Underground cables

Underground cables are used for power applications where it is impractical, difficult, or
dangerous to use the overhead lines. They are widely used in densely populated urban
areas, in factories, and even to supply power from the overhead posts to the consumer
premises.

The underground cables have several advantages over the overhead lines; they have smaller
voltage drops, low chances of developing faults and have low maintenance costs. However,
they are more expensive to manufacture, and their cost may vary depending on the
construction as well as the voltage rating.

Underground Power Cable System

An underground power cable system is a network of cables that are installed underground to
transmit electricity from power generation sources to consumers. These cables are typically
made of copper or aluminum conductors that are insulated with a special material to
prevent electrical leakage. The cables are then placed in protective conduits or pipes that
are buried beneath the ground to protect them from damage and to ensure they are not a
safety hazard.

Construction of Cables
Underground power cables are typically made up of several layers of materials, each with its
own function and properties. Here are the common layers of a typical underground power
cable:

Conductor: This is the core of the cable and is responsible for carrying the electric current. It
is typically made of copper or aluminum.

Insulation: This layer is applied over the conductor to prevent electrical leakage and short
circuits. Insulation is usually made of a special material such as cross-linked polyethylene
(XLPE), which has good electrical properties and is resistant to heat, chemicals, and
moisture.

Screen: This layer is applied over the insulation to reduce electrical stress and ensure
uniform distribution of the electric field. It is typically made of semi-conductive material
such as carbon black.

Metallic shield: This layer is made of copper or aluminum and provides protection against
electrical interference and external environmental factors such as lightning strikes and
electromagnetic fields.
Insulating jacket: This layer provides additional insulation and protects the cable from
mechanical damage and corrosion. It is usually made of a material such as PVC or PE.

Protective sheath: This layer is designed to protect the cable from external factors such as
moisture, chemicals, and mechanical damage. It is usually made of a tough material such as
polyethylene, PVC, or lead.

Insulating Material for cables

Rubber
Rubber may be obtained from the milky sap of tropical trees or it may be produced from oil
products. It has relative permittivity varying between 2 and 3, dielectric strength is about 30
kV/mm and resistivity of insulation is 1017 Ω cm. 

Although pure rubber has reasonably high insulating properties, it suffers from some major
drawbacks viz., readily absorbs moisture, the maximum safe temperature is low (about
38ºC), soft and liable to damage due to rough handling and ages when exposed to
light. Therefore, pure rubber cannot be used as an insulating material.

Impregnated Paper
It consists of chemically pulped paper made from wood chippings and impregnated with
some compound such as paraffinic or naphthenic material. 

This type of insulation has almost superseded the rubber insulation. It is because it has the
advantages of low cost, low capacitance, high dielectric strength, and high insulation
resistance. 

Varnished Cambric

It is a cotton cloth impregnated and coated with varnish. This type of insulation is also
known as empire tape. 

The cambric is lapped on to the conductor in the form of a tape and its surfaces are coated
with petroleum jelly compound to allow for the sliding of one turn over another as the cable
is bent. 

As the varnished cambric is hygroscopic, therefore, such cables are always provided with a
metallic sheath. Its dielectric strength is about 4 kV/mm and permittivity is 2.5 to 3.8.

Polyvinyl chloride (PVC)

This insulating material is a synthetic compound. It is obtained from the polymerization of

acetylene and is in the form of white powder. 

For obtaining this material as cable insulation, it is compounded with certain materials
known as plasticizers which are liquids with high boiling point. The plasticizer forms a gell
and renders the material plastic over the desired range of temperature.
Polyvinyl chloride has high insulation resistance, good dielectric strength and mechanical
toughness over a wide range of temperatures. 

It is inert to oxygen and almost inert to many alkalies and acids. Therefore, this type of
insulation is preferred over VIR in extreme environmental conditions such as in cement
factory or chemical factory. 

Classification of Cables
1. Low Tension (or LT) Cables:
These cables are meant for use up to 1,000 V. For voltages up to 6,600 V, the
electrostatic stresses developed in cables are very small and thermal conductivity is also
of not much importance so no special construction is required. The insulating materials
used may be impregnated paper, varnished cambric, vulcanized rubber, or vulcanized
bitumen.

The lt cables are of two types of viz. single core and multi-core cables. The former type
has the advantages of simplicity of construction and availability of larger conductor
section.

