Manual For Laying 110-500 KV XLPE Power Cables

TD–16–01 L
Manual
for laying 110-500 kV XLPE Power Cables
This manual serves as guidelines and is written

for project and installation companies
© 2016 Training Centre “The Laying and Installation”. All rights reserved.
2 ТD– 16 – 01L • Manual for laying 110-500 kV XLPE Power Cables •
Table of Contents
1. Application Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Cable Laying Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Storage and Transportation of Cable Drums. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Cable Laying Requirements, a Cable Route and Cable Laying Equipment . . . . . . . . . . . . . 4
5.1. General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.2. Cable Laying In the Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3. Cable Laying in Pipes and Cable Blocks at the Intersections with Communications,
Roads, Railways, Engineering Constructions And Natural Barriers . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4. Cable Laying in the Air in Cable Structures, Production Premises, on Supports and
Constructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5. Laying Cable and Wire with Cable Screen Cross Bonding. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6. Cable Laying with Built-in Optic Fiber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.7. Requirements to Laying Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.8. Preparation Works, Selection and Installation of Laying Equipment. . . . . . . . . . . . . . . . . . 28
5.9. Rout Acceptance Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.10. Cable Laying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6. Cutting of Cable Ends and Preparing for Cable Storage at the Route. . . . . . . . . . . . . . . . . 35
7. Cable Sheath Test and Optic Fiber Testing, Sheath and Optic Fiber Repairs . . . . . . . . . . . 36
8. Associated Technical and Regulatory Documentation:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9. Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Appendix A Requirements for a Cable Drum Handling and Transportation Procedures. . . . . . . . . 31
Appendix B Caps Recommended for Sealing Cable Ends (Typical Sizes and
Installation Technology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Appendix C Recommendations for Preheating Cable Drums in Winter Time. . . . . . . . . . . . . . . . . . 36
Appendix D Cable Positioning During Laying in the Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Appendix E Positioning of Joints during Cable Laying in the Ground. . . . . . . . . . . . . . . . . . . . . . . . . 46
Appendix F List of Substances Harmful for a Cable Sheath. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appendix G Protection of Cables in the Ground with PE Protective Signaling Sheets. . . . . . . . . . . 50
Appendix H Cable Positioning During the Cable Laying in Pipes at the Intersections with Roads,
Runways, and Railways. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Appendix I Fastening of Cables and Joints on Metal Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix J List of Equipment, Devices, Tools, And Materials Necessary for Laying One Cable
Factory Length (Approximately). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Appendix K Equipment Installation for Cable Laying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Appendix L Corner Rollers Installation at the Route Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Appendix M Cable Sheath Repair Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3
1. Scope of Application
1.1. This manual covers a process of cable route preparation and XLPE cables laying 110-500 kV.
1.2. When planning cable laying 110-500 kV, the requirements of this guidance must be taken
into account. One should also consider the requirements specified in cable laying manuals and
instructions, if any, provided by cable manufactures.
2. General Instructions
2.1. Cable laying is allowed only after the completion of construction and erection works on the
cable route and acceptance of route and cable structures.
2.2 Only authorized experienced installation companies with proper equipment can perform cable
laying, padding, fastening, and fireproof covering on the cable. These works must be performed
under control of the organization qualified for installation supervision.
2.3 This manual specifies all the operations for laying of cable factory length.
2.4 Cable laying must be done according to this manual as well as local regulations for installation
and electrical safety, fire and ecological safety.
2.5 The manual covers conditions and methods of cable laying in ground (trenches), cable
spaces, pipes, tunnels, trestles, ducts and conduits. It does not cover underwater laying as well as
special laying conditions which are not specified in this document. For these cases conditions and
methods of cable laying are determined in the project of a cable line with regard to certain laying
conditions. These conditions and methods must be approved by the cable supplier.
3. Cable Laying Safety Rules

3.1 In the process of construction, handling, transportation and cable laying works, it is obligatory
to follow the safety rules in compliance with the local requirements of regulatory documents.
3.2 Hoisting machinery and equipment must correspond to the maximum weight of hoisted
loads.
3.3 A cable pulling rope must correspond to the maximum possible pulling force during cable
laying.
3.4 A cable feeding unit with a cable drum must be fastened with special anchors or by any other
way, if necessary, to prevent it from overturning during cable pulling.
3.5 Rollers installed at the route turns, ducts inlets and outlets as well as on metal structures
and supports must be securely fastened.
3.6 Trenches and bays in the ground must be secured with wooden shields with crossbars, if
necessary, to prevent ground failure (note: during cable laying, one should take into account a
possibility of ground failure after being defrosted).
3.7 If necessary, special measures must be taken in order to avoid water flooding of the cable
routeat all laying stages from cable route preparation to backfilling termination.
3.8 Communication between personnel on the cable route must be provided in order to give
necessary commands (for example, a command for emergency stop of the winch). If command
transmission by voice is not possible, a radio or telephone communication must be provided.
3.9 During the laying process, people are prohibited to be inside turns in order to prevent
injuries in case a cable or a pulling rope might slip off the rollers or the rollers might dismount
!
from a fixing point.
4 ТD – 16 – 01L • Manual for laying 110-500 kV XLPE Power Cables •
3.10 During the laying process, it is prohibited to adjust rollers or a cable pulling rope cable with
hands. Use special hooks without sharp edges and lips for that purpose.
3.11 In case of a dangerous situation during the laying process, anyone who has noticed it must
give a command to stop the winch. When the cause for the stop is eliminated, a command to
continue the cable laying should be given.
3.12 In case cables are laid not under above specified conditions additional safety measures
must be worked out and approved within a project.
4. Storage and Transportation of Cable Drums

4.1 Cable drums should be stored and transported in compliance with the technical standard
documentation of the cable manufacturer.
4.2 Cable drums as well as empty drums must be handled with cranes or other hoisting
devices in compliance with the lifting equipment safety rules.
4.3 Order of handling and transportation procedures for cable drums are defined during works
planning in accordance with a technical standard documentation.
4.4 Cable drums must be moved and installed avoiding impacts. It is prohibited to throw
! drums off the trucks and other vehicles in the process of unloading. It is prohibited to load and
unload a cable drum by rolling it off or on a vehicle. The only exception is when the bottom of the
vehicle (or the railway truck etc.) is level with the ramp to which (or from which) a cable drum is
loaded.
! 4.5 Handling and transportation of cable drums without or damaged lug is prohibited.
4.6 In the process of handling cable drums, a quick lift hook (a loading traverse) must be used
to avoid damaging flanges and lug of the drum.
For the figures of the requirements to the cable drum handling and transportation procedures
refer to Appendix А.
4.7 When preparing for transportation, cable drums must be securely fastened in the vehicle
cargo section (in the truck body, trailer, railway platform etc.). Transportation of cable drums flat
! (on the flange) is prohibited.
4.8 Transportation speed must ensure safety of cable drums in case of emergency braking.
4.9 A place for drums storage must be leveled horizontally (without pits and lips, for example,
big stones, etc.). One should secure the place in order to prevent the drum lug from pressing
through. This might be a floor of reinforced concrete slabs, steel sheets and other suitable
materials.
4.10 During storage cable ends must be hermetically sealed with shrinking caps according to
the technology specified in Appendix B. If a cable pulling head is installed on one end of the cable
on the drum, it must be sealed with a shrinking tube.
4.11 In the process of a cable drum rolling it is necessary to follow the rotation direction. It is
indicated on the drum flange with an arrow. It is prohibited to roll drums when cable ends are
protruding. The cable ends must be fastened on the drum.
4.12 Cable storage and transportation must correspond to environmental requirements of the
manufacturer.
5
5. Requirements to Cable Laying, Cable Route and Cable Laying Equipment

5.1 General Requirements
5.1.1 Cables can be laid without pre-heating at an ambient temperature not lower than -5°С.
The following cables may be laid with pre-heating:
- Cables with PE sheath at a temperature not lower than -20оС;
- Cables with PVC or polymer halogen free compound sheath not lower than -15оС.
Before and during the process of laying, temperature of the cable must be higher than -5o С.
Pre-heating time is determined by such factors as weight and size of the cable drum, material
of the cable drum, temperature of a cable and ambient temperature, weather conditions (wind,
snow storm), and heating conditions (in heated or unheated space, covers, tarpaulin tent, heat-
insulated tent, etc.). Recommendations for heating cable drums in winter time (with approximate
heating time specification for different cases) are in Appendix C. A heating technology must be
taken into account in the process of work planning and approved by the cable supplier.
5.1.2 Cable laying with a lack of light or during hours of darkness is prohibited. In case of
emergency cable laying is possible, provided that there is enough light to perform normal visual
control over cable work performance. Lighting level is determined by a representative of the
company supervising the cable laying.
5.1.3 A minimum permissible cable bending radius during the laying depends on the cable
dimensions and design and it is determined by the cable manufacturer. During the cable laying
the cable internal bending radius must be approximately:
a) Not less than 20 D for cables 110- 220 kV, where D is an outer diameter of the cable. After
laying along the route the bending with the radius of 15 D is possible, provided that a special
template is used (for example at terminations and other cases).
b) Not less than 25 D for cables 330- 500 kV, where D is an outer diameter of the cable. After
laying along the route the bending with the radius of 20 D is possible, provided that a special
template is used (for example at terminations and other cases).
c) Cable bending radius values specified in paragraphs а) and b) is for indication only.
In this regard during the work on the cable line project, it is necessary to check with the cable
supplier about the cable bending radius specified in the project documentation.
5.1.4 During the cable laying, a cable pulling must be performed with a rope winch pulling grip
fastened on the cable sheath or attached to the cable conductor by means of a clamp.
5.1.5 Cable pulling force Р, which occurs during the cable laying, must not exceed values
calculated by the formula:
Р=×S,
where P is cable pulling force, N;
S is a cable conductor section area, mm2;
is the maximum mechanical stress in the cable conductor permissible during the cable pulling.
The maximum permissible mechanical stress in a cable conductor during the laying is determined
by the manufacturer or the cable supplier. Approximately it is as follows:
- 30 N/mm2 for the cable with an aluminum conductor;
- 50 N/mm2 for the cable with a copper conductor.
The values specified above are for indication only. During cable line design stage when calculating
pulling forces, it is necessary to check values with the cable manufacturer.
5.1.6 If during the laying under conditions set by the cable manufacturer or supplier, there is the
largest permissible lateral stress on the cable, the lateral force must be calculated taking into
account certain laying conditions and must not exceed the value set by the cable manufacturer
or supplier.
5.1.7 While designing a cable line, the design organization must calculate a cable pulling force
as well as lateral force on the cable (if necessary). This must be approved by the cable supplier
and taken into account when ordering a cable factory length and planning the cable laying.
5.1.8 In some cases for cable laying on difficult parts of the route, it is possible to use additional
cable feeders (one or more) which are installed upstream of the difficult parts. During the work of
this cable feeder its pulling force must be synchronized with the pulling force of the main pulling
winch. In this regards it is preferable to use cable feeders with hydraulic transmission from the
motor (electric or internal combustion) to the pulling device.
5.1.9 For additional pulling force during the cable laying under hard conditions, it is possible to
use an additional winch and cable pulling grips with two loops (split or non-split design). These
could be for example cable pulling grips by Vetter GmbH (Germany) as specified in the information
material of cable laying 110-500 kV equipment by Vetter GmbH. In this case a grip with two loops
is positioned on the cable upstream of the difficult section. An additional winch with combustion
or electric motor is installed downstream of the difficult section. A pulling winch rope is connected
to two loops on the grip through a swivel. Cable pulling is performed by two winches: the main
one attached to the cable end and the additional one attached to the grip with two loops. During
pulling, it is necessary to observe that the additional winch is synchronized with the main one.
One should also take care that a pulling grip with two loops, a swivel, and an additional winch
rope do not damage the cable sheath. To avoid damage, it is necessary to do the pulling in such
a way that the grip loops, the swivel, and the rope do not press the cable sheath. Pulling force
with the additional winch must be approximately max. 6 kN. A certain permissible pulling force
is determined during planning of cable laying taking the cable dimensions and laying conditions
into account.
5.1.10 If it is impossible to put a winch at the end of the route section where the pulling is
performed (for example, at the place of a cable brining-in to cable spaces: substation transformer
chambers, undergrounds of gas-insulated substations, manifolds etc.) one can pull a rope
through a wire rope block fixed at the end of the route section with a pulling winch that is located
outside the cable space. If such cable pulling method is used, special attention should be paid
to selection of the block by dimensions and permissible load. It is necessary to calculate the
block load when cable pulling and fix the block in the cable space taking this calculation into
account. When fixing the block, special attention should be paid to the personnel safety provision
during the cable laying. During the pulling a rope must move over rollers (linear, corner, run-
out), provided that when the rope comes through the route sections in ducts (for example, when
passing from the trench to the substation underground), the rollers must be installed in such a
way that the rope does not damage the ducts during pulling.
5.1.11 When the cable is laid on vertical route sections in mines and channels, the cable weight
must be taken into account for pulling force calculation.
In case of vertical cable laying in mines and ducts, the rope tear force must be 5 times more than
the operational pulling force. Connection of the cable with a pulling grip or a pulling head must be
performed with a particular care; the grip must be fixed on the cable to avoid possible movement.
When the cable is installed on a vertical section in a downward direction, it is necessary to use
7
special hoisting winches with brakes, and the cable must be lowered with the rope duly secured
on the cable.
If necessary, when the cable is installed on a vertical section downward and the cable weight is
more than 500 kg, it is possible to use special braking devices with rubber pads installed on the
vertical section. The braking action in these devices is performed due to the friction of the rubber
pads against the cable sheath. The number and construction of braking devices is selected
based on the installation conditions. In this case it is not required to use a special hoisting winch.
When installing a cable less than 500 kg only the brakes on the cable winding unit can be used
(provided that brakes provide smooth braking).
Cable installation upwards is safer however it also requires a special hoisting winch with specially
designed brakes. During upwards cable installation in mines and ducts one must avoid reduction
of the pulling force, holdups or reverse movement. It can result in the grip touching the shaft or
duct and consequently the grip slipping. After that the cable will fall down.
5.1.12 Appendix D presents possible cable positioning in the ground. When laying the cables
in ground, the cables are laid on and covered with a sand gravel mix, which has lower thermal
resistance than soil, in order to improve the heat transfer from the cables and prevent cable
sheath damage.
Thermal resistivity of a sand gravel mix must be max. 1.2 Km/W (approximate composition of the
sand gravel mix consists of sand with the grain size of up to 2 mm and gravel with the particle
size from 5 to 10 mm, in the weight ratio 1:1).
Sand gravel mix may be replaced by a mix of a different composition subject to mandatory
recalculation of cable line capacity by a design company or the cable supplier.
Sand gravel mix is also used for covering cables in ducts located in ground and in the air as well
as for pipes in the ground.
5.1.13 For parallel cable laying in flat formation (in ground and air), the horizontal clear distance
between different phase cables of one line must not be less than the value of the cable outer
diameter.
In the case of installation of joints on the cable line in ground, the clear distance between the
joint body and the nearest cable must be at least 250 mm.
In case of installation of joints on the cable line in the air, the clear distance between the joint
body and the nearest cable must be at least 100 mm.
5.1.14 If the cable line with two or more circuits is laid in the ground, center spacing between the
two neighboring circuits must be at least 0.9 m. This is valid for cable laying directly in the ground
as well as cables laying in the ground in pipes and closed ducts filled with sand gravel mix. If it is
necessary to reduce center spacing between two neighboring circuits, the line capacity must be
re-calculated by the design company or the cable supplier.
5.1.15 Depth and width of the cable trench is defined by the dimensions of cables and pipes
(if cables are laid in pipes), thickness of reinforced concrete plates installed at the trench walls
(in case of cable laying without pipes), the distance between the cables of two or more circuits
(in case of multi-circuit cable lines). One must also consider that the cables or pipes with cables
must be surrounded with sand gravel mix all-around (see the figures in Appendix D).
The laying depth may be decreased up to 0.5 m on sections with the length of up to 5 m
when bringing cables into buildings and cable structures as well as at their intersections with
underground structures/ In this case the cables must be protected from mechanical damage (for
example, laying in pipes filled with concrete).
While determining the trench width one must consider dimensions of spots for installation of
rollers during the cable laying and thickness of wooden shields installed at the trench walls to
avoid soil run. The shields are installed from both sides along the whole length of the trench and
in bays for joints installation. The shields must be braced. The shields must be at least 15 cm
higher than the trench or pit edge (see Fig. D8 in Appendix D).
5.1.16 The clear distance from the cable laid in the ground to buildings or structures foundation
must be at least 0.6 m. Cable laying directly in the ground under buildings or structural foundation
is not allowed.
5.1.17 Cables must have a length reserve that is enough to compensate for possible soil
movement and thermal deformation of the cables themselves and structure in which they are
laid. Winding cable reserve in coils in not allowed.
5.1.18 When pulling forces are close to maximum ones, it is necessary to provide at least 2 m
cable reserve from the end which can be damaged during pulling and cut-off after laying.
5.1.19 If several cables are laid in the trench, the cable ends to be jointed should be positioned
according to the project (joints in one row or with at least 2 m on neighboring cables). In this case
the technological cable reserve required for jointing must be provided. Winding cable reserve in
coils in not allowed.
Under tight conditions, with a large number of cables to be laid, it is possible to lay the reserve
vertically, lower than the cable laying level, provided that the joint and cable sections (1 m
long each) adjacent thereto must be coaxial, and the cable bends are outside only those cable
sections that are coaxial with the joint. Examples of the approximate location of joints in the bay
during the cable laying in ground are given in Appendix Е.
Note that for the installation of joints and terminations on cables with fiber optics additional cable
reserve as specified in the installation manual is required. Example of fasting of cable reserve for
termination installation is shown on Fig E3, Appendix E.
The value of cable reserve required for joints installation as well as the cut-off length with
deformations are defined during installation planning.
5.1.20 Separate cables (not tied in a trefoil formation) must be laid in such a way that there
are no closed metal magnetic loops around them. In this regard it is prohibited to use magnetic
materials for bandages, fixing and other arrangements (shackles, clamps, sleeves, screens)
surrounding cable with a closed loop circuit. Laying separate cables inside the magnetic pipes
(for example, steel or cast ones) as well as through orifices in reinforced concrete walls, floors
and plates surrounded by steel closed circuits is prohibited. It is recommended to fasten labels
on the cable with caprone, plastic thread or non-magnetic wire (for example, from stainless steel
or copper).
5.1.21 Cable metal structures must be grounded.
5.1.22 To prevent moisture penetration into the conductor or under the sheath, all stub ends
of the cable must be closed with shrinking caps immediately after being cut. Cap installation
technology is provided in Appendix В. Moreover, caps must be installed instead of the damaged
ones during the cable laying and instead of the caps removed for cable sheath test and optic fiber
tests. Before a new cap installation, the remains of the old one must be completely removed from
the cable sheath.
5.1.23 When designing a cable route, it is necessary to consider the minimum cable bending
radius, position of a cable drum and a winch, possibility of the cable delivery to installation area,
the laying method and arrangement of the rollers necessary for cable laying (especially on the
route turns, inlets and outlets of pipes, during the laying in manifolds, trestles, tunnels and other
9
cable spaces).
5.1.24 When designing the cable route in cable channels covered with concrete slabs located
in the ground (completely or partially) as well as in the air, it is necessary to consider not only the
minimum cable bending radius but the size of the rollers used for laying and type of fastenings
especially for corner rollers as well leading rollers at the entrance and exit of the cable channel.
To provide a smooth turn, the angle of the duct junction on the route turns must be small. Gaps
at duct junctions must be filled with concrete. Protection from removal of a sand gravel mix by soil
water must be provided in the ducts located slopes.
Cables in reinforced concreted ducts closed on the top can be buried with a sand gravel mix or
fastened on metal structures with cable clamps which must be grounded. In case the cables are
not buried with a sand gravel mix in ducts and have a PE sheath, they must be covered all the way
along with a fire-resistant material which prevents spread of fire.
5.1.25 In case of a high level of ground water in the territory of the outdoor switch gear, above-
ground cable laying is preferable (in ducts or channels). Above-ground ducts and plates for their
covering must be made from reinforced concrete. Ducts must be laid on special concrete pads
with a slope of at least 0.2% along the planned route not to block storm water runoff. If there are
hatches at the bottom of above-ground ducts for storm water discharge, the slope is not required.
5.1.26 In case of construction of cable lines in permafrost regions, it is necessary to take
physical phenomena connected to permafrost nature into account, for example, frosted heaving
soil, frost splits, landslides, etc. Depending on the local conditions, cables can be laid in the
ground (in trenches) below the zone of seasonal frost, in the zone of seasonal frost active dry well
draining soil, in man-made fills from heavy structural dry imported soil, in ducts on soil surface,
on trestles. It is recommended to lay cables together with heating, water, sewerage and other
pipelines in special structures (manifolds).
5.1.27 Different types of cable laying in permafrost regions must be performed taking the
following into account:
а) For cable laying in ground trenches draining soil (rocky, pebble, gravel, crushed rock and gritty
soil) is the most suitable. Heaving and collapsible soils are not suitable for cable laying. Cable
laying directly in the soil is possible, provided that the number of cables is maximum four. According
to permafrost soil and environmental requirements cable laying in pipes located in the ground
is prohibited. At intersections with other cable lines, roads and underground communications,
cables must be secured with reinforced concrete slabs.
Cable laying near buildings is prohibited. Brining-in cables from a trench to the building without
ventilated crawl space must done above zero level.
b) Cable laying in channels is possible in places where the active layer consists of frost free
heaving soil and has an even surface with the slope of at least 0.2%, which provides surface water
runoff. Cable channels must be made of water-proof concrete covered with a reliable waterproof
protection from the outside. From the top the channels must be covered with reinforced concrete
slabs. Channels can be buried and not buried in the soil (above soil). In second case, the channel
must rest on a bedding from a dry soil at least 0.5 m thick.
5.1.28 If the cable line is laid parallel to a heat pipeline, the clear distance between the cable
and the pipeline wall must be at least 2 m. Otherwise, the pipeline must have such thermal
insulation along all the length parallel to the cable line so that the soil additional temperature
increase at cable line does not exceed 5 o С at any time of the year.
5.1.29 Before cable laying trenches and cable structures must be inspected for presence of
substances or garbage that can harm the cable sheath such as:
- For cables with PE sheath – pollutions of petroleum oils rich in aromatic hydrocarbons (including
cable, transformer ones) or other substances specified in Appendix F (Note: PVC cable sheath is
resistant to petroleum oil);
- Back-fill material containing slag or construction waste;
- Sections located closer than 2 m from waste pits and scrapyards;
If it is impossible to bypass these places (during the cable laying in a trench), the cable must
be laid in pure neutral soil in free-flow asbestos-cement pipes covered inside and outside with
asphalt mastic or in PVC pipes with hermetic joints. In places without petroleum oils rich in
aromatic hydrocarbons (including cable, transformer ones), it is practical to use low pressure PE
pipes.
If covered by neutral soil, the trench must be additionally widened from both sides up to
0.5-0.6 m and deepened up to 0.3-0.4 m.
5.1.30 All data about the cable route, cable laying depth and position of cables in a trench,
the type of the cable coating, thickness of the sand gravel mix layer, and the distance between
parallel lines in the trench and in the air are defined according to local regulations as well as the
cable supplier’s requirements.
5.1.31 After filling-up with a sand gravel mix and installation of mechanical protection (polymer
protection warning sheets or reinforced concrete slabs) it is necessary to test the cable sheath
and built-in optic fiber (if present).
5.1.32 After the cable laying garbage, wastes of used cables and materials which pollute the
environment must be removed from the cable route.
5.1.33 During and after the cable laying before testing and filling up the trench with the soil a
protection must be ensured from theft and damage.
5.1.34 Each cable line must have its own number or name and be marked accordingly.
5.2 Laying Cables In the Ground

