Handbook of Underground

Power Cables Vol. 2:

Design, Construction &
Installation of Underground
Power Cable Systems

Copyright © 2012
International Copper Association Southeast Asia Ltd
Provincial Electricity Authority, Thailand

All rights reserved. No part of this publication may be reproduced or

distributed in any form or by any means, or stored in a database or
retrieval system, without the prior written permission of the publisher.

Printed in Singapore
Foreword|
The Provincial Electricity Authority of Thailand supplies electricity to 99% of Thailand.
It has developed and applies state of the art technology for its distribution and dispatching
systems; thus improving the efficiency, reliability and quality of service to the rural areas
of Thailand which in return improves the quality of life of the rural population. I am
pleased that this achievement of PEA serves as a benchmark for other utilities in the
Lower Mekong Sub-region (LMS) countries with similar geographical conditions.

Two years ago, PEA signed a Memorandum of Understanding (MOU) with International
Copper Association Southeast Asia (ICASEA) to further strengthen regional cooperation
through the implementation of the regional cooperation strategy roadmap for the
harmonization of power distribution systems in the Lower Mekong Sub-Region (LMS)
plus upgrading the competency and capacity of both technical and managerial staff.

The impetus of this MOU has enabled PEA, with its knowledge, skill and experience, to
play an active role in the transfer of technology to utilities in LMS. The development of
this Handbook is a good example of our contribution. It will enable the LMS countries to
make further progress towards harmonization and the realization of the objectives as set
out in the strategic roadmap for the harmonization of power distribution systems in the
LMS.

I am also pleased to note that PEA has also been providing training services to LMS
Utilities on underground and submarine power cables under the LMS Harmonization
Program. PEA has also benefited from this partnership as evidenced by the support of
ICASEA for the development of underground power cable systems in large towns as part
of its long term power system development plan. Under this program PEA focus is on
high technology industrial areas, high density tourism spots and places of historical
significance, amongst others. There is no denying that the key success for the
implementation of an underground power cable system is the close co-operation and
mutual understanding between the power utility and all the municipalities.

The partnership between PEA and ICASEA has been effective and remains strong. We
will continue to work collectively to strengthen the technical and managerial capacity of
power utilities in LMS for the harmonization of power distribution systems, exchange
knowledge and experiences of PEA with other utilities in the LMS and move towards
greater harmonization in the development of power distribution systems in LMS.

Mr. Narongsak Kamales

Governor
Provincial Electricity Authority (PEA)
Thailand
Introduction|
The Lower Mekong Sub-region (LMS)
Harmonisation Programme

ambodia, Lao People’s Democratic Republic (Lao PDR),

C Thailand and Vietnam have achieved different levels of
economic development. These countries in the Lower Mekong Sub-
region (LMS) have strong economic inter-dependence.

Being developing countries, their power distribution systems, which are an essential
infrastructure, play a significant role in their economic development. Energy end-
users are dependent on the availability, reliability, and quality of electricity from the
power distribution systems. The level of development and advancement of power
distribution systems has direct impact on the developmental potential and economic
growth, especially in urban areas.

The power distribution systems in the urban areas of these LMS countries, however,
are not at the same level of physical and technological development. It is widely
acknowledged that harmonisation in the development of power distribution systems
can benefit these countries and accelerate their economic growth.

In 2005, six power utilities signed a Memorandum of Understanding (MOU) with

the expressed intention of close cooperation to share knowledge and experiences
towards harmonisation of power distribution systems in four LMS countries:
Cambodia, Lao PDR, Thailand and Vietnam. The founding partners are:

Electricité du Cambodge (EDC), Cambodia

Electricité du Laos (EDL), Lao PDR
Ho Chi Minh City Power Company (HCMC PC), Vietnam
Hanoi Power Company (HNPC), Vietnam
Metropolitan Electricity Authority (MEA), Thailand
International Copper Association Southeast Asia (ICASEA) [formerly known as
Copper Development Centre • Southeast Asia]

This MOU initiated a comprehensive review of power distribution systems of the

signatory utility partners in Cambodia, Lao PDR and Vietnam which resulted in the
preparation of a regional cooperation roadmap and action plan.
Building on the success of the first MOU, ICASEA and MEA inked a second MOU
to continue their strategic partnership in conducting further studies and facilitating
programmes as outlined in phase 2 of the road map and action plan. This impetus is
to enable the LMS countries to make further progress towards harmonisation and the
realisation of the objectives as set out in the MOU with all the partner utilities.

The study of power distribution systems in the LMS countries under the first MOU
had revealed that there exist many differences in the design and operation of power
distribution systems in this region. The objective of this second MOU was to
narrow down the differences in six key areas and enable the LMS countries to move
towards greater harmonization of their power distribution systems.

Since then, the following LMS Utilities have joined the Harmonisation Programme:

Danang Power Company (DNPC), Vietnam in 2009

HaiPhong Power Company (HPPC), Vietnam in 2009
Provincial Electricity Authority (PEA), Thailand in 2010
Central Power Corporation (EVNCPC), Vietnam in 2010
Northern Power Corporation (EVNNPC), Vietnam in 2012
Southern Power Corporation (EVNSPC), Vietnam in 2012
Preface|
T he idea for PEA and ICASEA to collaborate on the development
of the Handbook of Underground Power Cables Vol. 2: Design,
Construction & Installation of Underground Power Cable Systems,
arose from the potential benefits that both Utilities in LMS and PEA
can derive from this handbook.
PEA appointed a technical working group comprising of experts from various
relevant and integrated units to define the framework and write the content of this
handbook together with ICASEA. It adapted best practices and guidelines from
PEA, incorporated additional information from discussions with EVN Hanoi Power
Corporation and observations made during visits to various underground power
cable system construction sites in Vietnam.

ICASEA managed the process for content development and production of the
handbook. It also tapped on technical expertise from its international and regional
resources to review and ensure that the best practices are based on international
standards.

The following contributed towards the development of the content for this
handbook:

PEA Technical Working Group on Underground Power Cable Systems:

Sompong Duangkaemanee Watchara Panchang

Retired Director, Substation Chief of Section, Transmission
Construction and Maintenance System Design Division
Department
Titti Trakulsinthong
Somchai Songsiri Assistant Manager, Power System
Manager, Power System Maintenance Division
Maintenance Division
Somchai Sripoom
Somchoke Boonchaisri Chief of Section, Special Project
Deputy Manager, Special Project Office 1
Office 2
Mana Patamakajonpong
Songwut Khandee Chief of Section,
Deputy Manager, System Planning Training Division
Division
Geerawat Longampai PEA Project Support Team:
Specialist Level 8, High Voltage
Training Division Sermsakool Klaikaew
Director, Personnel Development
Komkrish Dornpromyung Department
Assistant Chief of Section, Power
System Standard Division Ms Jurailuk Chotiwana
Retired Director, Personnel
Nongluk Suvanjumrat Development Department
Chief of Section, Power System
Maintenance Division Dr Pradit Fuangfoo
Manager, Training Division
Phisutthisak Dulyapaphat
Assistant Chief of Section, Power Mana Patamakajonpong
System Construction Division Chief of Knowledge Management
Section, Training Division

EVN HANOI Team for joint Ms Chutinart Suthisom

consultation and site visit: Chief of Section, Training Division

Trinh Xuan Nguyen

Manager, Technical Department International Copper Association
Southeast Asia (ICASEA):
Dinh Tien Dung
Senior Expert, Technical Department Louis Koh, Program Manager
Power Distribution

Technical Reviewer & Editor: Piyadith Lamaisathien

Country Manager (Thailand)
Surapon Soponkanaporn
Chairman, LMS Technical Working
Group #1 and #3
Acknowledgements|
T he harmonization of power distribution systems in the LMS will
contribute to the expansion of the ASEAN Power Grid.
However, harmonization requires a robust partnership and sustained
effort over many years.
The harmonization of technical specifications together with the development of this
handbook is taking the process a step closer towards the realization of the objectives
as set out in the strategic roadmap for the harmonization of power distribution
systems in the LMS.

Strengthening regional cooperation to build the capacity of both technical and

functional staff would not have been possible without the endorsement and support
of:

Electricité du Cambodge (EDC), Cambodia:

Keo Rottanak, Managing Director

Chan Sodavath, Deputy Managing Director

Electricité du Laos (EDL), Lao PDR:

Sisavath Thiravong, Managing Director and CEO

Boum Oum Syvanpheng, Deputy Managing Director

Hanoi Power Corporation (EVNHANOI), Vietnam:

Tran Duc Hung, General Director

Vu Quang Hung, Deputy General Director

Ho Chi Minh Power Corporation (EVNHCMC), Vietnam:

Le Van Phuoc, General Director

Tran Khiem Tuan, Deputy General Director
Northern Power Corporation (EVNNPC), Vietnam:

Nguyen Phuc Vinh, General Director

Cam Thieu Kim Quynh, Deputy General Director

Central Power Corporation (EVNCPC), Vietnam:

Tran Dinh Thanh, General Director

Nguyen Thanh, Deputy General Director

Southern Power Corporation (EVNSPC), Vietnam:

Nguyen Thanh Duy, General Director

Ho Quang Ai, Deputy General Director

EVNHANOI Haiphong Power Company, Vietnam:

Vu Duc Hoan, Director

EVNCPC Danang Power Company, Vietnam:

Le Thanh Minh, Director

Provincial Electricity Authority (PEA), Thailand:

Narongsak Kamales, Governor

Seree Prachayakul, Deputy Governor – Human Resource Development
Suttidej Suttisom, Retired Deputy Governor – Human Resource Development

Metropolitan Electricity Authority (MEA), Thailand:

Arthorn Sinsawad, Governor

International Copper Association Southeast Asia (ICASEA):

Steven Sim, Chief Executive Officer

Bek Chee Jin, Chief Operating Officer
Table of Content
CHAPTER 1 - Introduction to PEA Underground Power Cable Systems
1.1 Introduction ........................................................................................................................... 1
1.2 Power Cable Systems ............................................................................................................ 1
1.3 Design and Construction ....................................................................................................... 3

CHAPTER 2 - Planning
2.1 Introduction ........................................................................................................................... 4
2.2 Planning and Selection of Supply Area ................................................................................ 4
2.3 Power System Reliability ...................................................................................................... 5
2.4 Engineering Criteria .............................................................................................................. 5
2.5 Medium voltage 22kV & 33 kV System Configuration Planning ........................................ 7
2.6 Low Voltage Distribution (≤ 1.0 kV) System Configuration Planning ................................ 10

CHAPTER 3 - Design
3.1 Introduction ........................................................................................................................... 15
3.2 Type of Construction ............................................................................................................ 15
3.3 Open-cut Method .................................................................................................................. 15
3.4 No-dig Method ...................................................................................................................... 18
3.5 Minimum Clearances between Power Cables and other utilities infrastructure ................... 20
3.6 Construction of Underground Cable ..................................................................................... 21
3.7 Cable Conduits ...................................................................................................................... 22
3.8 Manholes ............................................................................................................................... 23
3.9 Riser Pole .............................................................................................................................. 26
3.10 Selection of conduits for underground cable......................................................................... 27
3.11 Pulling Tensions for Underground Cable ............................................................................. 30
3.12 Grounding ............................................................................................................................. 31
3.13 Underground Cable Dimensioning and Selection ................................................................. 35
3.14 Cable Terminations and In-line Splices ................................................................................ 35

CHAPTER 4 - Civil Work Procedures

4.1 Introduction ........................................................................................................................... 44
4.2 Pre-planning and Preparation ................................................................................................ 44
4.3 Construction of Duct Bank.................................................................................................... 48
4.4 Construction of Manholes ..................................................................................................... 55
4.5 Horizontal Directional Drilling (HDD) ................................................................................. 64
4.6 Pipe Jacking .......................................................................................................................... 73

CHAPTER 5 - Electrical Work Procedures

5.1 Introduction ........................................................................................................................... 82
5.2 Cable Pulling ......................................................................................................................... 84
5.3 Erection of supporting structure and installation of cable riser............................................. 89
5.4 Cable Termination................................................................................................................. 90
5.5 HV termination kits with polymeric stress cones for cables rated at 69kV & 115k ............. 99
5.6 Splicing of Underground Cables ........................................................................................... 116
CHAPTER 6 - Cable Testing
6.1 Introduction ........................................................................................................................... 121
6.2 Factory Testing ..................................................................................................................... 121
6.3 Type Tests ............................................................................................................................. 122
6.4 Routine Tests......................................................................................................................... 123
6.5 Summary of Tests ................................................................................................................. 124
6.6 Field Test............................................................................................................................... 127

CHAPTER 7 - Operation and Maintenance

7.1 Introduction ........................................................................................................................... 134
7.2 Operation............................................................................................................................... 134
7.3 Preventive Maintenance ........................................................................................................ 135
7.4 Corrective Maintenance ........................................................................................................ 136
7.5 Condition Based Maintenance .............................................................................................. 136

REFERENCE
Appendix I ....................................................................................................................................... 139
Appendix II ..................................................................................................................................... 163

FIGURES

Figure 2.1 Closed Loop Configurations for Underground System (High Stability) ·········· 7
Figure 2.2 Opened Loop Configurations for Underground System (Medium Stability) ···· 8
Figure 2.3 Opened Loop Configurations for Underground System for ····························· 8
Municipality Area
Figure 2.4 Opened Loop with Special Spare Feeder Configuration for Underground ···· 9
System For Municipality Area (with Special Spare Feeder for switching)
Figure 2.5 Radial configuration for low voltage distribution underground system ·········· 10
Figure 2.6 Open loop configuration for low voltage underground power cable ··············· 10
distribution system (2 transformers configuration)
Figure 2.7 Open loop configuration for low voltage underground power ························· 11
cable distribution system (3 or more transformers configuration)

Figure 3.1 Concrete Encased Duct Bank ··········································································· 16

Figure 3.2 Cross-section of Semi-direct Burial ································································· 17
Figure 3.3 Cross-section of Direct Burial·········································································· 18
Figure 3.4 Horizontal Directional Drilling (HDD) ··························································· 19
Figure 3.5 Pipe Jacking ····································································································· 20
Figure 3.6 High-Density Polyethylene (HDPE) and corrugate HDPE conduits ··············· 23
Figure 3.7 Fiberglass or Reinforced Thermosetting Resin (RTRC) conduits ···················· 23
Figure 3.8 Y-splitting and branching of cable circuits ······················································ 24
Figure 3.9 In-line splicing, Y-splitting, branching at major traffic intersections ·············· 25
Figure 3.10 In-line splicing, Y-splitting and branching ······················································· 25
Figure 3.11 Cable joints and branching at road intersections ············································ 25
Figure 3.12 In-line splicing, Y-splitting and branching ······················································· 26
Figure 3.13 Riser pole for voltages of 22 and 33 kV···························································· 26
Figure 3.14 Riser pole for voltages ≥ 115 kV ······································································ 27
Figure 3.15 Basket grips type······························································································· 31
Figure 3.16 Pulling eyes type ······························································································· 31
Figure 3.17 Single-point bonding method ············································································ 32
Figure 3.18 Both-ends bonding method ··············································································· 33
Figure 3.19 Mid-point bonding method ··············································································· 33
Figure 3.20 Multi-point bonding method ············································································· 33
Figure 3.21 Cross-bonding method······················································································ 34
Figure 3.22 Stress cone (right) and electric field distribution in a stress cone (left)··········· 37
Figure 3.23 Electric field distribution in HI-K Material ····················································· 37
Figure 3.24 Porcelain type outdoor sealing end ·································································· 38
Figure 3.25 Slip-on type termination ··················································································· 39
Figure 3.26 Cold Shrink type termination············································································ 39
Figure 3.27 Heat shrink termination ···················································································· 40
Figure 3.28 In-line Splice····································································································· 41
Figure 3.29 Self-amalgamating tape in-line splice ······························································ 42

Figure 4.1 Cable Route Survey Plans ················································································ 45

