 630sq. mm for cables of 33kV grade.

This type of kit comprises

i. Stress cone which consists of highly track resistant insulating section vulcanised to a semi-
conducting section.
ii. A semi conducting pad which is used to make the connection between screen and cone. The
pad material has cold flow properties. When it is taped into position, the active pressure of the
tape induces the cold flow property of the material so that it fills in all the cavities at the screen
edge and in the folds of the material itself.
This push on method suit all type of core screen including extruded or taped. This can be used
on both type of conductors i.e. circular compacted or sector shaped.
iii. The number of rain sheds to be provided is determined by the operating voltage and the location
of the termination. The same termination can be used on 3.3 kV to 33kV by only increasing or
reducing the number of rain sheds. Rain sheds are generally provided for outdoor terminations.
However rain sheds can also be used on indoor terminations to increase creepage path in very
highly polluted atmosphere or to match limited space availability. M-seal push on has an
approx. creepage of 4cm/kV.
iv. A lug seal (for outdoor terminations is also provided to prevent any ingress of moisture.
Important steps to be followed while carrying out M-seal push-on termination are given as
under:
 Strip the end of the cable to be terminated i.e. stripping of outer sheath, armour, inner
sheath, insulation screen, core insulation etc.
 Push on the stress cone on the prepared cable core as shown in figure no. 1.
 Connect the stress cone and cable outer screen with semiconducting cold flow material as
shown in figure no. 2.
 Wind the self bonding insulating tape over the semiconducting cold flow material with active
pressure. This active pressure ensures that voids are eliminated between the termination
and the cable insulation as shown in figure no. 3.
Figure 1 Figure 2 Figure 3
 Now if the termination is to be used for indoor use, provide the cable lug and crimp it using
suitable crimping tool. This completed termination is ready for indoor use as shown in figure
no. 4.

 For out door termination, provide rain sheds and top cap. Number of rain sheds vary with
voltage rating of the cables as shown in figure no. 5.
 Crimp the cable lug by using suitable crimping tool and provide lug seal. This completed
termination is ready for outdoor use as shown in figure no. 6.
Figure 4 Figure 5 Figure 6
5.7 Earthing and Bonding of Cables

(Ref: Para 13 of IS: 1255 – 1983)
 The metal sheath, metal screen (if any) and armour of any cable should be efficiently earthed at
both ends.
 In case of single-core cables of larger sizes, the armour, lead sheath and metal screen, if any, is
bonded at times only at one point. Attention is drawn in this case to the presence of standing
voltages along armour or lead sheath and to the considerable increase in such voltages when
cables carry fault currents. These voltages must be taken into account when considering safety
and outer sheath insulation requirement.
 All metal pipes or conduits in which the cables have been installed should be efficiently bonded
and earthed.
 Where cables not having metallic sheath are used, embedding additional earth electrodes and
connecting the same with steel armour of cable becomes necessary.
 Earthing and bonding should be done in accordance with IS: 3043-1987.
5.8 Testing Of Cable Installation
5.8.1 Insulation Resistance Test on Newly Installed Cables Before Jointing.
(Ref: Para 14.1 of IS: 1255 – 1983)
All new cables should be tested for insulation resistance before jointing. After satisfactory results are
obtained cable jointing and termination work should commence. It should be noted here that
insulation resistance test gives only approximate insulation resistance and the test is meant to reveal
gross insulation faults. A fairly low insulation resistance reading compared to the values obtained at
factory testing should not be a cause of worry since the insulation resistance varies greatly with
parameters such as length and temperature. This is particularly more pronounced in the case of PVC
cables. The voltage rating of the insulation resistance tester for cables of different voltage grades
should be chosen from the following table.

Voltage Grade of Cable Voltage Rating of IR Tester

1.1kV 500V
3.3kV 1000V
6.6kV 1000V
11kV 1000V
22kV 2.5kV
33kV 2.5kV
Note : For long feeders, motorized insulation resistance tester should be used.
5.8.2 Tests on Completed Cable Installation
(Ref: Para 14.2 of IS: 1255 – 1983)
The test of completed installation may be measured and entered into record book for comparison
purposes during service life of cable installation and during fault location.
5.8.2.1 Insulation Resistance
Insulation resistance is measured by a suitable bridge. In non-screened cables, the insulation
resistance of each core is measured against all the other cores and armour/metal sheath connected
to earth. With screened construction the insulation resistance of each core is measured against all
the other core and the metal screen connected to earth.
5.8.2.2 Conductor Resistance (dc)
(a) The resistance of conductor is measured by a suitable bridge. For this purpose conductors at
other end are looped together with connecting bond of at least same effective electrical cross-
section as conductor. The contact resistance is kept to a minimum by proper clamped or bolted
connections. With properly installed and jointed cables, values thus measured and corrected
to 20°C, are in general agreement with values given in test certificates.
(b) The measured loop resistance is converted to ohms per km per conductor as:
Rt = R / 2L
Where
R = measured loop resistance in ohms at temperature, t°c;
Rt = measured resistance per conductor at t°C in ohms per km.
L = length of cable (not the loop) in km.
The ambient temperature at the time of measurement to be recorded and the conductor
resistance to be corrected to 20°C by the following formula:
R20 = Rt ohm/km at 20°C.

(1+  ) (t-20)
Where
R20 = conductor dc resistance at 20°C in ohm/km,
t = ambient temperature during measurement in °C, and
 = temperature coefficient of resistance (3.93 x 10-3 ohms/°C for aluminium).

5.8.2.3 Capacitance
For unscreened cables, capacitance is measured for one conductor against others and metal
sheath/armour connected to earth. In case of screened cable it is measured between conductor and
screen. Capacitance bridge is used for this purpose. This measurement may be carried in case of
cables above 11kV; alternatively values given in test certificate are considered sufficient.
5.8.2.4 High voltage test
Cables after jointing and terminating are subjected to dc high voltage test. The recommended
values of test voltages are given in table. The leakage current shall also be measured and
recorded for future reference.
Rated voltage of cable Test voltage between Duration

Any conductor and metallic Conductor to conductor
Uo/U
sheath/ screen/ armour (For Unscreened cables)
kV kV kV Minutes
0.65/1.1 3 3
1.9/3.3 5 9
3.3/3.3 9 9
3.8/6.6 10.5 18
6.6/6.6 18 18 5
6.35/11 18 30
11/11 30 30
12.7/22 37.5 --
19/33 60 --
 Generally dc test should be preferred as test equipment required is compact, easily portable
and power requirements are low.
 The cable cores must be discharged on completion of dc high voltage test and cable should
be kept earthed until it is put into service.
 DC test voltage for old cables is 1.5 times rated voltage or less depending on the age of cables,
repair work or nature of jointing work carried out etc. In any case, the test voltage should not
be less than the rated voltage. Test voltage in these cases should be determined by the
engineer-in-charge of the work.
 It may be noted that frequent high voltage tests on cable installations should not be carried out.
This test should be carried only when essential. During the high voltage test, all other electrical
equipment related to the cable installation, such as switches, instrument transformers, bus
bars, etc. must be earthed and adequate clearance should be maintained from the other
equipment and framework to prevent flashovers.
 In each test, the metallic sheath/screen/armour should be connected to earth.