5.2.1 Before cable laying directly in the ground a bedding of sand-gravel mix min 100 mm thick
must be provided in a trench. After laying cables must be covered with a sand gravel mix layer min
100 mm thick.
A protocol with confirmation of a sand gravel mix or other fill-up material technical parameters
must be submitted to a supervisor and representative of the operating company.
It is not recommended to add a layer of a sand gravel mix in joint bays before cable laying. It is
recommended to add this layer after cable laying and joints installation.
After installation and placing of joints cable on both sides of joints must be coaxial at least for 1
m with joints. To achieve it it is recommended to place joints and cables on bags filled with a sand
gravel mix or sand (see Fig. E1 and Fig. E2 in Appendix E). To make further adding of a sand gravel
mix easier it is recommended to place as well remaining sections of cables on bags with a sand
gravel mix or sand in several spots. When laying cables and joints one must ensure at least 100
mm clear spacing between cables and joins as well as between cables and joints and pit walls
and longitudinal partitioning between circuits (in case of a double circuit cable line). Those gaps
must be filled with a sand gravel mix later. After filling it is recommended to check the thickness
of the layer with a folding meter or metallic ruler. Thickness of a compacted layer of a sand grave
mix under joints must be at least 150 mm. Under remaining cable sections (not adjoining joints
at 1 m distance) thickness of a compacted layer of a sand gravel mix must be at least 150 mm.
Afterwards joints and cables in the pit are finally filled with a layer of a sand gravel mix. At that the
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top layer of a sand gravel mix between cable with joints and reinforced concrete slabs which will
be installed over the filling must be at least 100 mm (see Appendix E).
Specified above requirements are also applicable to installation of joints in concrete channels.
It is prohibited to do the filling of the open cable sections and joints with a sand gravel mix directly
from an excavator bucket, auto-loader or truck dump body in order to prevent the sheath damage
!
by foreign objects and inclusions which a sand gravel mix can contain. For filling-up cable and
joints is necessary to use the tool without sharp edges and lips, to prevent the cable sheath
damage. The filling-up of cable and joints with a sand gravel mix must be performed under visual
control of the installation company supervisor.
Note that cables in trefoil formation must not change their position when they are covered with
a sand gravel mix.
When cables are laid in the ground in pipes, these pipes are also laid in trenches on a sand-gravel
mix layer at least 100 mm thick. On top of the pipes another min 100 mm a sand gravel mix layer
must be applied.
A sand gravel mix layer at least 100 mm thick must be provided from the sides between cables
and protective concrete slabs installed vertically at the trench walls as well as between pipes and
the trench walls when cables are laid in pipes.
5.2.2 For installation of joints on the cable route suitable bays must be prepared. They should
be coaxial with the trench and they should be at least 2 m wide for single-circuit line and 3 m in
wide for double-circuit line and at least 1.5 m deep. The bay must be at least 6 m long.
When determining the bay width, note that the clear distance between the joint body and the
neighboring cable must be at least 250 mm.
In case of multi-circuit lines bay dimensions are based on the specific conditions.
It is not recommended to position joint pits above and under communications, above underground
structures and floor slabs as well as within direct proximity to railways.
It is not recommended to install cable accessories on a steeply inclined route sections. If
necessary level platforms must be arranged and measures be taken to prevent a sand gravel mix
from washing out.
During laying cables in ducts joints and additional s-shaped cable slacks must be positioned at
special wide ducts.
5.2.3 Cables at the entire length and joints in bays must be protected from mechanical damage
with reinforced concrete slabs min 50 mm thick from sides and top.
The bottom of the joint bay must be leveled for the cable laying. Reinforced concrete slabs min
3 m long must be placed on the bottom of the joint bay (without level difference at junctions) or
the bay must be casted with reinforced concrete. If possible reinforced concrete slabs must be
min 6 m long.
It must be ensured that no slabs offset can occur during service. Joints in the bay must be
positioned in such a way that least 1 m of the cable from the joint is located above the reinforced
concrete slab or the concreted bay bottom (see Fig. E1 and Fig. E2 in Appendix E).
It is possible to perform joints installation in concrete channels.
Joint bays for 330-500 kV lines may be completely imbedded in concrete upon demand of the
joint manufacturer.
In case of two or more circuits laid directly in the ground in the trenches with central spacing
less than 0.9 m (but at least 0.6 m), a vertical reinforced concrete partition must be additionally
erected between two neighboring circuits.
The vertical partition from reinforced concrete slabs must be also installed between neighboring
circuits of the cable line in joint bays.
In case of a single-circuit line laid in a trench from 700 to 1000 mm wide side protective reinforced
concrete slabs are installed as shown in Fig. D12 in Appendix D. In this case the width of a sand
gravel mix layer must be at least 100 mm on sides of the cable.
In case of cable laying in the ground without pipes, protective reinforced concrete slabs min 50
mm thick are laid directly above the cables and joints on the sand gravel mix layer. Protective
reinforced concrete slabs in the trench with cables and joints are covered by soil.
In order to protect cables, they can be laid in the ground in pipes. In case of cable laying in pipes,
covering of the cable line with reinforced concrete slabs is not required (except cable laying in
pipes under passways, roads and streets, see Section 5.3).
! It is now allowed to fill cable line with frozen ground clots, soil with big stones, metal or concrete
pieces etc.
Examples of a single-circuit and double-circuit cable lines laying in the ground in the trench are
given in Appendix D. In Appendix D, Figure D1 illustrates the single-circuit cable line laying in the
trench of up to 700 mm wide. Figure D2 illustrates a single-circuit cable line laying in the trench
above 700 mm wide. Figure D3 illustrates a double-circuit cable line laying in the trench. Figure
D4 illustrates a double-circuit cable line laying in the trench under tight conditions with central
spacing less than 0.8 m between circuits. Figure D5 illustrates a single-circuit cable line laying in
the trench in pipes. Figure D6 illustrates a double-circuit cable line laying in the trench in pipes.
5.2.4 Cables in the ground in the trench may be laid in reinforced concrete ducts filled with a
sand gravel mix covered with reinforced concrete slabs on the top. An example of such a double-
circuit cable line laying is given in Appendix D in Figure D7. Cables in ducts must have a sand
gravel mix bedding at least 100 mm, and a sand gravel mix layer on the top min 100 mm above
the duct edge. Protective reinforced concrete slabs are laid on this layer. With time this layer
compacts and fills spaces between cables and the duct walls.
5.2.5 To protect cables and joints from mechanical damage from top and sides polymer,
protective signaling sheets may be used instead of reinforced concrete slabs. Cable protection in
the ground with polymer protective signaling sheets is given in Appendix G. Sheets are laid on the
cable route overlapped and fastened with special rivets. These rivets should be ordered together
with the sheets.
5.3 Cable Laying in Pipes and Cable Blocks at the Intersections with Communications,
Roads, Railways, Engineering Constructions and Natural Barriers
5.3.1 Basic requirements for cable protection at their intersections with service lines, roads,
railways, engineering constructions and natural barriers are listed in the local electrical regulatory.
For protection cables must be laid in pipes, blocks or ducts with concrete filling or covered by
reinforced concrete slabs. Cable laying in the ground in pipes is also used on route sections
where tree roots expansion can happen in gaps between cables. The protection method and
construction are determined in the project and must be approved by the cable supplier.
At the intersection of cable lines with railroads and motor roads, the cables must be laid in
tunnels, blocks or pipes full-width of the buffer zone at the depth mint 1 m below the road-bed
and min 0.5 m below the bottom of the draining ditches. In case of no buffer zone, the specified
laying conditions must be fulfilled only at the intersections plus 2 m to both sides from the road-
bed.
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5.3.2 At the intersections with heat pipelines, the spacing between cables and the pipeline must
be at least 1 m and at least 0.5 m in constrained environment. In this case at the intersection
plus 3 m from both sides of outer cables, the heat pipeline must have such thermal insulation
that the earth temperature does not exceed 5°С at any time of the year.
To protect cables from overheating, thermal insulating materials such as foamed concrete,
expanded clay or polystyrene foam blocks with bitumen waterproofing, etc., can be additionally
used. During design stage of thermal insulation the maximum permissible temperatures of the
cable and the heat pipeline at the maximum ambient temperature as well as specific conditions
of intersection of the heat pipeline and the cable line must be taken into account.
5.3.3 Inner diameter of the pipe or block channel for one cable must be at least 1.5 D where D
is an outer diameter of the cable.
During the laying in pipes it is recommended to lay one cable per pipe (block channel).
5.3.4 For cable laying design the total pipe (block channel) length must be defined according
to cable design parameters and laying conditions. The length is determined depending on the
required capacity of the cable line, design peculiarities of the route, diameter and condition
of the pipe inner surface. Besides the pipe or the block channel length must be designed in
consideration with maximum permissible pulling force of the cable.
5.3.5 Pipes must be made of LPPE, asbestos cement, ceramic or of other non-magnetic
insulation material (for example reinforced fiberglass).
Single-phase cable laying in a metal pipe from magnetic material (steel, cast) is prohibited!
Only three phases together can be laid in one magnetic metal pipe.
5.3.6 Pipes must be connected by joints, connecting pipes, sleeves, welding or other means and
if necessary secured with cement grout.
It is not allowed to use sleeves, joints and connecting pipes made of magnetic materials (for
example, steel sheet) for pipe connection if they form a closed circuit around single phase in the
pipe to be connected.
Inner diameter of the joint, sleeve, connecting pipe cannot be less than the inner diameter of the
pipe itself.
5.3.7 LPPE, asbestos cement, ceramic and other pipes must be laid in a straight-line without
offset from the pipe axis. Pipe entries from the inner side must be rounded with a radius of
at least 5 mm and have no lips, bends, burrs. Pipe connections must have a processed and
smooth surface not to damage cable sheath during laying and service. Testing for straightness
and absence of obstacles is performed by illumination with an electric lamp or a torch on the
opposite side of the passage.
In the process of laying PE pipe in the soil by horizontal drilling a smooth out-of-straightness
bending of pipes is allowed. Requirements to cable laying through pipes with bending are
specified below in paragraph 5.3.11.
After laying a gaging of pipes or round channels and cleaning them from concrete, construction
waste, soil, sand, etc. must be done. If necessary a leakage test needs to be performed. Cleaning
with a swab must be obligatorily performed just before cable laying.
For gaging of pipes and round channels it is recommended to use special testing metal or
polyamide drawbars with the following dimensions:
- The outer diameter is approximately 80-85% from the inner diameter of a pipe or a channel;
- The length of the cylinder (drawbar) is approximately at least double to the inner diameter of a
pipe or a channel.
On both butt ends of the cylinder (drawbar), there must be shackles. One for fastening a rope for
pulling by a winch through a pipe or channel and the other for pulling back in case the cylinder
is stuck.
On short pipe sections without joints in which the inner surface of pipes may be checked visually,
gaging with control cylinder is not required.
After gaging calibration with a control cylinder (drawbar), the inner surface of pipes or channels
must be cleaned of concrete, soil, sand, etc., with one or several special brushes (tube cleaners).
The outer diameter of this brush must not be less than the inner diameter of the pipe or channel.
Special brushes (tube cleaners) one or several may be attached right behind the control cylinder
(the drawbar) connected to a pulling rope. From the other side, the rope for pulling back in case
of jamming is connected to the brush. All together they are pulled by a winch through a pipe or a
channel (control cylinder or drawbar must be the first). Brushes (tube cleaners) can be metal as
well as plastic (for example, nylon) ones.
After cleaning, the inner surface of pipes or channels must be cleaned with a swab and if
necessary tested for leakage. The plug may be made of cleaning waste wrapped in a single piece
of fabric (fluffy fabric is recommended). The plug must fit tight in the pipe or channel and be
pulled through the whole pipe or channel with a rope. After pulling the plug through its fabric must
not be torn. Cleaning with a swab must be performed just before cable laying.
After installation, calibration, cleaning, cleaning with a swab and leakage test the pipes must be
sealed by caps from both sides till cable laying.
5.3.8 To avoid getting sand and gravel into pipes during cable pulling, the trench bottom in front
of the pipe entries must be 10-15 cm lower than the pipes at a distance of at least 0.5 m.
5.3.9 During the cable laying, the cable must be straight and coaxial with a pipe at a distance of
at least 0.4 m on both sides of the pipe. The cable bending at the inlet or outlet of the pipe and
pressing it against the pipe edge is not allowed because of danger to damage a sheath.
5.3.10 In case of cable entries or exits from pipes positioned on a route turn, the trench section
near pipes must be widened to provide space for a permissible bending radius of the cable and
an installation place for corner and guide rollers as well as for lead-in cones required for laying
(with or without rollers depending on the laying conditions). Rollers and lead-in cones must be
installed in such a way that the cable would be straight and coaxial with the pipe at the inlet and
outlet of the pipe. Cable laying in pipes with a sharp bending is not allowed as it can lead to the
cable sheath damage, significant increase in pulling force, possible breakage of a pulling grip or
rope and the cable sticking in the pipe.
5.3.11 When PE pipes are installed in the ground by horizontal drilling depending on laying
conditions the cable route may be with a smooth bending from the straight direction. The most
typical bends are upwards and downwards at the beginning and at the end of the intersection of
the cable route with service lines, roads, railways, engineering constructions and natural barriers.
Steeply-inclined incoming and outgoing of pipes route is allowed at intersections (for example,
at the intersection of the cable line and underground lines, rivers, etc.). During the cable laying
in pipes with bending, the cable and the pulling rope rub against the inner walls of the pipes
which can result in the cable sheath and pipes damage. This can also cause an increase of the
pulling force during laying. Therefore before such type of laying pulling force calculation must
be performed and laying technique must be determined and coordinated with the cable laying
supervising organization.
According to paragraph 5.3.9 the cable must be straight and coaxial with the pipe of at least
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0.4 m on both sides from the pipe. To provide coaxiality of the cable and pipes in the process of
cable laying on transition from trench to and from the pipe and to keep the bending radius above
minimum during laying, it is possible to place bags with sand temporarily at these places in the
trench and install rollers necessary for cable laying on the bags.
5.3.12 The pipes on a cable route must be fastened to prevent them from moving during the
cable laying and service of the cable line. If necessary the pipes must be imbedded in concrete if
it is specified in the project.
5.3.13 During pipe jacking or pipe laying by horizontal drilling across roadways and streets
pipe end sections coming into the cable trenches must be imbedded in concrete (see Fig. H1
in Appendix H). Pipe ends must outstand at least 100 mm out of the concrete to prevent cables
from damage in case of the ground sagging.
5.3.14 When crossing roads, passages, railways, and tramways for three-phase line four pipes
(one spare) must be laid.
In some specially complicated cases a spare cable is laid in the spare pipe at the customer’s
request. An example of the double-circuit cable line laying in pipes under the road is given in
Appendix H. Figure H2 illustrates single-circuit cable line laying in pipes under the road, Figure H3
illustrates double-circuit cable line laying in pipes under the road.
Pipes must be laid directly on reinforced concrete slabs and imbedded in concrete so that at
least 100 mm of the pipe outstand on each side of the concrete slab. If the pipe ends outstand
less than 100 mm further than concrete slab it is possible that during the soil sagging cables are
pressed against concrete edges and damaged.
5.3.15 Cable laying at the intersection of a cable line and railways is recommended to do in pipes
(LPPE, asbestos-cement or ceramic) fastened to metal cross-members inside a steel pipe (pipe
fastenings must not form closed magnetic circuits around separate cables). Brickwork between
pipes must be performed (with a hole at the top for filling with concrete) on both ends of a metal
pipe. When brickwork is set the space between the pipes in which cables are located and the
metal pipe is filled with concrete. Ends of pipes in which cables are located must outstand at
least 100 mm of the brickwork.
Filling with concrete must be performed in such a way that no air cavities are left inside concrete.
Special attention must be paid to filling with concrete middle and top part of the steel pipe.
Air cavities in concrete increase thermal resistance and can result in cable overheating during
service and reduction of the cable line capacity. An example of double-circuit cable line laying
when crossing railways is given in Appendix H in figure H4 (for double-circuit cable line in one
common steel pipe laying depth under the railway line is recommended at least 1500 mm).
5.3.16 In the process of pipes jointing and construction of blocks (block channels), it is
recommended to pull a wire or a rope into the pipes (block channels) which afterwards will be
used for pulling through a steel rope (cable-laid rope) for the pipe (channel) cleaning and pulling
the cable.
5.3.17 Before cable pulling in a pipe (block channel), it is necessary to take off caps and make
sure that there is no sand, soil, concrete, construction waste etc. inside which could get inside
from time of pipe laying till cable pulling. If necessary perform cleaning or swabbing and a leakage
test in compliance with paragraph 5.3.7.
5.3.18 To reduce the pulling force during cable pulling through channels or pipes, the cable
or the inner surface of the pipe must be covered with lubricant (with petroleum jelly or special
lubricant) which contains no substances harmful to the cable sheath specified in Appendix F. If
petroleum jelly is used its approximate consumption is 8-10 kg per every 100 m of the cable.
As special lubricants the following types may be used which do not pollute the environment and
recommended by Vetter GmbH (Germany):
- Gel lubricant “Polywater” J type (in plastic 560 ml bags or in 3.8 and 19 l buckets, it is
recommended for lubrication during the laying indoors and at vertical sections of the route as it
does not leak out and make dirty the room);
- Water based cable lubricant “SP” (in 3.8 l bottles, 19 l buckets and 209 l drums).
Water based liquid cable lubricant “SP” is bio-degradable and applied by special double porous
balls RSG type by “Vetter”. They absorb lubricant and are pulled through the pipe with a wire or
rope. The diameter of the RSG ball must correspond to an inner pipe diameter (balls for pipes
with an inner diameter from 80 to 300 mm are available for sale). For filling a pipe with lubricant
use of a funnel with a 2 m hosepipe GET 32 type is recommended.
Lubrication devices from other manufacturers may also be used.
The amount of special lubricant required is based on dimensions of the cable and pipes, and the
lubrication method.
When using lubrication in the process of pulling through pipes, pay attention that no stones,
garbage, sand and other objects are stuck to the sheath lubricated surfaces because the can
damage the cable sheath by friction against a pipe or a channel wall. Besides, if after coming out
of the pipe the cable is to be pulled further along the route and rollers, the cable must be cleaned
of lubricant at the exit from the pipe (otherwise, sand and small stones from a cable route can
stick to the cable sheath lubricated surface and damage the cable sheath when the cable passes
over the rollers).
Lubrication is especially recommended for pulling in pipes the cables with built-in optic fibers.
5.3.19 If during the cable laying in pipes by pulling by a rope connected to the cable end, a rated
pulling force is higher than the permissible value, it is recommended to use additionally one or
several cable feeders installed in front of the pipe inlet to push the cable into the pipe. Lubricant
is applied on the cable sheath only after it has passed through the cable feeder.
5.3.20 Ideally it is recommended to pull the cable through channels and pipes without
interruptions to avoid high starting pulling forces.
5.4 Cable Laying in the Air, Cable Structures, Production Premises, on Supports and
Constructions
5.4.1 During cable laying in the air in cable structures, production arears, on supports and
constructions it is necessary to use cable with semi-conducting layer on the outer sheath in
order to provide a possibility to test cable outer sheath after installation.
5.4.2 When positioning cables in the air in cable structures and spaces, it is necessary to
provide the minimum spacing of 20 mm to the walls or the floor (to ensure even convective heat
exchange).
5.4.3 When positioning cables in the air in case of a trefoil with spatial separation the clear
distance between cables must be at least 250 mm. In this case during the laying the cable
phases must form an equal triangle.
5.4.4 When locating cables in air, in case of a trefoil formation with touching each other the
cables must be fastened together as a triangle at spots along the cable line with an interval 1.0
to 1.5 m (on the route bends at 0.5 m maximum distance from the bend).
Fastening with above mentioned spacing must be done all along the cable line except sections
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near joints and terminations. Fastening of three phases into a triangle must be done with tapes
(for example, with a binding tape of P-162 type illustrated in figure I4 in Appendix I), clamps or
shackles. Spacing, type, design and material of fasteners are determined during cable line design
stage taking into account cable weight as well as mechanical forces developed by magnetic fields
during short circuit faults and thermal effects during “cooling-heating” cycles.
For fastening three phases of one cable line into a triangle it is possible to use magnetic clamps
or shackles (for example, steel) subject to compulsory use of elastic inserts for cable sheath
protection.
Steel clamps, shackles and fasteners must have anticorrosive coating that provides effective
protection from corrosion for the entire service life of the cable line.
5.4.5 During design stage solar radiation must be considered. If necessary, a protective
sunscreen should be provided. If cables are laid in geographical latitude higher than 65º the
sun protection is not required. The level of solar radiation influence on the cables is taken into
account during design stage of the cable line performed by the design organization or specialists
of the cable supplier.
5.4.6 When the cables are located in air inside cable structures with exception of trestles, joint
bays, channels and chambers, one must ensure natural or artificial ventilation to ensure that
ambient temperature does not exceed the maximum allowed for cable line value. Ventilation
of each cable structure compartment must be independent. Calculations of cable structure
ventilation are based on maximum temperature difference of 10ºC between incoming and
outgoing air. One must ensure that there are no dead hot air pockets in tunnels, turns, bypasses
etc.
Ventilation devices must be equipped with air-gates (traps) to stop feeding air in case of fire.
Ventilation system design must allow automatic stoppage of air feeding into buildings.
When cables are laid indoors it is necessary to prevent cables from overheating due to higher
ambient temperature and influence of technological equipment.
5.4.7 To avoid cable damage, cable laying should be started only after construction and
installation works on the cable route, in cable structures, production facilities and on constructions
are finished. All construction works must be finished and constructions for cable fastening must
be installed before cable laying in the tunnel.
Welding in the tunnel after cable laying is not allowed, except welding conductors as indicated
in the installation manual. Brick of firewalls must be erected after cable laying. !
5.4.8 If cables with PE sheath are laid in the air in cable structures and factory buildings
additional fire-protection measures must be taken, for example, applying fire-resistance coatings
on the cable sheath.
5.4.9 In cable structures, it is recommended to lay cables as one factory length and do the best
to avoid joints.
5.4.10 Joints of cables laid in blocks must be located in bays.
5.4.11 If a walkthrough tunnel switches to a crawl tunnel or to a non-accessible channel, the
joints must be located in the walkthrough tunnel.
5.4.12 Spacing between structural supports is defined in accordance with working drawings and
local electrical standards. Constructions on which cables are laid must be designed in a way that
does not allow any mechanical damage of the sheath.
5.4.13 If the joints to be installed in cable structures (facilities) separate shelves are required on
the structural support for each joint. Joints must be laid on lodgements and fastened. There must
be an insulating elastic insert at least 4 mm thick located between the joint and the lodgement.
The insert must protrude approx. 5 mm outside the lodgement. Cables on both sides of the joint
must be at least 1 m coaxial with the joint and fastened to metal structure with at least 2 non-
magnetic material clamps or shackles. Cable can be bent only beyond the second clamp from
the joint.
In Appendix I, Figure I1 is shown an example of fastening cables and joints with screen cross-
bonding on the metal structure in the cable facility. In Appendix I. Figure I2 are presented locating
blocks from “RKS-plast” LLC, designed for fastening joints on the metal structure. Figure I3
illustrates fastening the joint and the cable on the metal structure by means of the lodgement
and cable clamps by “RKS-plast” LLC. Figure I4 illustrates a polyester adhesive binding tape type
P-162 fiberglass reinforced which is recommended for fixing the joint on the lodgement. The tape
is winded 5-6 turns around the joint and the lodgement in two points.
Fireproof cases around the joints installed in cable structures (facilities) are not required for
cables with PE insulation.
5.4.14 Cable fastening must be performed in such a way that it prevents cables and joints from
deformation under their own weight as well as mechanical stresses occurring during “heat-cool”
cycling and magnetic impacts during short circuits.
Fasteners spacing, type, design and material are defined during cable line design stage depending
on cable locations (on trays, cantilevers etc.), route profile, cable design and technical spec of
the cable line.
In general cables laid along the structures, cantilevers, racks, walls, flooring, frameworks,
shelves, in ducts, etc. should be fastened according to requirements specified in paragraphs
5.1.20, 5.4.1, 5.4.2 and 5.4.3:
- Right at terminations and joints in two points at the straight sections of 1-1.5 m long;
- At route turns to both sides from bending not further than 0.5 m;
- At the vertical sections every 1-1.5 m;
- At the horizontal sections (on cantilevers, on supports, on shelves) every 1 m;
- At the other route sections (at the bends, transitions to different levels, etc.), along the cable
length with 1-2 m spacing (places are determined specifically for each project based on cable
specification and laying conditions).
Cables laid vertically along the structures and walls must be fastened each keeping the phase
sequence every 1-1.5 m.
During laying separate cables on the cantilever or transverse supports fastened on the floor
of the cable facility, on the shelf or in the duct bottom these cables must be fastened on each
cantilever or transverse support.
The distance between cantilevers and supports on the floor (on the shelf) for horizontal cables
must be maximum 1 m.
Effective length of a cantilever must be maximum 500 mm at the straight sections of the route.
Vertical location of cantilevers and the clear distance along the cable structure length between
metal support structures (cantilevers) must correspond to local electrical standards.
In case of vertical location of cantilevers it is necessary to take into account dimensions of cable
fastenings and choose a vertical distance between cantilevers suitable for fastenings installation.
5.4.15 Terminations fastening on power transmission line towers.
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In Appendix I, Figure I5 illustrates an example of fastening 110 kV cables and terminations on