Figure 4.2 Cross Sectional Construction Drawing ···························································· 45
Figure 4.3 Cable route survey and demarcation································································ 46
Figure 4.4 Mapping Utilities services with GPR Machine ················································ 46
Figure 4.5 Pilot hole – helps to locate existing underground utilities ······························· 47
Figure 4.6 A typical S-curve······························································································· 47
Figure 4.7 Safety warning signs and barricades for work site ·········································· 48
Figure 4.8 HDPE pipes ······································································································ 48
Figure 4.9 Concrete spacer blocks····················································································· 48
Figure 4.10 HDPE coupling and assembly drawing···························································· 49
Figure 4.11 HDPE 90° elbow and assembly drawing ························································· 49
Figure 4.12 Round bars and formworks ·············································································· 49
Figure 4.13 A typical cross-sectional drawing of a 2 x 2 duct bank ···································· 50
Figure 4.14 Trench excavation ···························································································· 50
Figure 4.15 HDPE pipes, round bars, concrete spacer blocks & formworks installation··· 50
Figure 4.16 Joining HDPE pipes using HDPE couplings ··················································· 51
Figure 4.17 Installation of 90° HDPE elbow ······································································· 51
Figure 4.18 Concrete pouring ······························································································ 52
Figure 4.19 Duct Bank after dismantling the formwork ······················································ 52
Figure 4.20 Backfilling and resurfacing of road·································································· 53
Figure 4.21 Installation of cable route markers ·································································· 53
Figure 4.22 Internal cleaning of HDPE pipes ····································································· 53
Figure 4.23 Inserting nylon rope into the HDPE pipes ······················································· 54
Figure 4.24 Dummy testing HDPE pipes ············································································· 54
Figure 4.25 Dummy testing for HDPE 90° elbow································································ 54
Figure 4.26 Riser poles – BEFORE and AFTER pouring of fire-rated concrete and·········· 55
installation of protective steel-guard
Figure 4.27 Manhole pit supported by steel sheet piles ······················································· 55
Figure 4.28 Pouring lean concrete at base of pit ································································· 56
Figure 4.29 Installing formwork and steel-bars for the manhole ········································ 56
Figure 4.30 Installation of ground Rods and pulling iron ··················································· 56
Figure 4.31 Pouring concrete for bottom slab ····································································· 57
Figure 4.32 Installing formworks for walls and duct bank windows ··································· 57
Figure 4.33 Installing pulling-irons ····················································································· 58
Figure 4.34 Pouring concrete for manhole walls ································································ 58
Figure 4.35 Dismantle the formwork for the manhole ························································· 58
Figure 4.36 End Bells Installed at manhole’s duct bank window ········································ 59
Figure 4.37 Duct bank window ···························································································· 60
Figure 4.38 Formworks and steel bars for top slab ····························································· 60
Figure 4.39 Pouring concrete for Top Slab ········································································· 60
Figure 4.40 Installation of manhole entrance ······································································ 61
Figure 4.41 Pouring concrete for manhole entrances ························································· 61
Figure 4.42 Manhole entrances with formworks dismantled ··············································· 61
Figure 4.43 Manhole with entrance covers and area after landscaping ····························· 62
Figure 4.44 Area cleared of all construction material and resurfaced road ······················· 62
Figure 4.45 Layout drawings for cable racks ······································································ 62
Figure 4.46 Cable rack supports and accessories ······························································· 63
Figure 4.47 Cable racks with cable installed······································································· 63
Figure 4.48 Grounding grid layout drawing and typical installation in a manhole ············ 63
Figure 4.49 Drawing for manhole type 2T-3 ······································································· 64
Figure 4.50 Sample bore profile plan ·················································································· 65
Figure 4.51 Main Components of HDD System ··································································· 66
Figure 4.52 Sonde Machine Calibration ·············································································· 66
Figure 4.53 Drill head assembly drawings ·········································································· 67
Figure 4.54 Drilling-fluid flow testing ················································································· 67
Figure 4.55 Cross sectional drawing showing drill entry for pilot bore ····························· 68
Figure 4.56 Tracking the pilot bore path ············································································· 69
Figure 4.57 Disassembly of drilling head ············································································ 69
Figure 4.58 Selection of back reamer ·················································································· 70
Figure 4.59 Assembly drawing for intermediate back reaming ··········································· 70
Figure 4.60 Connection between expander chuck and pipe················································· 71
Figure 4.61 Before pullback of bundled pipes ····································································· 72
Figure 4.62 After pullback of bundled pipes ········································································ 72
Figure 4.63 Dummy testing of HDPE pipes ········································································· 72
Figure 4.64 Typical arrangement for pipe jacking ······························································ 74
Figure 4.65.1 Jacking Pipe ····································································································· 74
Figure 4.65.2 Generator ········································································································· 74
Figure 4.65.3 Winch ················································································································ 75
Figure 4.65.4 Hydraulic machine ··························································································· 75
Figure 4.65.5 Hydraulic Jacks ································································································ 75
Figure 4.65.6 Weld Components ····························································································· 75
Figure 4.65.7 Truck with crane ······························································································· 75
Figure 4.65.8 Air blower ········································································································· 75
Figure 4.66 Preparing the launch and reception pits ·························································· 76
Figure 4.67 Aligning the jacking frame ··············································································· 76
Figure 4.68.1 Installing a pipe segment on the jacking frame ··············································· 77
Figure 4.68.2 Clean edge of pipe segment ·············································································· 77
Figure 4.68.3 Welding of small metal plates ··········································································· 77
Figure 4.68.4 Welding pipe segments together ······································································· 77
Figure 4.68.5 Rust-proofing the welded area ········································································· 78
Figure 4.69 Soil excavation in progress ·············································································· 78
Figure 4.70 Removing excavated soil from launch pit ························································· 78
Figure 4.71.1 Jacking of pipe segment···················································································· 79
Figure 4.71.2 Level check ······································································································· 79
Figure 4.72 Rechecking level using surveyor’s equipment ·················································· 79
Figure 4.73.1 Positioning of deformed bars within steel pipe ················································ 80
Figure 4.73.2 Welding deformed bars on the inside of steel pipe ··········································· 80
Figure 4.74 HDPE pipes installed on deformed bars ·························································· 80
Figure 4.75.1 Steel pipe for grouting ······················································································ 81
Figure 4.75.2 Formworks installed ························································································· 81
Figure 4.75.3 Grouting with mortar ······················································································· 81
Figure 4.76 View of completed pipe jacking with HDPE pipes encased in concrete ·········· 81

Figure 5.1 Electrical Work Area ························································································ 82

Figure 5.2 Safety Management ·························································································· 83
Figure 5.3 Cable Roll-Off Direction ·················································································· 83
Figure 5.4 Dummy Test and Profile Drawing for Dummy Test ········································· 83
Figure 5.5.1 Winch ················································································································ 84
Figure 5.5.2 Sling ·················································································································· 84
Figure 5.5.3 Swivel················································································································ 84
Figure 5.5.4 Dynamometer ··································································································· 84
Figure 5.5.5 Roller ················································································································ 84
Figure 5.5.6 Pulling Eye ······································································································· 84
Figure 5.5.7 Cable Cutter Saw······························································································ 84
Figure 5.5.8 Gas tank with safety valve, nozzle, high pressure hose, torch handle & burner 84
Figure 5.5.9 Cable Lubricant ································································································ 85
Figure 5.5.10 Heat Shrinkable Tube ······················································································· 85
Figure 5.6 Remove Cable Jacket and Insulation································································ 85
Figure 5.7 Pulling eye installation ····················································································· 85
Figure 5.8 Rubber taping the Pulling eye and Cable ························································· 86
Figure 5.9 Heat shrinking protective jacket ······································································· 86
Figure 5.10 Installation of aluminum tube and swivel ························································· 86
Figure 5.11 Roller and Dynamometer Installation ······························································ 87
Figure 5.12 Winching of cable sling ···················································································· 88
Figure 5.13 Smearing the cable with cable lubricant ·························································· 88
Figure 5.14 Setting and terminating cable at riser pole ······················································ 88
Figure 5.15 Cables ends protected by PVC End-caps. ························································ 89
Figure 5.16 Supporting structure ························································································· 89
Figure 5.17 Cable Support Clamps ······················································································ 90
Figure 5.18 Cable riser alignment ······················································································· 90
Figure 5.19 Cable preparations on supporting structure ···················································· 90
Figure 5.20 Common tools for MV cable termination ························································· 91
Figure 5.21 Type of Terminations ························································································ 91
Figure 5.22 Components of a Termination Joint ································································· 92
Figure 5.23 A typical cable termination kit·········································································· 92
Figure 5.24 Removing the outer protective jacket ······························································· 93
Figure 5.25 Installation of Moisture Sealing Tape ······························································ 94
Figure 5.26 Removing semi-conducting screen ··································································· 94
Figure 5.27 Installing Cable Terminal Lug ········································································· 95
Figure 5.28 Installing Void Filler Tape ·············································································· 95
Figure 5.29 Installing Stress Control Tubing······································································· 96
Figure 5.30 Moisture Sealing······························································································· 96
Figure 5.31 Installation of Non-Tracking Sleeve ································································· 97
Figure 5.32 Installation of Creepage Extenders ·································································· 97
Figure 5.33 Number of Creepage Extenders at various voltage ratings······························ 98
Figure 5.34 Termination of 22kV Cable to riser pole ·························································· 99
Figure 5.35 Megohmmeter for insulation resistance testing················································ 99
Figure 5.36.1 Cable Heater with Temperature Control·························································· 100
Figure 5.36.2 Cable cutter saw ······························································································· 100
Figure 5.36.3 Cable Screen & Insulation Removal Tool ························································ 100
Figure 5.36.4 Power Sanders ·································································································· 100
Figure 5.36.5 Vernier and Tape Measure ··············································································· 100
Figure 5.36.6 Coffing Hoist ···································································································· 100
Figure 5.36.7 Angle Steel 0.75-1.5 ton···················································································· 100
Figure 5.36.8 Cable Cutter Knifes, Pliers, Screw Drivers, Hammers, Jacket Removal ········ 101
Tools and Brass Brushes
Figure 5.36.9 Torque Wrench ································································································· 101
Figure 5.36.10 Fitting Tool for Stress cone ·············································································· 101
Figure 5.36.11 Hydraulic Crimping Tool with Crimping Dies ················································· 101
Figure 5.36.12 Torch Handle, Nozzles, High Pressure Hose, Compact Gas, Safety Valve ······ 101
Figure 5.36.13 Wrench·············································································································· 102
Figure 5.36.14 Thermometer····································································································· 102
Figure 5.36.15 Heavy-duty Figure ··························································································· 102
Figure 5.36.16 Hot Air Gun ······································································································ 102
Figure 5.36.17 Glass Blade······································································································· 102
Figure 5.36.18 Gloves ··············································································································· 102
Figure 5.36.19 Marker ·············································································································· 102
Figure 5.36.20 Plastic wrap ······································································································ 102
Figure 5.36.21 Dust mask ········································································································· 102
Figure 5.36.22 Cleaning cloth ·································································································· 102
Figure 5.37 Cable Installation ····························································································· 103
Figure 5.38 Cutting the cable······························································································· 103
Figure 5.39 Heating the cable ······························································································ 104
Figure 5.40 Measure the length of termination insulator ···················································· 104
Figure 5.41 Base-plate installation ······················································································ 104
Figure 5.42 Cable preparation ···························································································· 105
Figure 5.43 Removing Flipper ····························································································· 105
Figure 5.44 Cable with metallic sheath ··············································································· 106
Figure 5.45 Removing the outer jacket ················································································ 106
Figure 5.46 Removing water barrier tape············································································ 107
Figure 5.47 Setting the copper wire screen·········································································· 107
Figure 5.48 Removing insulation screen ·············································································· 107
Figure 5.49 Insulation screen being shaped to requirement ················································ 108
Figure 5.50 Applying the power sander tool ········································································ 108
Figure 5.51 Applying the plastic wrap ················································································· 108
Figure 5.52 Cable insulation after it has been shaped ························································ 109
Figure 5.53 Compressing the top connector ········································································ 109
Figure 5.54 Wrapping the connector with tape···································································· 110
Figure 5.55 Stress control unit ····························································································· 110
Figure 5.56 Marking the position for the stress control unit ··············································· 111
Figure 5.57 Setting-up the base plate ·················································································· 111
Figure 5.58 Base plate with insulators ················································································ 111
Figure 5.59 Inspecting Stress Cone ···················································································· 112
Figure 5.60 Smearing silicone grease on XLPE insulation ················································· 112
Figure 5.61 Installing Stress Cone on the cable ·································································· 112
Figure 5.62 Cleaning the silicone grease ············································································ 113
Figure 5.63 Apply the copper mesh tape ·············································································· 113
Figure 5.64 Preparing the insulator for installation···························································· 113
Figure 5.65 Cable with Stress Cone installed ······································································ 114
Figure 5.66 Installing the insulator ····················································································· 114
Figure 5.67.1 Heating process ································································································ 114
Figure 5.67.2 Pouring into insulator ······················································································ 114
Figure 5.68 Installing the Top Cover ··················································································· 115
Figure 5.69 Preparing the ground connection ····································································· 115
Figure 5.70 Combining the copper wires into a ground connecting lead ···························· 115
Figure 5.71 Connection to grounding terminal ··································································· 116
Figure 5.72 69/115 kV Riser-pole ························································································ 116
Figure 5.73 Joint body with separated ground shield ·························································· 118
Figure 5.74 Installing connector ·························································································· 118
Figure 5.75 Installing joint body ·························································································· 119
Figure 5.76 Lubricating with silicone grease ······································································ 119
Figure 5.77 Installation of shield ground ············································································ 120
Figure 5.78 Installing outer sheath ······················································································ 120

Figure 6.1 DC Hi-Pot Test Set and Megohmmeter ···························································· 128

Figure 6.2 Connection of a Megohmmeter for an Insulation Resistance Test on a Cable· 130
Figure 6.3 VLF Test Set ····································································································· 132
Figure 6.4 PEA field testing template ················································································ 133

Figure 7.1 OWTS test set for medium voltage system ························································ 137
Figure 7.2 An example of PD Mapping result ··································································· 138
Figure 7.3 PEA’s XLPE Power Cable Preventive Maintenance Test Form ······················ 139
TABLES

Table 1.1 PEA’s Key Network Statistics ··········································································· 1

Table 1.2 Submarine Power Cable Route Details – PEA Thailand ································· 2

Table 2.1 Proposed network design criteria and security level ······································· 5
Table 2.2 PEA voltage criteria for system planning························································· 6
Table 2.3 PEA loading criteria for system planning ························································ 6
Table 2.4 PEA security criteria for system planning ························································ 6
Table 2.5 Conduit and Cable sizing ················································································· 13
Table 2.6 Conduit and Cable sizing ················································································· 14

Table 3.1 Minimum clearances between power cables and other public ························· 20
utilities infrastructure
Table 3.2 Nominal Outside Diameter of Underground Cables in PEA···························· 27
Table 3.3 % PAF ·············································································································· 28
Table 3.4 PAF, Clearance and Jam Ratio ········································································ 29
Table 3.5 Sample matrix for spare conduits ····································································· 30
Table 3.5A Application of cable screen bonding methods ·················································· 34
Table 3.6 Underground cable dimensioning and selection for varying depth of ············· 35
installation
Table 3.7 Creepage distance for differing levels of pollution ·········································· 36

Table 5.1 Minimum Clearances for Cable Termination at various voltage ratings········· 98

Table 6.0A Cable ratings and impulse voltage tests ··························································· 125
Table 6.0B Cable ratings and power frequency voltage tests ············································· 126
Table 6.1 Insulation Resistance Test Values Electrical Apparatus and Systems ············ 129
(ANSI/NETA ATS 2009)
Table 6.2A DC Hi-Pot test voltages for MV Cable up to 36 kV·········································· 130
Table 6.2B DC Hi-Pot test voltages for HV Cable up to 123 kV ········································ 131

Table 7.1 Recommended Maintenance for differing values of PDIV ······························· 137
Chapter 1
Introduction to PEA Underground Power Cable Systems

1. Introduction

The Provincial Electricity Authority (PEA) is a government establishment entrusted with

managing and operating the power distribution network in Thailand. PEA’s service area
extends to more than 99% of the country.

PEA’s key network statistics as at end of 2010 is as shown in Table 1.1

Item Description Unit

1. Transmission Line 9,214 circuit-km
2. Substation 470
3 MV Distribution Line 296,245 circuit-km
4. LV Distribution Line 457,595 circuit-km
5. Installed Capacity – Distribution Transformers 72,110 MVA
6. Peak Demand 16,098.82 MW
7. Energy Sales 100,748.80 GWh
8. System Losses 4.91%
9. Customers 15,560,305
10. Employees 27,818

Table 1.1: PEA’s Key Network Statistics

PEA is statutorily required to supply electricity to every household within its declared service
area. Previously, distribution of electricity to islands was via standalone diesel engine
generators. Due to the growing population and infrastructure developments on these islands,
power supply is now from the power grid and submarine power cables played an important
role in delivering power to these islands.

2. Power Cable Systems

2.1. Submarine Cables

By 2012, PEA will have 26 submarine power cables routes linking the power network on the
mainland to islands and as well as between islands. The ratings of these submarine power
cables are at 115 kV, 33 kV and 22 kV. Submarine power cable systems are mainly located
in southern and eastern parts of Thailand - with the majority installed in the southern region.
The details of each submarine power cable route are as shown in Table 1.2

1
Item Submarine Cable Route Year of Rated Circuit Cable Cable
Installation Voltage Length Size Type
(kV) (km) (sq.mm)
1 Kanhom – Samui Island 1986 33 23.5 185 XLPE
2 Laem Ngob – Chang Island (Route 1) 1994 22 6 185 XLPE
3 Kanhom – Samui Island (Route 1) 1996 115 23.5 185 Oil
Filled
4 Samui Island – Phangun Island 1996 33 14.6 185 XLPE
5 Krabi-Klang Island 2001 33 0.7 120 XLPE
6 Phuket-Yao Noi Island-Yao Yai Island 2001 33 12 120 XLPE
7 Khao Laem Ya - Samed Island 2002 22 4 120 XLPE
8 Phang nga – Kho Khao Island 2002 33 0.62 120 XLPE
9 Satun (Thaphae) – Tunyong Uma 2002 33 1.5 120 XLPE
Island
10 Tunyong Uma Island-Yala Tod Nui 2002 33 2 120 XLPE
Island
11 Yala Tod Nui Island- Yala Tod Yai 2002 33 1 120 XLPE
Island
12 Kanhom – Samui Island (Route 2) 2007 115 26.95 240 XLPE
13 Satun (Tum Ma Lung)-Pu Yu Island 2008 33 3.8 120 XLPE
14 Pu Yu Island-Yao Island 2008 33 3.8 120 XLPE
15 Krabi(Laem Hin)-Sri Bo Ya Island 2008 33 1 185 XLPE
16 Sri Bo Ya Island - Pu Island 2008 33 2 185 XLPE
17 Pu Island – Phi Phi Don Island 2008 33 24 185 XLPE
18 Krabi(Nam Mao Bay)-Rai Lay Bay 2008 33 3.8 120 XLPE
19 Krabi(Ban Hua Hin)-Lanta Noi Island 2008 33 2 185 XLPE
20 Lanta Noi Island-Lanta Yai Island 2008 33 0.75 185 XLPE
21 Chomburi(Laem Mai Louk)-Lan Island 2008 33 8.6 120 XLPE
22 Si Racha-Sichang Island 2008 33 10 120 XLPE
23 Laem Ngob – Chang Island (Route 2) 2010 115 9.38 185 XLPE
24 Trang(Yong ling)-Mook Island 2011 33 7.4 70 XLPE
25 Trang(Yantakhao)-Sukorn Island 2011 33 4.6 70 XLPE
26 Trang(Kantang)-Libong Island 2011 33 4.57 70 XLPE

Table 1.2: Submarine Power Cable Route Details – PEA Thailand

Due to the increasing demand for electricity on Samui Island, PEA has planned a new project
to upgrade the submarine power cable to 115kV XLPE. This submarine power cable will be
56km in length, linking Kanhom on the mainland to Samui Island. Work on this project is to
start in October 2012.

2.2. Underground Cables

Installation of underground power cable systems in PEA’s network started in the 1980’s.
Most of underground power cable systems installed then connected the indoor substation with
existing overhead distribution network especially for crossing highways, major intersections
and flyover bridges. Projects for conversion to underground power cable systems in urban
areas started in 2002 for large cities. The first pilot project implemented was in Chiang Mai.
To-date PEA has completed many conversion projects especially in cities such as Chiang
Mai, Nan, Pattaya, Hat Yai, Phuket, Khon Kaen, Mukdahan, Nong Khai, Phi Phi Island, etc.
2
Rapid urbanization, network reliability, public safety, network interconnections &
topography, operational requirements plus public demand for environmental aesthetics are
some of the key reasons for PEA to convert from an overhead line system to an underground
cable system. In this regard, PEA plans to complete the conversion projects for 12 selected
cities by 2022.

3. Design and Construction

There are many processes related to the design and construction of an underground power
cable system. Each one of these processes is as important as the other and each of them is
given equal consideration. There are six main steps to these processes as listed below:
 STEP 1 - Planning
 STEP 2 - Design
 STEP 3 - Construction
 STEP 4 - Commissioning
 STEP 5 - Operation
 STEP 6 - Maintenance
Non-compliance to these design and construction steps can affect network performance,
capital expenditure & project cost, operation & maintenance expenditure, system operation,
emergency restoration, maintenance and quality of power supply to customers. Therefore,
this handbook will guide you through these processes and will describe in detail the
recommended steps for design and construction of an underground power cable system.