5.9 Cable Installation Plan

(Ref: Para 15 of IS: 1255 – 1983)
On completion of laying, terminating and jointing of the cables, a plan should be prepared, which should
contain the following details of the installation.
a. Type of cables, cross-section area, rated voltage. Details of construction, cable number and
drum number.
b. Year and month of laying.
c. Actual length between joint-to-joint or end.
d. Location of cables and joints in relation to certain fixed reference points, for example,
buildings, hydrant, boundary stones, etc.
e. Name of the jointer who carried the jointing work.
f. Date of making joint.
g. Results of original electrical measurements and testing on cable installation.
All subsequent changes in the cable plan should also be entered.
*****

CHAPTER 6 FAULTS IN CABLE
6.1 Types of Cable Faults

Following are the types of Cable faults commonly found In the Cables. Voltage Rating of IR Tester
(Meggar) should be 500V for 1.1KV cables.
6.1.1 Open-Circuit Faults

This fault involves an open circuit in the conductors. When one or more cable conductors (cores)
break, it leads to discontinuity. This discontinuity also occurs when the cable comes out of its joint
due to mechanical stress. This is known as Open circuit fault.
To test open circuit fault in three phase cables, all the three conductors (cores) are short circuited at
one end. The two terminals of meggar are touched with two conductors (cores) of the cables at a
other end at same time . Meggar indicates zero reading it means the conductors are continuous, but
when the Meggar indicates infinity reading it means there is an open circuit in the conductor
6.1.2 Short-circuit fault
When two or more conductors of a multi-core cable come in contact with each other, then this is
called a short circuit fault. A short-circuit fault occurs when the individual insulation of the conductor
core is damaged.
In case of testing short circuit test The two terminals of meggar are touched with two
conductors(cores) of the cable. Meggar indicates zero reading it means the two conductors are short
circuited. The same procedures are adopted for other conductors.
6.1.3 Earth faults
When any of the conductors of the cable comes in contact with the earth, it is called an earth fault.
This type of fault allows the current, carried by the conductor to leak to the earth directly or indirectly
instead of going to the apparatus to which the conductor is connected. This usually occurs when the
outer sheath is damaged due to chemical reactions with soil or due to vibrations and mechanical
crystallization
Before starting the testing procedure it may be ensured that the far end of the cable is open and free
from earth connection. In case of testing earth fault the ‘L’ terminal of the meggar is touched with
each conductor(core) of the cable and the ‘E’ terminal is permanently connected with a earth lead.
Meggar indicates zero reading it means the respective conductor(core) is earthed.
6.1.4 Low insulation fault
Sometimes when the cable core insulation material is deteriorated by ageing, moisture, excessive
heating or dirt the insulation resistance is dropped to very low value (several hundred to several kilo
ohms) it is called as low insulation fault.
If the resistance between any two conductors is low, the megger may show reading between several
hundred ohms to Kilo Ohms.

6.2 Causes of Cable Faults

Some of the causes of cable faults are as given below:
 Ageing.
 Corrosion of sheath.
 Moisture in the insulation.
 Heating of cable.
 Fire and lightning surges.
 Electrical puncture
 Damage during laying.
 Damage while in use due to excavation works.
6.3 Different Types of Tests to Locate Faults in Cables.
(Ref: Para 17.3 of IS: 1255 – 1983)
The fault localization tests may be classified as follows:
a) Direct loop test
b) Varley loop test
c) Murray loop test
d) Fall of potential test
e) De charge and discharge test
f) AC capacitance test
g) AC inductance test
h) Radar test
j) Induction test
k) Capacitor discharge test
m) Pulse echo test and
n) Acoustic cable tracing and fault locator
Detail of above tests are given in Para 17.3 of IS: 1255 – 1983. There are various
equipment/testers/cable fault locators are available in the market for testing/checking the location
of faults in the cable.

ANNEXURE – I: THICKNESS OF INSULATION FOR PVC & XLPE INSULATED CABLE
PVC Insulated Cable XLPE Insulated Cable

Ref:Table-2 of IS 1554 (Part-I) – 1988 Ref:Table3 of IS 7098 (Part-I) -1988
Nominal area Nominal thickness of Insulation Nominal area Nominal thickness of Insulation
of conductor Single Core Single Core of conductor Single Core Single Core
Armoured Unarmoured Armoured Unarmoured
Cables and multi Core Cables and multi Core
Cables Cables
(1) (2) (3) (1) (2) (3)
mm mm mm mm mm mm
1.5 1.1 0.8 1.5 1.0 0.7
2.5 1.2 0.9 2.5 1.0 0.7
4 1.3 1.0 4 1.0 0.7
6 1.3 1.0 6 1.0 0.7
10 1.3 1.0 10 1.0 0.7
16 1.3 1.0 16 1.0 0.7
25 1.5 1.2 25 1.2 0.9
35 1.5 1.2 35 1.2 0.9
50 1.7 1.4 50 1.3 1.0
70 1.7 1.4 70 1.4 1.1
95 1.9 1.6 95 1.4 1.1
120 1.9 1.6 120 1.5 1.2
150 2.1 1.8 150 1.7 1.4
185 2.3 2.0 185 1.9 1.6
240 2.5 2.2 240 2.0 1.7
300 2.7 2.4 300 2.1 1.8
400 3.0 2.6 400 2.4 2.0
500 3.4 3.0 500 2.6 2.2
630 3.9 3.4 630 2.8 2.4
800 3.9 3.4 800 3.1 2.6
1000 3.9 3.4 1000 3.3 2.8

ANNEXURE - II : THICKNESS OF INNER SHEATH FOR PVC & XLPE INSULATED CABLE
All dimensions in millimeters
(Ref:Table-4 of IS 1554 (Part-I) – 1988 & Table 5 of IS 7098 (Part-I) -1988)
Calculated diameter over laid up cores (Ref: IS:10462(Part-I) - 1983 Thickness of inner sheath
(Minimum)
Over Upto and Including
(1) (2) (3)
-- 25 0.3
25 35 0.4
35 45 0.5
45 55 0.6
55 -- 0.7
Fictitious calculation method for determination of dimensions of protective coverings of cables: Part I
Elastomeric and thermoplastic insulated cables.