the power transmission line tower. Figure I6 illustrates lifting a termination already installed on
the cable to the tower. In figure I6, you can see that the termination has been installed on the
ground and are fastened to base plates and a metal structures for the cable fastening under this
termination. The cable is fastened to this metal structure under the termination in two points.
Only after that the termination with the cable fastened to the metal structure is lifted onto the line
tower it is support, fastened, grounded and cables are fastened on the line tower (cables of each
phase of the cable line are fastened separately).
5.4.16 Cable fastening with reinforced polyamide clamps in cable spaces.
In Appendix I, Figure I7 illustrates fastening cables laid in trefoil formation with spacing on the
cantilevers by reinforced polyamide clamps.
In Appendix I, Figure I8 illustrates fastening of cables laid in flat formation spacing on the fastened
to the floor transverse supports by reinforced polyamide clamps.
In Appendix I, Figure I9 illustrates fastening cables laid in trefoil formation on the transverse
supports fastened on the floor with reinforced polyamide clamps.
5.4.17 Description and figures with dimensions of reinforced polyamide cable clamps of VKK
(for separate cables) and VKK3 (for three cables) types produced by “RKS-plast” LLC are given in
Appendix I. In Appendix I, Figure I10 illustrates a general assembly of the VKK cable clamp, Figure
I11 illustrates dimensions of the VKK cable clamp produced by “RKS-plast” LLC.
At the horizontal route sections cable fastening with the help of VKK cable clamps is done without
elastic insert.
At the vertical route sections VKK cable clamps are used together with silicone rubber inserts
PST-80 type as shown in figure I12 of Appendix I. An insert thickness in the middle is 6 mm, two
inserts are required for one VKK cable clamp (one for each half of the clamp). PST-80 silicon
inserts are recommended to be used for fastening separate cables with metal clamps shown
below in paragraph 5.4.20.
In Appendix I, Figure I13 illustrates a general assembly of the VKK3 cable clamp fastened on the
installation profile: Figure I14 illustrates dimensions of the VKK3 cable clamp by “RKS-plast” LLC.
In Appendix I, Figure I15 illustrates fastening cables on the metal structures with VKK cable
clamps together with PST-80 silicon insert (at the outlets of ducts to terminations).
In Appendix I on Fig. I15 is shown fastening cable on metal structures by clamps VKK type with
silicon inserts PST-80 (at the exit from trays towards terminations).
On special order VKK and VKK3 cable clamps may be delivered complete with fasteners
necessary for their installation on the metal structures. If fasteners are made of carbon steel
they must be galvanized. Fasteners made of stainless steel without a protective coating may be
also used. When choosing fasteners it is necessary to take a fastener steel grade into account.
Other types of polyamide cable clamps can be used subject that their service life is the same as
the service life the cable line
5.4.18 When based on characteristics and working conditions of a cable line thermal extension
compensation is required cables should be installed in “S” shape horizontally and vertically (see
Fig. 5.4.1 and Fig. 5.4.2). Spacing between points of cable rigid fastening can be approximately
calculated according to formulas specified under the figures. Final project calculations must be
based on specific cable parameters, structures of fastening points, properties of the cable route,
service conditions of the cable line and environmental conditions.
Fig. 5.4.1 Vertical “S” Shape Cable
The distance l (in meters) between the points of rigid fastening of the cable must be equal or less:
l≤ Dе2/65W, (m)
where: W- is weight of one cable meter (kg/m);
Dе - is an outer diameter of the cable (mm);
f0 – is an initial sag.
Fig. 5.4.2 Horizontal “S” Shaped Cable
The distance l (in meters) between points of rigid fastening of the cable must be approximately:
l=Dе/20, (m)
where: Dе - is an outer diameter of the cable (mm);
f0 – is an initial deflection.
Single cables as well as cables in trefoil formation can be installed with a bend.
If after cable installation it is required that it has vertical or horizontal bends provision for
extra cable length must be made. This extra length must provide the bend calculated between
fastening points. This cable slack as well as the cable bending method must be determined in
the cable line design.
5.4.19 In case of bending, cable line design must provide measures that prevent cable sheath
damage because of friction against a clamp, cantilever, floor or support during cable movement
due to thermal expansion or electromagnetic effect during the operation.
! 5.4.20 Attention! During cable installation on metal structures with thermal extension gaps (for
example, on the bridge or rack spans), cables installed with one or several bends (“S” shape) must
21
have a length reserve at these gaps. A cable fastening point design at these points must ensure
cable consistency under all service conditions and extreme environmental conditions. Additionally,
special stoppers must be provided to prevent a cable from moving aside from the plane of bending.
5.4.21 During the laying three phases line in trefoil formation with touching, the cables in intervals
between the points of rigid and hinge fastening to cantilevers must be fastened together. This
must be done every meter by clamps or several layers of a polyester bonding tape reinforced with
fiber glass for example Р-162 type (see Fig. I4 in Appendix I). In Appendix I, Fig. I16 illustrates an
example of laying cables in trefoil touching formation in a tunnel with three cables fastened by
clamps and hinge fastening to cantilevers (recommended for earthquake regions).
Spacing between points of rigid or hinge fastening of three phases of the same line on a metal
structure, number of binding band layers used for fastening, cable clamp type, extent of cable
bending in the gap between rigid fastening points are determined by calculation based on specific
technical parameters and operational conditions of the cable line.
The length of the special clamp, shackle or seat for the bent cable fastening must be not less than
the outer diameter of the cable, and the cable supporting plane must have edges with downward
bevels to prevent the cable sheath from damaging.
5.4.22 In Appendix I, Figures I17, I18 and I19 illustrate examples of cable installation with
bending using special stainless steel cable seats “ELLIS”. A cable is laid on the seat and fastened
from top by a stainless steel band fastener with a plastic coating (the seat is supplied with a
band fastener). In Appendix I, Figure I17 illustrates fastening of cables 400kV in flat formation
on “ELLIS” seats in the tunnel. Figure I18 illustrates a general view of “ELLIS” seats for three
cables (band fastener is not shown). Figure I19 illustrates a cross section in the middle of “ELLIS”
seat with three cables 500kV with an outer diameter from 131 mm to 133 mm fastened by the
band fastener. When “ELLIS” seats are used elastic insert between the cable and the seat is not
required.
5.4.23 Different versions of cable fastening to the metal structure by clamps (shackles) made of
metal sheet are shown in Figures I20, I21, and I22 in Appendix I. Figure I20 illustrates a clamp
for three phase cables of one line made of galvanized metal sheet or a steel stripe 5 mm thick.
Clamps (shackles) for fastening single cables are shown in figures I21, I22. They must be made of
non-magnetic material (for example, aluminum or aluminum alloy in the form of straps or links 5
mm thick and 60 mm wide).
When cables fastened to the metal structures by the clamps as shown in figures I20, I21, and I22,
if necessary, additional supporting plates with downward bevels made of aluminum or aluminum
alloy (to prevent a cable sheath from damage in case of a cable bending downward). Also disk
spring washers can be used (a set of several disk spring washers for each fastening bolt to
compensate mechanical impact when short-circuit current flowing).
Necessity to use these additional cable fastening elements is determined during cable line design
stage with account for specific requirements.
Material for clamps must be selected taking the following parameters into account:
• Clamp functionality (for fastening separate cables or cables laid in trefoil formation): clamps
for fastening separate cables must be non-magnetic.
• Corrosion resistivity: intended usage environment of the cable line and fasteners material
resistance to those conditions must be considered.
• Mechanical properties: forces under the cable own weight, loading in heating-cooling cycles
during operation, and resistance to short circuit current must be taken into account.
• Survival during the entire service life under operational conditions.
Choose the clamp type which is confirmed to be resistant to short circuit current and made from
specific material.
Fasteners and disk spring washers for clamps may be made of carbon or stainless steel. Carbon
steel fasteners must be galvanized.
5.4.24 In some cases clamps (shackles) of different design made of different materials can be
used. For example, clamps (shackles) from cast aluminum (silumin) as shown in Figure I 23 in
Appendix I. Amongst others Sudkabel GmbH (Germany) recommends to fasten cables with such
clamps with rubber inserts under GIS compact sealing ends of EHSV 245 type, transformer sealing
ends of EHTV 245 type and some other accessories types. When cables are fastened with these
clamps with elastic inserts, it is necessary to take into account that when mounting the clamp its
halves must not be pulled tight to each other. After mounting the clamp with an elastic insert, there
must be a 4 to 5 mm gap between the clamp halves. An exact size of the gap depending on the
clamp size category (a size) is specified in table I3 in figure I23 in Appendix I.
These and similar clamps may be used not only for installation Sudkabel GmbH accessories, but
in other technically justified cases.
5.4.25 At the points of rigid fastening of cables on the structures with metal shackles or clamps
elastic inserts must be provided (for example, rubber, neoprene, silicon ones), if this is required
in the clamp (shackle) design. Insert must protrude 5-8 mm beyond the clamp edges across the
width. Rubber inserts may be used indoors with environmental parameters which ensure operation
of rubber gaskets during 30 years without deterioration.
5.4.26 Cables located indoors and outdoors at places where mechanical damage are possible
(traffic, loads and mechanisms movement, access for unqualified personnel and unauthorized
persons) must be protected up to the safe level, but not less than 2 m above the ground or floor
level and 0.3 m deep in the ground. It is recommended to make protection with the help of pipes
or ducts (non-magnetic for single cables of different phases). When a cable comes out to the
transmission line tower which is in the urban area protection measures for the cable on the tower
must be taken against vandalism and theft.
5.4.27 During cables installation in vertical pipes (risers), their fastening should be provided.
If cables are in pipes, cables must be fastened at the sections without pipes (in gaps between
separate pipe sections or at the inlet and outlet of the pipe). Fastening points and structure are
determined during design stage and must be approved by the cable supplier.
5.4.28 Cables passages through walls, division walls, floors at production facilities and cable
structures must be organized in nonmetal (plastic, free flow, asbestos cement, concrete, etc.) pipe
sections, machine holes through reinforced concrete structures or openings. Inner surfaces of
asbestos cement or concrete pipes edges or reinforced concrete structures or openings must be
rounded with a radius of at least 5 mm to avoid the cable sheath mechanical damage.
Gaps in pipe sections, apertures and openings must be filled up after cable laying with fire-proof
material (for example, cement with sand 1:10, clay with sand-1:3, clay with cement and sand-
1,5:1:11, expanded perlite with gypsum plaster -1:2, fire clay, etc.) across the entire width of the
wall or a division wall. The other certified fire-proof materials which are eligible for use may be also
used during the cable laying.
Gaps at passages in walls do not need to be filled up if the walls are not fire-proof barriers
5.4.29 Cable entrance facilities to buildings, cable structures and other room must be done
in plastic, asbestos-cement, concrete or ceramic pipes. Inner surface of asbestos cement or
concrete pipes ends must be rounded with a radius of at least 5 mm to prevent the cable sheath
mechanical damage.
23
The pipes must protrude into the trench at least 100 mm from a wall or a foundation edge to
prevent cables from damaging in case of soil shrinkage.
For sealing cables in pipes, certified heat shrink cable seals for cable transits may be used (in this
case pipes must protrude out of the wall or the foundation at a length indicated in the cable heat
shrink seal manual).
5.4.30 Measures must be taken to prevent entering water, insects, small animals to buildings,
cable structures and other facilities from the trench.
5.4.31 Cable laying without pipes in foundations is not allowed.
5.5 Cable and Wires Installation in Case of Screen Cross Bonding

