ELECTRICAL ESTMATION AND COSTING 18EE822

SUBJECT: ELECTRICAL ESTMATION AND COSTING (18EE822)

Module 2 : Wiring

Syllabus: Introduction, Distribution of energy in a Building, PVC Casing and Capping, Conduit
Wiring, Desirabilities of Wiring. Types of cables used in Internal Wiring, Multi Strand Cables,
Voltage Grading and Specification of Cables Wiring (continued): Main Switch and Distribution
Board, Conduits and its accessories and Fittings. Lighting Accessories and Fittings, Types of Fuses,
Size of Fuse, Fuse Units, Earthing Conductor. Internal Wiring: General rules for wiring, Design of
Lighting Points (Refer to Seventh Chapter of the Textbook), Number of Points, Determination of Total
Load, Number of Sub –Circuits, Ratings Main Switch and Distribution Board and Size of Conductor.
Current Density, Layout. ..

Introduction:
➢ Then network of wires connecting various accessories for distribution of electrical
energy from supplier meter board to the numerous electrical devices is known as
Wiring.
➢ The supplier service cable feeding an installation terminates called Service Cutout.
➢ The point at which the consumers wiring are connected into the cutout is known as
consumer’s terminals.
➢ From the consumer terminals onwards the supply cables are entirely under the control
of consumer and laid out as per the selection.
➢ The typical house wiring is as shown.

Systems of Distribution of Electrical Energy

As per the recommendation of Indian standards the maximum number of points of lights
and fans that can be connected in one circuit is 10 and the maximum load that can be connected in
such a circuit is 800 Watts, in case more load or points are required to be connected to the supply,
then it is to be done by having more than one circuit to distribute supply.
There are 2 types of Distribution systems.
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➢ Distribution Board System

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➢ Tree System
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Distribution Board System

➢ The most commonly adopted system for distribution of electrical energy.
➢ The fuses of the various circuits are grouped together on a distribution board.
➢ The system is as shown below

➢ The two copper strips, known as Bus bars fixed in the distribution board of hard
wood or metal case are connected to the supply mains through the linked switch.
➢ So that the installation can be switched off as a whole from both the poles of the
supply if required.
➢ A fuse is inserted in the phase wire of each circuit so that each circuit is
connected through its own fuse.
➢ The no of circuits and sub circuits is decided as per no of points to wired and
load to be connected to a supply system.

Tree System

➢ In this system the smaller branches are taken from the main branch, as shown in
fig, the wiring resembles a tree.

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➢ As the branch is taken off, a fuse is inserted.

➢ This system used to be employed in early days.
➢ This system has following drawbacks
• The voltage across all the lamps does not remain the same.
• The no of joints are involved in every circuit.
• Fuses are scattered.
• In occurrence of fault all the joints are required to be open for testing
purpose.

Methods of Electrical Wiring Systems

Wiring a process of connecting various accessories for distribution of electrical energy from
supplier’s meter board to home appliances such as lamps, fans and other domestic appliances
is known as Electrical Wiring) can be done using two methods which are

• Joint box system or Tee system

• Loop – in system

Joint Box or Tee or Jointing System

➢ In this method of wiring, connections to appliances are made through joints.
➢ These joints are made in joint boxes by means of suitable connectors or joints cut-
outs.
➢ This method of wiring doesn’t consume too much cables size.
➢ This method is suitable for temporary installations and it is cheap.

Loop-in or Looping System

➢ This method of wiring is universally used in wiring.
➢ Lamps and other appliances are connected in parallel so that each of the appliances
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can be controlled individually.

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ELECTRICAL ESTMATION AND COSTING 18EE822

➢ When a connection is required at a light or switch, the feed conductor is looped in by

bringing it directly to the terminal and then carrying it forward again to the next point
to be fed.
➢ The switch and light feeds are carried round the circuit in a series of loops from one
point to another until the last on the circuit is reached.

➢ The phase or line conductors are looped either in switchboard or box and neutrals are
looped either in switchboard or from light or fan. Line or phase should never be
looped from light or fan.