ANNEXURE – III : DIMENSIONS OF ARMOUR – ROUND WIRES AND STRIPS FOR

PVC & XLPE INSULATED CABLE
All dimensions in millimeters
(Ref: Table-5 of IS 1554 (Part-I) – 1988 & Table 6 of IS 7098 (Part-I) -1988)
Calculated diameter under Armour (Ref: Nominal Thickness Nominal diameter

IS:10462(Part-I) - 1983 of Steel Strip of round wire
Over Upto and Including
(1) (2) (3) (4)
a) For all diameter in excess of 13 or 0.8 --
b)-- 13 -- 1.40
13 25 0.8 1.60
25 40 0.8 2.00
40 55 1.4 2.50
55 70 1.4 3.15
70 -- 1.4 4.00
Note: (a) and (b) indicate the methods of practice in the application of armouring.
Fictitious calculation method for determination of dimensions of protective coverings of cables: Part
I Elastomeric and thermoplastic insulated cables.

ANNEXURE – IV: THICKNESS OF OUTER SHEATH FOR PVC & XLPE INSULATED CABLE
[Clauses 14.4.1, 14.4.2 and 15.1 (c)]
(Ref: Table-7 of IS 1554 (Part-I) – 1988 & Table 8 of IS 7098 (Part-I) -1988)
Calculated diameter under the outer sheath Thickness of outer Minimum

[Ref IS: 10462 (part I) – 1983] sheath for unarmoured thickness of outer
cables sheath for
Over Up to and including Nominal Minimum armoured cables
(1) (2) (3) (4) (5)

-- 15 1.8 1.24 1.24
15 25 2.0 1.40 1.40
25 35 2.2 1.56 1.56
35 40 2.4 1.72 1.72
40 45 2.6 1.88 1.88
45 50 2.8 2.04 2.04
50 55 3. 2.20 2.20
55 60 3.2 2.36 2.36
60 65 3.4 2.52 2.52
65 70 3.6 2.68 2.68
70 75 3.8 2.84 2.84
75 -- 4.0 3.00 3.00
Fictitious calculation method for determination of dimensions of protective coverings of cables:
Part-I Elastomeric and thermoplastic insulated cables.

ANNEXURE – V : SIZE AND REQUIREMENTS OF MESSENGER CONDUCTOR

(Ref: Table-3 of IS:14255 – 1995)
S.N. Nominal Cross Messenger Conductor

Sectional Area of
Phase Conductor Nominal Cross Maximum dc Minimum Breaking
(Sq.mm) Sectional Area Resistance Load (kN)
(Sq.mm) at 20°C (ohm/km)
i) 16 25 1.38 7
ii) 25 25 1.38 7
iii) 35 25 1.38 7
iv) 50 35 0.986 9.8
v) 70 50 0.689 14
vi) 95 70 0.492 19.7

ANNEXURE – VI: RELATIVE MERITS/ DEMERITS OF DIFFERENT METHODS OF CABLE LAYING

(Ref: Appendix-B of IS: 1255-1983)
Sr. Subject Direct in Ground Laid in duct Laid on Racks Laid inside
No. in Air Tunnel
1. Application General application Normally for short- In factories, In power
for all site conditions runs across power stations, stations,
and types of railway carriages sub-stations, switching yards,
distribution way, etc. but etc. usually control rooms
extensively used in joints are where a large
American cabling eliminated on number of
practice racks. cables run in
parallel.
2. Preferred type of Armoured having Unarmoured with Armoured or Armoured or
cable finish ordinary/ special or without ordinary unarmoured unarmoured
servings serving
3. Conductor Very good Poor God if Fair if well
economy or sunshields are ventilated
current carrying provided
capacity
4. Initial preparatory Nominal Most significant Significant Most significant
work before laying
5. Initial cost of Comparatively low Higher High Highest
laying
6. Cost of repair and Higher High Fair Low
maintenance
7. Time requirement Significant Most significant Little Little
for locating a fault
8. Cost of cable High Low Lower loest
replacement for
load growth
9. Cost of cable for Least Highest High Low
repairing following
a fault
10. Susceptibility to Considerable Infrequent Little Little
electrolytic/
galvanic corrosion
11. Susceptibility to Little Little Considerable Considerable
cable sheath
failure by inter-
crystaline fatigue

Sr. Subject Direct in Ground Laid in duct Laid on Racks Laid inside
No. in Air Tunnel
12. Susceptibility to Considerable Infrequent Little Negligible
mechanical
damage
13. Damage to Rare Huge Considerable Considerable
adjacent cables
following a fault in
a cable
14. Special Nominal but special a. Care against a. Protection a. Protection to
precautions care may be abrasion during to cable at cable at
necessary required in pulling clamp clamp
b. Proper position position
aggressive site
alignment of b. Insulating b. Insulating the
conditions. duct the cable at cable at
c. Precautions metallic metallic
against clamp clamp
damage to positions positions
cable at duct c. Provision to c. Provision to
entry positions. reduce reduce thrust
d. Provision for thrust at at joints
pumping water joints, if position
from any. d. Provision for
manholes. drafting of
accumulate
water
ventilation
and lighting.