5.5.1 For cable screen cross bonding connections wires from different phases cables screens are
taken out from installed cross bonding joints. Taken out screen wires are connected to separate
cross-bonding wires or to coaxial cables which are run to the cross bonding link box. Surger
arrresters are also installed in the box.
5.5.2 A cross bonding link box must be positioned as close as possible to the cross-bonding joint.
The length of wires or coaxial cables connecting cable screens with the cross bonding link box
must be maximum 10 m (this is the length of the wire or coaxial cable from outlet of the cross
bonding joint to the link box).
Separate wires from cable line three phases screens must be fastened together in trefoil on the
whole length with 1 m intervals at all possible places.
5.5.3 In case of cable laying in the ground the cross bonding link box must be located in a special
bay near a cable route just beside cable screen wires taken out from the cross bonding joint. The
bay must be water-proof, wires or coaxial cables entry to the bay must be done in pipes and sealed.
The bay must be equipped with a double hatch (the lower one with a lock) or a door with a lock,
metal stairs or shackles to come down to the bay. The box must be accessible to installers during
service (if necessary there must be a way to open the box lid, dismount jumper-straps and switch
off surger arrresters). The bay must have an earthing loop connected to a grounding device. A
ground wire from the box is connected to the bay earthing loop.
5.5.4 Wires or a coaxial cable in the bay with joints when leading to the box must not be laid
directly on a cable or a joint when crossing other phases. A cable and joints must be covered with
at least 100 mm of a sand gravel mix and above it wires or a coaxial cable must be laid. At exitway
from the bay where protective reinforced concrete slabs are installed wires or a coaxial cable must
be covered with PE pipe sections (for protection from mechanical damage).
When cables are positioned in the air in cable spaces, the box must be located in the space just
beside cable screen wires coming out from the cross bonding joint. It must be grounded and
accessible by installation personnel during service.
5.5.5 If wires with a semi-conducting layer on sheath are used, this layer must be removed from
end sections of a wire for installation.
5.5.6 Cables and wires laying with cable screen cross-bonding must be done only according
to compulsory electric cable line diagram with phase sequence. This diagram must specify the
following:
• Relative position of cross-bonding joints and cross bonding link boxes along the cable route;
• Location and phase sequence of wires for taking out cable screen from the cross bonding
joints;
• Location and phase sequence of wires for arrange cable screen at the inlet and outlet of the
cross bonding boxed.
5.6 Laying Cables with Built-in Optic Fiber