2. Super-Tension Cables:
For cables above 11,000 V a special construction is adopted. For use up to 33 kV, the
cables used are screened cables where leakage currents are conducted to earth through
metallic sheaths.

(a) H-type and

(b) S L type.

(a) H-Type Cables:

In the “H” type cable, invented by Hochstadter, no belt insulation is used, but each of
the core is insulated with paper to the desired thickness and over this is provided a
layer of metallized paper perforated to facilitate the process of impregnation, the
coefficient of expansion and contraction is same as that of dielectric. Additional layer of
the cotton tape with fine wires of copper is wrapped round all the three cores.

(b) S L Type Cables:

In S L type cables, each core is first insulated with an impregnated paper and then each
of them, is separately lead sheathed. Now the three cores are just equivalent to three
separate cables, each having its own lead sheath. The three cables are laid up with
fillers in the ordinary way, armoured and served overall with impregnated hessian tape
as usual. No lead covering is provided surrounding all the three cores in addition to
their individual lead sheaths.
Laying of underground cables
Direct Laying Of Underground Cables

This method is the most popular as it is simple and cheap. The cables to be laid using this
method must have the serving of bituminised paper and hessian tape so as to provide
protection against corrosion and electrolysis. The direct laying procedure is as follows.

Laying Procedure
A trench of about 1.5 meters deep and 45 cm wide is dug.

Then the trench is covered with a 10 cm thick layer of fine sand.

The cable is laid over the sand bed. The sand bed protects the cable from the moisture from
the ground.

Then the laid cable is again covered with a layer of sand of about 10 cm thick.

When multiple cables are to be laid in the same trench, a horizontal or verticle spacing of
about 30 cm is provided to reduce the effect of mutual heating. Spacing between the cables
also ensures a fault occurring on one cable does not damage the adjacent cable.

The trench is then covered with bricks and soil to protect the cable from mechanical injury.

Insulation resistance of single core cables

The insulation of proper thickness over the conductor is provided in order to prevent
leakage current. 

The leakage current is a current which flows in a path that don’t intend to provide to it. As
the conductor is circular, the path of leakage current is radial.

Let us

Radius of the single core conductor of cable = r1

Internal sheath radius = r2

Length of cable = L

Resistivity of cable insulation = ρ

Let us consider very small thickness of insulation dx at radius x distance.

Area of leakage current flows = 2πxL

Length through leakage current flows = dx

Insulation resistance of layer dx = ρ ( dx / 2πxL )

Capacitance of single core cables

It is equivalent to two long co – axial cylindrical. The core of the conductor is inner cylinder
whereas the lead sheath is outer cylinder. 

The lead sheath is at earth potential.

Let us consider that the core diameter is d meter and inner sheath diameter is D meter. 

The charge per axial length of the cable is Q coulombs and e is permittivity of the insulation
material between core and lead sheath.

Core diameter = d

Sheath diameter = D

Charge per axial length of cable = Q

Permittivity of insulating material between core and lead sheath = ε

Permittivity ε = ε0εr

Where ε0 = Absolute permittivity

               = 8.854 × 10 – 12 Farad / meter

           εr = Relative permittivity

Consider a cylinder of radius x meter and axial length 1 meter. The surface area of cylinder =
( 2πx )  × ( 1 )  = 2πx meter2

Electric flux density at any point P on the cylindrical surface is

Dx = Q / 2πx Coulomb / meter2

Electric Intensity at point P

Ex = Dx / ε

    = Q / 2πx ε

    = Q / 2πx ε0εr

If unit positive charge moves from point P through distance dx in the direction of electrical
field, the work done is Ex dx. 
Types of cable faults
Cables are generally laid directly in the ground or in ducts in the underground distribution
system. For this reason, there are little chances of faults in underground cables. However, if a
fault does occur, it is difficult to locate and repair the fault because conductors are not
visible. Nevertheless, the following are the Types of Cable Faults most likely to occur in
underground cables.

1.Open Circuit Fault:

When there is a break in the conductor of a cable, it is called open circuit fault. The open-
circuit fault can be checked by a megger. For this purpose, the three conductors of the 3-
core cable at the far end are shorted and earthed. Then resistance between each conductor
and earth is measured by a megger. The megger will indicate zero resistance in the circuit of
the conductor that is not broken. However, if the conductor is broken, the megger will
indicate infinite resistance in its circuit.