ANNEXURE-VII: EXAMPLES OF METHODS OF INSTALLATION PROVIDING INSTRUCTIONS FOR OBTAINING

CURRENT-CARRYING CAPACITY
(Clause 5.2.4.3)
Item Methods of Installation Description Reference Method of

No. Installation to be
Used to Obtain
Current-Carrying
Capacity
1 Insulated conductors on single-core A1

cables in conduit in a thermally
insulated wall
2 Multi-core cables in conduit in a A2

thermally insulated wall
3 Multi-core cables in conduit in a A2

thermally insulated wall
4 Insulated conductors or single-core B1

cables in conduit on a wooden or
masonry wall or spaced less than
0.3 x conduit diameter from it
5 Multi-core cable in conduit on a B2

wooden or masonry wall or spaced
less than 0.3 x conduit diameter
from it

cables in cable trunking (includes
multi-compartment trunking) on a
7 wooden or masonry wall
- Run horizontally
- Run vertically
8 Multi-core cable in cable trunking Under considerationd

(includes multi-compartment method B2 may be
trunking) on a wooden or masonry used
9 wall
- Run horizontally

- Run vertically

cable in suspended cable trunking
11 Multi-core cable in suspended cable B2

trunking
12 Insulated conductors or single-core A1

cable run in mouldings
15 Insulated conductors in conduit or A1

single-core or multi-core in
architrave
16 Insulated conductors in conduit or A1

single-core or multi-core cable in
window frames
20 Single core or multi core cables: C

- Fixed on, or spaced less than 0.3
x cable diameter from a wooden
or masonry wall
21 Single core or multi core cables: C, with item 3 of

Table 36
- Fixed directly under a wooden or
masonry ceiling
22 Single core or multi core cables: Under consideration

Method E may be
- Spaced from a ceiling
used
23 Fixed installation of suspended C with item 3 of

current-using equipment Table 36

30 Single-core or multi-core cables: On C with item 2 of

unperforated tray run horizontally or Table 36
vertically
31 Single-core or multi-core cables: E or F

On perforated tray run horizontally or
vertically
NOTE: Refer to S-6.2 of Annex S of
IS 732:2019 for description

On brackets or on a wire mesh tray
run horizontally or vertically

Space more than 0.3 times cable Or method G
diameter from a wall

On ladder
35 Single-core or multi-core cable E or F

suspended from or incorporating a
support wire or harness

36 Bare or insulated conductors on G

insulators
40 Single-core or multi-core cable in a 1.5 De  V  5 De

building void B2
5De  V  20 De B1
41 Insulated conductor in conduit in a 1.5 De  V  20 De

building void B2
V  20 De B1
42 Single-core or multi-core cable in Under consideration

conduit in a building void The following may
be used
1.5 De  V  20 De
B2
V  20 De B1
43 Insulated conductors in cable 1.5 De  V  20 De

ducting in a building void B2
V  20 De B1

cable ducting in a building void The following may
be used
1.5 De  V  20 De
B2
V  20 De B1
45 Insulated conductors in cable 1.5 De  V  5 De

ducting in masonry having a thermal B2
resistivity not greater than 2K. m/W
5 De  V  50 De B1

cable ducting in masonry having a The following may
thermal resistivity not greater than be used
2K.m/W
1.5 De  V  20 De
B2

V  20 De B1
47 Single-core or multi-core cable: 1.5 De  V  5 De

- In a ceiling void B2
- In a raised floor 5 De  V  50 De B1

cable in flush cable trunking in the
floor
51 Multi-core cable in flush cable B2

trunking in the floor

cables in flush cable trunking
53 Multi-core cable in flush trunking B2
54 Insulated conductors or single-core 1.5 De  V  20 De

cables in conduit in an unventilated B2
cable channel run horizontally or
V  20 De B1
vertically
55 Insulated conductors in conduit in an B1

open or ventilated cable channel in
the floor
Sheathed single-core or multi-core

56 B1
cable in an open or ventilated cable
channel run horizontally or vertically
Single-core or multi-core cable

57 C
direct in
masonry having a thermal resistivity
not greater than 2 K·m/W
Without added mechanical
protection

Single-core or multi-core cable

58 C
direct in
masonry having a thermal resistivity
not greater than 2 K·m/W
With added mechanical protection

cables in conduit in masonry
60 Multi-core cables in conduit in B2

masonry
Multi-core cable in conduit or in

70 D1
cable ducting in the ground
Single-core cable in conduit or in

71 D1
cable ducting in the ground
73 Sheathed single-core or multi-core D2

cables direct in the ground
– With added mechanical protection
1. The inner skin of the wall has a thermal conductance of not less than 10 W/m2·K.
2. Values given for installation methods B1 and B2 in Annex S are for a single circuit. Where there is
more than one circuit in the trunking the group reduction factor given in Table 36 is applicable,
irrespective of the presence of an internal barrier or partition.
3. Care shall be taken where the cable runs vertically and ventilation is restricted. The ambient
temperature at the top of the vertical section can be increased considerably. The matter is under
consideration.
4. Values for reference method B2 may be used.
5. The thermal resistivity of the enclosure is assumed to be poor because of the material of
construction and possible air spaces. Where the construction is thermally equivalent to methods
of installation 6 or 7, reference method B1 may be used.

6. The thermal resistivity of the enclosure is assumed to be poor because of the material of
construction and possible air spaces. Where the construction is thermally equivalent to methods
of installation 6, 7, 8, or 9, reference methods B1 or B2 may be used.
7. The factors in Table 36 may also be used.
8. De is the external diameter of a multi-core cable:
— 2.2 x the cable diameter when three single core cables are bound in trefoil, or
—3 x the cable diameter when three single core cables are laid in flat formation.
9. V is the smaller dimension or diameter of a masonry duct or void, or the vertical depth of a
rectangular duct, floor or ceiling void or channel. The depth of the channel is more important than
the width.
10. De is the external diameter of conduit or vertical depth of cable ducting.
11. De is the external diameter of the conduit.
12. For multi-core cable installed in method 55, use current-carrying capacity for reference method
B2.
13. It is recommended that these methods of installation are used only in areas where access is
restricted to authorized persons so that the reduction in current-carrying capacity and the fire
hazard due to the accumulation of debris can be prevented.
14. For cables having conductors not greater than 16 mm2, the current-carrying capacity may be
higher.
15. Thermal resistivity of masonry is not greater than 2 K·m/W, the term “masonry” is taken to include
brickwork, concrete, plaster and the like (other than thermally insulating materials).
16. The inclusion of directly buried cables in this item is satisfactory when the soil thermal resistivity
is of the order of 2.5 K·m/W. For lower soil resistivity, the current-carrying capacity for directly
buried cables is appreciably higher than for cables in ducts.