5.6.1 When laying the cable with built-in optic fiber on complex route sections with bends
maximum laying speed 9 m/min is recommended. Final speed of cable laying is determined by
the engineering supervisor based on specific laying conditions.
5.6.2 When laying the cable with built-in optic fiber at the route turns it is recommended to use
corner rollers with two vertical rollers in a swivel holder. This type of roller allows to distribute
side load equally on each roller. For example corner EWS 3 rollers set with BN nails (equipment
information is available in catalogues and information documentation of Vetter GmbH, Germany).
A rated radial force on one wheel of a corner roller must not exceed 1850 N.
5.6.3 To reduce friction and pulling force during the cable laying with built-in optic fiber in pipes,
lubrication is recommended (see paragraph 5.3.17).
5.6.4 During laying the cables with optic fiber, it is possible to pull the cable with a pulling grip
attached to insulation at the cable end section with the sheath removed, provided that the cable
sheath near the cut part must be fastened to insulation (sheath fastening method is determined
by the engineering supervisor). If such pulling method is used, it is necessary to provide sealing of
the cable end with heat shrink tubes at the transition from the cable sheath to a semiconducting
layer over insulation, as well as at the transition from the semiconducting layer over insulation to
a conductor or a pulling head (sealing method is defined by the engineering supervisor).
5.6.5 After laying separate factory lengths of cables with optic fiber at the route sections between
joints as well as at the sections between terminations and joints, optic fiber in the cable must be
tested.
Such optic fiber tests may be performed:
- Before cable covering with a sand gravel mix, after cable laying in proper position;
- After cable burial with a sand gravel mix;
- After cable burial with a sand gravel mix, and laying protective reinforced concrete slabs or PE
sheets and backfilling of the cable route with soil.
Testing cable optic fiber must be compulsory:
- Joints installation: after splicing optic fiber at joints and installation of a housing before housing
soldering, before joint sealing (in this case optic fiber is tested at the section between joint pit on
both side from joint pit where the joint is installed. Or if at one side on the section terminations
are installed the test is done on the section between terminations and joints in the first pit after
terminations);
- After installation of all joints and terminations along the whole cable route before the final testing
for commissioning.
After testing optic fiber opened cable ends on both sides must be sealed with caps according to
the technology specified in Appendix В.
5.7 Installation Equipment Requirements
5.7.1 For cable laying 110-500 kV it is recommended to use Vetter GmbH equipment (Germany)
described in company catalogues and informational documentation.
5.7.2 The winch pulling force must be not less than the rated pulling force for the cable laid.
25
Winch rope strength limit must be higher than the rated pulling force.
5.7.3 The pulling winch must be equipped with special devices which allow:
- Control the cable pulling force;
- Register the pulling force on a diagram during all cable pulling procedure;
- Perform automatic shutoff or limiting the pulling force if it exceeds the rated value;
If the pulling winch has no device to control pulling force a stand-alone dynamometer may be used.
It is installed for cable pulling at straight sections between the puling cable and the pulling grip at
the cable end. The dynamometer must have a valid calibration-test certificate.
5.7.4 It is recommended to use the cable pulling equipment which allows smooth change of
pulling speed until full stop.
5.7.5 It is recommended to use the cable pulling equipment which allows measure the pulled
cable in meters.
5.7.6 Dimensions, design and load capacity of the cable pay-off unit and loading accessories
must correspond to dimensions and weight of cable drums.
5.7.7 A pay-off unit must be equipped with braking gear or device. It is recommended to use a
shaft with bearings on the cable pay-off unit.
5.7.8 In some cases cable feeders are required for the cable installation at complex sections. The
cable feeder force must be synchronized with pulling force of the main pulling winch. That is why
it is better to use cable feeders with hydraulic transmission between the motor (electric motor or
internal combustion engine) and a pulling device.
5.7.9 Design and configuration of rollers and blocks for cable laying must be selected taking into
account cable size and weight as well as pulling force and roller and block fastening methods. In
case of significant pulling force and cable weight it is recommended to use steel pipe rollers. They
are wear resistant and have high carrying power.
When laying the cables with an outer diameter more than 100 mm at the route turns it is
recommended to use corner rollers with two vertical rollers in a swivel holder. This type of roller
allows to distribute side load equally on each roller. For example corner EWS 3 rollers set with BN
fixing nails by Vetter GmbH (Germany).
5.7.10 Design and dimensions of rollers with cones installed at the cable entry to pipes must
correspond to cable dimensions and the inner diameter of pipes.
5.7.11 Design and type of pulling devices (cable grips, cable heads, shackles, etc.) as well as
swivels must correspond to the cable dimensions and the rated pulling force. Description and
data of cable heads attached to conductors, cable grips, shackles and swivels with standard sizes
produced by Vetter GmbH (Germany) are specified in Vetter GmbH catalogues and informational
documentation. Shackles must be galvanized and have a special streamlined form for good
slipping through pipes and moving through rollers. Similar grips, shackles, and swivels of other
manufacturers are also possible to use.
5.7.12 Rollers must be clean, easy and free in rotation and have no sharp edges and burrs which
can damage the cable outer sheath.
5.7.13 The string length for pulling the winch rope into pipes must be not less than the length of
the longest pipe at the cable route.
5.7.14 Means of communication must provide reliable communication along the entire cable
route. At the places where radio connection is not possible (for example, in the underground
tunnels) field telephone connection must be provided.

5.8 Preliminary Works, Selection and Arrangement of Laying Equipment
5.8.1 Prepare necessary accommodation for working teams, engineering technicians, production
base as well as storage room for equipment and tools stockholding. Take labor safety, fire
prevention and environmental protection measures in compliance with local standards, ensure
protection.
5.8.2 Perform visual inspection of drums with the cable to be laid (inspection must be performed
in presence of the engineering supervisor and the technical supervision representative). Make
sure that drum lag is not broken and moisture protection of the cable ends (caps and head sealing)
is not damaged. Check records which have been made during cable drum storage. If cable drums
are damaged, draw up a report. If the cable factory acceptance test report is attached to the cable
drum, take it off and keep it for further handing to the operating company. If the cable factory
acceptance test report is absent for any reasons, although it must be attached to the cable drum,
inform the engineering supervisor about it in order to receive a copy of the test report from the
manufacturer.
5.8.3 Bring and position cable drums, laying mechanisms and devices at the route in compliance
with the technical development plan. Prepare laying tools and materials (see Appendix J). Install
rollers and other laying devices in compliance with the technical development plan.
5.8.4 To provide smooth feeding of the cable from the drum, a cable run out roller or a roller way
must be installed at the drum located at the inlet to the trench which ensures cable positioning
on first rollers at the route (see Fig. K1 in Appendix К). Guiding rollers (roller way) must be also
installed at the inlets and outlets on the trenches, block channels, and in all transitional bays (if
any at the route).
5.8.5 If necessary, when the cable is bent in several planes or under hard laying conditions, four-
side guide rollers may be installed and fixed (see Fig. K2 in Appendix К).
5.8.6 At the cable route rollers should be installed in such a way that the cable would not slack
during the laying. The distance between rollers at the straight sections must be maximum 4 m (see
Fig. K3 in Appendix K)
5.8.7 At the route turns corner rollers must be installed which provide smooth bending of the
cable with a bending radius not less than the smallest permissible value for the cable laid.
If the smallest permissible bending radius value is less than 3.5 m, corner rollers must be installed
at the entire section of the route turn. The number of installed corner rollers depends on the route
turning angle, cable and roller size as well as the smallest permissible bending radius of the cable
during the laying.
In Appendix L, Figure L1 illustrates an example of installation of ERS 3 corner rollers with BN 70
nails by Vetter GmbH (Germany) at the route turn at the angle of 90o in the ground trench for laying
cables with bending radius 1000 mm, 1500 mm, 2000 mm, 2500 mm and 3000 mm. As shown
on the picture there can be from 4 to 9 ERS 3 rollers at the 90o turn.
In Appendix L, Figure L2 illustrates an example of installation of EWS 3 corner rollers with BN 100
nails by Vetter GmbH (Germany) at the route turn at the angle of 90o in the ground trench for laying
cables with bending radius 2500 mm, 3000 mm, and 3500 mm. As shown on the picture there
can be from 9 to 13 EWS 3 rollers at the 90o turn.
In case of other angles different from 90o the number of rollers is determined according to the
same principle, i.e. corner rollers selected based on the cable size must be fastened to each other
and fill the entire route turn.
27
If the cable smallest permissible bending radius is more than 3.5 m, corner rollers may be installed
separately without fastening to each other (see Fig. L3 in Appendix L).
During cable laying on metal structures and in channels at CL route turns four-sided rollers
(throughout the whole route curve) can be installed and fastened as well. On Fig. K2 Appendix K
is shown an installation of four-sided rollers during 500 kV cable laying in channels on the cable
route curve. If necessary four-sided rollers can be equipped with special fastening elements which
design is based on certain cable laying conditions.
Corner rollers and four-side guide rollers must be securely fastened. During the laying in soil
horizontally, rollers should be fastened with nails punched into soil. When cables are not laid in
ground (in ducts, along racks, in channels, rooms and so on), corner rollers should be fastened to
arcs made of metal pipes which are bent according to the route bending. In these cases special
bypass devices which consist of steel or aluminum rollers already fastened to metal arcs may be
used (see Fig. L4 in Appendix L). Preparation of bypass devices or cable corner rollers for laying in
the ground with vertical turns may be performed in the same way (they should be fastened taking
into account specific laying conditions). Example of use of deviation devices is presented on Fig.
L4 in Appendix.L.
If necessary at the vertical and horizontal route sections four-side guide rollers can be installed
before and after of corner rollers for a cable fixing.
5.8.8 During the cable laying in blocks, in the tunnel it is necessary to install rollers (corner, guide,
rope rollers and so on) and other equipment required for roller installation and directing cable
(shackles for rollers, bypass devices, lead-in cones, etc.) along the route in compliance with the
technical development plan.
5.8.9 At the end of LPPE, asbestos-cement, ceramic, epoxy, fiber-glass reinforced or ceramic
pipes lead-in cones or special cable guide rollers with cones must be installed. To avoid sharp
edge developing because of the passing rope it is necessary to install special guide rollers at the
exits of the pipes.
5.8.10 Install a winch (pulling device) at the route end or behind the cable pit and fasten it.
5.8.11 Install and check telephone or radio communication between the person escorting the
cable end and personnel in places of drums location, a winch, turns, baffles and crossings of the
route.
5.8.12 Put the cable drum on jacks, supports or a pay-off unit in such a way that the cable end
would get off the top of the drum when unwinding. Drum expansion sleeves have tight fit (fixed)
in a drum flange, for that purpose it is necessary to tighten nuts on studs. Take off lagging, take
out nails and shackles from the drum flanges which can damage coming off the drum cable. If
necessary, fasten a pay-off unit, jacks or supports.
5.8.13 Check if the lower cable end is fastened (if necessary, fasten it additionally).
5.8.14 Check the cable condition on the drum (check-up must be performed in presence of the
engineering supervisor and the technical supervision representative). Draw up a protocol about the
cable condition on the drum in which checkup results of the cable drum with lag must be specified
according to paragraph 5.8.2. This protocol is handed to the cable line operating company during
line commissioning.
5.8.15 Install braking devices to control the drum rotation speed during the pulling and bringing it
to halt stop as well as preventing inertial rotation of the drum.
5.8.16 At cable factory lengths where a grip is already installed on the conductor of the upper
end the transition spot between cut insulation and the outer sheath must be sealed. In this case
when getting ready for cable laying it is necessary to check the grip and how it is fixed and sealed.
If the sealing is damaged it is necessary to restore it. The sealing method must be defined by the
engineering supervisor.
If there is no head on the cable, the wire pulling head must be mounted at the cable end above
the cap. The wire pulling head must be fastened in such a way that it does not damage the cap at
the cable end. To prevent the grip from slipping off the cable, it must be banded with a thin steel
wire and an adhesive PVC tape.
5.8.17 Preparing cable for pulling in pipes or block channels, it is necessary to pay attention that
dimensions of a wire pulling head or grip used would allow pulling the cable without jamming in
the pipe or the block channel. Approximately dimensions at the cross section of a pulling head or
a grip mounted on the cable (with a bandage and taping) must not exceed the outer diameter of
the cable more than by 15 %.
5.8.18 Spread the pulling winch rope along the route (with the help of a special string at the
sections with pipes) and attach it to a pulling loop on the grip or the pulling head through a swivel.
If necessary install a shackle between the grip (pilling head) and the swivel.
If there is no device to control the pulling force on the winch, install a stand-alone dynamometer
between the pulling rope and the loop on the wire pulling head or the grip attached to the cable
end which is used for pulling (during the laying at the straight sections of the route). During the
laying compare the dynamometer readings with the cable rated pulling force to check rollers
correct installation. In this case after laying a special report about the maximal pulling force used
for cable laying (according to the dynamometer readings) is drawn up.
5.9 Rout Acceptance Requirements

5.9.1 Before the route acceptance the cable line project must be available and approved.
5.9.2 Before cable laying the route must be approved from builders, and an acceptance protocol
must be drawn up. It is allowed to approve the route section by section from joint to joint.
5.9.3 The route approval must be done by representatives of the customer, operating company,
installation and supervising installation organizations.
5.9.4 During cable route approval special attention must be paid to its compliance to the project
documentation, Customer and cable supplier requirements and this Manual.
5.9.5 During cable route approval there must be present documents (protocols) for concealed
works on laying reinforced concrete slabs in joint bays and other works which are impossible to
inspect visual.
5.9.6 Prior to cable laying:
a) Finish all the construction works;
b) Install termination supports;
c) Perform works at the intersections with all service lines;
d) Prepare passages for cable entries to buildings through foundations and walls with pipes
inserted into them;
e) Install supporting structures with apertures for cable fastening according to the project;
f) Pump out water, remove stones and other foreign objects from the trench, plan the trench
bottom. If necessary, secure the trench walls with wooden shields with trench braces;
g) Prepare a sand gravel mix along the entire route;
29
h) Prepare reinforced concrete slabs for cable covering as provided in the project;
i) Prepare joint pits for joints installation, pump out water from them, lay reinforced concrete slabs
in bays at the places of joint location;
j) Put a sand gravel mix layer 100 mm thick on the trench bottom or in ducts (note: it is not
recommended to put sand gravel mix layer in joint bays before cable laying, sand gravel mix layer
300 mm thick is recommended to put under joints and the cable after joints installation);
k) Prepare synthetic bags with sand or a sand gravel mix for putting under joints and cables;
l) If necessary, dig up pockets at the inlets of pits and wells for cable laying after joints installation;
in case of cable bending in the horizontal plane prepare widened sections of the trench and
widened ducts for cable “s-shaping”;
m) If necessary, in case the joints are not installed right after cable laying and cable ends must be
stored on the rout, prepare stock of sand gravel mix and wooden shields or plastic boxes for cables
burial and protection (see paragraph 6.5).
5.9.7 If ducts are used, they must be laid on the trench bottom without disturbing soil structure and
joined in such a way that excludes their relative movement against each vertically or horizontally.
Duct joints at the turn angles must be secured with concrete.
5.9.8 At sections with running or wet soil, the trench walls must be strengthened with wooden
shields that are at least 15 cm higher than the crest edge to avoid soil washing down during rains.
Shields must not disturb the further cable laying.
5.9.9 Check pipes for straightness and absence of obstacle with the help of a lamp or a torch
from the opposite side of the passage.
After laying the pipes, they must be closed with end-caps on the both sides. Before cable laying
end-caps must be taken off and pipe cleaning must be performed according to paragraph 5.3.7.
5.9.10 Check trenches in front of inlets to the pipes. The trench bottom at the inlets of the pipes
must be 10-15 cm lower than the pipes at the distance of at least 0.5 m from the pipes to prevent
sand and gravel from getting into the pipes.
5.9.11 The block cable runs must be prepared considering the following requirements:
- Depth of block laying must hold to design ground level;
- Laying correctness and waterproofing of joints between concrete blocks and pipes must be
provided;
- Cleanliness and alignment of channels must be provided (channels must be cleaned of concrete
derbies, sand, stones, garbage and must have no nib points inside);
- Cable pits must be equipped with double hatches (the lower one with a lock) or doors with locks,
and have metal steps or shackles for getting down into the bay.
5.9.12 Check sites for installation of cable drums and a pulling winch. The sites must be prepared
according to the technical development plan. The sites must be level and without a slope.
5.9.13 Check the pay-off device (supports or jacks) with the cable drum. In case of heavy cable
drum if necessary the pay-off device must be installed on concrete slabs or concrete-encased
platform. If necessary measures must be also taken to prevent the pay-off with cable drum device
(supports or jacks) from rolling over during cable laying, for example, fixing with a guywire.
5.9.14 Check if the pulling winch is fixed. The pulling winch fastening method depends on its
location (on the ground, indoors, etc.) and must provide the pulling winch being securely fixed on
site at cable maximum pulling force.
5.9.15 Check how the deviation devices with rollers, feeding funnels on pipes and rollers are
fastened on the route (especially corner and four-sided ones).
5.9.16 After inspection the route acceptance report must be drawn up, signed by representatives
specified in paragraph 5.9.3.
5.10 Cable Laying

5.10.1 The cable laying method is determined during the work planning in compliance with the
requirements of the cable supplier and this Manual.
5.10.2 If supervision is provided during the cable laying, decisions of the cable supplier or the
representative of the laying supervising organization are mandatory.
5.10.3 If the pulling force exceeds the permissible value cable laying must be stopped. Than one
should check position and working condition of the rollers, cable tension along the route, at turns
and transitions, lubricant (or water) in pipes and possibility of cable jamming in pipes. A decision
about further cable pulling is taken by the cable supplier representative or the representative of
the supervising organization.
5.10.4 Pulling speed must not exceed:
- 18 m/min for cables with no built-in optic fiber,
- 9 m/min for cables with built-in optic fiber,
Depending on the type of the route, weather and pulling conditions the installation supervisor
must choose such a speed so that there is no damage to the cable and safety violations.
5.10.5 Arrangement of workers at the mechanisms and along the cable route, communication
between them and the supervisor must be determined during work planning.
A tentative scheme of workers arrangement during the cable laying:
- 2 persons at the drum for braking;
- 2 persons for the cable run off the drum;
- 1 person at the cable coming to the trench (inlet, outlet of the tunnel);
- 2 persons for the cable end tracking;
- 2 persons are at the winch;
- 1 person per every turn;
- 1 person per every passage in pipes through division walls or floors, at the inlet to the room
building - 1 person;
- at the straight sections -as required.
5.10.6 The construction supervisor must accompany a cable end movement along the route.
5.10.7 A command to start the winch is given only by the construction supervisor after arrangement
of personnel and communication test. Command “Stop” to switch-off the winch must be given by
anyone who has noticed malfunctions during the cable pulling.
5.10.8 If the laying process has been interrupted, pulling restarts with a low acceleration to avoid
big pulling force.
5.10.9 The cable drum braking must be done to avoid sagging, loosening, and slack of cable coils.
At the same time over-braking must be avoided. If the lower cable end on the drum is loosened,
31
stop laying, pull the end back and fix it.