Advantages of Loop-In Method of Wiring

• It doesn’t require joint boxes and so money is saved
• In loop – in systems, no joint is concealed beneath floors or in roof spaces.
• Fault location is made easy as the points are made only at outlets so that they are
accessible.
Disadvantages of Loop-In Method of Wiring
• Length of wire or cables required is more and voltage drop and copper losses are
therefore more
• Looping – in switches and lamp holders is usually difficult.

Electrical Wiring Systems

• Cleat wiring
• Wooden Casing and capping
• CTS wiring or TRS wiring or batten wiring
• Metal sheathed wiring or lead sheathed wiring
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• Conduit wiring
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ELECTRICAL ESTMATION AND COSTING 18EE822

Conduit wiring

• In this system PVC (polyvinyl chloride) or VIR cables are run through metallic or
PVC pipes providing good protection against mechanical injury and fire due to short
circuit called surface conduit.
• They are either embedded inside the walls or supported over the walls, and are known
as concealed wiring or surface conduit wiring (open conduit) respectively called
concealed conduit
• The conduits are buried inside the walls on wooden gutties and the wires are drawn
through them with fish (steel) wires.
• The system is best suited for public buildings, industries and workshops

Advantages:
• No risk of fire and good protection against mechanical injury.
• The lead and return wires can be carried in the same tube.
• Earthing and continuity is assured.
• Waterproof and trouble shooting is easy.
• Shock- proof with proper earthing and bonding
• Durable and maintenance free
• Aesthetic in appearance
Disadvantages:
• Very expensive system of wiring.
• Requires good skilled workmanship.
• Erection is quiet complicated and is time consuming.
• Risk of short circuit under wet conditions (due to condensation of water in tubes).
Precautions
• In order to avoid condensation of water, the conduits must be well ventilated in order
to allow circulation of air.
• Edges of conduit should be filed before laying to remove burrs,etc to save cable
insulation.
• The threads should be coated with aluminium paint in order to keep the conduit
electrically continuous.
• In walls conduit is drawn into the joints of brick work so that the conduit is held
firmly.
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• The conduit must be placed in the position before drawing the wires
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FACTORS to be consider during CHOICE OF WIRING SYSTEM

The choice of wiring system for a particular installation depends on technical factors and
economic viability.
• Durability: Type of wiring selected should conform to standard specifications, so that
it is durable i.e. without being affected by the weather conditions, fumes etc.
• Safety: The wiring must provide safety against leakage, shock and fire hazards for the
operating personnel.
• Appearance: Electrical wiring should give an aesthetic appeal to the interiors.
• Cost: It should not be prohibitively expensive.
• Accessibility: The switches and plug points provided should be easily accessible.
There must be provision for further extension of the wiring system, if necessary.
• Maintenance Cost: The maintenance cost should be a minimum
• Mechanical safety: The wiring must be protected against any mechanical damage

WIRE AND CABLE

The single wire may be bare or covered with insulation, is known as wire. The several wires
stranded together called cable.
The cable consists of three parts:
• A conductor or core; the metal wire or strand of wires carrying current.
• The Insulation: A covering of insulation material to avoid leakage of current from the
conductors
• The protective layer for protection of insulation from mechanical damage.

Conductor materials used in a cable

The function of the conductor usually known as a core, in a cable is to carry electrical
current.
1. Copper: The copper is the cheaper and best conductor available the electrical
conductivity is comparatively high. It is mechanical strong, hard, extremely tough,
durable and ductile. It is highly resistive to corrosion. It can withstand the dampness
and high temperature. The copper conductors may be annealed or hard drawn. The
annealed copper is soft used for indoor. Where as hard drawn copper have high tensile
strength used for overhead lines in a bare form.
2. Aluminum: Aluminum is frequently used in a place of copper for bare electric
cables used for long distance power transmission. The electrical conductivity of
aluminum is 60%of that of copper. When cost of insulating a large conductor the
aluminum cables comes cheaper in larger sizes.
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Insulating Materials
• The conductor is covered with the Insulating Material to prevent leakage of current
from the conductor
• The various Insulating Materials are
• Rubber
• Vulcanized India Rubber
• Impregnated Paper
• Polyvinyl Chloride(PVC)
• Silk and Cotton