Reference:

1. PEA - Highlight Report 2011

2. PEA Power System Maintenance Division - Submarine Cable Maintenance Database

3
Chapter 2
Planning

1. Introduction

PEA uses power system analysis software to analyze and prepare the power distribution
expansion plan for both overhead line and underground power cable systems, consisting of a
five-year plan and a rolling plan. This chapter explains the planning process for underground
power cable system at different voltage levels within PEA declared service area.

To design an underground power cable system, the planning process involves steps as
described in Section 2.0.

2. Planning and Selection of Supply Area

PEA customers are served by either an overhead line system or an underground power cable
system. Both of these systems extend into most of PEA’s declared service area, both in the
urban and rural areas. Due to constraint in available funding for capital investments, PEA has
to prioritize its investment in underground power cable systems. Priority in investment is in
the following areas:

Area 1: High Technology Industry Area

Area 2: Provincial Large Town Central Business District
Area 3: Commercial Tourist Center Area
Area 4: Historical and/or Aesthetically Important Areas
Area 4: Suburban New Housing Development Area
Area 5: Municipal Policy and Funding; areas designed for underground power cable
system

The power distribution for Areas 1, 2 and 3, is designed for high stability, reliability and high
power quality. Because area 4 is of historic and aesthetic importance, it is necessary to design
the supply system to blend with the original environment with minimum disturbance to the
surrounding landscape. Area 5 being a new housing development area, an undergrounding
power cable system will be incorporated into the overall design of the township, taking into
consideration the latest available technology for future development of the supply system.

The key success factor for underground power cable system development is the close co-
operation between power utility company and local municipal authority with a project
committee that is empowered to decide upon and support the investment cost, granting of
permit to facilitate construction, etc.

4
3. Power System Reliability

3.1 Contingency Criteria:

[N-1] (N minus one) means that the power system has a reserved capacity or a configuration
such that in the event of an outage of any single component, the power supply can be
continued or restored without the need to repair the faulted system component.

[N-0] (N minus zero) means that the power system has a reserved capacity or a configuration
such that in the event of an outage of any single component, the power supply cannot be
continued.

Note: N =number of system components, 0 and 1 is the number of spare system components.

3.2 Security Level Criteria:

Power system is divided into three levels of reliability during [N-1] outages as follows:

 For Level 1, the power system will provide power continuously, with no loss of supply
due to the fault (no interruption).
 For Level 2, the power system will provide power such that customers will be affected by
power failure of not more than 1 minute after the occurrence of a fault (interruption of
short duration).
 For Level 3, the power system will provide power such that customer will be affected by
power failure of more than 1 minute after the occurrence of a fault (interruption of long
duration).

The proposed security levels and design criteria for the various supply areas is given in Table 2.1.

Area Description Network Design and Security Level

Type
1 Provincial large town [N-1], open loop line, Level 2, or [N-1],
central business district closed loop line, Level 1
2 Area of historic and/or [N-0], radial line, or
aesthetically importance [N-1], open loop line, Level 3
3 Commercial tourist centre [N-1], open loop line, Level 3
4 High technology industry area [N-1], closed loop line, Level 1
5 Suburban new housing development [N-1], open loop line, Level 3
6 Municipal Policy and Funding: [N-0], radial line, or
areas designed for underground power cable system [N-1], open loop line, Level 3
Table 2.1: Proposed network design criteria and security level

4. Engineering Criteria

Power system planning criteria is used as a guide for power system planning. It consists of
technical details of power system equipment i.e. type, size, number of use, construction
structure and installation configuration, etc.

5
4.1 Voltage Criteria

Supply voltage limits for power system under normal and emergency conditions are as shown
in Table 2.2:
Rated Normal Condition (Volts) Emergency Condition (Volts)
Voltage
Minimum Maximum Minimum Maximum
115,000 109,200 120,700 103,500 126,500
33,000 31,300 34,700 29,700 36,300
22,000 20,900 23,100 19,800 24,200
380 342 418 342 418
220 200 240 200 240

Table 2.2: PEA voltage criteria for system planning

4.2 Loading Criteria

Load limits for power system under normal and emergency conditions are stated in Table 2.3:

Equipment Normal condition Emergency condition

Transmission line

Radial type 80% of rated current 100% of rated current no limit

Loop type 50% of rated current 100% of rated current no limit

Medium voltage distribution line

Radial type 80% of rated current 100% of rated current no limit

Loop type 50% of rated current 100% of rated current no limit

Low voltage distribution line

All types 80% of rated current 100% of rated current no limit

Table 2.3: PEA loading criteria for system planning

4.3 Security Criteria

Security level for each type of network configuration and restoration time is as stated in
Table 2.4 (Note: PEA standard requires restoration to 90% of service area within 4 hours):

Network Configuration Restoration time

Closed Loop < 1 min.

Open Loop with automatic control < 3 min.

Open Loop with manual control < 45 min.

Radial Follow Standard

Table 2.4: PEA security criteria for system planning

6
5. Medium voltage 22kV & 33 kV system configuration planning

5.1 Area 1: Industrial and Real Estate Area

The underground system shall be dedicated for supply to the industrial area only (not to
outside). The configuration of underground system shall be:

5.1.1 High stability case: SAIFI and SAIDI approach zero (zero outage time), the
system shall be closed loop configuration, fully underground Ring Main Unit
(RMU) with circuit breaker installed as detailed in Figure 2.1

5.1.2 Medium stability case: For areas with limited budget for capital investment,
system can be designed such that it can be interrupted within service criteria
limits. The system shall be opened loop configuration fully underground, RMU
with load break switch installed, as detailed in Figure 2.2

Figure 2.1: Closed Loop Configuration for Underground System (High Stability)

7
 Figure 2.2: Opened Loop Configuration for Underground System (Medium Stability)

5.2 Area 2: Municipality Area, Central Business Area and Important Area

System shall be of opened loop configuration (Figure 2.3) or Open Loop with Special Spare
Feeder configuration (Figure 2.4). Loading of each loop cannot exceed 16 MVA for 22kV
and 20 MVA for 33 kV. RMU with load break switch are installed.

Figure 2.3: Opened Loop Configuration for Underground System for Municipality Area

8
 Figure 2.4: Opened Loop with Special Spare Feeder Configuration for Underground System for
Municipality Area (with Special Spare Feeder for switching)

5.3 General Requirement

5.3.1 Underground Cable: Copper conductor 240sq.mm or 400sq.mm - current rating

is dependent upon number of feeders and cable installation depth (refer to
Table 3.6).

5.3.2 Type of cable installation is based upon available project budget and soil
characteristic:

5.3.2.1 Open Cut Method: Cable is installed semi-buried and with duct bank.

5.3.2.2 No Dig Method: Cable installation using directional boring or small sleeve
and pipe jacking

5.3.3 Voltage variation under normal condition shall be 5% of nominal voltage and
in emergency condition shall be 10% of nominal voltage.

9
6. Low Voltage Distribution (≤ 1.0 kV) System Configuration Planning
For configuration of underground cable at low voltages, the power distribution system is
designed either as a radial circuit or open loop line. The following technical criteria are to be
considered when selecting the circuit type:

6.1 Radial circuit configuration: This is as shown in Figure 2.5. All transformers are
loaded at not more than 80% of their rated capacity for normal supply conditions.

Figure 2.5: Radial configuration for low voltage distribution underground system

6.2 Open loop configuration: In this case at least 2 transformers shall have spare
capacity available. Spare circuits are installed to supply the load to prevent supply
interruption in case of failure of one transformer. This type of configuration is
suitable for supplying central business district and historic & aesthetically important
areas.

6.2.1 For a 2 transformers configuration, each transformer is loaded at not more than
60% of their rated capacity for normal supply conditions. This configuration is
as shown in Figure 2.6.

Figure 2.6: Open loop configuration for low voltage underground power cable
distribution system (2 transformers configuration)

6.2.2 For system configuration using 3 or more transformers, each transformer is

loaded at not more than 80% of their rated capacity for normal supply
conditions. This configuration is shown in Figure 2.7.

10
 Figure 2.7: Open loop configuration for low voltage underground power cable distribution system (3 or
more transformers configuration)

6.3 General Requirement

6.3.1 The sizes of copper conductor with PVC insulated 750 V (NYY) and copper
conductor with XLPE insulated 0.6/1.0 kV (CV) for underground cables are
selected using current ratings calculation method based on IEC 60287.

6.3.1.1 The IEC 60287 current ratings calculation method considers the following
design conditions:

 Load factor: 100 %

 Maximum conductor temperature:
o 70 ºC for Copper conductor with PVC insulated (NYY)
o 90 ºC for Copper conductor with cross linked polyethylene (XLPE)
insulated (CV)
 Ambient temperature: 30 ºC
 Soil thermal resistivity: 1.2 K.m/W

6.3.2 Calculation formula

  Wd 0.5T1  nT2  T3  T4 
1/ 2
 
I  
 RT1  nR1  1 T2  nR1  1  2 T3  T4 

6.3.2.1 The current rating value may vary since the actual conditions on site are
different from the assumed design conditions

11
 6.3.2.2 The HDPE conduit type PN 6.3 with a diameter of 110 mm was selected
for the calculations.

6.4 For cable installation, suitable methods that have minimum impact on the landscape
along the project route is to be considered:

6.4.1 Open Cut method: The cable should be installed inside insulated pipe buried in
the ground

6.4.2 No Dig method: This utilizes “Horizontal Directional Drilling” method to

install pipes into the ground for road crossings

6.4.3 Cable conduits using pipes shall be selected for the appropriate installation
method using the selection charts in Table 2.5 and Table 2.6

6.4.4 Provision shall be made for sufficient spare insulated pipe conduits for future
projects and maintenance requirements

6.4.5 Location and quantity of manholes depends on feeder circuit configuration,

total length and application. According to current edition of PEA standard,
spacing between each manhole shall not exceed 250 meters

6.4.6 Cable riser depends on feeder configuration and application

6.4.7 All cable joints must be made either within the manhole or hand-hole

6.4.8 For radial circuits for low voltage underground power distribution system
without load-center board, all low voltage branch cables size must be equal to
the main primary circuit cable size

6.4.9 Ground resistances at each installation point shall preferably not exceed 5 ohm.
If there is some difficulty in obtaining this value due to soil characteristics,
ground resistances not exceeding 25 ohm will be acceptable.

12
 Size of Conduit Outside Diameter Of Each Cable
Type Of (Minimum Inside Single Two Three Four
Conduit Diameter of
Cable Cables Cables Cables
Conduit, mm)
(mm) (mm) (mm) (mm)
40 (35.4) up to 25.7 up to 12.3 up to 11.3 up to 8.8
50 (44.4) up to 32.3 up to 15.5 up to 15.5 up to 10.0
HDPE 63 (56.2) up to 40.9 up to 19.6 up to 19.6 up to 14.0
conduit
75 (66.8) up to 48.6 up to 23.3 up to 23.3 up to 16.6
90 (80.2) up to 58.3 up to 28.0 up to 28.0 up to 20.0
110 (98.0) up to 71.3 up to 34.2 up to 34.2 up to 24.4
125 (111.6) up to 81.2 up to 38.9 up to 38.9 up to 27.8
140 (125.0) up to 91.0 up to 43.6 up to 43.6 up to 31.1
160 (142.8) up to 103.9 up to 49.8 up to 49.8 up to 35.6
180 (160.8) up to 117.0 up to 56.1 up to 56.1 up to 40.1
200 (178.6) up to 130.0 up to 62.4 up to 62.4 up to 44.5
30 (30) up to 21.8 up to 10.4 up to 8.5 up to 7.4
50 (50) up to 36.4 up to 17.4 up to 17.4 up to 12.4
CORRUGATED 80 (80) up to 58.2 up to 27.9 up to 27.9 up to 19.9
conduit 100 (100) up to 72.8 up to 34.9 up to 34.9 up to 24.9
125 (125) up to 91.0 up to 43.6 up to 43.6 up to 31.1
150 (150) up to 109.2 up to 52.4 up to 52.3 up to 37.4
200 (200 up to 145.6 up to 69.8 up to 69.7 up to 49.9
51 or 2 inch (51) up to 37.1 up to 17.8 up to 17.8 up to 12.7
RTRC 76 or 3 inch (76) up to 55.3 up to 26.5 up to 26.5 up to 18.9
conduit 102 or 4 inch up to 74.2 up to 35.6 up to 35.6 up to 25.4
(102)
127 or 5 inch (51) up to 92.4 up to 44.3 up to 44.3 up to 31.6
152 or 6 inch (51) up to 110.6 up to 53.1 up to 53.0 up to 37.9

Table 2.5: Conduit and Cable sizing

13
 Size of Conduit Outside Diameter of Each Cable
(Minimum
Type Of Single
Inside Two Cables Three Cables Four Cables
Conduit Cable
Diameter of (mm) (mm) (mm)
Conduit, mm) (mm)
15 (15.62) up to 5.4 - up to 3.8
20 (20.86) up to 7.2 up to 4.2 up to 5.2
25 (26.60) up to 9.2 up to 7.0 up to 6.6
32 (35.04) up to 12.2 up to 11.0 up to 8.7
STEEL 40 (40.88) up to 14.2 up to 14.0 up to 10.2
conduit 50 (52.48) up to 18.3 up to 18.3 up to 13.0
65 (62.60) up to 21.8 up to 21.8 up to 15.6
80 (77.88) up to 27.2 up to 27.2 up to 19.4
90 (90.08) up to 31.4 up to 31.4 up to 22.4
100 (102.26) up to 35.7 up to 35.7 up to 25.5
125 (127.36) up to 44.5 up to 44.5 up to 31.7
150 (152.98) up to 53.4 up to 53.4 up to 38.1
200*(200.50) up to 70.0 up to 70.0 up to 50.0
15 (13.40) up to 9.7 up to 4.6 - up to 3.3
18 (17.40) up to 12.6 up to 6.0 - up to 4.3
20 (21.35) up to 15.5 up to 7.4 up to 4.4 up to 5.3
25 (27.10) up to 19.7 up to 9.4 up to 7.3 up to 6.7
PVC 35 (33.85) up to 24.6 up to 11.8 up to 10.6 up to 8.4
conduit 40 (38.80) up to 28.2 up to 13.5 up to 13.0 up to 9.6
55 (49.70) up to 36.1 up to 17.3 up to 17.3 up to 12.4
65 (65.70) up to 47.8 up to 22.9 up to 22.9 up to 16.3
80 (75.90) up to 55.2 up to 26.5 up to 26.5 up to 18.9
100 (98.70) up to 71.8 up to 34.4 up to 34.4 up to 24.6

Table 2.6: Conduit and Cable sizing

References:

(1)PEA - Planning Criteri

(2)PEA - Engineering Criteria and Guideline
(3)IEC 60287: Calculation of the current rating – Parts 1, 2 & 3

14
Chapter 3
Design

1. Introduction

The design of underground power cable systems is also done using power system design and
analysis software, similar to the design of overhead line systems. With a Computer Aided
Design (CAD) application, the time taken to design an underground power cable system and
the dimensioning and selection of a suitable cable type, which is based on many parameters
such as voltage level, electrical load, the route length, ambient temperature, power factor, the
depth of cable trench, soil thermal resistance, type of duct bank, etc., is very much shorten.

The aim of this chapter is mainly to explain the typical design, construction and installation
methodology, inclusive of civil works, electrical works and related cable accessories applied
by power utilities for an underground power cable system.

2. Type of Construction

The cost of constructing an underground power cable system is directly related to the design
and method of installation. The Design Engineer thus has to design an underground power
cable system that satisfies both the financial and desired reliability requirements. Some factors
normally considered by the Design Engineer include:

 Available budget
 Environment and landscape along proposed cable route
 Construction site – central business district, urban, suburban, rural
 Potential obstructions and deviations to proposed cable route
 Proposed cable type and size – single-core, three-core, oil-filled, polymeric
 Cable protection scheme
There are two (2) types of construction methods generally applied for underground power
cable installation:
2.1. Open-cut method
2.2. No-dig method

3. Open-cut Method

3.1. Concrete Encased Duct Bank

This method of construction covers underground power cable systems at distribution, sub-
transmission and transmission voltage levels of 22, 33 and 115 kV. The cable runs
through a conduit made of either High Density Polyethylene (HDPE) pipe or Reinforced

15
Thermosetting Resin Conduit (RTRC) and encased in concrete for protection from
mechanical impacts (Figure 3.1).

This method of construction is suitable for installing many cable circuits in a single trench
since it allows for easy arrangement of circuits, repair and replacement of failed cable
circuits and improved safety. The disadvantage of this method when compared to other
conventional methods is; (a) longer construction time (b) poor heat transfer from cable to
surroundings due to higher thermal resistivity of the materials used.

Figure 3.1: Concrete Encased Duct Bank

3.2. Semi-direct Burial

This method of construction covers underground power cable systems at distribution, sub-
transmission and transmission voltage levels of 22, 33 and 115 kV. The cable runs
through a flexible corrugated conduit made of either High Density Polyethylene (HDPE)
pipe or Reinforced Thermosetting Resin Conduit (RTRC).
This construction method needs blocks of concrete spacers to maintain the distance
between each conduit. This semi-direct burial method is not encased in concrete but a
concrete slab together with warning strip is laid on top as shown on Figure 3.2.
This method of construction requires a shorter construction period and provides better
heat transfer compared to the Concrete Encased Duct Bank method. One disadvantage of
this method is that the cable is prone to mechanical damage because the cable ducts are
not set in concrete for additional mechanical protection.

16
 Figure 3.2: Cross-section of Semi-direct Burial

3.3. Direct Burial

Direct burial is suitable for underground power cable systems at distribution, sub-
transmission and transmission voltage levels of 22, 33 and 115 kV. The cable does not run
through conduits in reinforced concrete. Instead, the cable is laid directly in the soil at a
depth that is recommended in the applied referenced standard, typically at a minimum
depth of 1.2 m.

Concrete slabs together with warning strip are placed on top of the cable along the entire
length of the cable route. Cable route markers are placed along the route to indicate
presence of an underground cable under the pavement.

This also serves as a warning to other utilities and municipality contractors to be cautious
when digging within the cable route area. Figure 3.3 show a cross-sectional view of this
method.

17
 This method of construction is suitable for installing a few circuits (typically one to two
circuits). Since the cable is buried directly in soil, sufficient distance must be allowed
between each circuit to prevent damage to one circuit when the other fails, reduce the
effects of mutual inductance between the cables and also to allow for efficient heat
transfer from the cables to the surrounding soil.
The advantages of this method is that the construction period is shorter, lower cost of
construction and better heat transfer when compared to the other methods. The
disadvantages are that replacement or upgrading of cables can be tedious, expensive and
time consuming. Further, the short circuit behavior of one cable circuit may impact other
cables circuits within the same trench.