ANNEXURE VIII: DIFFERENT CORRECTION FACTOR TO BE APPLIED TO THE CURRENT-CARRYING

CAPACITIES FOR CABLES
TABLE 24: Correction Factor for Ambient Air Temperatures Other Than 30 °C to be Applied to the Current-
Carrying Capacities for Cables In The Air
(Ref: Table 33 of IS 732:2019)
Insulation
Ambient (Mineral1)
Temperature PVC XLPE and EPR PVC Covered or Bare not Exposed
°C Bare and Exposed to Touch
to Touch 70 °C 105 °C
(1) (2) (3) (4) (5)
10 1.22 1.15 1.26 1.14
15 1.17 1.12 1.20 1.11
20 1.12 1.08 1.14 1.07
25 1.06 1.04 1.07 1.04
30 1.00 1.00 1.00 1.00
35 0.94 0.96 0.93 0.96
40 0.87 0.91 0.85 0.92
45 0.79 0.87 0.78 0.88
50 0.71 0.82 0.67 0.84
55 0.61 0.76 0.57 0.80
60 0.50 0.71 0.45 0.75
65 – 0.65 – 0.70
70 – 0.58 – 0.65
75 – 0.50 – 0.60
80 – 0.41 – 0.54
85 – – – 0.47
90 – – – 0.40
95 – – – 0.32
1) For higher ambient temperatures, consult the manufacturer

Table 25: Correction Factors for Ambient Ground Temperatures Other Than 20 °C to be applied to the
Current-Carrying Capacities for Cables in Ducts in the Ground
Ground Temperature Insulation
°C PVC XLPE and EPR
(1) (2) (3)
10 1.10 1.07
15 1.05 1.04
20 1.00 1.00
25 0.95 0.96
30 0.89 0.93
35 0.84 0.89
40 0.77 0.85
45 0.71 0.80
50 0.63 0.76
55 0.55 0.71
60 0.45 0.65
65 – 0.60
70 – 0.53
75 – 0.46
80 – 0.38
Table 26: Correction Factors for Cables Buried Direct in the Ground or in Buried Ducts for Soil Thermal
Resistivity Other Than 2.5 K·m/W to be Applied to the Current-Carrying Capacities for Reference Method D
Thermal Resistivity, Kui/W 0.5 0.7 1 2. 2 3. 3

Correction Factor for Cables in Buried Ducts 1. 1.20 1. 1. 1. 1 0.96
Correction Factor for Direct Buried Cables 2. 2. 2. 1. 1. 1 0.90
NOTES
1 The correction factors given have been avenged over the range of conductor sizes and types of
installation included in Tables 21 to Table 24. The overall accuracy of correction factors is within 5
percent.
2 The correction factors are applicable to cables drawn into buried ducts; for cables laid direct in the
ground the correction factors for thermal resistivity less than 2.5 K. SW will be higher. Where more
precise values are required they may be calculated by methods given in IEC 60287 series.
3 The correction factors are applicable to ducts buried at depths of up to 0.8 m.
4 It is assumed that the soil properties are uniform. No allowance had been made for the possibility of
moisture migration which can lead to a region of high thermal resistivity around the cable. If partial
drying out of the soil is foreseen, the permissible current rating should be derived by the methods
specified in IEC 60287 series.

Table 27: Reduction Factors for One Circuit or One Multi-core Cable or for a Group of more than One
Circuit, or more than one multi-core cable
Below table to be used with Current-Carrying Capacities of table -32 of annexure-IX
To be Used
Arrangement Number of Circuits or Multi-core Cables with Current-
Item (Cables Carrying
Touching) Capacities,
Reference
1 2 3 4 5 6 7 8 9 12 16 20
1 Bunched in air, on a 1.00 0.80 0.70 0.65 0.60 0.57 0.54 0.52 0.50 0.45 0.41 0.38 Tables 21 to
surface, embedded 32 Methods
or enclosed A to F
2 Single layer on 1.00 0.85 0.79 0.75 0.73 0.72 0.72 0.71 0.70
wall, floor or
Tables 21
unperforated cable
to 26
tray systems
No further reduction Method
3 Single layer 0.95 0.81 0.72 0.68 0.66 0.64 0.63 0.62 0.61 factor for more than C
fixed directly nine circuits or
under a wooden multicore cables
ceiling
4 Single layer on a 1.00 0.88 0.82 0.77 0.75 0.73 0.73 0.72 0.72
perforated
Tables 27 to
horizontal or 32 Methods E
vertical cable tray and F
systems
5 Single layer on 1.00 0.87 0.82 0.80 0.80 0.79 0.79 0.78 0.78
cable ladder
systems or cleats
etc.,
NOTES
1. These factors are applicable to uniform groups of cables, equally loaded.
2. Where horizontal clearances between adjacent cables exceeds twice their overall diameter, no reduction factor need be
applied.
3. The same factors are applied to:
a. groups of two or three single-core cables;
b. multi-core cables.
4. If a system consists of both two- and three-core cables, the total number of cables is taken as the number of circuits,
and the corresponding factor is applied to the tables for two loaded conductors for the two-core cables, and to the
tables for three loaded conductors for the three-core cables.
5. If a group consists of n single-core cables it may either be considered as n/2 circuits of two loaded conductors or n/3
circuits of three loaded conductors.
6. The values given have been averaged over the range of conductor sizes and types of installation included in Tables 21 to
Table 32 the overall accuracy of tabulated values is within 5 percent.
7. For some installations and for other methods not provided for in the above table, it may be appropriate to use factors
calculated for specific cases, see for example, Table 39 and Table 40.

TABLE 28: Reduction Factors for More Than One Circuit, Cables Laid Directly in the Ground –
Installation Method D2
Below table to be used with Current-Carrying Capacities of table-33 of Annexure-IX for Single-Core
or Multi-Core Cables
Cable to Cable clearance

Number
Cables (Nil One cable Diameter
of 0.125 m 0.25 m 0.5 m
Touching)
Circuits
2 0.75 0.80 0.85 0.90 0.90
3 0.65 0.70 0.75 0.80 0.85
4 0.60 0.60 0.70 0.75 0.80
5 0.55 0.55 0.65 0.70 0.80
6 0.50 0.55 0.60 0.70 0.80
7 0.45 0.51 0.59 0.67 0.76
8 0.43 0.48 0.57 0.65 0.75
9 0.41 0.46 0.55 0.63 0.74
12 0.36 0.42 0.51 0.59 0.71
16 0.32 0.38 0.47 0.56 0.38
20 0.29 0.35 0.44 0.53 0.66
Multi-core cables
Single core cable
NOTES
1. Values given apply to an installation depth of 0.7 m and a soil thermal resistivity of 2.5 Km/W. They
are average values for the range of cable sizes and types quoted for Tables 21 to Table 24. The
process of averaging, together with rounding off, can result in some cases in errors up to 10 %.
(Where more precise values are required they may be calculated by methods given in IEC 60287-2-
1).
2. In case of a thermal resistivity lower than 2.5 Km/W the corrections factors can, in general, be
increased and can be calculated by the methods given in IEC 60287-2-1.
3. If a circuit consists of m parallel conductors per phase, then for determining the reduction factor, this
circuit should be considered as m circuits.