5.10.10 When lowering the cable into the trench it is necessary to control that the cable is moving
on the rollers and does not slip from them or rubs against pipes and walls in the passages.
5.10.11 At the inlet and outlet of the pipe, it is necessary to make sure that the cable protective
layers are not damaged against the pipe edge.
5.10.12If the cable sheath is damaged it is necessary to:
- Stop laying;
- Inspect the damage place in presence of the engineering supervisor. He must define the necessity
and possibility of the cable sheath repair before laying is finished;
- Draw up a protocol on the cable sheath damage;
- Repair the cable sheath.
5.10.13 At turns, workers must be outside the cable turning to prevent injuries in case a cable or
a pulling rope slips off the rollers or the rollers dismount from fixing points. It is prohibited to adjust
rollers, pulling rope or cable with hands during the process of laying.
5.10.14 A worker at the winch must supervise the winch operation, control pulling force and
switch the winch on and off upon commands.
5.10.15 Workers accompanying the cable end must make sure that the cable moves on rollers,
adjust rollers if necessary and also direct the cable end. It is prohibited to handle the rope or
cable end with hands. Special hooks must be used for directing it. Hooks with sharp edges are
prohibited to use.
5.10.16 Before pulling is finished, pull out the cable end in the pulling direction for a reserve
length that is required according to the project for terminations or joints installation (length
reserve according to the technical development plan). In case of high pulling force (close to
permissible value) pull cable reserve in the winch direction and cut off the end with possible
damage that happened during laying but at least 2 meters. A decision about the cable reserve
required for accessories installation and cut-off length is taken by the engineering supervisor.
When determining the cable reserve one must consider the cable amount left on the drum. When
cable comes from the drum it must be long enough for accessories installation. Example of a cable
reserve for termination installation is shown on Fig E3, Appendix E.
5.10.17 When the pulling is finished detach the pulling winch rope, take off the pulling head
(or grip). Before cutting the cable, lay the cable according to the project and only after that cut
the cable laid from the cable left on the drum (cutoff point is determined by the engineering
supervisor).
After cutting immediately seal the cable laid according to the project with a cap using the technology
specified in Appendix B.
If the pulling was done by a pulling grip after taking it off check the cable end cap that was under
the grip. If the cap was damaged it must be replaced with a new one. Sizes of caps recommended
for cable end sealing as well as their installation technology are specified in Appendix B.
If the cable was pulled by the pulling head attached to the cable conductor at the factory and this
head cannot be detached, check its sealing. If the head sealing is damaged, repair it with the help
of heat-shrink tube putting it over the head and adjacent to it cable outer sheath.
If this head can be detached (or cut off) the cable end which the head was must be sealed with a
cap using the technology specified in Appendix B.
5.10.18 For more reliable sealing of the cable end double capping may be used:
- the inner cap is set on the upper semi-conductive layer over the cable insulation (the conductor
is sealed);
- the outer cap is set over the inner cap and the cable sheath.
Necessity of double capping is defined by the engineering supervisor.
5.10.19 If necessary lead in the cable end through an appropriate hole to the chamber, pit, room,
through a floor or on the termination support. Doing it one must observe permissible bending
radius of the cable. Mark the phase and the line number with paint before the hole through which
the cable has been led in.
5.10.20 After cable laying remove all the tools and equipment from the trench.
5.10.21 Take the cable from rollers, lay it, tie it, if necessary and fasten it according to the project.
5.10.22 Enter all the laying data to the protocol and enclose to it the winch recorder diagram on
which pulling force during the cable laying was recorded (if the winch is equipped with the one).
6. Cutting off Cable Ends and Preparing Cables for Storage on the Route
6.1 In case the cable is left on the drum after laying it is necessary to cut off an excess of the
cable. After cutting off make a note on the drum about the cable length left.
6.2 After cutting caps must be installed on the cable ends according to the technology specified
in Appendix B. Additional measures of sealing defined by the engineering supervisor may be taken.
6.3 In case the cable is left on the drum after laying, after cutting off the cable and caps
installation, it is necessary to draw up a certificate about the cable left on the drum after laying in
the presence of the cable supplier or the supervising organization representative. The certificate
should include the building site and location of laying (a cable line, pit, substation name, etc.),
the cable line number, the cable type, the cable manufacturer, the drum number, the length of
the cable left on the drum (in meters), information on shrinkage and caps conditions on the cable
ends, date of certificate, full names of compilers of the certificate and their signatures.
6.4 After cable laying is finished, the cable ends must be raised over the trench bottom and
fastened in such positions.
6.5 If accessories installation does not start right after cable laying the cable ends should be
laid on the sand gravel mix layer, covered with wooden shields or plastic boxes and covered with a
sand gravel mix layer at least 100 mm thick and soil afterwards. There must be no protruding nail
in wooden shields. When preparing for burial, coiling of cable ends is prohibited. It is recommended
to mark the place of buried ends with recovery marks.
7. Cable Sheath Test and Optic Fiber Test, Sheath and Optic Fiber Repair
7.1 Optic fiber test is performed in accordance with the requirements specified in paragraph
5.6.5.
7.2 If a cable laid in the ground a cable sheath test is performed only after the cable burial
with a sand gravel mix layer at least 100 mm thick and after laying protective reinforced concrete
slabs or PE sheets. If the cable is laid in the air the sheath is only tested after the cable has
been fastened on metal structures. If the cable sheath has conductive layer at least 200 mm
of this layer must be removed from cable ends before the test. The cable ends with the stripped
conductive layer must not touch the ground and grounded metal structures.
33
7.3 In order to get early failure detection it is recommended to do cable sheath and optic fiber
tests right after cable laying between joint pits or at separate sections of the cable line with the laid
cable and installed accessories.
Second test of the cable sheath and optic fiber is done after installation of the whole line. Before
testing, the conductive layer must be also taken off from the cable outer sheath (if present) at
least 200 mm long at the joints in accordance with the termination installation manual. It is also
necessary to check, whether the conductive layer has been removed from cable ends for the cable
screen cross-bonding and grounding wire. This should be performed in accordance with the cross-
bonding and earthing boxes installation manuals (if these cables and wires are present on the
cable line with the conductive layers on their sheath).
Attention! Before cable sheath testing with cable screen bonding in link boxes with surge arresters
(SA) all the links connecting screens between each other, to SA and ground wire must be removed.
After the test the links must be re-installed again in the boxes according to the cable screen
connection scheme and the boxes must be hermetically sealed.
In case if terminations are earthed through boxes with SA (without SA) on the cable line, before the
cable sheath test links in these boxes must be removed:
- Between the insulated wire connected to the cable screen bond lead in the termination and the
SA (if the box has SA);
- Between the insulated wire connected to a cable screen bond lead in the termination and the
earthing wire connected to the earthing circuit (if the box has no SA).
After testing, links in boxes must be re-installed and the boxes must be hermetically sealed.
7.4 The cable sheath (one factory length, several factory lengths with joints installed or all
factory lengths on the cable line installed) must pass a10 kV DC voltage test for 1 minute. Test
voltage is applied between the cable metal screen and the ground and/or the cable outer sheath
conductive layer.
7.5 When all tests and checkups are finished the cable ends opened for testing of sheath and
optic fiber must be sealed with new caps using the technology specified in Appendix B.
7.6 In case if the cable sheath or optic fiber has failed the test, it is necessary to locate the
damage of the sheath or optic fiber and open it for inspection.
7.7 The defect inspection must be done in presence of the engineering supervisor with drawing
up a report. The possibility of repairs of the cable sheath, optic fiber and other cable construction
elements is decided by the engineering supervisor.
7.8 The cable sheath repairs must be done by qualified personnel only using the technology
specified in Appendix M. The technology specified in Appendix M covers repair works for the cable
sheath damage, if the cable structural elements under the sheath are not damaged. In case if
both the cable sheath and the structural elements under the sheath are damaged, the possibility
of the cable repairs cable and its further use is defined by the engineering supervisor. If repairs
are possible, its technology is determined by the engineering supervisor based on the nature of
damage. After the sheath repairing, it is necessary to draw up a report. This report should include
the object and location of repair works, the cable line name, the cable line number, the phase and
a sketch of cable factory lengths relative position. If possible the place of repairs must be locked-
on to neighboring buildings and constructions with their addresses, the distance in meters along
the cable route up to the nearest joint pit or up to terminations with a pit number or terminations
location, the cable mark, the cable manufacturer name, short information on the sheath defect,
description of repairing technology with a heat-shrink sleeve mark and length, date of sheath
repairs, name of the installation company which has performed repair works, names and titles
of personnel who have performed repair works, date of the report, names and tiles of the report
drawers with signatures. When the cable line is accepted the certificate is handed to the cable
operating company for entering data to the cable line data sheet.
7.9 In case of optic fiber damage it must be repaired (with opening cable sheath). After repairs
an optic fiber test is performed once again. After repairs, it is necessary to draw up a report on the
data of the cable line, the cable, and repairs location similar to those which are specified above in
paragraph 7.8. The report should include such information as a nature of optic fiber damage, optic
fiber repair technology (reference to the optic fiber repair manual if available), the length of the
cable sheath opened for optic fiber repairs, the mark and general length of the heat-shrink sleeves
used for repairs, name of the installation company which has performed repair works, names and
titles of personnel who have performed repair works, date of the report, names and tiles of the
report drawers with signatures. During the cable line commissioning the report is handed to the
cable line service organization for entering data to the cable line data sheet.
7.10 Repairs data specified in reports according to paragraphs 7.8 and 7.9 must be also entered
to the cable log-book if the local standards make provision for it.
7.11 After optic fiber repairs it must be tested again.
After the cable sheath repairs, the cable must be covered by sand gravel mix and a 10 kV DC
voltage test must be performed once again for 1 minute. Based on the test results, a report must
be drawn up.
7.12 The cable ends opened for testing after cable sheath and optic fiber repairs must be sealed
with new caps after testing according to the technology specified in Appendix B.
7.13 Data about cable sheath testing and optic fiber checkup must be entered to the cable laying
report.
7.14 After successful cable sheath tests and if provided optic fiber checkup it is necessary to put
protective reinforced concrete slabs or PE sheets on the sand gravel mix layer at the cable route,
remove shields and crossbars (in any) and perform backfill of the cable route with ground.
8. Associated Technical and Regulatory Documentation:

a) Manual on Transportation and Storage of Drums with Power Cables with XLPE Insulation for 110
- 500 kV and Cable Accessories ETI-15-06, “Estralin PS” LLC, 2015.
b) STUDY COMMITTEE 21: HV INSULATED CABLES. Cоnstruction, laying and installation techniques
for extruded and self-contained fluid filled cable systems. Technical brochure WG21-17. August
2001.
c) Current regulatory documents on electrical safety, safety of construction and installation works,
fire and ecological safety valid in the country where such works are performed.
35
9. Appendices
Appendix A
Figures for Cable Drum Handling and Transportation Requirements
Do’s! Don’t’s!
37
Do’s! Don’t’s!
Appendix B
Caps Recommended for Cable Ends Sealing (Typical Sizes and Installation Technology)
1. Typical Cap Sizes
1.1 Cable ends sealing caps are selected subject to sizes depending on the outer diameter
of the cable which the cap will be installed on. It is necessary to use caps with adhesive (glue)
compound applied to the cap inner surface or with special adhesive bushes.
1.2 Caps produced by Tyco Electronics Raychem GmbH (Germany) with 102L reinforced
seal (with hot-melt adhesive) are recommended for sealing cable ends. Their parameters are
specified in table B1.
Table B1 (all sizes in mm)
Recommended
Размеры
Cable Diameter
min max Order Identification Inner Inner Diameter After Length Thickness After
Diameter Before Free Shrinking After Free Free Shrinking
Shrinking Db(max) Shrinking Wb
Da(min) Lb
65 95 102L055-37-R05/S 100 45 162 3,8
95 115 102L066-37-R05/S 120 70 145 3,8
1.3 Caps produced by Gala Thermo Shrink PVT. Ltd (India) with hot-melt adhesive can also be
used. Parameters of these caps are specified in table B2.
Table B2 (all sizes in mm)
Recommended
Sizes
Cable Diameter
min max Inner Diameter Inner Diameter After Length Thickness After
Order Identification Before Shrinking Free Shrinking After Free Free Shrinking
Ds(min) Df(max) Shrinking Tf
L(min)
45 90 GEC 501 100 45 160 4,0

64 120 GEC 601 130 60 160 4,6
70 145 GEC 701 158 60 165 4,6
1.4. In coordination with the engineering supervisor other caps similar in quality and sizes are
also acceptable.
2. Cap Installation Technology
2.1 Measure the length of the cap barrel.
2.2 Mark a line for the cap installation section on the cable sheath at a length from the cable
end 15-20 mm longer than the cap barrel.
2.3 Remove all unevenness, ribs, and bulged captions by a scraper from the sheath surface at
the cap installation section.
39
2.4 If the cap is installed on a cable with sheath with a conductive layer, it is necessary to
remove by a scraper this conductive layer from the cable at the cap installation section. Then it is
necessary to check surface resistance at the cleaned area with the help of a megaohmmeter with
operating voltage 2.5 kV and five copper wire bandages (1-2 turns) mounted at equal distance
from each other at the sheath test section. The megaohmmeter is used to measure the resistance
between neighboring bandages. Resistance between each pair of bandages must be at least 200
MOhm.
2.5 Work the sheath surface at the cap installation section with a sanding paper till lateral
scratches, cavities, shells, etc. are removed and degrease the area with acetone (rubber or
petroleum solvent or white spirit can be used).
2.6 Take the cap corresponding to the cable sheath diameter without ribs and put it on the
cable end (an adhesive layer must be present between the cap and the cable sheath) leaving a
5-7 mm gap between the cable edge and the cap bottom.
2.7 Shrink the cap with a light flame of a gas burner beginning from the end (when heating the
cap and its shrinking to the free cable sheath adhesive compound must be squeezed out evenly).
2.8 Let the installation section cool down below + 35°С. Before cooling down no mechanical
impact on the installation section is allowed.
3. Damaged Cap Replacement