Figure 3.3: Cross-section of Direct Burial

4. No-dig Method

4.1. Horizontal Directional Drilling (HDD)

This method of construction covers underground power cable systems at distribution,

sub-transmission and transmission voltage levels of 22, 33 and 115 kV. The cable
runs through a conduit made of High Density Polyethylene (HDPE) pipe. This
construction method does not require to open cut the road pavement and also does not
use encasement in concrete or concrete slabs to protect the cable.

This construction method requires work pits for drilling and pulling the conduits as
shown on Figure 3.4. Cable route markers are installed to indicate cable location and
route.

This construction method is best applied to highly urbanized or built-up areas such as
central business districts. The space limitation, congestion and high volume of traffic

18
 makes this method the optimum choice of installing underground power cables.
Another advantage is that the period of construction is shorter compared to open-cut.
One disadvantage is the high cost of construction per circuit-km when compared to the
open-cut method.

Figure 3.4: Horizontal Directional Drilling (HDD)

4.2. Pipe Jacking

This method of construction covers underground power cable systems at distribution,

sub-transmission and transmission voltage levels of 22, 33 and 115 kV without open
cut of road surface. High density polyethylene conduit (HDPE) or Reinforced
Thermosetting Resin Conduit (RTRC) is placed in a steel casing into which concrete
is injected to encase the conduits as shown on Figure 3.5.

Like the HDD method, the pipe jacking method also requires a work pit to facilitate
pipe installation. The method also ensures greater reliability and protection for the
cable because the steel casing enhances the mechanical protection for the HDPE or
RTRC conduits are placed in it.

19
 Figure 3.5: Pipe Jacking

5. Minimum Clearances between Power Cables and other utilities infrastructure

Underground power cables, especially in urban areas, are sometimes installed within the
vicinity of other public utilities infrastructure. To prevent physical damage to power cables
and to allow for maintenance and repair, a safe working distance is maintained between them.
Unshielded telecommunication cables if installed too close to power cables may experience
induced electrical disturbance. Therefore, to minimize such incidences the underground cable
is installed at a certain fixed distance from these other public utilities infrastructures as shown
in Table 3.1. [Note: * Values recommended by PTT Plc (Petroleum Authority of Thailand)
Extracted from Underground Transmission Systems Reference Book 1992 Edition]

Public Utility Minimum distance (mm)

Parallel path Cross path
Storm Sewer 300 300
Water Line 450 450
Gas Line 300 300 to 1500*
Electrical Duct Bank 3000 600
Telephone Duct Bank 300 300
Steam Line 3000 1200
Table 3.1: Minimum clearances between power cables and other public utilities infrastructure

20
6. Construction of Underground Cable

6.1. Types of Cables

There are several types of underground power cables available for application in
power utilities. For example:
 Paper insulated cables
o mass impregnated type
o non draining type
o gas pressure
 internal pressure type
 external pressure type
 Fluid-filled cables
o Oil-filled type
 Polymeric cables
o XLPE type
o EPR type
o PE type
 PVC insulated cables

The Paper Insulated Cable commonly known as PILC type was the cable of choice
until the 1970’s. Since then, Polymeric Cables, namely XLPE and EPR have
dominated the electrical power industry. These cables are popular today because they
have superior dielectric properties, higher conductor temperature, higher load
carrying capacity and are easier to work with when compared to PILC type cables.

6.2. Conductor Material

Copper and Aluminium are used as conductor material in cables. Both these
materials are favored because of their high electrical conductivity. In PEA, cables
with copper conductors are preferred.

Conductors are made of layers of bare wires that are stranded together and compacted
to reduce air spaces between the individual wires. The conductors are either circular
or sector shaped.

For sizes up to 16mm2 and for higher voltage ratings, where electrical stress at the
conductor surface is important, the construction is circular. For the majority of multi-
core power cables up to 11kV, a sector shape is used to keep dimensions to a
minimum. The corner radii are adjusted according to the cable voltage for reasons of
electrical stress and influence on the dielectric during bending.

6.3. Conductor Temperature

During service operation, cables suffer electrical losses that appear as heat in the
conductor, insulation and metallic components. The current rating is dependent on
the way this heat is transmitted to the cable surface and then dissipated to the

21
 surroundings. Temperature is clearly an important factor and is expressed as a
conductor temperature to establish a reference point for the cable itself.

6.4. Dielectric Materials

The dielectric materials used as insulants for power cables should have the following
properties:

 High insulation resistance

 High dielectric strength
 Good mechanical properties
 Preferably non-hygroscopic, but if hygroscopic it should be provided with an
economical water tight covering or sheath.
 Capable of being operated at high temperatures
 Low thermal resistance
 Low power factor

6.5. Metal Sheathing and Armoring

Metal sheathing is required to provide an impervious layer to protect the cable from
moisture ingress, which can lead to degradation of the dielectric insulating material.

Power cables are usually armored to carry earth-fault currents and to give some
protection against mechanical damage both during installation and in service.

Single or double wire amour is used depending upon the degree of protection
required. Double wire armor is used for cables requiring increased tensile strength –
for example along sloping routes, in mines, etc.

For single-core cables in a.c. circuits, it is preferable to use non-magnetic material

(e.g. tin-bronze or silicon-bronze) to reduce cable heating due to magnetic induction.
Sometimes single-core cables are left unarmored. More information on cable design
and construction is available in Appendices 1 and 2.

7. Cable Conduits

There are many types of conduits that are used for underground power cable installation.
Sometimes conduits are also called ducts. Cable conduits are typically made of High-
Density Polyethylene (HDPE). Conduits can also be made of Fiberglass or Reinforced
Thermosetting Resin (RTRC). Conduits that are corrugated on its outer surface can easily
bend and adapt to the profile of the cable trench.

Typical application of conduits in underground cable installation is as follows:

 Linear construction: HDPE or RTRC

 Non-linear construction: HDPE or Corrugated HDPE
 Concrete encased ducts: HDPE or RTRC

22
 Figure 3.6: High-Density Polyethylene (HDPE) and corrugate HDPE conduits

Figure 3.7: Fiberglass or Reinforced Thermosetting Resin (RTRC) conduits

8. Manholes

Manholes are cable jointing pits and vaults for use with underground power cables
systems. A manhole may be constructed from pre-cast reinforced concrete, in-situ
reinforced concrete or brickwork construction, depending on the location of the pit within
the street and geographically within the city. The manhole frame and its steel cover are
typically designed to withstand a load of 18 metric tons.

23
The design and application of manholes is dependent upon the following factors:

 Alignment of conduits with respect to the cable route

 The size, number & type of conduits and allowance for future installations: The
manhole’s physical dimensions will vary with this requirement. If the manhole is
also to be used as a cable joint pit, it is recommended to have two manhole
entry/exit points to improve ventilation and for fast evacuation of personnel during
emergencies.

8.1. Location of Manholes

Location of manholes in the underground power system should take into

consideration the following factors:

 Must not obstruct the smooth flow of vehicular traffic

 Blend with the surrounding landscape
 Installed as close as possible to the base of riser poles to allow for easier cable
location and identification during cable fault location.
 Maximum distance between two manholes should be at least ≤ 250 m. This is to:
 keep cost of construction economic
 maintain equal distances between points for cross-bonding of cable sheaths
 make it easier to install cable circuits in cable duct banks
 Maintain good alignment and leveling to ease installation and to reduce
mechanical stresses on the cable.
 Design of manhole must support the design and be appropriate for the intended
application of the underground power cable system

8.2. Types of Manholes

There are two types of manholes depending on their application:

 Manholes for distribution and sub-transmission underground power systems

for voltages ranging from 22 to 33kV
 Manholes for transmission underground power systems for voltages ≥ 115 kV

8.2.1. Manholes for distribution and sub-transmission underground power systems

8.2.1.1. Manholes for Y-splitting and branching of cable circuits

Figure 3.8: Y-splitting and branching of cable circuits

24
 8.2.1.2. Manholes for in-line splicing, Y-splitting, branching and for cable
installation at major traffic intersections

Figure 3.9: In-line splicing, Y-splitting, branching at major traffic intersections

8.2.1.3. Manholes for in-line splicing, Y-splitting and branching of cable circuits

Figure 3.10: In-line splicing, Y-splitting and branching

8.2.2. Manholes for transmission underground power systems for voltages ≥ 115 kV

8.2.2.1. Manholes for cable joints and branching of cable circuits at road
intersections

Figure 3.11: Cable joints and branching at road intersections

25
 8.2.2.2. Manholes for In-line splicing, Y-splitting and branching of cable circuits

Figure 3.12: In-line splicing, Y-splitting and branching

9. Riser Pole

Cable Riser Pole construction facilitates the conversion of existing overhead lines system
to an underground cable system. Riser pole construction can be of either single-pole or
double-pole and is dependent upon system configuration. Single-pole riser is for
distribution and sub-transmission power systems. Double-pole riser is for transmission
power systems for voltages ≥ 115 kV.

Figure 3.13: Riser pole for voltages of 22 and 33 kV

26
 Figure 3.14: Riser pole for voltages ≥ 115 kV

10. Selection of conduits for underground cable

One critical aspect of a conduit installation is conduit sizing. When the conduit size is chosen,
the conduit inside diameter should be large enough to install all of the cables that were
selected to be installed in that conduit without damage to any of the cables. The conduit
should also be large enough to minimize any adverse heating effects on the conduit or on the
cables that are contained within the conduit.

The selection of appropriate conduit size is dependent on the nominal cross-sectional diameter
of the conductor and the number of conductors planned for installation in the conduit. The
nominal outside diameter of conductors for cables installed in PEA underground cable
network is as shown in Table 3.2 below:

Nominal Cross-sectional
35 50 120 185 240 400 500 800
Area of Conductor (mm2)
Rated Voltage (kV) Nominal Outside Diameter of Cable (mm)
22 28 30 34 38 42 48 52 -
33 - 35 40 44 47 55 58 -
115 - - - - - - - 98

Table 3.2: Nominal Outside Diameter of Underground Cables in PEA

10.1. Conduit Fill Factor

Conduit Fill Factor or Percent Area Fill, states the maximum amount of space that
the installed cables should occupy in a given size conduit. It is expressed as a
percentage of the cross-sectional area of the conduit that the cables are allowed to
occupy, and it depends on the number of conductors that are to be installed in the
conduit. The allowable percentage of conduit fill is based on the combined heating

27
 effects of all of the cables that are installed in the conduit. Knowledge of the
allowable percentage of conduit fill helps the Design Engineer to select the proper
size of conduit for a particular installation.

Conduit Fill Factor or Percent Area Fill can be determined by applying the
following formula:

% Percent Area Fill (% PAF) = [ ]

where, OD = Nominal Outside Diameter of Cable (mm)

ID = Nominal Internal Diameter of Conduit (mm)
n = Number of conductors to be installed
Table 3.3 below gives sample values of % PAF for the type of cables and conduits
currently installed in PEA underground cable network.

Percent Area Fill (% PAF)

Number of Conductors n
Types of Cable
n=1 n=2 n=3 n=4 n>4
All 53 31 40 40 40
Lead Sheathed 55 30 40 38 35

Table 3.3: % PAF

10.2. Jam Ratio

The natural weight of the cables that are contained in the conduit will cause them to
settle to the lowest part of the conduit that the conduit space will allow. Depending
on the size, configuration, and number of cables, the cables could get jammed in the
conduit during installation. A useful unit-less value that is used when cables are
installed in conduit is called the Jam Ratio.

The jam ratio is used primarily during cable pulling tension calculations but it is also
used in the conduit selection process. The jam ratio is the ratio of the conduit
internal diameter to the outside diameter of the largest cable that will be installed in
the conduit.

The jam ratio provides a factor that describes the probability that the cable will jam
during its installation in the conduit. The equation below is used to calculate the jam
ratio:
Jam Ratio =

where, D is the conduit internal diameter

d is the diameter of the largest cable that is in the conduit
1.05 includes a correction factor of 5% that accounts for the oval cross-
section of conduit bends

If the jam ratio is greater than 3.0, jamming is not likely to occur, and cable
clearance can be ignored. If the jam ratio is between 2.8 and 3.0, jamming is

28
 probable; if the jam ratio is between 2.5 and 2.8, serious jamming is probable. If
jamming is probable, the Design Engineer should evaluate the need to increase the
size of the conduit.

10.3. Clearance

Cable clearance is the distance between the uppermost cable in a conduit and the
inside top of the conduit. A gap should be present between the uppermost cable in a
conduit and the top of the conduit to prevent rubbing while pulling and providing
for expansion and contraction.

For a single cable installation, the cable clearance is calculated through use of the
following equation:
Clearance = (D – d)

where, D is the conduit inside diameter.

d is the diameter of the largest cable that is in the conduit

For a three cable installation, the cable clearance is calculated using the following
equation:

Clearance = √ ( )

Table 3.4 below shows the relationship between PAF, Clearance and Jam Ratio for
a three cable installation.

Conduit Three cable installation

internal
Outside
diameter PAF Clearance Jam
Diameter
D (mm) (%) (mm) Ratio
D ( mm )
96.8 – 102.0 up to 32 32.78 32.86 3.17

110.0 – 114.0 up to 37 33.94 35.92 3.12

123.4 – 127.0 up to 42 34.75 39.19 3.1

140.0 - 144.6 up to 48 35.26 43.67 3.1

150.0 – 152.0 up to 50 33.33 50 3.15

177.2 – 180.8 up to 60 33.04 60.86 3.16

Table 3.4: PAF, Clearance and Jam Ratio

10.4. Spare Conduit

When designing an underground cable power system, provision is made for future
expansion of the network to meet increasing load demands and maintenance or repair
requirements. Therefore, some spare conduits are incorporated into the design. Table
3.5 shows a sample matrix for determining spare conduits.

29
 Number of Conduits

Planned 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Spare 1 1 2 1 2 2 2 3 2 4 3 2 4 3

Total 3 4 6 6 8 9 10 12 12 15 15 15 18 18

Table 3.5: Sample matrix for spare conduits

11. Pulling Tensions for Underground Cable

To install a cable into a conduit, it must be pulled from one end of the conduit to the other
with a strong wire. When a cable is pulled into a conduit, there are maximum pulling
tensions that the cable can withstand without damage.

There are various types of pulling equipment that can be used to pull a cable into a
conduit. Each different type of pulling equipment has a maximum pulling tension (or
pulling force) that it can withstand.

The configuration of the conduit, the type of cable that is to be installed, and the types of
pulling equipment that are chosen for the installation should all be evaluated so that
damage to the cable or to any installation equipment does not occur.

Pulling tensions depend on many factors such as:

 Diameter of underground cable – lager diameter cable requires more pulling
tension compared to cables of smaller diameter
 Size of conduit – cables are easily pulled in bigger conduits
 Length of conduit - long runs of conduits require higher pulling tensions
 Linearity of conduit path - cable are easily pulled in straight conduits

There are various ways to reduce the pulling tension for a given cable installation:
 the rigging equipment can be varied
 the size of the conduit can be increased
 the conduit configuration (e.g. turns or angles) can be altered
 the pull point frequency can be changed

11.1. Pulling Grips

Pulling grips are used to fasten the pulling line to the cable that is to be pulled into
the conduit. There are two basic types of pulling grips that are frequently used for
cable installations:

 basket grips
 pulling eyes

A basket grip is a flexible metal device that slips over the end of the conductor that
is to be pulled; a pulling line is attached to the basket grip so the cable can be pulled
through the conduit. The basket grip has a web-like grip that tightens as tension is

30
 applied to the pulling line. To avoid cable twist during the pulling, a swivel is
installed onto the pulling line where it attaches to the basket grip.

Figure 3.15: Basket grips type

Pulling eyes are used to pull larger sizes and long sections of cable; pulling eyes
allow for a higher pulling tension than basket grips. A pulling eye is a steel eye that
is usually fastened directly to the cable conductors. The cable conductors are
securely fastened and solder-wiped to the shank of the pulling eye. A swivel is
connected between the pulling line and the pulling eye to avoid cable twist during
the pulling.

Figure 3.16: Pulling eyes type

The pulling tensions can be calculated for each type of cable and is dependent on
cable conductor (copper or aluminum), cable cross-sectional area and number of
cables in conduit. However, the cable manufacturer’s recommendation for pulling
tensions should be observed.

12. Grounding
Power system grounding has many functions:
 acts as a reference point against which other voltages are measured
 provides a common return path for fault currents
 as a safety measure with a direct physical connection to earth
In mains powered equipment, the metal parts are connected to ground. This is a safety measure
to prevent contact with live parts during equipment electrical faults and short-circuits.
Similarly, for underground cables, metallic screens and protective armor are connected to
ground as a safety measure to carry fault currents during cable failures short-circuits and system
faults. It also creates an equipotential bond between all equipment within the substations or
installations, for protection against touch and step voltages.

31
Underground power cables typically have their metallic screens and protective armoring
grounded during cable terminations for connection to riser poles and power equipment such as
transformers and switchgears. Cable screens and protective armoring of underground cables
may also be grounded at in-line joints especially during cross-bonding of cable screens.
In PEA, the acceptable ground resistance value is typically ≤ 2Ω for 115kV system and ≤ 5Ω
for 22kV and 33kV systems. For areas where soil conditions prohibit low ground resistance, a
value of not more than 25Ω is acceptable.
An overview of common method for grounding underground power cable systems at 22kV,
33kV and 115kV, are presented in the pursuing sections.

12.1. Single-point bonding of cable screens

In this method, during cable terminations, the cable screens at one end of cable are
connected to ground while at the other end the cable screens are not connected but
isolated from ground. With this method, voltage is induced in the cable screens but
there is no current flow. Typically, this method of bonding is applied to very for
short length of cables of ≤ 500m.

Figure 3.17: Single-point bonding method

12.2. Both-ends bonding of cable screens

In this method, during cable terminations, the cable screens at both ends of cable
are connected to ground. With this method, no voltage is induced in the cable
screens but there is current circulating in the screens. This circulating current
causes additional heating of the cable thus requiring a de-rating of its current
carrying capacity. Typically, this method of bonding is applied to very for short
length of cables of ≤ 500m.

32
 Figure 3.18: Both-ends bonding method

12.3. Mid-point bonding of cable screens

This is a modified form of the single point bonding method where the grounding
point is now moved to the middle of the cable length. This allows for possible
doubling of route length as the maximum allowable standing voltage is tolerated at
each of the cable terminations.

Figure 3.19: Mid-point bonding method

12.4. Multi-point bonding of cable screens

This is a modified form of the both-ends bonding method. The cable screens are
grounded at both terminations and additionally at each in-line joint.