TABLE 29: Reduction Factors for More Than One Circuit, Cables Laid in Ducts in the Ground - Installation
Method D1
Below table to be used with Current-Carrying Capacities of table-33 of Annexure-IX for Single-Core
or Multi-Core Cables
A) Multi-Core Cables in Single-Way Ducts

Number of Cables Duct to Duct
clearance
Nil (Ducts Touching) 0.25 m 0.5 m 1.0 m
2 0.85 0.90 0.95 0.95

3 0.75 0.85 0.90 0.95
4 0.70 0.80 0.85 0.90
5 0.65 0.80 0.85 0.90
6 0.60 0.80 0.80 0.90
7 0.57 0.76 0.80 0.88
8 0.54 0.74 0.78 0.88
9 0.52 0.73 0.77 0.87
10 0.49 0.72 0.76 0.86
11 0.47 0.70 0.75 0.86
12 0.45 0.69 0.74 0.85
13 0.44 0.68 0.73 0.85
14 0.42 0.68 0.72 0.84
15 0.41 0.67 0.72 0.84
16 0.39 0.66 0.71 0.83
17 0.38 0.65 0.70 0.83
18 0.37 0.65 0.70 0.83
19 0.35 0.64 0.69 0.82
20 0.34 0.63 0.68 0.82

Table 29: (Concluded)

B) Single-core Cables in Non-Magnetic Single-Way Ducts

Number of Single- Duct to Duct Clearance
Core Circuits of Two Nil (Ducts
or Three Cables Touching) 0.25 m 0.5 m 1.0 m
2 0.80 0.90 0.90 0.95
3 0.70 0.80 0.85 0.90
4 0.65 0.75 0.80 0.90
5 0.60 0.70 0.80 0.90
6 0.60 0.70 0.80 0.90
7 0.53 0.66 0.76 0.87
8 0.50 0.63 0.74 0.87
9 0.47 0.61 0.73 0.86
10 0.45 0.59 0.72 0.85
11 0.43 0.57 0.70 0.85
12 0.41 0.56 0.69 0.84
13 0.39 0.54 0.68 0.84
14 0.37 0.53 0.68 0.83
15 0.35 0.52 0.67 0.83
16 0.34 0.51 0.66 0.83
17 0.33 0.50 0.65 0.82
18 0.31 0.49 0.65 0.82
19 0.30 0.48 0.64 0.82
20 0.29 0.47 0.63 0.81
a Multi-core cables
b Single-core cables
NOTES
1. Values given apply to an installation depth of 0.7 m and a soil thermal resistivity of 2.5 K·m/W. They are
average values for the range of cable sizes and types quoted for Table 20 to Table 24. The process of
averaging, together with rounding off, can result in some cases in errors up to 10 percent. Where more
precise values are required they may be calculated by methods given in the IEC 60287series.
2. In case of a thermal resistivity lower than 2.5 K·m/W the corrections factors can, in general, be increased
and can be calculated by the methods given in IEC 60287-2-1.
3. If a circuit consists of n parallel conductors per phase, then for determining the reduction factor this circuit
shall be considered as n circuits.

TABLE 30: Reduction Factors for Group of More Than One Multi-Core in Free Air - Method of Installation E
Below reduction factor to be applied to reference Current-Carrying Capacity for multi-core cables in table-
table-32 of Annexure-IX & table 27 to 28 of IS732:2019
Method of Installation as per Number Number of Cables Per Tray or Ladder
Table 19 of IS 732:2019 of Trays
or 1 2 3 4 6 9
Ladders
Perforat 1 1.00 0.88 0.82 0.79 0.76 0.73

ed
cable
tray 31
system
s
2 1.00 0.87 0.80 0.77 0.73 0.68
3 1.00 0.86 0.79 0.76 0.71 0.66
6 1.00 0.84 0.77 0.73 0.68 0.64
1 1.00 1.00 0.98 0.95 0.91 –
2 1.00 0.99 0.96 0.92 0.87 –
3 1.00 0.98 0.95 0.91 0.85 –
Vertic
al
perfor 31 1 1.00 0.88 0.82 0.78 0.73 0.72
ated
cable 2 1.00 0.88 0.81 0.76 0.71 0.70
tray
1 1.00 0.91 0.89 0.88 0.87 –
syste
ms
2 1.00 0.91 0.88 0.87 0.85 –
Unperfo 31 1 0.97 0.84 0.78 0.75 0.71 0.68

rated
cable 2 0.97 0.83 0.76 0.72 0.68 0.63
tray
systems 3 0.97 0.82 0.75 0.71 0.66 0.61
6 0.97 0.81 0.73 0.69 0.63 0.58


Number of Number of Cables Per Tray or Ladder
Trays or
Method of Installation as per Table 19 of IS Ladders
732:2019
1 2 3 4 6 9
Cable ladder 1 1.00 0.87 0.82 0.80 0.79 0.78

systems,
cleats, etc. 32 2 1.00 0.86 0.80 0.78 0.76 0.73
(Note 3) 33 3 1.00 0.85 0.79 0.76 0.73 0.70
34 6 1.00 0.84 0.77 0.73 0.68 0.64
1 1.00 1.00 1.00 1.00 1.00 –
2 1.00 0.99 0.98 0.97 0.96 –
3 1.00 0.98 0.97 0.96 0.93 –
NOTES
1. Values given are averages for the cable types and range of conductor sizes considered in Tables
27 to Table 32. The spread of values is generally less than 5 percent.
2. Factors apply to single layer groups of cables as shown above and do not apply when cables are
installed in more than one layer touching each other. Values for such installations may be
significantly lower and has to be determined by an appropriate method.
3. Values are given for vertical spacing between cable trays of 300 mm and at least 20 mm between
cable trays and wall. For closer spacing the factors should be reduced.
4. Values are given for horizontal spacing between cable trays of 225 mm with cable trays mounted
back to back. For closer spacing the factors should be reduced.