2.1 For replacement of a damaged cap:
- Remove a damaged cap;
- Work the sheath surface at installation area with a sanding paper;
- Degrease the cleaned sheath with acetone (rubber or petroleum solvent or white spirit can be
used);
- Take a cap which corresponds to the cable outer diameter and install it on the cable end
according to the technology specified in section 2 of Appendix В.
Appendix C
Recommendations for Preheating of Cable Drums in Winter Time
Cable preheating before laying needs to be done at an ambient temperature below -5°С. After
preheating laying of cables with PE sheath can be done at the temperature not lower than - 20°С
and with PVC sheath at the temperature not lower than -15°C. Before and during the laying
process the cable temperature must not be lower than - 5°С. Preheating time is determined
taking into account weight and size of the cable drum, cable drum material, the cable and
ambient temperature, weather conditions (wind, snow storm), and heating conditions (in a
heated or unheated space, covers, linen tent, heat-insulated tent, etc.). Recommendations for
heating cable drums in winter time are the following:
1. Before preheating the cable drum, remove lag from the drum and inspect a cable in the
presence of the engineering supervisor. If preheating is planned in the tent some of the lag
battens at the top of the drum may be left to avoid contact of a tent roof material with a cable
which can worsen the heating.
2. In tents or other mobile facilities heating may be done by electrical heaters (with fans or
convection ones) or burner heaters (gas, gasoline ones, etc.). During the heating procedure,
follow the safety rules for heating devices specified in appropriate operation manuals (including
fire protection rules), especially when using burner heaters. When heating in tents and other
mobile facilities it is recommended to use two heaters with heating efficiency from 10 to 15 kW
and the air flow rate of at least 700 m3 /h (each).
Heaters are installed from both sides of the cable. It is recommended to direct the heaters air
flow not directly to the cable but downwards to the floor so that the cable would be blown over
with a reflected flow.
If heating efficiency of heaters is low and cable heating is performed in small tents or under the
cover, the following heating method may be used:
а) remove lagging from the bottom and partially from the top and sides of the drum (to ensure
the air flow to come under the drum lagging and to avoid air flow from the drum being blocked by
the tent material).
b) install two heaters at the bottom of the drum on both sides. The air flow is directed to the
bottom of the drum where that lagging is removed in such a way that the hot air blows over lower
side of the cable coils, passes further between the cable and the lagging and comes out at the
top where the lagging is also removed.
In stationary facilities heating may be performed using this facility heating system. If the efficiency
of the facility heating system is not sufficient, it is possible to use additional heat sources same
as used in tents and other mobile facilities.
3. During the heating process, ambient temperature is measured by a thermometer installed

at the height of maximum 0.5 m from the floor of the facility in which the cable is heated. If there
are heating devices at the facility, the thermometer must be installed at the place without direct
heating from a heating device (away from the hot air flow).
4. During the heating process cable temperature control is performed with the help of the
electronic thermometer sensor inserted between cable coils on the drum in the area where a
heated air from the heaters does not get to.
If the heated air is blown directly onto the cable, it is also recommended to measure sheath
temperature during the heating process from time to time in the area of maximum heating in
order to prevent cable from over-heating. This should be done by an electronic thermometer
41
sensor pressed manually to the cable sheath. The cable sheath temperature value must not
exceed +70°С during heating.
5. The heating process must be controlled. Ambient and cable sheath temperatures
measurements are recommended to be done every 30 minutes and the values should be entered
into the special cable heating log-book before laying.
6. Heating time and cable temperature after heating are determined by the engineering
supervisor based on weight of the cable and the drum, the drum material (wood or metal), initial
temperature of the cable on the drum, ambient temperature, cable heating conditions on the
drum, time of delivery of the heated cable to the installation site, approximate time of cable
laying at the route section taking specific conditions into account, laying conditions (ambient
temperature, laying in the trench or along the rack in air, wind, snowfall occurrence, etc.).
7. If for cable heating two heaters with heating efficiency from 10 to 15 kW and an air flow
rate of at least 700 m3 /h (each) are used approximate recommended time for heating is the
following:
- At least 24 hours if the cable drum has been stored for 48 hours before heating at an ambient
temperature from -5°С to -10°С;
-At least 30 hours if the cable drum has been stored for 48 hours before heating at an ambient
temperature from -10°С to -15°С;
-At least 36 hours if the cable drum has been stored for 48 hours before heating at an ambient
temperature from -15°С to -20°С.
This is only a guideline. Heating time and conditions for big and heavy cable drums (approximately
10 to 25 tons) are determined in coordination with the cable supplier.
8. Cable temperature measurement during the cable laying is recommended to be done

with an electronic thermometer. The electronic thermometer sensor must be pressed to the
cable sheath through thermal insulating material which low heat absorption and a high heat
resistance (for example, foam polystyrene used for packaging). The sensor must be pressed
to the sheath until the electronic thermometer readings are stabilized. After stabilization
of the thermometer readings the cable sheath temperature is taken. The interval for sheath
temperature measurements must be determined by the engineering supervisor based on the
laying conditions.
Appendix D
Cable Positioning When Laying in the Ground
Fig. D1. Single Circuit Cable Line Laying in the Trench up to 700 mm Wide
1- Cable; 2 -Sand gravel mix; 3- Reinforced concrete slab or polymer protective signaling sheet;
4- Fill-up soil
Fig. D2. Single Circuit Cable Line Laying in the Trench over 700 mm Width
1- Cable; 2 -Sand gravel mix; 3 -Reinforced concrete slab or polymer protective signaling sheet;
4 -Fill-up soil
43
Fig. D3. Double Circuit Cable Line Laying in the Trench
1 Cable; 2 Sand gravel mix; 3 Reinforced concrete slab or polymer protective signaling sheet;
4 Fill-up soil
Fig. D4. Double Circuit Cable Line Laying in the Trench under Constrained Conditions with a
Central Spacing between Circuits up to 0.9m
1 Cable; 2 Sand gravel mix; 3 Reinforced concrete slab or polymer protective signaling sheet;
4 Fill-up soil
Fig. D5. Single Circuit Cable Line Laying in the Ground in Pipes
1 Cable; 2 Sand gravel mix; 3 Pipe; 4 Fill-up soil
Fig. D6. Double Circuit Cable Line Laying in the Ground in Pipes
1 Cable; 2 Sand gravel mix; 3 Pipe; 4 Fill-up soil
45
Fig. D7. Double Circuit Cable Line Laying in the Ground in the Trench in Closed Ducts
1 Cable; 2 Sand gravel mix;3 Reinforced concrete duct; 4 Reinforced concrete slab or polymer
protective signaling sheet; 5 Fill-up soil
Appendix D
Fig. D8. Wooden Shields at the Cable Route to Avoid the Ground sloughing
47
Appendix E
Location of Joints during the Cable Laying in the Ground
Fig. E1. Position of Joints When Laying a Single-Circuit Cable Line in the Ground
Fig. E2. Position of Joints When Laying a Double Circuit Cable Line in the Ground
49
Fig. E3. Example of fastening of a cable reserve for terminations installation

Appendix F
List of Substances Affecting Cable Sheath
This list specifies data of cable sheath material (HDPE) resistance (satisfactory, limited or
unsatisfactory) to the impact of different substances at zero inner pressure and outer mechanical
stress and at temperatures between 20°С and 60°С.
1. The cable sheath material has unsatisfactory resistance at temperature values between
20°С and 60°С to the influence of the following substances:
- Bromine (liquid or gas), iodine in alcohol solution and in potash carbonate, fluorine (gas);
- Halogen derivatives: methyl bromide, bromoform, dichloroethylene, dichlorobenzene,
dochloropropylene, methylcyclohexane, propylene dichloride, tetrachloroethylene,
trichlorobenzene, trichloroethylene, tribromomethane, benzene chloride, chloroform,
chlorosulphonated acid, thionyl chloride, ethylchloride, ethylene chloride, methyl chloride,
methylene chloride;
- Aromatic hydrocarnobs;
-depentene, tetradecane, tetrahydrofuran, sulfur trioxide, diethyl ether, depentene, isipenthane,
isopropylamine, isopropyl amine, ethyl mercaptan, notrobenzene, nitrotoluene, N-pentane,
oleum, pentane-2, furfurol, cyclohexane, O-Zylene, P-Zylene, ethyl benzene;
- nitric acid (95% and higher), chloroazotic acid (HCl / HNO3=3/1), sulfuric acid (fluid);
- kerosene, turpentine oil (oleoresin).
2. The cable sheath material has limited resistance at 20°С and unsatisfactory resistance
at 60°С to the impact of the following substances: ethyl acrylate, decane, dibutyl amine, carbon
disulphide, carbon tetrachloride, xylene, ligroin, lysol, methylcyclohexane, N-heptane, ozone,
styrol, titanium tetrachloride, tetrachloridemethan, borium trifluoride, toluene, braking fluid,
chlorine (saturated water solution or gas), allylchloride.
3. The cable sheath material has satisfactory resistance at 20°С and unsatisfactory resistance
at 60°С to the impact of the following substances: isopryl ether, nitroethane, octyl alcohol, olive
oil, octyl alcohol, hydrogen peroxide (90%), sulphuric acid (from 80 to 98%), perchloric acid
(70%), ethyl acetate.
4. The cable sheath material has limited resistance at 20°С and 60°С to the impact of the
following substances: acetone, amyl acetate, benzole petroleum benzene, diacetone alcohol,
diethyl ketone, hexachlorophene, camphor oil, calcium sulphide.
5. The cable sheath material has satisfactory resistance at 20°С and limited resistance at
60°С to the impact of the following substances: diesel oil, petroleum products, solid lubricant,
grease lubricant, aniline, hexane, benzaldehyde, benzole chloride, isooctane, sulphuric acid
(70%), acetic acid (over 96%), oil acid, chromic acid, perchloric acid (50%); furfural spirit, ethyl
alcohol, hydrogen peroxide and some other substances.
Note: The cable sheath material has satisfactory resistance at 20°С and 60°С to the impact
of motor oil (avtol and others), bitumen, castor oil, sunflower, corn, and cotton oils, petroleum
jelly, silicone grease.
The list is based on the data provided by Borealis Company, the information source is ISO/TR
7472, 7474; Carlowitz: “Kunststofftabellen-3. Auflage”
51
Appendix G
Protection of Cables in the Ground with Polymer Protective Signaling Sheets
Fig. G1. Protection of a Double Circuit Cable Line with Polymer Sheets in the Trench
Appendix H
Cable Position During the Cable Laying in Pipes at the Intersections with Roads, Runways,
and Railways
Fig. H1. Example of Cable Laying in Pipes Laid by Jacking or Horizontal Directional
Drilling under Runways and Roads
1 Cable; 2 Pipe; 3 Concrete; 4 Road Surface
Note: pipe ends must protrude at least 100 mm beyond concrete
Fig. H2. Example of Single Circuit Cable Line Laying in Pipes Under Runways and Roads
1 Cable; 2 Sand gravel mix; 3 Pipe; 4 Reinforced concrete slab; 5 Concrete; 6 Sand gravel mix or
sand; 7 Road bed
Note: pipe ends must protrude at least 100 mm beyond a reinforced concrete plate edge
53
Fig. H3. Example of Double Circuit Cable Line Laying in Pipes Under Runways and Roads
1 Cable; 2 Sand gravel mix; 3 Pipe; 4 Reinforced concrete slab; 5 Concrete; 6 Sand gravel mix or
sand; 7 Road bed
Note: pipe ends must protrude at least 100 mm beyond a reinforced concrete plate edge
Fig. H4. Example of Double Circuit Cable Line Laying in Pipes at the Intersection with Railway
Lines
1 Cable; 2 Pipe (LPPE, ceramic or asbestos-cement one); 3 Metal pipe; 4 Metal crossbar; 5
Concrete; 6 Ground
Notes:
1. A distance of at least 1500 mm must be from metal pipe axis to a railway.
2. Pipe (pos. 2) ends must protrude at least 100 mm beyond brickwork.
3. Pipes must be fastened on metal crossbars.
4. In construction of pipe fasteners, there must be no elements creating a closed magnetic loop
around sungle cables (for example, steel clamps or shackles which fasten separate pipes with a
cable on the metal crossbar). The closed magnetic loop is allowed when fastening four pipes at
once for three cables of one cable line.
55
Appendix I
Cables and Joints Fastening on Metal Structures
Fig. I1. Cables and Joints Fastening with Screen Cross Bonding on the Metal Structure in the
Cable Facility
Fig. I2. Lodgment by RKS-plast LLC for Fastening Joints on the Metal Structure
Fig. I3. Fastening a Joint and a Cable on the Metal Structure with the Help of a Lodgment
Note: a joint must be fixed in the middle part of the lodgment with the help of the P-162 binding
tape reinforced with glass-fiber (4-5 turns) or non-magnetic clamps with elastic gaskets.
Fig. I4. Type P-162 Polyester Adhesive Binding Tape Reinforced with Glass Fiber
The tape width is 50 mm; thickness is 0.15 mm; length of the reel 55 m.
57
Fig. I5. 110 kV Terminations and Cables installation on the power transmission line tower
Fig. I6. Uplifting a Termination with a Cable 110 kV onto the power transmission line tower
Fig. I7. Fastening Cables Laid in Trefoil Formation with Spacing on Cantilevers with Reinforced
Polyamide Clamps (Shackles)
Fig. I8. Fastening Cables Laid in Flat Formation on Transverse Supports Fastened on the Floor
with Reinforced Polyamide Clamps (Shackles).
59
Fig. I9. Fastening Cables Laid in Trefoil Formation on the Transverse Supports Fastened on the
Floor with Reinforced Polyamide Clamps (Shackles).
Fig. I10. VKK Cable Clamp Assembly Produced by RKS-plast LLC with Inserts and Fasteners
Fastened on the Mounting Profile
61
Fig. I11. Dimensions of VKK Cable Clamps Produced by RKS-plast LLC
Table I1 (all dimensions in mm)
VKK type L Į h a b d R
65/90 175 140 50 19 14 13 46
85/105 185 150 64 20 11 13 53
100/125 204 170 67 19 14 13 63
125/150 234 200 81 20 14 13 75
Notes:
1. Width of all VKK clamp shackles is 70mm.

2. For one fastening point two shackles shown in the figure are required.
Fig. I12. PST-80 Silicon Insert for VKK Cable Clamps by RKS-plast LLC
Note: Two PST-80 inserts are required for one VKK clamp.
63
Fig. I13. VKK3 Cable Clamp Assembly produced by RKS-plast LLC,

fastened on the mounting profile
1 Bottom layer; 2 Lid; 3 Cable; 4 Mounting Profile; 5 Pin; 6 Washer; 7 Nut
Note: Ø D is an outer diameter of the cable.

Fig. I14. Dimensions of VKK3 Cable Clamps produced by RKS-plast LLC
L Į Ød c a b g R h H
Name
min. max. min. max.
VКК3-65/90 290 234 18 80 95 130 135 32,5 166 225 198 260
VКК3-85/110 330 274 18 80 95 155 150 42,5 166 236 226 296
VКК3-110/135 380 324 20 80 100 190 155 55 175 245 265 335
65
Fig. I15. Fastening Cables on Metal Structures by VKK Cable Clamps Together with PST-80
Silicon Inserts (at the Outlets of Ducts to Terminations)
Fig. I7. Fastening Cables Laid in Trefoil Formation with Spacing on Cantilevers with Reinforced
Polyamide Clamps (Shackles).
Fig. I 17. Fastening 400 kV Cables in Flat Formation in the Tunnel on “ELLIS” Sadlles
67
Fig. I18. General View of the “ELLIS” Sadlle (clamp is not shown)
Fig. I19. Cross Section of the Middle Part of the “ELLIS” Sadlle with Three 500 kV Cables with
an Outer Diameter from 131 mm to 133mm Fixed by a Clamp
Fig. I20. Fastening Three Cables in Trefoil Formation on the Metal Structure by a Metal Clamp
1 Cable; 2 Metal clamp (shackle) made of a steel sheet or a steel strip, galvanized, 3 PST-80
insert (silicone, 6 mm width), 4 Supporting plate made of aluminum or aluminum alloy 5 mm
thick (used when required).
Notes:
1. D is an outer diameter of the cable.
2. Fasteners are not shown. Fasteners and disk spring washers may be made of carbon steel
or stainless steel. Carbon steel items must be galvanized.
3. A supporting plate made of aluminum alloy and disk spring washers are used when required.
Construction and dimensions of plates and disk spring washers as well as a number of disk
spring washers are determined in the project according to the specific requirements.
4. For one clamp three PST-80 silicon inserts are required, an excess length of inserts is bent
inside or cut off.
5. Inserts made of chloroprene rubber 5-6 mm thick may be used instead of PST-80 silicon
inserts; such insert must protrude at least 5 mm beyond the clamp across the width from both
sides.
69
Fig. I21. Fastening One Cable on the Metal Structure by a Metal Clamp (Hardware Version)
1 Cable; 2 Metal clamp (shackle) made of aluminum or aluminum alloy (from a sheet or a bus of
60-70 mm wide and 5 mm thick; 3 PST-80 insert (silicone, 6 mm thick), 4 Supporting plate made
of aluminum or aluminum alloy 5 mm thick (used when required)
Notes:
2. Fasteners are not shown. Fasteners and disk spring washers may be made of carbon or
stainless steel. Carbon steel items must be galvanized.
4. For one clamp two PST-80 silicon inserts are required, an excess length of inserts is cut off.
5. Inserts made of chloroprene rubber 4-6 mm thick may be used instead of PST-80 silicon
inserts; such insert must protrude at least 5 mm beyond the clamp across the width from both
sides.
Fig. I22. Fastening Three Cables in Flat Formation on the Metal Structure with Metal Clamps
(Hardware Version)
1 Cable; 2 Metal clamp (shackle) made of aluminum or aluminum alloy (from a sheet or a bus of
60-70 mm wide and 5 mm thick according to Fig. I 21; 3 PST-80 insert (silicone, 6 mm thick), 4
Supporting plate made of aluminum or aluminum alloy 5 mm thick (used when required)
Notes:
2. Fasteners are not shown. Fasteners and disk spring washers may be made of carbon or
stainless steel. Carbon steel items must be galvanized.
3. For one clamp two PST-80 inserts are required, an excess length of insert is cut off.
4. Insert made of chloroprene rubber of 4-6 mm thick may be used instead of PST-80 silicon
insert; such insert must protrude at least 5 mm beyond the clamp across the width from both
sides.
71
Fig. I 23. Clamps (Shackles) Made of Cast Aluminum (Silumin)