Types of Cables used in Internal wiring

• Based on the conductor material used
• Copper
• Aluminium
• Based on the number of cores
• Single core
• Twin core
• Three core
• Two core with earth continuity conductor
• Based on the Insulating Material
• Vulcanized India Rubber insulated cables
• Tough rubber sheathed
• Lead sheathed
• PVC cables
• XLPE Cable
Vulcanized India Rubber
• VIR Cables Consists of tinned copper conductor covered with the VIR
insulation
• Over the rubber Insulation cotton tape sheathed covering is provided with
moisture resistant compound bitumen Wax to make moisture proof.
• The thickness of the cable is depending on voltage rating.
• The copper conductor is tinned to provide the protection against the corrosion
due to presence of traces of sculpture in VIR.
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Tough rubber sheathed (TRS)

• The TRS cables are nothing but VIR cables with an outer protective covering
of tough rubber.
• This provides additional insulation and protection against wear and tear
• These cables are water proof hence can used in wet conditions
• These are cheaper and lighter in weight than lead sheathed cables.
• These cables are available as single core, circular twin core, circular three
cores, flat three core with an earth continuity conductor.
• In wiring of 3 pin plugs separate earth wire may be used.
• These cables are cheaper in cost and lighter in weight than lead sheathed
cables.

Lead sheathed
• These are VIR cables covered with sheet of lead.
• Lead sheath provides good protection against absorption of moisture and
mechanical injury.
• This can be used without casing and capping.
• It is available in single core, circular twin core, circular three cores, flat three
cores with an earth continuity conductor.

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PVC cables
• These are used in casing and capping.
• The cable conductor is insulated with PVC insulation
• PVC is harder than rubber hence gives mechanical protections.
• Widely used in internal wiring due to smaller diameter.

Advantages
• Better insulating qualities
• Flexibility
• No chemical effect
• Good ageing characteristics and not affected by vibrations.

XLPE cables (CROSS LINK POLY ETHYLENE)

• These are PVC cables but differ in polymer added to the insulation material.
• Polymers are substances consisting of macromolecules built up of small
molecules or groups of molecules as repeated units.
• This gives high elasticity, tensile strength
• Advantages over PVC
• Higher current rating
• Longer service life
• Can withstand 130 C for short time and is favourable to endure short
circuit stresses.
• Low dielectric loss.
• Excellent mechanical features.
• Due to chemical cross linking internal stress are reduced.
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General specifications of cables

• Size of the cable in metric system giving the number of strands used and diameter of
each strand. ex: 7/2.24.
• Type of the conductor used in cables (copper or aluminium).
• Number of cores that the cable consists.
• Voltage grade
• Type of the cable.

Main switch and Distribution board

• As per the IE rule 50 a suitable linked switch is to be provided immediately after the
meter board.
• A suitable cut-out must be provided just after the linked switch to protect against
excessive current.
• These two may be provided as a one unit or separate unit.
• The combined unit is known as Iron clad switch.
• It may be double pole for controlling single phase two wire circuits or triple pole for
controlling three phase 3-wire circuits with neutral link for controlling 3- phase ,4
wire circuits.
• Since no fuse is to be provided in neutral, in DPIC switch fuses, where provision is
made for fuses in both wires, one fuse carrier is furnished with fuse element and
other with a thick copper wire.
• The Distribution board is an assembly of parts, including one or more fuses or circuit
breakers, arranged for distribution of energy.
• The boards are usually a meta case in sheet steel or hard wood-cased.
• The earthing terminal and locking arrangements are provided.
•
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Separate fuse boxes are to provided for light and power circuits.
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Conduits
An electrical conduit is a tube used to protect and route electrical wiring in a building or
structure. Electrical conduit may be made of metal, plastic, fiber, or fired clay. Most
conduits is rigid, but flexible conduit is used for some purposes,
The conduits are classified into
➢ Light gauge steel plain
➢ Heavy gauge steel screwed.
➢ Flexible conduit
➢ PVC conduit