TABLE 31: Reduction Factors for Groups of One or More Circuits of Single-Core Cables in Free Air - Method
of Installation F
(Ref: Table 40 of IS732:2019)
Below reduction factor to be applied to reference Current-Carrying Capacity for One or More Circuits of
Single-Core Cables in table-32 of Annexure-IX & table 27 to 28 of IS732:2019
Number of Three-Phase Use as a

Number of Circuits Per Tray or Multiplier to
Method of Installation as per Table 19 of Trays or Ladder Current-Carrying
IS732:2019 Ladders Capacity
1 2 3 for
Perforated 31
cable tray
systems
(Note 3) 1 0.98 0.91 0.87 Three cables in
2 0.96 0.87 0.81 horizontal
3 0.95 0.85 0.78 formation
Vertical 31
perforated 1 0.96 0.86 – Three cables in
cable tray 2 0.95 0.84 – vertical formation
systems
(Note 4)
Cable ladder 32
systems, 33 1 1.00 0.97 0.96 Three cables in
cleats, etc 34 2 0.98 0.93 0.89 horizontal
(Note 3) 3 0.97 0.90 0.86 formation

Number of Three-Phase Use as a

Number of Circuits Per Tray or Multiplier to
Method of Installation in Table 19 Trays or Ladder Current-
Ladders Carrying
1 2 3 Capacity
for
Perforated
cable tray
systems 1 1.00 0.98 0.96 Three cables
(Note 3) 2 0.97 0.93 0.89 in trefoil
31 3 0.96 0.92 0.86 formation
Vertical
perforated 31
cable tray 1 1.00 0.91 0.89
systems 2 1.00 0.90 0.86
(Note 4)
Cable ladder
systems, 32
cleats, etc. 33
(Note 3) 34 1 1.00 1.00 1.00
2 0.97 0.95 0.93
3 0.96 0.94 0.90
NOTES
1. Values given are averages for the cable types and range of conductor sizes considered in
Table 27 to Table 32. The spread of values is generally less than 5 percent.
2. Factors are given for single layers of cables (or trefoil groups) as shown in the table and
do not apply when cables are installed in more than one layer touching each other. Values
for such installations may be significantly lower and should be determined by an
appropriate method.
3. Values are given for vertical spacing between cable trays of 300 mm and at least 20 mm
between cable trays and wall. For closer spacing the factors should be reduced.
4. Values are given for horizontal spacing between cable trays of 225 mm with cable trays
mounted back to back. For closer spacing the factors should be reduced.
5. For circuits having more than one cable in parallel per phase, each three phase set of
conductors should be considered as a circuit for the purpose of this table.
6. If a circuit consists of m parallel conductors per phase, then for determining the reduction
factor this circuit should be considered as m circuits.

ANNEXURE IX: CURRENT CARRYING CAPACITY (IN AMPERES) IN DIFFERENT INSTALLATION

(Normative)
(Ref: Annex-T of IS 732:2019)
TABLE 32: Current Carrying Capacity in (A1/A2/B1/B2/C/E/F/G) Installation
(Ref: Table 41 of Annex-T of IS 732:2019)
Below table is simplification of the Tables 21 to 24 of IS 732:2019 for A1, A2, B1, B2 & C installation & 29
to 32 of IS 732:2019 for E& F installation
Reference Number of Loaded Conductors and Types of Insulations

methods
in Table
20
A1 3PVC 2PVC 3XLPE 2XLPE
A2 3PVC 2PVC 3XLPE 2XLPE
B1 3PVC 2PVC 3XLPE 2XLPE
B2 3PVC 2PVC 3XLPE 2XLPE
C 3PVC 2PVC 3XLPE 2XLPE
E 3PVC 2PVC 3XLPE 2XLPE
F 3PVC 2PVC 3XLPE 2XLPE
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Size Current Carrying Capacity (In Amp.)
(mm2)
Copper
1.5 13 13.5 14.5 15.5 17 18.5 19.5 22 23 24 26 --
2.5 17.5 18 19.5 21 23 25 27 30 31 33 36 --
4 23 24 26 28 31 34 36 40 42 45 49 --
6 29 31 34 36 40 43 46 51 54 58 63 --
10 39 42 46 50 54 60 63 70 75 80 86 --
16 52 56 61 68 73 80 85 94 100 107 115 --
25 68 73 80 89 95 101 110 119 127 135 149 161
35 -- -- -- 110 117 126 137 147 158 169 185 200
50 -- -- -- 134 141 153 167 179 192 207 225 242
70 -- -- -- 171 179 196 213 229 246 268 289 310
95 -- -- -- 207 216 238 258 278 298 328 352 377
120 -- -- -- 239 249 276 299 322 346 382 410 437
150 -- -- -- -- 285 318 344 371 395 441 473 504
185 -- -- -- -- 324 362 392 424 450 506 542 575
240 -- -- -- -- 380 424 461 500 538 599 641 679
Aluminium
2.5 13.5 14 15 16.5 18.5 19.5 21 23 24 26 28 --
4 17.5 18.5 20 22 25 26 28 31 32 35 38 --
6 23 24 26 28 32 33 36 39 42 45 49 --
10 31 32 36 39 44 46 49 54 58 62 67 --
16 41 43 48 53 58 61 66 73 77 84 91 --
25 53 57 63 70 73 78 83 90 97 101 108 121
35 -- -- -- 86 90 96 103 112 120 126 135 150
50 -- -- -- 104 110 117 125 136 146 154 164 184

70 -- -- -- 133 140 150 160 174 187 198 211 237

95 -- -- -- 161 170 183 195 211 227 241 257 289
120 -- -- -- 186 197 212 226 245 263 280 300 337
150 -- -- -- -- 226 245 261 283 304 324 346 389
185 -- -- -- -- 256 280 298 323 347 371 397 447
240 -- -- -- -- 300 330 352 382 409 439 470 530
Note: The appropriate table of current carrying capacity given in Annexure S should be consulted to determine the range
of conductor sizes for which the above current carrying capacities are applicable, for each installation method.
TABLE 33: Current Carrying Capacity in D1/D2 Installation

(Ref: Table 42 of Annex-T of IS 732:2019)
Below table is simplification of the tables 21 to 24 of IS 732:2019 for D1/D2 installation

Installation Size in sq.mm Number of Loaded Conductors and Type of Insulation
Method 2 PVC 3 PVC 2 XLPE 3 XLPE
D1/D2 Copper
1.5 22 18 26 22
2.5 29 24 34 29
4 38 31 44 37
6 47 39 56 46
10 63 52 73 61
16 81 67 95 79
25 104 86 121 101
35 125 103 146 122
50 148 122 173 144
70 183 151 213 178
95 216 179 252 211
120 246 203 287 240
150 278 230 324 271
185 312 258 363 304
240 361 297 419 351
300 408 336 474 396
Aluminum
D1/D2 2.5 22 18.5 26 22
4 29 24 34 29
6 36 30 42 36
10 48 40 56 47
16 62 52 73 61
25 80 66 93 78
35 96 80 112 94
50 113 94 132 112