Figure 3.20: Multi-point bonding method

33
12.5. Cross-bonding of cable screens

This cross-bonding method is typically applied to single-core cables. In this

method, the cable terminations at both ends are connected to ground. At each in-
line joint, the cable screens are transposed and cross-connected as follows:

 Phase A to Phase B
 Phase B to Phase C
 Phase C to Phase A

The cable screens are cross-connected and grounded via a link box. This link box
allows re-setting of cable screens to ‘normal’ during cable testing and cable fault
location.

There is no circulating current in the cable screens. Induced voltage is present and
reaches its maximum value at the link box. Its magnitude can be limited to a
predetermined value with the use of Surge Voltage Limiters (SVL).

With this method, the current carrying capacity of the cable is equivalent to cables
with the single-point bonding but for much longer lengths.

Figure 3.21: Cross-bonding method

12.6. Application

Table below summarizes the conditions for application of various cable screen
bonding methods:

Cable screen bonding method Cable voltage rating Maximum length

(kV) (m)
Single-point 115 ≤ 500
Both-ends 22, 33 ≤ 500
Mid-point 115 500 < L ≤ 1000
Multi-point 22, 33 > 500
Cross-bonding 115 > 1000

Table 3.5A: Application of cable screen bonding methods

34
13. Underground Cable Dimensioning and Selection

The dimensioning and selection of cable is dependent on cable type, installation method
and number of neighboring circuits, its rated current carrying capacity in air and depth of
installation. Table 3.6 gives typical values for 22kV and 33kV XLPE cables for varying
depths of installation.

Rated Current Carrying Capacity per Circuit (A)

Total Depth of Installation (m)

Number
of Circuits 240 mm2 XLPE 400 mm2 XLPE

1 2 3 4 5 1 2 3 4 5

1 402 384 374 367 362 510 485 470 462 456

2 342 320 310 302 296 430 402 387 378 370

3 302 280 270 262 257 378 350 336 327 320

4 281 258 246 240 234 350 320 307 297 290

5 260 237 226 220 214 323 295 280 272 265

6 245 223 212 205 200 305 277 263 254 248

7 233 210 200 193 188 290 262 248 240 233

8 221 200 190 183 178 275 248 235 227 220

9 212 190 180 175 170 263 237 224 216 210

10 204 184 174 168 163 253 228 215 207 201

Table 3.6: Underground cable dimensioning and selection for varying depth of installation

14. Cable Terminations and In-line Splices

The design, testing and quality of all terminations, in-line splices and their associated
accessories installed in PEA underground cable power system conforms to international
standards and or equivalent national standards.

The design of outdoor terminations are based on the required pollution classification as
guided by IEC/TS 60815 Selection and dimensioning of high-voltage insulators intended
for use in polluted conditions. Outdoor terminations for installation in areas with heavy
industrial pollution or along coastal areas shall be classed Pollution Class IV with a
creepage distance of 31mm/kV while those for installation in normal pollution areas shall
be of Pollution Class III with a creepage of 25 mm/kV.
For repairs and upgrading works, PEA gives preference to terminations with silicone
rubber housing because it is light-weight and easy to install. Table 3.8 shows the creepage
distance for each pollution class and level of pollution.

35
 System Pollution Creepage Level of
Voltage Class Distance Pollution
22kV Class III 25mm/kV Normal
22kV Class IV 31mm/kV High pollution
33kV Class III 25mm/kV Normal
33kV Class IV 31mm/kV High pollution
115kV Class III 25mm/kV Normal
115kV Class IV 31mm/kV High pollution

Table 3.7: Creepage distance for differing levels of pollution

14.1. Types of Cable Terminations

Whenever a medium or high voltage cable with insulation shield is tapped or

terminated, the end of the terminated cable must withstand the electrical stress
concentration that is developed when the geometry of the cable is changed. As
long as the cable maintains the same physical dimensions, the electrical stress
will remain consistent.
When cable is tapped or terminated, the shield ends abruptly and the insulation
medium changes from that in the cable to air. The concentration of electrical
stress is at the interfaces between air, conductor and the insulation shield.
In order to reduce the electrical stresses at the end of cable, the insulation shield
is removed for sufficient distance to provide an adequate leakage distance
between the conductor and shield. The distance is dependent on the voltage
rating as well as the anticipated environmental conditions.
In most cases, the resulting stresses are high enough to cause dielectric
degradation of the material at the edge of the shield unless steps are taken to
reduce these stresses. Terminating the cable is one such method to deal with the
stresses produced.
To design a cable termination of acceptable quality, performance and durability,
it is necessary to relieve the voltage stresses at the edge of the cable insulation
shield. This is known as stress relief control. The conventional method is to use
a stress cone.
A stress cone increases the spacing from the conductor to the end of shield. This
method spreads out the electrical lines of stress and provides additional
insulation at the high stress area.
In IEEE Standard 48-1990, two types of stress relief control is described:

14.1.1. Geometric Cone or Stress Cone

This is designed in the shape of a cone. It has very high dielectric constant that
changes the distribution of voltage density around the shield termination. By
changing the electrical field surrounding the termination, the stress concentration
is reduced from several hundred volts per mil to less than 50 volts per mil.
Figure 3.14 shows a typical stress cone and electric field distribution in a stress
cone.

36
Figure 3.22: Stress cone (right) and electric field distribution in a stress cone (left)

14.1.2. High Permittivity Materials (HI-K Material)

The permittivity of a dielectric material is a characteristic that describes how it

affects any electric field set up in it. A high permittivity material, that is, with
high dielectric constant K, tends to reduce any electric field present in it. Based
on different dielectric constants for two different dielectric materials, refraction
and propagation of the electric filed will be take place. Therefore, there will be a
reduction in stress concentration. Figure 3.15 shows application of HI-K
Material in cable termination design and electric field distribution in HI-K
Material.

Figure 3.23: Electric field distribution in HI-K Material

14.1.3. The Porcelain Sealing Ends

This is use to connect the underground power cable to overhead line power
network and to outdoor installations such as bus-bars, power transformers and
switchgears. They are also installed in areas with high atmospheric pollution.
The porcelain sealing end is the oldest type still in service today although sealing
ends of other synthetic materials are available.
The porcelain sealing end is made of brown or grey glazed porcelain with two
aluminum flanges at the top and bottom. The hollow porcelain insulator is filled
with a dielectric insulating fluid e.g. insulating oil. The dielectric fluid creates a
positive pressure inside the sealing end, keeping out moisture and dust,

37
presenting a homogenous environment inside the insulator with good insulating
properties.
Sealing ends are range taking i.e. one type can fit cables with differing conductor
diameters. It is heavy and requires careful handling during installation.
Mishandling can result in hairline cracks and chipped porcelain.

Figure 3.24: Porcelain type outdoor sealing end

14.1.4. Slip-on termination

This termination is made from polymeric material and is available in kit form. It
is not range taking and has small design tolerances to ensure a good tight fit
when installed.

It does not require special tools or heating during installation. The modular
components are slipped over the prepared cable termination using a special
lubricant.

Different voltage levels are achieved by varying the number of sheds. The cable
can be energized immediately upon completion of the termination. The
termination joint can be installed in either a vertical, angled or an inverted
position.

38
 Figure 3.25: Slip-on type termination

14.1.5. Cold Shrink termination

This termination is made from polymeric material and is available in kit form. It
is range taking but for small differences in cable sizes and has, small design
tolerances to ensure a good tight fit when installed. It does not require special
tools or heating during installation.

Cold Shrink terminations use a series of pre-stretched tubes, which are factory
expanded and assembled onto a removable core. The core is removed after the
tube is positioned for installation over a terminal lug, allowing the tube to shrink
and provide a waterproof seal.

Figure 3.26: Cold Shrink type termination

39
14.1.6. Heat Shrink termination

This termination is made from polymeric material and is available in a

standard kit form. It is range taking and has small design tolerances to ensure
a good tight fit when installed.

It does not require special tools during installation but a gas blow torch with
flame control is required to shrink the insulating tubes onto the prepared cable
cores.

It is critical to prepare and dimension the cable cores as per the jointing
instructions supplied with the joint kit to ensure a good fit.

The cable cores should also be clean and free of dust prior to heat shrinking.
Contamination can initiate partial discharges and degradation of cable
insulation leading to failure.

Figure 3.27: Heat shrink termination

40
14.2. Type of In-line Splices
In-line splice or commonly known as straight-through joint, permits the
connection of two underground cables of any length. Ideally, the two
underground cables must be of the same conductor size and insulating material.
But cables of differing conductor sizes and insulating material can also be spliced
together with special purpose in-line splice kits.
The material for the in-line splice must have mechanical, dielectric, chemical,
thermal and electrical characteristics that are comparable with and equivalent to
that of the original cable material.
Cable preparation and dimensioning is critical for in-line splices to ensure there is
no unwanted mechanical and electrical stresses put onto the completed joint.

Figure 3.28: In-line Splice

14.2.1. Self-amalgamating tape

The first jointing systems employed for polymeric cables (i.e. XLPE,
EPR) were all based on tapes, either self-amalgamating or adhesive type.
It does not require special tools or heating during installation.

Some features of Self-amalgamating tape include:

 excellent physical and electrical properties with a high degree of
stability
 amalgamates rapidly when applied under tension to provide a void-
free homogeneous wrapping without the need of external heat or
pressure
 compatible with a wide range of polymeric cable insulation
 has excellent resistance to water and ozone
 tape will remove cleanly when cut
 has a service temperature of between -40°C to +100°C

This type of joint is not in common use today and has been replaced by
either cold-shrink or pre-moulded type.

41
 Figure 3.29: Self-amalgamating tape in-line splice

14.2.2. Pre-molded In-line splices

This type of in-line splices are made from polymeric material, such as,
EPDM, EPR or silicone rubber, and are only suitable for polymeric
cables. These are single-piece joints, factory made and tested, of
consistent quality and is easily installed by pushing over the prepared
cable. It does not require special tools or heating during installation.

It is not range taking and has small design tolerances to ensure a good
tight fit when installed. Therefore, it is important to know the physical
dimensions and construction of the cable prior to selecting the
appropriate joint kit.

Two techniques described below maybe used to install pre-molded joints:

14.2.2.1. Slip-on

The lubricant supplied with the joint kit is applied to the prepared cable
conductors and the joint is then pushed over to one side (either left or
right) while the cable conductors are being connected using either
mechanical or crimp connector.

The joint is then pushed over the connector and adjusted to ensure it is
correctly positioned. The installation is fast and simple. The cable can
be energized immediately upon completion of the joint.

14.2.2.2. Cold Shrink

Cold Shrink joints are pre-stretched, expanded and assembled onto a

removable core at the factory. During installation, the joint is moved
over to one side (either left or right) while the cable conductors are being
connected using either mechanical or crimp connector.

The joint is then repositioned over the connector, the core is removed,
allowing the joint to shrink and provide a waterproof seal. The
installation is fast and simple. The cable can be energized immediately
upon completion of the joint.

42
 14.2.3. Heat Shrink In-line splices

Heat Shrink in-line splices are designed to provide long-term reliable

performance with excellent mechanical and environment protection. It is
easy to install, is range taking and has small design tolerances to ensure a
good tight fit when installed. It does not require special tools during
installation but a gas blow torch with flame control is required to shrink
the insulating tubes onto the prepared cable cores.

The prepared cable conductors are connected using either mechanical or

crimp connector. A sealing mastic tape is taped over the connectors
before the heat shrink tubing is positioned over it.

The heat shrink tubing comes ready to use. It can be either thin, medium
or thick walled and adhesive lined. With the application of moderate
heat, it automatically molds to a skin-tight fit over the prepared cable
conductor to provide a waterproof seal. The installation is fast and
simple. The cable can be energized immediately upon completion of the
joint.

Reference:
1. The Engineering Institute of Thailand - Standard for Electrical Installation in
Thailand (EIT) 2010
2. PEA - Underground cable guideline

43
Chapter 4
Civil Work Procedures

1. Introduction

Experience has shown that the reliability of an underground cable power system is very
dependent upon the transportation, handling and installation of the cable, its termination and
jointing at the project site.

In this chapter, installation of underground cables in ducts is described. Cable installation in

ducts has the major advantage over direct burial method in that the civil works can be done
earlier thus avoiding the problems associated with leaving the cable trenches open in urban
areas for prolong periods.

Procedures for installation of underground cables in ducts are in general class into two major
works:

1.1. Civil work – This chapter describes in detail the civil work procedures.
1.2. Electrical work – Chapter 5 focuses on the electrical work that involves cable testing,
terminating and splicing.

These two main works are very important tasks due to their high capital investment and the
lead time required for their planning and preparation.

In PEA, there are two methods for civil works:

1.3. Open trench method – construction of duct banks and manholes takes place with open
digging of trenches along the cable route. This is only possible in areas where there is
sufficient space for construction works without obstructing normal traffic flow.
1.4. Trenchless methods – make use of Horizontal Directional Drilling (HDD) and/or Pipe
Jacking. This method is for areas where open trench digging is not possible.

2. Pre-planning and Preparation

Pre-planning helps to determine the construction method and prepares the construction site
accordingly. Before any construction work can begin, the following tasks shall be
completed:

2.1. Review the cable route survey plans and the construction cross-sectional drawings for
the cable ducts and manholes. This ensures that the construction works are within the
boundary approved by the relevant authorities.

44
 Figure 4.1: Cable Route Survey Plans

Figure 4.2: Cross Sectional Construction Drawing

2.2. Approval from local municipality and/or highway authority – before work can start at
the project site, permission from local municipality and/or the highway authority is
required. These authorities will require the submission of cable route survey plans,
construction drawings, construction method and traffic management plans for
approval.

2.3. On site survey and demarcation of cable route – before work can start, the cable route
is surveyed and demarcated. This is prepared according to the plans approved by the
local municipality and/or highway authority.

45
 Figure 4.3: Cable route survey and demarcation

2.4. Mapping of other utilities services – to avoid the risk of damaging existing services
belonging to other utilities and also to ensure safety of the work crew and the general
public, these services must be located. Their location is marked on the cable route and
construction plans for reference, prior to starting work. If these services are damaged,
the power utility and the appointed contractor are responsible for all repairs and
compensation for loss of services.
Two methods are used to survey and map existing underground power cables and
other public services. The first method makes use of a Ground-Penetrating Radar
(GPR) machine as shown in Figure 4.4 and the other method is to dig several pilot
holes along the proposed cable route as shown in Figure 4.5.

Figure 4.4: Mapping Utilities services with GPR Machine

46
 Figure 4.5: Pilot hole – helps to locate existing underground utilities

2.5. Work progress monitoring and management – a project plan is the standard against
which work progress is measured. A good project plan starts with a detailed Work
Breakdown Structure (WBS) which maps out every deliverable, activity, schedule,
milestone, budget, etc.

The S-curve is an important project management tool that monitors and tracks
progress. Analysis of S-curves allows the project manager to quickly identify project
progress on an ongoing basis and to identify potential problems that could adversely
impact the project if not mitigated immediately. Project managers also use it to assess
progress against estimates.

The S-curve is a visual representation of the project path. The S-curve is an S-shaped
graph produced by the Sigmoid formula which calculates the cumulative expenditure
of certain parameters e.g. man-hours, output, cost, etc., against time.

Figure 4.6: A typical S-curve

47
2.6. Safety management – the general public and work crew are not to be subjected to
direct or indirect safety risk when near to or within the work site. Measures shall be in
place to ensure compliance with all electrical safety and occupational safety & health
regulations.

Secure and barricade the work site complete with sufficient safety and warning signs
to alert public and work crew of all dangers present. Access to work site is to be
restricted to authorized personnel.

Figure 4.7: Safety warning signs and barricades for work site

3. Construction of Duct Bank

This type of construction makes use of open trench method where the construction of duct
banks and manholes takes place with open digging of trenches along the cable route.

The main materials used in duct bank construction are High Density Polyethylene Pipe
(HDPE), Concrete Spacer Block, coupling for HDPE, 90° elbow joint for HDPE, round bars
and formworks. Figure 4.8 to Figure 4.12 displays pictures of these materials. Figure 4.13
shows a typical cross-sectional drawing of a 2 x 2 duct bank.

Figure 4.8: HDPE pipes Figure 4.9: Concrete spacer blocks

48
Figure 4.10: HDPE coupling and assembly drawing

Figure 4.11: HDPE 90° elbow and assembly drawing

Figure 4.12: Round bars and formworks

49
 Figure 4.13: A typical cross-sectional drawing of a 2 x 2 duct bank

3.1. Step by Step Construction Guide

The step by step guide for the construction of a typical duct bank is illustrated below:

3.1.1. Excavate trenches to required dimensions and depth.

Figure 4.14: Trench excavation

3.1.2. Install HDPE pipes, round bars, concrete spacer block and formworks.

Figure 4.15: HDPE pipes, round bars, concrete spacer blocks and formworks
installation

50
3.1.3. Join the HDPE pipes with the HDPE couplings.

Figure 4.16: Joining HDPE pipes using HDPE couplings

3.1.4. Install 90° HDPE elbow at the riser poles.

Figure 4.17: Installation of 90° HDPE elbow

51
3.1.5. Concrete pouring - well mixed concrete with a minimum compressive strength
Fc’ = 180 Kg/sq.cm (aged 28 days) is poured over the assembled duct bank.

Figure 4.18: Concrete pouring

3.1.6. Dismantling of formwork – the concrete surface will dry after 3 days. The
formwork can then be dismantled. The constructed duct bank can be seen
taking shape.

3.1.7. Furnishing of duct bank – The jointing between the duct bank and manholes
are mostly adjusted to be in line for easy cable laying, and some furnishing
works should be performed to ensure that no sharp curve occurs.

Figure 4.19: Duct Bank after dismantling the formwork

52
3.1.8. Backfilling and resurfacing – the trench is backfilled with the original soil that
is compacted and landscaped to its original condition. The road is also
resurfaced and restored to its original condition.

Figure 4.20: Backfilling and resurfacing of road

3.1.9. Installation of cable route markers – these are installed at fixed intervals to
mark the cable route and also to warn others, especially contractors, of the
existence of underground power cable system.

Figure 4.21: Installation of cable route markers

3.1.10. Internal cleaning of HDPE pipes – the inside of all HDPE pipes are cleaned of
all debris and waste material left behind during construction. A flexible
cleaning tool is pushed through the pipe to clean it.

Figure 4.22: Internal cleaning of HDPE pipes

53
3.1.11. Inserting nylon rope into HDPE pipes – nylon rope is inserted into each
HDPE pipe to pull the pulling-line through the HDPE pipes prior to
installing the pulling-grip assembly onto the cable. The pulling-grip is
used to pull the cable through the ducts. The nylon rope is pushed
through the HDPE pipes using a flexible duct rod.