Light gauge steel plain conduit:

This type of conduit is used on the surface usually in connection with special grip
fittings. The fittings are generally steel lug grip type, which clamp the conduit on tightening
of screws. In this way, both mechanical joint and reasonable electrical continuity can be
provided that enamel has been removed from the conduit ends. It is the cheapest and
quickest of the conduit installations.

Heavy gauge screwed steel conduit

This is the most expensive conduit available, but this type of conduit provides a
permanent installation with a maximum protection for cables. The joints into fittings are by
means of screw threads which provide mechanical strength and good electrical continuity.
There are two types of heavy gauge conduit: welded and solid drawn. Both types are
obtained with enameled surface or rust proofed.

Flexible steel conduit

This usually consists of light gauge galvanized steel strip wound and to some extent
, interlocked, so as to form a tube. It is provide with an exterior covering of corrugated
sleeving. The flexible conduits are available in lengths upto 250mtrs, so coupling is required
and hence no threading. Since conduits are flexible and are easily bent, no elbow required.
For connecting flexible conduit to ordinary conduits special brass adapters are used. these
are most commonly used in motors due to its flexibility.

PVC conduit
This type of conduit has wide application in internal wiring due to its light weight,
shock proof, antitermite, self fixing and fire resistant, corrosion resistant.these are used in
surface and concealed conduit wiring. Conduits may be joined by the screwed or plain
couplers depending upon whether the conduits of screwed type or plain type. These are
usually used in installations with corrosion problem. One disadvantage is that a separate
earth wire must be run inside the tubing.
Fuse
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A Fuse or an Electric Fuse is an Electrical / Electronic device that protects the circuit from
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different electrical faults like over current and overload.

ELECTRICAL ESTMATION AND COSTING 18EE822

The principle of a fuse is based on the heating effect of the electric current. A simple
fuse consists of a small conductive material with low resistance and it is placed in series with
the circuit.
The cross section area of this conducting material is designed such that it allows a
certain amount of current that is permitted to flow in the circuit.
When the current in the circuit exceeds this permitted value (which may be caused
due to overload, short circuit or load mismatch), this excessive current will melt the
conductive element in the fuse and opens the circuit.
This will disconnect the power supply and thus, the rest of the circuit is protected
from being damaged. The following image shows a block diagram of how a fuse is connected
in the circuit.

Characteristics of a Fuse
There are different types of Fuses available in the market for different types of applications
like residential, industrial, automotive, etc. All the fuses are often characterized by the
following characteristics.

• Current or Ampere Rating

• Melting Time
• Voltage Rating and
• Interrupting Rating or Breaking capacity
• Packaging
• Temperature

Advantages of an Electrical Fuse

• It is the cheapest form of protection, and it does need any maintenance.
• Its operation is completely automatic and requires less time as compared to circuit
breakers.
• The smaller sizes of fuse element impose a current limiting effect under short-circuit
conditions.
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• Its inverse time-current characteristic enables its use for overload protection.
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Disadvantages of an Electrical Fuse

• Considerable time is required in replacing a fuse after the operation.

• The current-time characteristic of a fuse cannot always be correlated with that of the
protective device.

Types of Electrical Fuse

1. Round type fuse unit
2. Rewirable or Kit-Kat type fuse
3. Cartidge type fuse unit
4. High rupturing capacity fuse(HRC)

Round type fuse unit

This type of fuse unit consists of porcelain or Bakelite box and two separated wire
terminals for holding the fuse wire between them. This is not commonly used because

• One of the terminals will be always energized and therefore, for replacement will be
dangerous
• Arcing takes place at the instant of blowing off fuse thus damages the terminals.