70 140 117 163 138

95 166 138 193 164
120 189 157 220 186
150 213 178 249 210
185 240 200 279 236
240 277 230 322 272
300 313 260 364 308

REFERENCES
1. IS 1554 (Part-I) – 1988 Specification for PVC Insulated (Heavy duty) Electrical cables for working
voltages upto and including 1100 V.
2. IS 7098 (Part-I) – 1988 Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables
for working voltages upto and including 1100 V
3. IS 1255 – 1983 Code of practice for Installation and Maintenance of Power cables upto and
including 33 kV rating.
4. IS 14255 – 1995 Aerial Bunched Cables-For Working Voltages Upto And Including 1100 Volts –
Specification.
5. IS 8130 : 2013 Conductors For Insulated Electric Cables and Flexible Cords — Specification.
6. IS 732:2019 Code of Practice for Electrical Wiring Installations ( Fourth Revision )

NOTE
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CONTACT US
CAMTECH is continuing its efforts in the documentation and up-gradation of information on maintenance
practices of electrical assets. Over the years a large number of publications on electrical assets have been
prepared in the form of handbooks, pockets books, pamphlets and video films, etc. These publications have
been uploaded on the internet as well as rail net.
For downloading these publications please do following:
1. On internet visit: www.rdso.indianrailways.gov.in
Go to Directorates  CAMTECH Other important links Publications for download Electrical

Engineering
2. On Railnet visit RDSO website at 10.100.2.19
Go to Directorates  CAMTECH Publications for download  Electrical Engineering
For any further information regarding publications please contact:
Dy. Director (Elect.) BSNL : 0751- 2470740 (O)
Rly. : 03747202, 9752447030 (CUG)
SSE/Electrical : 9755549297 (CUG)
E-mail : direlcamtech@gmail.com
Fax : 0751- 2470841
Write at : Dy. Director (Electrical)
Indian Railways, Centre for Advanced Maintenance Technology

In front of Hotel Adityaz, Airport Road, Maharajpura, Gwalior, Pin code – 474 005


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QUALITY POLICY

“We at RDSO, Lucknow are committed to maintain and update

CHAPTER 1 GENERAL DESCRIPTION OF CABLE ................................................................................ 1

1.1 Introduction .................................................................................................................... 1

1.2 Classification of Electrical Cables .................................................................................... 1

1.3 Classification of Power Cables ........................................................................................ 2

1.3.1 Classification as Per Designed Voltage ............................................................................ 2

1.3.2 Classification as Per Type of Insulation Used ................................................................... 2

CHAPTER 2 PVC , XLPE AND AB CABLE .......................................................................................... 3

2.1.1 Comparison between XLPE & PVC insulated cable .......................................................... 3

2.1.2 Core Identification of PVC & XLPE cables ........................................................................ 3

2.1.3 Features of PVC & XLPE cables....................................................................................... 4

2.2 Aerial Bundled (AB) Cables ............................................................................................. 5

2.2.1 Introduction .................................................................................................................... 5

2.2.2 Advantage & Disadvantage ............................................................................................. 5

2.2.3 Materials ........................................................................................................................ 6

2.2.4 Construction ................................................................................................................... 6

2.2.5 Code Identification .......................................................................................................... 6

CHAPTER 3 SELECTION OF CABLES ............................................................................................... 7

3.1 Selection of Type of Cable .............................................................................................. 7

3.2 Size of Cable .................................................................................................................. 8

3.2.1 Procedure for selection of size of cable are as below:- .................................................... 8

3.2.3 Identify the Method of Installation of Cable ...................................................................... 9

3.2.6 Applying reduction factor due to grouping ..................................................................... 11

CHAPTER 4 INSPECTION, TESTING & STORAGE ............................................................................ 16

4.1 Classification of Tests ................................................................................................... 16

4.1.1 Type Tests:................................................................................................................... 16

4.1.2 Acceptance Tests: ........................................................................................................ 18

4.1.3 Routine Tests: .............................................................................................................. 20

4.1.4 Additional test at site ..................................................................................................... 20

4.2 Identification of XLPE, PVC & AB Cable ......................................................................... 21

4.3 Packing & Marking of XLPE,PVC & AB Cables ............................................................... 22

4.4 Handling (Unloading At Site) ......................................................................................... 22

CHAPTER 5 LAYING AND INSTALLATION OF CABLES .................................................................... 24

5.1 Selection of the Cable Route ......................................................................................... 24

5.2 Minimum Permissible Bending Radii ............................................................................. 24

5.3 Methods of Cable Laying & Installation .......................................................................... 24

5.3.1 Laying Direct in Ground ................................................................................................ 25

5.3.3 Cable Over Bridges ....................................................................................................... 27

5.5 Cable Jointing ............................................................................................................... 27

5.5.1 Basic Types of Joints .................................................................................................... 28

5.5.2 Types of Cable Jointing Accessories ............................................................................. 28

5.6 Cable End Terminations ................................................................................................ 30

5.7 Earthing and Bonding of Cables..................................................................................... 32

5.8 Testing Of Cable Installation .......................................................................................... 32

5.8.2 Tests on Completed Cable Installation ........................................................................... 33

5.9 Cable Installation Plan ................................................................................................... 35

CHAPTER 6 FAULTS IN CABLE ...................................................................................................... 36

6.1 Types of Cable Faults.................................................................................................... 36

6.1.1 Open-Circuit Faults ....................................................................................................... 36

6.1.2 Short-circuit fault .......................................................................................................... 36

6.1.3 Earth faults ................................................................................................................... 36

6.1.4 Low insulation fault ....................................................................................................... 36

6.2 Causes of Cable Faults ................................................................................................. 37

6.3 Different Types of Tests to Locate Faults in Cables. ....................................................... 37

ANNEXURE – V : SIZE AND REQUIREMENTS OF MESSENGER CONDUCTOR ...................................... 42

ANNEXURE - VII: EXAMPLES OF METHODS OF INSTALLATION PROVIDING INSTRUCTIONS FOR

ANNEXURE- VIII: DIFFERENT CORRECTION FACTOR TO BE APPLIED TO THE CURRENT-CARRYING

Figure 1: Core Identification ............................................................................................................... 6

Table 1: Rated voltage of cables ................................................................................................ 2

Table 2: Comparison between XLPE & PVC insulated cable ........................................................ 3

Table 4: Core Identification of XLPE & PVC insulated cable ......................................................... 3