Figure 4.23: Inserting nylon rope into the HDPE pipes

3.1.12. Dummy testing HDPE pipes – a dummy testing of all HDPE pipes is done to
identify and remove obstructions in the pipes prior to installing the cable. The
dummy test is done for both the linear and elbow bend sections.

Figure 4.24: Dummy testing HDPE pipes

Figure 4.25: Dummy testing for HDPE 90° elbow

54
 3.1.13. Cables at riser pole – fire rated concrete is poured at the base of the riser pole
where the cable terminates. Protective steel-guards are installed at the foot of
the riser pole to protect the cable against damage due to vandalism or traffic
accident.

Figure 4.26: Riser pole – BEFORE and AFTER pouring of fire-rated concrete and
installation of protective steel-guard

4. Construction of Manholes

Manholes are cable jointing pits and vaults for use with underground power cables systems.
A manhole may be constructed from pre-cast reinforced concrete, in-situ reinforced concrete
or brickwork construction, depending on the location of the pit within the street and
geographically within the city.

The construction details for manholes are as follows:

4.1. Excavate pit to required dimensions and depth for manhole. Temporarily support the
sides with interlocking steel sheet piles to prevent soil from collapsing into the pit and
endangering the work crew.

Figure 4.27: Manhole pit supported by steel sheet piles

55
4.2. Pour lean concrete at the base of the pit to required level.

Figure 4.28: Pouring lean concrete at base of pit

4.3. Formworks and steel bars for the base and side walls of the manhole are installed.

Figure 4.29: Installing formwork and steel-bars for the manhole

4.4. Ground rods and pulling iron installation for the bottom slab are completed.

Figure 4.30: Installation of ground Rods and pulling iron

56
4.5. Well mixed concrete with minimum compressive strength Fc’= 210 Kg/sq.mm (aged
28 days) is poured for the bottom slab

Figure 4.31: Pouring concrete for bottom slab

4.6. Install formworks for walls and duct bank windows. Duct bank windows connect the
cable ducts to the manhole.

Figure 4.32: Installing formworks for walls and duct bank windows

57
4.7. Install pulling-irons to the manhole walls.

Figure 4.33: Installing pulling-irons

4.8. Pour concrete for the manhole walls.

Figure 4.34: Pouring concrete for manhole walls

4.9. When the concrete has set, dismantle the formworks.

Figure 4.35: Dismantle the formwork for the manhole

58
4.10. At the interface between the cable duct bank and the duct bank window of the
manhole, install end-bells or bell-mouths for the HDPE pipes to prevent potential
obstruction when pushing cable through the HDPE pipes.

Figure 4.36: End Bells Installed at manhole’s duct bank window

59
4.11. View of a completed duct bank window.

Figure 4.37: Duct bank window

4.12. Install formwork and steel bars for top slab.

Figure 4.38: Formworks and steel bars for top slab

4.13. Pour concrete for top slab.

Figure 4.39: Pouring concrete for Top Slab

60
4.14. Install formwork, steel bars and manhole entrance frame complete with steps.

Figure 4.40: Installation of manhole entrance

4.15. Pour concrete for manhole entrances

Figure 4.41: Pouring concrete for manhole entrances

4.16. Dismantle formworks for manhole entrances

Figure 4.42: Manhole entrances with formworks dismantled

61
4.17. Install covers for the manhole entrances, backfill, and compact and landscape the soil.
Clear the area of all waste material and resurface the road.

Figure 4.43: Manhole with entrance covers and area after landscaping

Figure 4.44: Area cleared of all construction material and resurfaced road

4.18. Install cable rack supports at every 1.5m intervals or at other interval distance as
approved by PEA. Typical number of cable racks installed for each cable type is as
follows:
a) HV cables rated at 69/115kV – one cable rack for each single-core cable
b) MV cables rated up to 33kV – one cable rack for each circuit of three single-
core cables

Figure 4.45: Layout drawings for cable racks

62
 Figure 4.46: Cable rack supports and accessories

Figure 4.47: Cable racks with cable installed

4.19. Establish grounding grid for manhole with 1 x 50 mm2 PVC insulated copper
conductor.

Figure 4.48: Grounding grid layout drawing and typical installation in a manhole

63
 Figure 4.49: Drawing for manhole type 2T-3

5. Horizontal Directional Drilling (HDD)

Horizontal directional drilling is a trenchless construction method. HDD construction is

used to install electric cables as well as infrastructure of other utilities such as water and
waste water pipelines, where conventional open trench construction is not feasible or will
cause adverse disturbances to environmental features, land use or physical obstacles.

In horizontal directional drilling three installation stages are considered:

 Pilot drilling
 Reaming the initial pilot borehole
 Pulling back the pipeline in the reamed borehole

The initial borehole is called a pilot hole. The borehole is drilled using drilling fluid, which
is brought into the borehole by the rotating drilling head. Due to the relative high pressure at
the drilling head the drilling fluid facilitates the transport of cut soil pieces towards the
surface.

The diameter of this pilot hole is enlarged using a reamer. Depending on the required final
borehole diameter, the borehole can be enlarged in several steps using reamers of increasing
diameters. Finally, the pipeline is pulled into the created borehole.

64
5.1. Pre-Site Planning

Pre-site planning involves making an assessment as to whether an HDD is technically and

geo-technically feasible by studying existing geological data and conducting field
investigations to assess the subsurface conditions and characteristics likely to be encountered
during the drill.

If an HDD is determined to be feasible, a drill path or bore profile plan is designed to meet
the requirements of the crossing and appropriate drill entry and exit locations are selected.
The bore profile plan includes the depth to which the HDPE pipes are pulled. This shall not
exceed 3.0 meters.

The bore profile plan is prepared using an appropriate software application and includes
details of the bore head and rod pitch.

An allowance is made in the design of the drill path for any potential changes in the drill path
due to obstacles. The drill entry and exit points are then refined accordingly.

Figure 4.50: Sample bore profile plan

5.2. Components of HDD System

The HDD system shall consist of the following main components:

65
 1 = Drill Rig
2 = Power Unit
3 = Mixing Module (It mixes clean water
and Bentonite)
4 = Drill Rods and Drilling Tools e.g.
Sonde Housing, Drilling Head, Back
Reamer
5 = Accessories for Receiver (It can also
be used as a cable/pipe locator), Data
Sonde or Ground-penetrating radar (it
contains sensors that measure tilt, roll
angle, temperature and battery life)
Figure 4.51: Main Components of HDD System

5.3. Procedure for HDD

5.3.1. Install drill head

Before installing the drill-head, calibrate the sonde machine. This calibration is a
requirement for each bore. The sonde machine has the following advantages:

 It diligently monitors the path of the drill head during drilling and pullback
to verify the path of the bore.
 It warns of close proximity (parallel or crossing) between a buried utility and
a horizontal bore
 It has built in data logging

Figure 4.52: Sonde Machine Calibration

66
 Figure 4.53: Drill head assembly drawings

5.3.2. Preparation of drilling-fluid

Drilling fluid is usually a mixture of freshwater and bentonite. Bentonite is naturally

occurring clay that is extremely hydrophilic (i.e., has high swelling characteristics).
Certain polymers may also be used that enhance the drilling fluid benefits.

The drill-fluid mixing module is filled with clean water and the required quantity of
bentonite is drawn in slowly until the consistency of the drilling-fluid is within the set
standards.

5.3.3. Drilling a pilot bore: drilling-fluid flow test

Test the flow of drilling-fluid flow before lowering the drill-head into the ground. The
drilling-fluid must flow out freely through all the jet nozzles.

Figure 4.54: Drilling-fluid flow testing

67
5.3.4. Drilling a pilot bore: drill entry location

An HDD drill rig and supporting equipment is set-up at the drill entry location
determined during the pre-site planning phase. A pilot hole is drilled along the
predetermined drill path.

When starting “from the ground surface” it is necessary to open a small starting pit. The
front wall of this starting pit must be right-angled to the drilling axle as shown in the
drawing below.

Figure 4.55: Cross sectional drawing showing drill entry for pilot bore

5.3.5. Drilling a pilot bore: tracking the pilot bore path

Periodic readings from a probe situated close to the drill bit are used to determine the
horizontal and vertical coordinates along the pilot hole in relation to the initial entry
point. The pilot hole path may also be tracked using a surface monitoring system that
determines the down hole probe location by taking measurements from a surface
point.

An operator with a receiver receives information from the Sonde or Ground

Penetrating Radar (GPR) relating to roll, tilt, depth, and location. The operator then
checks this against the bore profile plan and guides the drill operator to keep the pilot
bore on the correct path.

68
 Figure 4.56: Tracking the pilot bore path

5.3.6. Back reaming: disassembly of the drill head

After the completion of the pilot bore, the drill head is disconnected and a reaming
head is connected to the drill rod at the exit pit. The reamer is pulled back whilst
being rotated through the pilot bore to enlarge it.

Figure 4.57: Disassembly of drilling head

69
5.3.7. Back reaming: selection of the back reamer
The pilot bore must be back reamed to pull in pipe bundles. The selected back reamer
must be larger than the overall size of new pipe bundles.

Figure 4.58: Selection of back reamer

5.3.8. Pullback process: Intermediate back reaming

The pullback process is carried out once the reaming process has been completed. The
new pipe is attached to the rear of the reaming head when it is at the exit pit.
For larger diameters of between 160mm to 215mm, intermediate back reaming is
required. This also applies to areas with hard soil conditions. Additionally the final
bore diameter is attained by back reaming without any pipe pulling.
The general “rule of thumb” is to ream the pilot bore hole to 1.5 times the outside
diameter of the pipes or bundled pipes to be installed. This diameter will provide for
an adequate allowance for the installation of the pipes.

The number of reaming passes will be determined by the hardness of the material
being reamed and the ability to remove cuttings from the hole

Figure 4.59: Assembly drawing for intermediate back reaming

70
5.3.9. Pullback process: pulling head and swivel assembly
As the drill string and reamer head is pulled back through the bore hole it rotates. To
avoid rotating the new pipe, the reaming head is connected to the pipe by means of
pulling head and swivel assembly.
Normally the back reamers are equipped with an assembled pulling eye. If this
facility is not available, the pulling eye must be screwed onto the back reamer.
It is recommended to assemble a casing at the rear of the back reamer to avoid gravel
and stones from falling between the back reamer and the expander chuck.

Figure 4.60: Connection between expander chuck and pipe

5.3.10. Pullback process: end of pipe pulling

The reaming head is used in the borehole during pullback to remove any loose debris
in the hole which may prevent the pipe from being successfully pulled back. This also
facilitates the use of drilling fluid which lubricates the process, assisting the pullback
of the pipe. The pullback process is continued until the new pipe reaches the drill rig.

71
 Figure 4.61: Before pullback of bundled pipes

Figure 4.62: After pullback of bundled pipes

5.3.11. Pullback process: Dummy test on HDPE pipes

Dummy test all HDPE pipes to identify and remove obstructions in the pipes. If
required the insides of all HDPE pipes are cleaned of all debris and waste material
using a flexible cleaning tool that is pushed through the pipes to clean it.

Figure 4.63: Dummy testing of HDPE pipes

72
5.4. Limitations of HDD
The Australasian Society for Trenchless Technology, in their guideline, advises that HDD
does not perform well in locations with gravel soils, boulders, and compact stone layers. The
changing ground formations and mixed soils create difficulty in controlling the drill direction
(e.g. Sandy soil or limestone layers), due to voids within the soil mixture. There is also the
possibility of loss of drilling fluid pressure.
Coarse-grained soils, or soils that contain boulders or cobbles, encountered during the HDD
process, can result in an increase in the overall project duration and cost. When these types of
situations are encountered, the HDD machine might not be able to drill through the ground.
This could result in delays due to requiring additional ground investigation to further clarify
the type of drill head required.

6. Pipe Jacking

Pipe Jacking (PJ) is another type of Trenchless Technologies normally utilised to install
below ground pipes such as ducts and culverts under protected sites and busy urban areas.
It is a very popular option for installing pipelines in a wide range of soil conditions.

It is used in areas where open excavation would prove too costly, socially unacceptable
(traffic diversions and route blockages), economically damaging to local business, and or
environmentally unacceptable.

Pipe Jacking uses powerful hydraulic jacks to push specifically designed pipes through
the ground behind a shield at the same time as excavation takes place within the shield.

A thrust wall is constructed at the entry shaft to provide a reaction against the jacking
force. A thrust ring is used to transfer the jacking forces from the cylinders to the pipe to
prevent damage to the pipe due to point loading. The thrust force is developed by a pair of
hydraulic cylinders acting against the thrust wall.

The jacking system comprises of the hydraulic jacks, a jacking frame and a bench.
Jacking capacity of up to 1000 tons is common. The frame is designed to provide the
level of pressure required and the suggested jacking force (JF) can be estimated by:

JF = π x OD x L x F

Where, OD = Pipe Outer Diameter (m)

L = Drive Length (m)
F = Friction Factor (tons/m2)

HDPE pipes are placed in the rigid steel pipe and concrete is injected into the steel pipe to
permanently hold the HDPE pipes in place. The maximum depth from road surface of the
steel pipe shall not exceed 2.50 meters. The depth and pipe jacking profile plan is
prepared using an appropriate software application for pipe jacking.

73
 Figure 4.64: Typical arrangement for pipe jacking

6.1. Main components for pipe jacking

The pipe jacking method consists of the following main components:
 jacking pipe
 generator
 winch
 hydraulic machine
 hydraulic jacks
 welding components
 truck with crane
 air blower/ventilator
The pictures below display these main components:

Figure 4.65.1: Jacking Pipe Figure 4.65.2: Generator

74
 Figure 4.65.3: Winch Figure 4.65.4: Hydraulic machine

Figure 4.65.5: Hydraulic Jacks Figure 4.65.6: Weld Components

Figure 4.65.7: Truck with crane Figure 4.65.8: Air blower

75
6.2. Procedure for pipe jacking

6.2.1. Prepare launch and reception pits. Shore the sides of these pits with
interlocking steel sheet pile to prevent the soil from collapsing into the pits and
endangering the work crew.

Figure 4.66: Preparing the launch and reception pits

6.2.2. Align and set the jacking frame - The jacking frame is set in the launch pit and
aligned with the planned pipe jacking path.

Figure 4.67: Aligning the jacking frame

6.2.3. Welding of pipe segments - Place one pipe segment onto the jacking frame.
Clean the edge of the pipe segment with a mechanical abrasion tool or angle
grinder. Degrease the edge after cleaning.

Temporarily, weld small rectangular plates to the clean edges of the pipe
segments. These plates will lock the pipe segments before welding them. On
completion of welding of the pipe segments, apply rust proof coating to the
welded area.

76
 Figure 4.68.1: Installing a pipe segment on the jacking frame

Figure 4.68.2: Clean edge of pipe segment Figure 4.68.3: Welding of small metal plates

Figure 4.68.4: Welding pipe segments together

77
 Figure 4.68.5: Rust-proofing the welded area

6.2.4. Soil extraction - Soil extraction can be either by hand mining or mechanical
excavation within a shield or by micro-tunnel boring machine (MTBM). The
excavation method selection is based on soil conditions.
In PEA, a hand auger loosens the soil within the pipe segment. This soil is then
placed onto a metal tray that is lifted out from the launch pit by a crane.
An air blower/ventilator provides fresh air intake into the pipe segment for the work
crew.

Figure 4.69: Soil excavation in progress

Figure 4.70: Removing excavated soil from launch pit

78
6.2.5. Jacking of pipe segments - The pipe segment is moved by hydraulic jacks located in the
launch pit. The thrust power of the hydraulic jacks’ forces the pipe segment forward
through the ground as the soil is excavated.
After each pipe segment has been installed, the rams of the hydraulic jacks are retracted so
that another pipe segment can be placed in position on the jacking frame for the pipe jacking
cycle to begin again.
While pipe jacking is in progress, a work crew will check the level of the pipe with a spirit
level. The project engineer using a surveyor’s leveling equipment or theodolite, can check
and reaffirm the alignment of the steel pipes to the planned pipe jacking path.

Figure 4.71.1: Jacking of pipe segment Figure 4.71.2: Level check

Figure 4.72: Rechecking level using surveyor’s equipment

6.2.6. Installation of deformed bars - Deformed bars support the HDPE pipes within the
steel pipe. These bars are installed at pre-determined intervals to maintain a linear
alignment and to support the weight of the cables to prevent addition mechanical
stresses on the cables due to sagging of HDPE pipes.

79
 Figure 4.73.1: Positioning of deformed bars within steel pipe

Figure 4.73.2: Welding deformed bars on the inside of steel pipe

6.2.7. Install HDPE pipes - Install HDPE pipes on the deformed bars according to planned
configuration.

Figure 4.74: HDPE pipes installed on deformed bars

6.2.8. Grouting with mortar - On completion of installation of HDPE pipes on deformed

bars, formworks are set-up at both ends of the completed jacked steel pipe. An
additional smaller diameter steel pipe is inserted to facilitate injection of mortar into
the jacked steel pipe to encase the HDPE pipes in concrete.

80
 Figure 4.75.1: Steel pipe for grouting Figure 4.75.2: Formworks installed

Figure 4.75.3: Grouting with mortar

6.2.9. Dismantling the formworks - Dismantle the formworks when the concrete has set. The
concrete may take up to three days to set.

Figure 4.76: View of completed pipe jacking with HDPE pipes encased in concrete

References:
1) PEA - Underground Cable Guideline
2) Horizontal Directional Drilling Instruction Manual
3) Australasian Society for Trenchless Technology - Guidelines for Horizontal
Directional Drilling, Pipe Bursting, Micro tunnelling and Pipe Jacking, 2009.

81
Chapter 5
Electrical Work Procedures

1. Introduction

Electrical works are initiated upon completion of civil works. Electrical works consists of
three main stages:

(i) Cable pulling

(ii) Cable termination & jointing (In-line splice)
(iii) Cable commissioning tests

Upon delivery, a cable drum shall be physically inspected for damage that may have occurred
during transportation. The manufacturer’s seal on the inner and outer cable ends should be
examined and the condition of armoring, serving and sheath shall also be inspected for
mechanical damage and corrosion.
If defects are found on the cable, it shall not be installed and the cable shall be returned to the
supplier for replacement.
As the cable is being unwound off the drum during installation, it shall be carefully
examined for signs of physical damage and abnormality. This physical inspection is
particularly important for the outer layers, where drum batten nails can cause damage.
If it is necessary to roll the cable drum, it shall be rolled in the direction indicated by the
arrow on the drum.
The drum should be mounted on jacks, cable trailer, or cable stands such that the cable is
preferably pulled from the top and always in the direction opposite to that indicated by the
arrow.
The first step prior to starting electrical works is to identify, demarcate and prepare the work site.

Figure 5.1: Electrical Work Area

82
Before starting electrical works, the following steps shall be observed:

1.1. Safety Management - electrical work area must be barricaded, so that unauthorized
person may not enter the construction site. Figure 5.2 shows safety barricades in place.