Rewirable or Kit-Kat type fuses

The most commonly used fuse in a house wiring and small current circuits is semi enclosed
Or rewire able fuse is also known as kitkat fuse. It consist of porcelain base carrying fixed
contacts to which an incoming line is connected and porcelain fuse carrier holding fuse
element,consisting of one or more strands of fuse wire stretched between its terminal the fuse
carrier is separate part can be taken out or inserted in the base without risk, even without
opening main switch and damaged wire can be replaced.

It has following disadvantages

o There is possibility of renewal by the fuse wire of wrong size

o The fuse wire decorates over a period due to oxidation
o low rupturing capacity
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o slow speed of operation

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Cartridge type fuse unit

These are totally enclosed type fuse unit. It consist of an insulating container of bulb or tube
shaped sealed at its ends with metallic cap known as cartridge. These is filled with powder
material known as filler such as sand, calcium carbonate, quartz etc.

This powder cools and condenses the vapors of the arc produce due to the short circuit since
it is totally enclosed it will not be possible to rewire and therefore whole unit have to be
replaced.

High rupturing capacity fuses (HRC)

The high rupturing capacity cartridge fuse is most popular it consists of heat resisting ceramic
body metal end cap to which are welded feasible silver current carrying elements. The
complete space within the body surrounding the elements is filled with a powder which acts
as an arc extinguishing agent.

The process of filling compromises operation;

1. Pre- arcing operation-melting of silver metal.

2. Arcing operation-vaporization of elements
3. Fusion of silver vapors and the filling powder.
4. Extinction of arc under fusion process.
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RESIDENTIAL BUILDING ELECTRIFICATION

General rules guidelines for wiring of residential installation and

positioning of equipment’s:

1. Every installation is to be properly protected near the point of entry of supply cables
by 2-linked main switch and a fuse unit.
2. Conductor used is to be of such a size that it carries load current safely.

3. Every sub-circuit is to be connected to a distribution fuse board.

4. Every phase is to be protected by a fuse of suitable rating.

5. Each sub circuit should not have more than 10 points of lights, fans and socket
outlets. The load on each sub circuit is to be restricted to 800W.

6. A switch board is to be installed so that its bottom lies 1.25mts above the floor.

7. All plugs & socket outlets are of 3-pin type

8. All incandescent lamps are to be hung at ht of 2.5mt above the floor

9. N o fuse or switch is to be provided in earthed conductor

10. In any building, light, fan power wiring is to be kept separately.

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11. Unless otherwise specified, the clearance between the bottom most point of the
ceiling fan and the floor shall be not less than 2.4 m. the minimum clearance between
the ceiling and the plane of the blade shall be not less than 30 cm.

12. Each 15 A socket outlet provided in building for the use of domestic appliances such
as AC, water cooler etc.

13. In case of 3- phase, 4 wire installation the load is to distribute equally.

Determination of Total Load

For the determination of the total load of an installation the following rating may be
assumed unless the values are known or specified.
1. Incandescent lamps, fans, and socket outlets -60W
2. Power sockets – 1000W
3. Fluorescent lamps – 40W

Determination of Number of Sub circuits

The number of sub-circuits is decided as per number of points to be wired and total load
to be connected to the supply systems. In one light and fan sub circuit the maximum load that
can be connected is 800W and the maximum number of points, which can be wired, is 10.In
one power sub-circuit the maximum load that can be normally connected is 3000 watts and
the number of sockets outlets , which can be provided is 2.

Determination of Ratings of Main switch and Distribution board

The current rating of the main switch is decided as per the total current of the circuit to
be controlled it.
The number of ways and current rating of the distribution board is decided as per
number of sub-circuits to be connected to it and current of the sub circuit having higher
current rating.

Determination of size of the conductor

There are three points, which must be taken into account, while determining the size of
the conductor for internal wiring for given circuit.
1. Minimum size mainly for mechanical reasons
2. Current carrying capacity
3. Voltage drop
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