2.Short Circuit Fault:

When two conductors of a multi-core cable come in electrical contact with each other due
to insulation failure, it is called a short circuit fault. Again, we can seek the help of a megger
to check this fault. For this purpose, the two terminals of the megger are connected to any
two conductors. If the megger gives zero reading, it indicates short-circuit fault between
these conductors. The same step is repeated for other conductors taking two at a time.

3.Earth Fault:

When the conductor of a cable comes in contact with earth, it is called earth fault or ground
fault. To identify this fault, one terminal of the megger is connected to the conductor and
the other terminal connected to earth. If the megger indicates zero reading, it means the
conductor is earthed. The same procedure is repeated for other conductors of the

Comparison of underground and overhead system

Voltage Levels

Underground cables currently have a limited voltage capacity and cannot carry more than
66kv. In contrast, overhead power lines can handle more than 400kv, making them ideal for
serving high-energy needs such as industrial applications.

Cost and Maintenance

Underground cables cost more to buy, install, and maintain compared to overhead power
lines. Digging trenches and installing manholes and other special equipment for
underground cables is more expensive than erecting pylons for overhead power lines.
Additionally, underground cables must be coated by a thick coating because of the
surrounding soil, which adds to their manufacturing costs. Overhead power lines use the
surrounding air as insulation, reducing costs significantly.

Outages and Repairs

Underground cables are less susceptible to outages compared to overhead power lines. The
latter is secured underground, but overhead power lines are exposed to destructive
elements such as extreme weather, birds, and critters.

However, underground cables are difficult to repair because of their rigid structure. It may
take hours or days to locate and fix the problem. Overhead power lines are easier to assess
and repair.

Application and Lifespan

Underground cables have approximately half the durability and lifespan of overhead power
lines. They last for about 35 years, while overhead power lines can last for up to 70 years.
Additionally, underground cables have a limited application scope because of their limited
voltage capacity. They are recommended for crowded cities where pylons are difficult to set
up.

Utilizing Overhead Power Lines with Protective Equipment

Overhead power lines often offer more benefits than underground cables. However, they
may be more susceptible to damages from critters, but this is a manageable problem
using Critter Guard products. We work with numerous utility and power distribution
companies to protect their equipment and prevent further access. Our Line Guard and Pole
Guard products can protect power lines and power poles from pesky critters including
squirrels, snakes, rats, opossums, raccoons, monkeys, and birds. Feel free to contact us for
more information.

Advantages and disadvantages of underground cables

1. Safe Operation :

If we consider about the advantages of Underground Power systems for power distribution
and transmission. Normally underground power cables are safer than the overhead power
line. So the probability of the hazard occurrence is very less.

2. Good General Appearance :

The appearance of the underground cables is really good than traditional overhead lines.
Since it located underground there is no such visibility of the line for people. So in most
urban cities and highly dense domestic areas, this type of cables are widely used to have a
better appearance compared with overhead power lines.

4. Less Maintenance Cost :

The maintenance cost for the underground lines is really less compared with traditional
overhead power lines.

5. Less Fault Occurrence:

Since it is properly covered by so many insulations layers with mechanical protections there
is really less chance for fault occurrence under electrical fault conditions.

6. Less Voltage Drop:

The underground power cables are designed to reduce the power losses so there is very less
voltage drop appear in underground power cables compare to overhead power transmission
and distribution lines.

Disadvantages of Underground Power systems

1. High Capital Cost:

One of the major disadvantages of the Underground Power systems is its initial cost.
Compare to overhead transmission or distribution the cost for construct underground
system is extremely high. So since it has more benefits, this main disadvantage is the main
cause for there is very less underground cable practically apply in the power industry.

2. Can’t Use for High Voltage Levels :

Another disadvantage is due to the time the insulation can get weaken so an air space can
form inside the insulation. Since the power delivers on high voltage level the air inside
getting ionized and the lead the breakdown of the insulation. So due to this problem the
underground cables are considered only suitable for the distribution on voltage level up to
11 kv and fewer values.

So hope that you have to get some idea on the advantages and disadvantages of
underground power lines compare to traditional overhead systems. we are also planning to
have a series of articles regarding the underground power cables in this site.