Figure 5.2: Safety Management

1.2. Cable roll-off direction - cable drums are mounted on cable-drum jacks and the direction
of cable roll-off shall be in line with the direction of cable pull as shown on figure 5.3.

Figure 5.3: Cable Roll-Off Direction

1.3. Dummy Test – prior to installing cable in the HDPE conduit, a dummy test is done
to ensure that the conduit is clean of any debris and is in good alignment. Figure 5.4
shows a dummy test being done.

Figure 5.4: Dummy Test and Profile Drawing for Dummy Test

83
2. Cable Pulling

There are several methods for cable pulling. Generally, the most common and economical
method employs power winches. Figure 5.5.1 to 5.5.10 shows tools required for cable
pulling.

Figure 5.5.1: Winch Figure 5.5.2: Sling

Figure 5.5.3: Swivel Figure 5.5.4: Dynamometer

Figure 5.5.5: Roller Figure 5.5.6: Pulling Eye

Figure 5.5.7: Cable Cutter Saw Figure 5.5.8: Gas tank with safety valve,
nozzle, high pressure hose, torch handle & burner

84
 Figure 5.5.9: Cable Lubricant Figure 5.5.10: Heat Shrinkable Tube

The following cable pulling procedure will help to ensure that the cable is not damaged
during installation.

2.1. Remove outer jacket and insulation equivalent to the length of the pulling eye.

Figure 5.6: Remove Cable Jacket and Insulation

2.2. Install pulling eye.

Figure 5.7: Pulling eye installation

85
2.3. Wrap the Pulling eye and Cable with the rubber tape.

Figure 5.8: Rubber taping the Pulling eye and Cable

2.4. Install and heat shrink protective jacket

Figure 5.9: Heat shrinking protective jacket

2.5. Cover Sleeve with aluminum tube and install swivel between pulling eye and sling.

Figure 5.10: Installation of aluminum tube and swivel

2.6. Install Dynamometer and Cable Rollers

The alignment of the cable trench or duct shall be set such that deviations from a straight line
occur over the largest possible bending radius. Any winch used to pull cables shall have
either a facility to automatically limit the pulling tension applied to a cable or a continuous
reading dynamometer incorporated in the pulling arrangement to enable the actual pulling
tension to be monitored.

86
 Figure 5.11: Roller and Dynamometer Installation

2.7. Pulling tension and pulling speed

When the cable sling is being pulled by a winch, the cable pulling tensions shall not exceed the
limits specified by the manufacturers for the particular type and size of cable (or as calculated.
Refer to Chapter 3 - Pulling Tensions for underground cable). The pulling force applied shall
be constant, smooth and continuous.
To avoid damaging the cable due to overruns, the cable shall be pulled at speed just sufficient
to keep the drum rotating smoothly. Higher speeds are permitted but only for smaller sized
cables in straight trenches or ducts with good conditions at the feeding and pulling ends.
Drums with long lengths of cable, however, should not be rotated rapidly since cable overrun
can damage the cable if pulling is suddenly slowed or abruptly stopped.

87
For cable bending radius, the recommended bending radius without any twists, knots, or
kinks are permitted.

Figure 5.12: Winching of cable sling

2.8. Smear cable with cable lubricant to reduce friction

During pulling, to reduce the risk of damage to the outer sheath of the cable, when it enters and
leaves the HDPE pipe, a cable lubricant is applied to the cable to reduce the friction between
the cable and the HDPE pipe.

Figure 5.13: Smearing the cable with cable lubricant

2.9. Pull the cable to riser pole and cut it to required length

Figure 5.14: Setting and terminating cable at riser pole

88
2.10. Wrap the cable ends in a plastic wrap and cover with PVC tubes.

Figure 5.15: Cables ends protected by PVC End-caps.

3. Erection of supporting structure and installation of cable riser

The next stage is to erect the supporting structure and install the cable riser in the correct circuit
configuration. The following steps will guide this procedure:

3.1. Supporting structure – This is installed with cross-arms at the required height to support
the cable riser.

Figure 5.16: Supporting structure

Mount the cable riser onto the support structure using cable clamps made of wood or other
non-magnetic material, for example, Fiber Reinforced Plastic (FRP). This type of clamps are
used to prevent localize heating at the clamping point due to induced eddy currents. Induced
eddy current heating occurs when magnetic materials are used and the heat generated will
damage the outer protective jacket of the cable.

89
 Figure 5.17: Cable Support Clamps
3.2. Cable riser alignment - clamping of the cable must be in-line with the cable termination
and in the required phase sequence to avoid unnecessary bending or crossing of the cable.

Figure 5.18: Cable riser alignment

3.3. Cable preparation on supporting structure - cable is prepared for mounting onto the
supporting structure. If the cable termination is not installed, the cable ends shall be
protected from ingress of moisture and contact with humidity by installing end-caps.

Figure 5.19 Cable preparations on supporting structure

4. Cable Termination

There are two termination types:

 MV termination kits for screened single-core polymeric insulated cables without

armor rated at 22kV and 33kV.
 HV termination kits with polymeric stress cones for cables rated at 69kV and 115kV.

90
The cable jointer, who is to install cable terminations, must be trained and competent to
complete the joint in accordance with the manufacturer’s instruction manual.

4.1. MV termination kits for screened single-core polymeric insulated cables without
armor rated at 22kV and 33kV

The common cable jointing tools required for this type of termination are shown in Figure
5.20 below.

Figure 5.20: Common tools for MV cable termination

Types of MV cable terminations and components are shown in Figure 5.21 and Figure 5.22.
Termination kit is shown in Figure 5.23.

Figure 5.21: Type of Terminations

91
 Figure 5.22: Components of a Termination Joint

Cable lug
Copper Tape

Stress Ground
control Void Shield
Packing Non- Filler
tubing
tracking
Sleeve Row Spring

Creepage for Terminator(skirt) Moisture Sealing

Figure 5.23: A typical cable termination kit

The following procedure is a guideline for a typical termination of screened single-core

polymeric insulated cables without armor rated at 22kV and 33kV. We have to bear in mind
that there will be some difference in the procedure for different brands.

4.1.1. Remove the outer protective jacket

The cable outer protective jacket is removed to the dimension as recommended by
termination joint manufacturer. Figure 5.24 shows the outer jacket being removed using a
cutting tool. The copper wire screen and copper contact tape are also exposed.

92
 Figure 5.24: Removing the outer protective jacket

4.1.2. Install Moisture Sealing Tape

To prevent ingress of moisture into insulation layer, moisture sealing tape or moisture
barrier tape (red color) is wrapped at the edge of outer jacket where it has been cut. The
copper wire screen is then pulled back to facilitate connection to ground.

93
 Figure 5.25: Installation of Moisture Sealing Tape

4.1.3. Mark and Remove Semi-conducting screen

Measure required dimension on semi-conductive screen and mark with PVC tape. Use a
round rat-tail file to cut through and remove the layer of semi-conductive screen.

Figure 5.26: Removing semi-conducting screen

94
4.1.4. Installing Cable Lug
Measure barrel length of the cable lug and mark it onto the XLPE insulation. Cut and
remove the XLPE insulation, exposing the copper conductor. Position the cable lug onto
the copper conductor and terminate it using either a crimping tool or mechanical
fasteners.

Figure 5.27: Installing Cable Terminal Lug

4.1.5. Installing Void Filler Tape

To prevent the occurrences of partial discharges at the interface between semi-conductive
screen and XLPE insulation, a void filler tape is installed at this interface.

Figure 5.28: Installing Void Filler Tape

95
4.1.6. Stress Control

To control the electric stresses at the interface between the semi-conductive screen and
the XLPE insulation, semi-conductive tubing is heat shrunk over this interface. This help
to distribute the electrical stresses evenly reducing the risk of insulation failure.

Figure 5.29: Installing Stress Control Tubing

4.1.7. Moisture Sealing

To prevent the penetration of moisture to conductor via cable terminal lug, moisture
sealing tape is installed along the barrel of the cable lug, extending over the interface
between the cable lug and XLPE insulation.

Figure 5.30: Moisture Sealing

4.1.8. Non-tracking Sleeve

To complete the joint an outer non-tracking sleeve is heat shrunk onto the cable. This
sleeve provides a final insulation and protection against moisture and environmental
pollution.

96
 Figure 5.31: Installation of Non-Tracking Sleeve

4.1.9. Creepage extenders for outdoor termination

For outdoor terminations, additional creepage distance is required compared to indoor
terminations to cater for weather and pollution conditions. Therefore, creepage extenders
are heat-shrunk on the outer non-tracking sleeve. The number sleeves required depends
on the voltage rating and the degree of pollution.

Figure 5.32: Installation of Creepage Extenders

97
 Figure 5.33: Number of Creepage Extenders at various voltage ratings

Table 5.1: Minimum Clearances for Cable Termination at various voltage ratings

98
 Figure 5.34: Termination of 22kV Cable to riser pole

5. HV termination kits with polymeric stress cones for cables rated at 69kV and
115kV

Underground cables come in various configurations and construction, for example, some
have wire screens or tape screens, corrugated sheaths, etc. Therefore, it is important to know
the cable construction so that the correct type of termination joint and accessories will be
selected for the cable. The following need to be checked:

 Cable dimensions such as size of conductors, thickness of insulation, thickness of

metallic screen, etc.
 Condition of the cable – roundness of cable insulation
 Condition of cable insulation – insulation resistance test
 Suitability of cable termination kit & accessories to the type and number of cables
 Expiry date of the cable termination kit

Figure 5.35: Megohmmeter for insulation resistance testing

99
Tools or equipment necessary for installation of cable termination is as shown in Figures
5.36.1 to 5.36.22.

Figure 5.36.1: Cable Heater with Temperature Control

Figure 5.36.2: Cable cutter saw Figure 5.36.3: Cable Screen & Insulation
Removal Tool

Figure 5.36.4: Power Sanders Figure 5.36.5:Vernier and Tape

Measure

Figure 5.36.6: Coffing Hoist Figure 5.36.7: Angle Steel

0.75-1.5 ton

100
 Figure 5.36.8: Cable Cutter Knifes, Pliers, Screw Drivers,
Hammers, Jacket Removal Tools and Brass Brushes

Figure 5.36.9: Torque Wrench Figure 5.36.10: Fitting Tool for

Stress cone

Figure 5.36.11: Hydraulic Crimping

Tool with Crimping Dies

Figure 5.36.12: Torch Handle, Nozzles,

High Pressure Hose, Compact Gas,
Safety Valve

101
 Figure 5.36.13: Wrench Figure 5.36.14: Thermometer

Figure 5.36.15: Heavy-duty Figure 5.36.16: Hot Air Gun

Soldering Iron

Figure 5.36.17: Glass Blade Figure 5.36.18: Gloves Figure 5.36.19: Marker

Figure 5.36.20: Plastic wrap Figure 5.36.21: Dust mask Figure 5.36.22: Cleaning cloth

102
The critical element in cable jointing is the skills demanded of a cable jointer especially during
removal of outer protective jacket, semi-conducting layer and the metallic screen. Even a minor
damage to the cable insulation during cable preparation can lead to cable joint failure.
The following procedure is a guide for the installation of a typical HV termination with polymeric
stress cones for cables rated at 69kV and 115kV. The jointing procedure remains common although
there may be some difference in the procedure for different brands.

5.1. Set the cable alignment and phase sequence. Clamp cable to support structure
securely.

Figure 5.37: Cable Installation

5.2. Cut off the cable approximately 200mm from the end.

Figure 5.38: Cutting the cable

103
5.3. Heat the cable with cable heaters to 80 0C for 4 hours and fix the steel angles to the
cable for 24 hours until the cable cools down to ambient temperature.

Figure 5.39: Heating the cable

5.4. Measure and record the length of termination insulator for reach phase. Mark these lengths
on the cables. The cables for each phase will be prepared for termination as per these
measured lengths.

Figure 5.40: Measure the length of termination insulator

5.5. Install the base-plate complete with the base-plate insulators. Use a spirit-level to
check the level of the base-plate.

Figure 5.41: Base-plate installation

104
5.6. Mark the measured dimensions onto the cable and prepare the cable for termination.

Figure 5.42: Cable preparation

5.7. If the cable has a layer of flipper on the outer jacket, the flipper and jacket will be
removed for approximately 300 mm in length.

Figure 5.43: Removing Flipper

105
5.8. For cables with laminated metallic sheath, this metallic sheath has to be prepared for
connection to ground.

Figure 5.44: Cable with metallic sheath

5.9. Remove the outer jacket to the length as specified in the instruction manual using the
Jacket Removing Tool. Care must be taken during this process not to damage the
cable insulation. Avoid using screw drivers to remove the jacket to reduce the risk of
damaging the insulation.

Figure 5.45: Removing the outer jacket

106
5.10. Remove the semi-conductive water barrier tape.

Figure 5.46: Removing water barrier tape

5.11. Pull back the copper wire screen and cut it to the required length.

Figure 5.47: Setting the copper wire screen

5.12. Remove the insulation screen using the Screen & Insulation removal tool.

Figure 5.48: Removing insulation screen

107
5.13. Shape the upper end of the insulation to the requirements stated in the jointing
instructions. Sand paper is used to shape the upper end of the insulation into a
“cone”.

Figure 5.49: Insulation screen being shaped to requirement

5.14. Sand the XLPE conductor insulation with a power sander tool.

Figure 5.50: Applying the power sander tool

5.15. Wrap insulation screen and XLPE insulation with the plastic wrap.

Figure 5.51: Applying the plastic wrap

108
5.16. The cable insulation after it has been shaped. A connector will be installed at the top
end of the cable.

Figure 5.52: Cable insulation after it has been shaped

5.17. Install the top connector and compress it with a hydraulic crimping tool with the
correct crimping die.

Figure 5.53: Compressing the top connector

109
5.18. Wrap the top of the connector and the interface between connector and insulation
with tape and heat-shrink it to get a smooth tight fit. Refer to the jointing manual for
instructions.

Figure 5.54: Wrapping the connector with tape

5.19. Installing the stress control – inspect the stress control unit for any defects. Make
sure that it is clean and free of dust. Do not use sharp tools to open the packaging of
the stress control to avoid risk of damage. The stress control unit shall be of
appropriate dimensions to tightly fit the cable size.

Figure 5.55: Stress control unit

5.20. Mark the position for the stress control unit with PVC tape. Clean the cable
insulation with recommended cable cleaning agent. Before installing the stress
control unit, ensure there are no scratches or sharp protrusions on the insulation
surface as this may damage the inner surface of the stress control unit.

110
 Figure 5.56: Marking the position for the stress control unit

5.21. Install the following beneath the base plate – heat shrinkable tube, screen-pot and tall
tube. The type of components to be installed depends on the type of termination
joint used.

Figure 5.57: Setting-up the base plate

5.22. Install the base plate with insulators on the supporting structure.

Figure 5.58: Base plate with insulators

111
5.23. Inspect the stress cone for defects and damage. If there are scratches inside the stress
cone, do not use. Replace it.

Figure 5.59: Inspecting Stress Cone

5.24. Grease the XLPE insulation and the inside of stress cone with clean silicone grease.

Figure 5.60: Smearing silicone grease on XLPE insulation

5.25. The stress cone is installed on the cable at the measured position

Figure 5.61: Installing Stress Cone on the cable

112
5.26. Clean the excess grease on the XLPE insulation and the stress cone. Wipe using a
lint-free cloth or industrial grade paper tissue and an approved cleaning agent.
Remove the PVC tape that marked the position of the stress cone.

Figure 5.62: Cleaning the silicone grease

5.27. Apply insulating tape on the XLPE insulation followed by copper mesh tape. Follow
the requirements in the instruction manual.

Figure 5.63: Apply the copper mesh tape

5.28. Installing the termination insulator and filling with dielectric insulating fluid – clean
the outside and inside of the insulator, cover the top and bottom with a plastic wrap.

Figure 5.64: Preparing the insulator for installation

113
5.29. Install the stress cone on the cable at the measured position. Clean the cable XLPE
insulation, stress cone and base plate with a lint-free cloth or industrial grade tissue
using an approved cleaning agent.

Figure 5.65: Cable with Stress Cone installed

5.30. The stress cone is installed on the cable at the measured position

Spread silicone grease onto the O-rings and position them on the base plate. Install the
insulator on the base plate and fix it to the base plate with bolts.

Figure 5.66: Installing the insulator

5.31. Heat the dielectric insulating fluid to the temperature specified in the instruction
manual and let it cool down to the required pour temperature. Pour the dielectric
insulating fluid into the insulator to the specified level.

Figure 5.67.1: Heating process Figure 5.67.2: Pouring into insulator

114
5.32. Wait for the dielectric insulating fluid to cool. When no air bubbles are visible, place
the top cover and bolt it to seal the insulator.

Figure 5.68: Installing the Top Cover

5.33. Grounding – pull back the copper wire screen, cut it to the required length and bind
with PVC tape. Place a heat shrinkable insulating tube over the copper wires and
heat shrink it firmly over the copper wire.

Figure 5.69: Preparing the ground connection

5.34. Combine the copper wires to form a single copper conductor, bind with PVC tape,
insert into a terminal lug of suitable size and compress it with a hydraulic crimping
tool. Place a short length of heat shrinkable tube (half over the terminal lug and half
over the copper wires) and heat shrink it.

Figure 5.70: Combining the copper wires into a ground connecting lead

115
5.35. Connect the ground connecting lead to the grounding terminal to facilitate its
connection to the sub-station ground.

Figure 5.71: Connection to grounding terminal

5.36. Connecting to HV riser-pole

Figure 5.72: 69/115 kV Riser-pole

6. Splicing of Underground Cables

Splicing of MV or HV underground power cables is required to maintain the electrical

continuity of the conductor and shields and also to maintain the insulation levels of the two
power cables joined together.

These cables are spliced by joining the two conductors: insulation is built up over the
exposed conductor to provide insulation properties similar to those of the cable insulation:
the cable shields are then joined to confine the electric field to the insulation.

Splicing is done on cables in straight alignment to reduce mechanical stresses on the joint.
Therefore spicing is also referred to as in-line splice or straight through joint.

Splicing is done either in man-holes for cables in ducts or joint-pits for direct buried cables.

Splicing shall only be done by a trained and certified cable jointer.

116
6.1. Objectives of Splicing Underground Cables

6.1.1. To extend the cable route length – cables are delivered coiled on drums in
lengths of 500m or 1000m. Splicing is thus required for cable route
length greater than the drum length.

For single-core cables, to reduce the effect of induced voltages on cable

metallic screen, single-point bonding or cross-bonding is used to ground
the metallic sheath.