Bolt
Cable
Size Group ØD L l h1 h2 B a M хg
Diameter
I 36-67 45-70 145 105 47 65 120 4 12x 90
II 61-82 70-85 170 130 58 75 120 4 12x 110
IIS 81-92 90-95 170 130 60 120 100 4 12x 160
III 86-117 95-120 210 170 73 95 120 4 12x 120
IV 110-142 120-145 260 210 85 115 120 5 16x 150
V 140-177 150-180 300 250 105 133 120 5 16x 200
Clamp material: cast alloy aluminum (silumin). Bolt, nut, washer material: stainless steel.
Dimensions are selected with allowance for rubber inserts.
Note: after a clamp (shackle) installation a gap from 4 to 5 mm must be left between clamp
halves (see a size in the figure and in the table).
Appendix J
List of Equipment, Devices, Tools And Materials Necessary for Laying One Cable Factory
Length (Approximate)
Table J1
№ Name Unit Quantity
1 Rope winch with electric motor or internal combustion engine, pulling force is not pcs. 1
less than maximum pulling force of the cable, rope capacity is not less than the laid
cable length, equipped with devices for pulling force control, pulling force recording
and automatic shutdown in case of exceeding permissible pulling force
2 Cable pay-off unit with capacity which is not less than a cable drum weight, with a pcs. 1
shaft, sleeves and drum fixers
3 Loading traverse for cable drums with ropes and gripping unit pcs. 1
4 Swivel pcs. 1
5 Cable pulling head or grip pcs. 1
6 Braking device pcs. 1
7 Shackle* pcs. As planned
8 Cable feeder, hydraulic (petrol engine or electric motor)* pcs. As planned
9 Transitional pulling device (winch) with a motor drive * pcs. As planned
10 Steel snatch block * pcs. As planned
11 Cable linear, corner, run out, guide rollers, shackles and retainers for rollers pcs. As planned
12 Rope rollers* pcs. As planned
13 Cable lead-in dismountable cones* pcs. As planned
14 Cable lead-in cones with rollers* pcs. As planned
15 Trench braces and frame pcs. As planned
16 Wooden shield pcs. As planned
17 Cable ties or P-162 binding band * pcs. As planned
18 Conduit calibre and brushes for pipe and channel cleaning pcs. As planned
19 Conduit string (when laying in pipes) pcs. 1
20 Hook for cable guidance pcs. As planned
21 Walkie-talkies, radio stations or field telephones pcs. As planned
22 Electric saw (circular or band one) pcs. 1
23 Cable scissors NBK-2 pcs. 1
24 Tool and accessory kit for cable works NKI-3 pcs. 1
25 ТU 36-913-75 pcs. 1
26 Spanner kit (sizes 10 to 27) pcs. 1
27 Screwdriver kit (6 pcs) pcs. 1
28 Combination Pliers 250 mm pcs. 1
29 File kit (fine file, normal file) pcs. 2
30 Carving knife pcs. 1
31 Crow-bar pcs. 1
32 Hammer 500 g pcs. 1
33 Axe pcs. 1
34 Crowbar pcs. 1
35 Panel saw kg As planned
36 Nails pcs. 1
73

37 Hacksaw pcs. 5
38 Hacksaw blade pcs. 1
39 Scraper pcs. 1
40 Megaohmmeter with working voltage 2.5 kV pcs. 1
41 Brush (15-20 mm wide) pcs. 1
42 B3-50 propane bottle with the DPI-1-65 reducer pcs. 1
43 Gas burner with hoses pcs. 1
44 Metal ruler 1000 mm pcs. 1
45 Vernier pcs. 1
46 Measure tape (5 meters) pcs. 5
47 Insulating adhesive PVC tape 19 mm wide (in rolls) m2 2
48 White cotton sheeting kg 2
49 Clean wiping rag kg 0,005
50 Exterior paint (yellow, green and red) kg As planned
51 Petroleum jelly or special cable grease** pcs. As planned
52 Cap*** pcs. As planned
53 Heat-shrink tube**** pcs. As planned
54 Industrial acetone***** l 0,5
55 Rolled stock and metal pipes (when necessary, for roller fastening on the metal pcs. 1
structure)
56 Welding kit (when necessary, for roller fastening on the metal structure) pcs. 1
57 Fire protection kit (assortment according to the project of CL) pcs. 1
58 First aid kit pcs. 1
Materials for cable sheath repair (determined during compiling Planning Sheet and Technical Development Plan)
Kit for repair works using a heat-shrink sleeve
1 Heat-shrink sleeve (size depends on the cable sizes) pcs. 1
2 Industrial acetone***** l 0,5
3 Bleached chintz or madapolam rm 1
4 Sanding paper (grade 80), 25 mm wide, 1 m long pcs. 1
Tools, equipment, kits, and materials used for optic fiber tests and repair
1 Working set for an optic cable mounting, including the following: ****** pcs. 1
1.1 KNIPEX cutters for cutting a strength member pcs. 1
1.2 Miller stripper for removing 250 µm optic fiber coating pcs. 1
1.3 Miller stripper for removing optic fiber sheath (0,8…2,6 mm) pcs. 1
1.4 Pin stripper for removing the IDEAL optic module fragments pcs. 1
1.5 Kabifix FK 28 stripper for removing cable outer sheath pcs. 1
1.6 Miller scissors for cutting aramid yarns pcs. 1
1.7 Pincers pcs. 1
1.8 Magnifier pcs. 1
1.9 Isopryl alcohol l 1
1.10 Dosing tank with a pump for alcohol (225 ml) pcs. 1
1.11 Kimwipes fibreless wipes (one set) pcs. 1
1.12 KNIPEX Pliers pcs. 1

1.13 KNIPEX side cutters pcs. 1
1.14 Screwdriver kit pcs. 1
1.15 Hacksaw blade pcs. 1
1.16 Hobby knife pcs. 1
1.17 Measuring tape pcs. 1
1.18 Torch pcs. 1
1.19 Identification self-adhesive labels (one set) pcs. 1
1.20 Adhesive tape pcs. 1
1.21 Trigger sprayer pcs. 1
1.22 Case pcs. 1
2 Normalizing multimode bobbin with optic fiber pcs. 1
3 50/125, min. 200 m (FS or SC slot) pcs. 1
4 FOD 7005 optic reflectometer for multimode fibers 50/125 (FS or SC slot) pcs. 1
5 Precision cleaver for optic fiber pcs. 1
6 Fujikura FSM60 automatic fusion splicer pcs. 1
7 Needle file pcs. AS planned
8 Kit for spliced joint protection pcs. 1
9 Insulating adhesive PVC tape of 19 mm wide (rolled) pcs. 1
Working set for repairing built-in power cable optic fiber (material list is defined by pcs.
the engineering supervisor based on optic fiber damage level)
Notes:
* - used when necessary;

** - used for cable laying through blocks or pipes;
*** - type and size are determined during design stage;
**** - for sealing when a cable is pulled with a grip attached to insulation or with a head attached
to the conductor. Type and a size are determined during design stage;
***** - rubber solvent, petroleum solvent or white spirit may be used instead of acetone;
****** - the list of equipment may be modified at the Customer’s request or as a result of tool
modernization.
75
Appendix K
Installation of Cable Line Laying Equipment
Fig. К1. Cable run off from the Drum to the Cable Route
Fig. К2 Guide Roller Installation During the 500 kV Cable Laying in Ducts
at the Cable Route Turn
77
Fig. К3. Cable Roller Installation at the Cable Route

Appendix L
Corner Roller Installation at the Route Turn
Figure L1 illustrates installation of ERS 3 corner rollers with BN 70 fixing nails by Vetter GmbH
(Germany) at the 90o route turn.
Depending on the cable bending radius, the number of rollers and fixing nails to be installed may
vary; amount is specified in table L1.
Table L1
Cable bending radius, mm Number of ERS 3 corner rollers, pcs. Number of BN 70 fixing nails, pcs.
R=3000 9 10
R=2500 8 9
R=2000 6 7
R=1500 5 6
R=1000 4 5
Notes:
- ERS 3 corner rollers are designed to lay cables with the diameter up to 100 mm;
- Length of BN 70 fixing nails is 70 cm.
Fig. L1. Corner Roller Installation at the 90o Route Turn

79
Figure L2 illustrates installation of EWS 3 corner rollers by Vetter GmbH (Germany) at the 90o route
turn. Depending on a cable bending radius a number of rollers and fixing nails to be installed may
be different; amount is specified in table L2.
Table L2
Cable bending radius, mm Number of EWS 3 corner rollers, pcs. Number of BN 100 fixing nails, pcs.
R=3500 13 14
R=3000 11 12
R=2500 9 10
Notes:
- EWS 3 corner rollers are designed to lay cables with a diameter up to 160 mm;
- Length of BN 100 fixing nails is 1000 mm.
Fig. L2. EWS 3 Corner Roller Installation at the 90o Route Turn
Fig. L3. Corner Roller Installation When Laying a Cable with the Minimum Bending Radius over
3.5 m
81
Appendix L Fig. L4. Installation of Cable Deviation Devices and a Cable Feeder during the
Cable Laying in the Pipe through a Cable Pit
Appendix M
Cable Sheath Repair Technology
Damage repair using a heat-shrink sleeves:

1.1 The technology covers repair works for cable sheath damage if cable structural
elements under the sheath are not damaged.
1.2 For cable sheath repair it is recommended to use heat-shrink sleeves by “Tyco
Electronics Raychem” GmbH 750-1500 mm long. Basic data and types of sleeves are specified
in reference table M1 to order.
Outer Diameter Sleeve Inner Diameter, mm

of the Cable to
Sleeve Type to order Length, mm
be Repaired, Before Shrinking After Shrinking
mm Da(minimum) Db(maximum)
CRSM Repair Heat-shrink Sleeves
CRSM 198/55-1000/239 1000
From 56 to 120 203 50
CRSM 198/55-1500/239 1500
From 103 to CRSM 250/98-1000/239 1000

257 91
150 CRSM 250/98-1500/239 1500
RFSM Glass Fiber Reinforced Heat-shrink Sleeves
RFSM 125/40-750/123 750
From 40 to 125 135 36 RFSM 125/40-1000/123 1000
RFSM 125/40-1500/123 1500
RFSM 165/55-750/123 750
From 55 to 165 178 50
RFSM 165/55-1500/123 1500
RFSM 205/65-750/123 750
From 65 to 20-5 222 59
RFSM 205/65-1500/123 1500
Similar quality heat-shrink sleeves from other manufacturers may be used as agreed with the
engineering supervisor.
1.3 Determine a boundary of the cable sheath to be repaired section (at least 100 mm from
both sides of defect edges along the cable in case if the sheath has no conductive layer).
1.4 Remove all unevenness, ribs, and embossed signs with the help of a scraper on the sheath
surface at the section under repair.
1.5 If the cable sheath to be repaired has a conductive layer remove it from the cable sheath
with a scraper on the length of 200 mm from both sides of the damaged place. Then check
surface resistance at the cleaned sections with a megaohmmeter with operating voltage 2.5 kV
and five copper wire bandages (1-2 turns) mounted at the equal spacing from each other on both
sections under test. The megaohmmeter is used to measure resistance between neighboring
bandages. Resistance between each pair of bandages must be at least 200 MOhm.
1.6 Work out the sheath surface under repairs with a sanding paper till lateral scratches,
cavities, shells, etc. completely disappear, and after that degrease it with acetone (use of cleaners
benzine, petroleum solvent or white spirit is possible).
1.7 Take a lock from the heat-shrink sleeve repair kit and cut off with a hacksaw a section from
it along the slots with a length approximately equal to the repaired section (rough up the edges
along the cut with a file to remove sharp edges and burrs). Cut off a section of the same length
from the sleeve.
1.8 Take off a protective film from the heat-shrink sleeve cut section, wrap the sleeve around the
83
repaired cable so that an adhesive interlayer (adhesive compound) of the sleeve adjoins to the
cable sheath, pull the lock over sleeve ridges.
1.9 Position the sleeve with the lock symmetrically to the damaged sheath section. Start heating
the sleeve from the middle on the side opposite to the lock with a low flame of a gas burner.
Moving the gas burner flame along and across the sleeve achieve its shrinking on the cable.
Make sure that the sleeve is not overheated.
1.10 After complete adjoining of the sleeve to the cable sheath heat the area near the sleeve
lock additionally. If the sleeve has shrunk correctly after heating adhesive compound must be
squeezed out evenly on both sides of the sleeve.
1.11 Let the sleeve cool down after shrinking to the temperature lower than + 35ºС.. No
mechanical impact on the repaired place is allowed before cooling down.

Manual For Laying 110-500 KV XLPE Power Cables

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Manual For Laying 110-500 KV XLPE Power Cables

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TD–16–01 L

This manual serves as guidelines and is written

3. Cable Laying Safety Rules

4. Storage and Transportation of Cable Drums

5. Requirements to Cable Laying, Cable Route and Cable Laying Equipment

5.2 Laying Cables In the Ground

In Appendix I, Figure I5 illustrates an example of fastening 110 kV cables and terminations on

Fig. 5.4.1 Vertical “S” Shape Cable

Fig. 5.4.2 Horizontal “S” Shaped Cable

5.5 Cable and Wires Installation in Case of Screen Cross Bonding

5.6 Laying Cables with Built-in Optic Fiber

tunnels) field telephone connection must be provided.

5.9 Rout Acceptance Requirements

5.10 Cable Laying

stop laying, pull the end back and fix it.

8. Associated Technical and Regulatory Documentation:

1. Typical Cap Sizes

45 90 GEC 501 100 45 160 4,0

3. Damaged Cap Replacement

Recommendations for Preheating of Cable Drums in Winter Time

3. During the heating process, ambient temperature is measured by a thermometer installed

8. Cable temperature measurement during the cable laying is recommended to be done

Fig. D3. Double Circuit Cable Line Laying in the Trench

Fig. E3. Example of fastening of a cable reserve for terminations installation

List of Substances Affecting Cable Sheath

Protection of Cables in the Ground with Polymer Protective Signaling Sheets

Cables and Joints Fastening on Metal Structures

Fig. I11. Dimensions of VKK Cable Clamps Produced by RKS-plast LLC

Table I1 (all dimensions in mm)

65/90 175 140 50 19 14 13 46

85/105 185 150 64 20 11 13 53

100/125 204 170 67 19 14 13 63

125/150 234 200 81 20 14 13 75

1. Width of all VKK clamp shackles is 70mm.

Fig. I13. VKK3 Cable Clamp Assembly produced by RKS-plast LLC,

1 Bottom layer; 2 Lid; 3 Cable; 4 Mounting Profile; 5 Pin; 6 Washer; 7 Nut

Note: Ø D is an outer diameter of the cable.

Fig. I14. Dimensions of VKK3 Cable Clamps produced by RKS-plast LLC

Table I2 (all dimensions in mm)

Fig. I 23. Clamps (Shackles) Made of Cast Aluminum (Silumin)

Table I3 (all dimensions in mm)

I 36-67 45-70 145 105 47 65 120 4 12x 90

II 61-82 70-85 170 130 58 75 120 4 12x 110

IIS 81-92 90-95 170 130 60 120 100 4 12x 160

III 86-117 95-120 210 170 73 95 120 4 12x 120

IV 110-142 120-145 260 210 85 115 120 5 16x 150

V 140-177 150-180 300 250 105 133 120 5 16x 200

№ Name Unit Quantity

№ Name Unit Quantity

* - used when necessary;

Fig. К3. Cable Roller Installation at the Cable Route

Corner Roller Installation at the Route Turn

Fig. L1. Corner Roller Installation at the 90o Route Turn

Damage repair using a heat-shrink sleeves:

Outer Diameter Sleeve Inner Diameter, mm

From 103 to CRSM 250/98-1000/239 1000

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