6.1.2. To repair or replace damage or faulted cables

6.2. Key components

6.2.1. Connector – this joins the conductor of the cables for continuity of current
flow.

6.2.2. Joint body – for electrical field control and insulation

6.2.3. Outer jacket – protection against ingress of moisture

6.3. Design

There are two design types:

6.3.1. Joint body with separated ground shield – this will have a small break in
outer sheet of joint body for separating the ground shield on both sides of
the cable as shown in Figure 5.73.

It is possible to convert joint body with separated ground shield to joint

body with direct grounded shield by using semi-conductive taping to
connect both sides of shield to ground.

Both sides of cable shall be in alignment. The cables are heated to 80 0C

for 4-6 hours before installation and allowed to cool for 12 hours. This
temperature is maintained at 800C. Otherwise, the cable will start to fuse
together connecting both the copper shields if temperature rises to 950C.

Thus, when a fault occurs, the fault current will flow back to the sub-
station through this ground shield.

Ground shield connectors are not installed on the joint body because as
load increases, the joint body will expand. The ground shield connector
will press against the joint body.

6.3.2. Joint body with directly grounded shield – this will have a continuous
outer sheet.

117
 Figure 5.73: Joint body with separated ground shield

6.4. Installation

Figures 5.74 to 5.78 illustrate a typical installation for an in-line splice.

Figure 5.74: Installing connector

118
 Figure 5.75: Installing joint body

Figure 5.76: Lubricating with silicone grease

119
 Figure 5.77: Installation of shield ground

Figure 5.78: Installing outer sheath

References:
1. PEA - Underground cable guidelines
2. Cable Termination Installation Instruction Manual

120
Chapter 6
Cable Testing

1. Introduction

The purpose of testing is to ensure that all underground power cables, terminations & splices
and associated accessories supplied by manufacturers or installed by contractors are within
the required design & performance specifications, installed in accordance with specified work
standards and are safe to put into operation.

The testing is also an important step in evaluating the quality of an underground cable.
Testing is typically done in two stages:

1.1. Factory Testing - This testing takes place at the manufacturer’s premises and is for new
cables before delivery to confirm that these cables are in conformance to contract’s
specifications.

1.2. Field Testing – Testing takes place at the work site for new installation prior to
commissioning, for maintenance especially when re-commissioning the cable circuit
after repairs and for fault location. This is to ensure that the circuit is safe to put into
operation.

In PEA, testing on cables complies with the following standards:

1.3. For MV XLPE cables rated at 22kV and 33kV

IEC 60502-2
Power cables with extruded insulation and their accessories for rated voltages from 1kV
to 30kV Part 2: Cables for rated voltages from 6kV up to 30kV

IEC 60502-4
Power cables with extruded insulation and their accessories for rated voltages from 1kV
to 30kV Part 4: Test requirements on accessories for cables with rated voltages from
6kV up to 30kV

1.4. For HV XLPE cables rated at 115kV

IEC 60840 Power cables with extruded insulation and their accessories for rated
voltages above 30kV up to 150kV- Test methods and requirements
.

2. Factory Testing

The objective of factory testing is to ensure that the cable and their accessories are in
conformance to the contract specification. If there is any deviation from contract
specification, the purchaser and manufacturer shall evaluate the deviations and come to an

121
agreement on the corrective action and re-testing before delivery to the project site or
purchaser’s warehouse.

There are two categories for factory test:

2.1. Type test – Tests done to establish performance characteristics to a particular standard.
These tests are done during development of a new type of cable or when changes are
made to the design of existing cable. These tests are not repeated during normal
manufacture of cable.

2.2. Routine test – These are tests done by the manufacturer on every finished drum of
cable to show compliance with contract specifications and the applied standards.

3. Type Tests

3.1. MV XLPE cables rated at 22kV and 33kV

The following tests are done at manufacturer’s factory or at an independent testing institution.
These tests are normally witnessed by the purchaser’s representatives.

 Partial Discharge test (PD test)

 Bending Test followed by Partial Discharge test
 Tan Delta Measurement
 Heating cycle test followed by Partial Discharge test
 Impulse Voltage Test followed by power frequency voltage test
 Voltage test for 4 hours
 Resistivity of semi-conducting screens
 Measurement of thickness of insulation and of non-metallic sheaths
 Test for determining the mechanical properties of insulation before and after ageing
 Test for determining the mechanical properties of non-metallic sheath before and after
ageing
 Water absorption test on insulation

3.2. HV XLPE cables rated at 115kV

IEC 60840, Clause 12.3.1 Test Voltage Values, requires that the following is done before
start of Type Testing:

Prior to the electrical type tests, the insulation thickness of the cable shall be measured by
the method specified in 8.1 of IEC 60811-1-1 on a representative piece of the length to be
used for the tests, to check that the average thickness is not excessive compared with the
nominal value.

If the average thickness of the insulation does not exceed the nominal value by more than 5%,
the test voltages shall be the values specified in Table 4 for the rated voltage of the cable.

122
If the average thickness of the insulation exceeds the nominal value by more than 5% but by
no more than 15%, the test voltage shall be adjusted to give an electrical stress at the
conductor screen equal to that applying when the average thickness of the insulation is equal
to the nominal value and the test voltages are the normal values specified for the rated
voltage of the cable.

The cable length used for the electrical type tests shall not have an average thickness
exceeding the nominal value by more than 15%.

The following tests are done at manufacturer’s factory or at an independent testing institution.
These tests are normally witnessed by the purchaser’s representatives.

 Bending Test followed by Partial Discharge test

 Tan Delta measurement
 Heating cycle test followed by Partial Discharge test
 Lightning Impulse Voltage Test followed by Power Frequency voltage test
 Measurement of thickness of insulation and of non-metallic sheaths
 Tests of outer protection for buried joints
 Examination of the cable system with cable and accessories on completion of the
above tests
 Resistivity of cable semi-conducting screens
 Test for determining the mechanical properties of insulation before and after ageing
 Test for determining the mechanical properties of non-metallic sheath before and after
ageing
 Ageing test for compatibility of materials
 Pressure test at high temperature on sheaths
 Hot set test
 Carbon black content of PE sheath
 Shrinkage test for XLPE insulation
 Water absorption test on insulation

4. Routine Tests

4.1. MV XLPE cables rated at 22kV and 33kV

Routine tests shall be done for each drum of cable.

The following tests are done at manufacturer’s factory. These tests are normally witnessed
by the purchaser’s representatives.

 Measurement of conductor resistance

 Partial discharge test (PD test)
 Voltage test
 Sample test (less than 10% of total length)
 Measurement of thickness of insulation and of non-metallic sheaths
 Voltage test for 4 hours
 Hot Set test for XLPE insulation

123
4.2. HV XLPE cables rated at 115kV
The following tests are done at manufacturer’s factory. These tests are normally witnessed
by the purchaser’s representatives.

 Measurement of conductor resistance

 Partial discharge test (PD test)
 Voltage test
 Sample test (less than 10% of total length)
 Measurement of thickness of insulation and of non-metallic sheaths
 Voltage test for 4 hours
 Hot Set test for XLPE insulation
 Measurement of cable capacitance

The number of tests to be done for Type and Routine Tests depends very much on what is
required in the specifications and what has been agreed to between the manufacturer and
purchaser.

5. Summary of Tests

A brief explanation for each test is given below:

5.1. Partial Discharge Test (PD Test)

The following limits are allowed for PD:

a. For MV XLPE cable rated at 22kV and 3 kV - apply 2 U0 and decrease to 1.73
U0. PD level must not exceed 10 pC.
b. For HV XLPE cable rated at 115 kV - apply 1.75 U0 and decrease to 1.5 U0.
PD level must not exceed 10 pC.
U0 is the phase to ground nominal voltage of the cable.

5.2. Bending Test

This test simulates the bending of cable during installation. This test is done by bending the
cable around a test cylinder followed by Partial Discharge test.

5.3. Tan Delta Measurement

This test measures the dielectric losses of cable insulation. Rated voltage U0 is applied to the
cable at a cable conductor temperature of between 95°C to 100°C.

5.4. Heating Cycle Test

This test simulates the operating condition of the cable. A current is injected into the cable
for 8 hours continuously until the conductor temperature reaches between 95°C to 100°C and
this is sustained for 2 hours. This shall be followed by at least 16 hours of natural cooling to
a conductor temperature within 10°C of the test ambient temperature. This test cycle is
repeated 20 times and is followed by Partial Discharge test for verification.

124
5.5. Impulse Voltage Test followed by Power Frequency Voltage Test

The cable shall withstand without failure or flashover 10 positive and 10 negative voltage
impulses.

After the impulse voltage test, the cable shall be subjected to a power frequency voltage test
for 15 minutes at 3.5 U0 for MV rated cables and 2.5U0 for HV rated cables. This test may be
carried out either during the cooling period or at ambient temperature.

No breakdown of the insulation or flashover shall occur. The applied impulse voltage is as
follows:
Rated Voltage Impulse Voltage
Uo/Um (kV) (kVpeak)
12/20 (24) ± 125
18/30 (36) ± 170
64/110 (123) ± 550
Table 6.0A: Cable ratings and impulse voltage tests

5.6. Voltage Test

A power frequency voltage of 4U0 for 4 hours (MV cables) and 2.5U0 for 1 hour (HV cables)
is applied to a sample cable of length 5.0m. No breakdown of insulation shall occur. This
test is done on cables with maximum rated voltage Um ≥ 7.2 kV.

Since this test has an impact on the cable life, it is restricted only to a sample of cable.

5.7. Resistivity of semi-conducting screens

This test measures the resistivity of the conductor screen and the insulation screen.
Measurements are made at a maximum conductor temperature of 90±2°C that is maintained
for at least 30 minutes.

The resistivity shall not exceed the following values:

 conductor screen: 1 000 Ω⋅m
 insulation screen: 500 Ω⋅m

5.8. Measurement of thickness of insulation and of non-metallic sheaths

This test measures the thickness of the insulation and all non-metallic sheaths to ensure that
the cable dimensions are to specifications.

5.9. Test for determining the mechanical properties of insulation before and after ageing,

This test is to prove and compare the tensile strength and elongation at break of insulating
material of the cable before and after accelerated ageing treatment.

125
5.10. Test for determining the mechanical properties of non-metallic sheath before and after
ageing

This test is to prove and compare the tensile strength and elongation at break of non-metallic
sheath of the cable before and after accelerated ageing treatment.

5.11. Water absorption test on insulation

This test measures water absorbed by the insulation. The insulation is immersed in water of
temperature of 85°C for 336 hours. The allowable increase in mass of the insulation shall be
≤ 1mg/cm2.

5.12. Measurement of conductor resistance

This test measures the conductor resistance at ambient temperature

The sample cable length shall be placed in the test room maintained at a reasonably constant
temperature for at least 12 h before the test. The measured value of resistance shall be
corrected to a temperature of 20°C and 1 km length in accordance with the formulae and
factors given in IEC 60228.

The D.C. resistance of each conductor at 20°C shall not exceed the appropriate maximum
value specified in IEC 60228.

5.13. Voltage test

The power frequency voltage is applied at ambient temperature during the test.

Rated Voltage Test Duration

U0/Um (kV) Voltage (minutes)
12/20 (24) 3.5 U0 5
18/30 (36) 3.5 U0 5
64/110 (123) 2.5 U0 30
Table 6.0B: Cable ratings and power frequency voltage tests

No breakdown of the insulation shall occur.

5.14. Sample Tests

Both IEC 60502-2 and IEC 60840 define sample tests as:

Tests made by the manufacturer on samples of completed cable or components taken from a
completed cable, at a specified frequency, so as to verify that the finished product meets the
specified requirements.

Sample tests are carried out on one length of cable from each batch manufactured for a cable
of the same type, voltage rating and cross-section. The sample length is limited to more than
10% of the number of lengths in any contract.

126
The following tests are considered as part of sample tests:

a. Conductor examination and check for dimensions - this test measures

insulation thickness and dimensions of cable construction materials to ensure
compliance with specification.
b. Hot Set test for XLPE insulation - a temperature of up to 200±3°C is applied
for 15 minutes to the sample and the elongation of XLPE material is measured.
It shall not exceed the specified value.
c. Ageing test of compatibility of materials - a temperature of up to 100±2°C is
applied for 168 hours to the sample. The tensile strength and the elongation of
XLPE material are measured. It shall not exceed the specified value.

5.15. Pressure test at high temperature on non-metallic sheaths

This test measures the resistance to deformation of the sheath when a high pressure at a high
temperature is applied. The depth of indentation must be ≤ 50%.

5.16. Carbon black content of PE sheath

This test measures the content of carbon black in the PE sheath. The quantity of carbon black
determines the resistance of PE sheath to UV radiation. A small piece of PE is weighed
before heat treatment at very high temperatures in a furnace. The residue of PE sheath is
weighed again after heat treatment. The percentage difference between them gives the
percentage of the carbon black content in PE sheath

5.17. Shrinkage test for XLPE insulation,

The test pieces are marked and then heated in an oven. The pieces are then allowed to cool in
air to room temperature and the distance between the marks on the test pieces are measured
again. The difference in percentage between the marks before and after heat treatment gives
the % of shrinkage for the XLPE insulation.

5.18. Measurement of Cable Capacitance

This test measures the capacitance per unit length of the cable. The capacitance is measured
between the conductor and the metallic screen. The cable capacitance influences the cable
charging current and the dielectric losses.

6. Field Test

Field Testing can be broadly grouped into three categories:

6.1. Acceptance Tests

Acceptance tests are conducted on cable after installation but before energizing. These tests
are designed to detect faults caused by physical damage due to improper handling,
transportation and installation.

127
6.2. Maintenance Tests
Maintenance tests are conducted after the cable has been energized or placed in service.
These tests are intended to detect in-service deterioration of cable insulation.

6.3. Fault Location Tests

Fault location tests; on the other hand, is used to pinpoint the location of cable failure along
the cable route. The distance is normally measured from the testing end or the remote end of
the cable feeder. Knowing the location of the cable failure helps to speed up repairs and
restoration of supply to consumers.

6.4. Field Testing of Cables

The following field tests on cables are conducted by PEA:

 Insulation Resistance Test (Megger Test)

 DC High Potential Test (DC Hi-Pot Test)
 Very Low Frequency Withstand and Diagnostic Tests (VLF Tests)

a. Insulation Resistance Test (Megger Test)

This test measures the insulation resistance of the cable insulation. It is a non-
destructive test conducted using a test instrument called Megohmmeter, which is also
commonly known as a Megger test set.

The insulation resistance measurement determines the condition and deterioration of

the cable insulation system. Over the years, the cable is exposed to environmental
factors such as dirt, moisture, temperature, mechanical stress and vibration. These
conditions can lead to insulation failure, resulting in severe damage to the cable.
Periodic maintenance tests can provide valuable information about the state of
deterioration and will help in predicting possible failure of the cable. Table 6.1 gives
the appropriate test voltages for application during insulation resistance tests.

DC Hi-Pot
Test Set

Megohmmeter

Figure 6.1: DC Hi-Pot Test Set and Megohmmeter

128
 Nominal Rating Minimum Recommended
of Equipment Test Voltage Minimum
(V) (V) Insulation
Resistance
(MΩ)
250 500 25
600 1000 100
1000 1000 100
2500 1000 500
5000 2500 1000
8000 2500 2000
15000 2500 5000
25000 5000 20000
34500 and above 15000 100000

Table 6.1: Insulation Resistance Test Values

Electrical Apparatus and Systems (ANSI/NETA ATS 2009)

The Recommended Minimum Insulation Resistance values given in Table 6.1 are valid
for an insulation temperature of 20°C. For all other temperatures, multiply the
insulation resistance readings with conversion factors at the selected base temperature.
Table 100.14 in ANSI/NETA-ATS 2009, gives the conversion factors for various base
temperatures.

b. Insulation Resistance Measurement on a cable

For personnel safety, observe the following steps when testing the cable for insulation
resistance. Refer to Figure 6.2 for connection details.

i. De-energize, discharge and disconnect the cable from the switchgear or bus-
bar. It is usually best to disconnect at both ends in order to test the cable by
itself, and to avoid error due to leakage across or through switchboards or bus-
bars.

ii. Connect the cable metallic screen to either sub-station or equipment ground or
temporary ground and also to the terminal marked E on the Megohmmeter.

iii. Connect the cable conductor to the terminal marked L on the Megohmmeter.

iv. Start the test and record the reading when it has stabilized. Note the ambient
temperature and insulation temperature when the readings are recorded.

Note: G is the guard terminal. It reduces the errors introduced by surface leakage
currents, especially when testing bushings and insulators.

129
Figure 6.2: Connection of a Megohmmeter for an Insulation Resistance Test on a Cable

Typically, the minimum acceptable value of insulation resistance for MV cable rated
at 22kV & 33kV and HV cable rated at 115kV shall not be less than 2000 MΩ.

c. DC High-Potential Test (DC Hi-Pot Test)

DC Hi-Pot testing is at much higher voltage levels than insulation resistance testing.
The higher voltage place more electrical stress on the cable insulation. There are two
applications for DC Hi-Pot Test. It is applied either as a:

(i). Voltage withstand test - This is a destructive test. Criteria for evaluation are on
PASS/FAIL basis.

(ii). Leakage current measurement - This is a diagnostic test that involves the
measurement of leakage current with the application of high voltage to the conductor,
while the metallic shield of the cable is connected to ground. The behavioral
characteristics of the leakage current are evaluated to determine the dielectric strength of
cable insulation.

The test voltages for DC Hi-Pot Test are as per Table 6.2A and Table 6.2B, for both
installation and maintenance testing.

U0 /U (Um) Installation Test Maintenance Test

(kV) Voltage Voltage
4U0 (0.75 x 4U0)
3.6/6 (7.2) 14.4 10.8
6/10 (12) 24 18
8.7/15 (17.5) 34.8 26.1
12/20 (24) 48 36
18/30 (36) 72 54

Table 6.2A: DC Hi-Pot test voltages for MV Cable up to 36 kV

130
 U0 /U (Um) Installation Test Maintenance Test
(kV) Voltage Voltage
3U0 (0.75 x 3U0)
36/60-69 (72.5) 108 81
64/110-115 (123) 192 144

Table 6.2B: DC Hi-Pot test voltages for HV Cable up to 123 kV

PEA recommends DC Hi-Pot testing only for medium voltage underground cable in
compliance with IEC TC 20 decision.

 Very Low Frequency Test (VLF Test)

The VLF test is very similar to DC Hi-Pot test except that it is an AC Hi-Pot test
at very low frequencies ranging from 0.01 to 0.1 Hz. VLF testing methods can be
described as withstand or diagnostic. The purpose of VLF testing is to check for
defective workmanship and damage to cable insulation, terminations & splices
during transportation, handling and installation at site, prior to commissioning the
cable into service.

IEEE Standard 400.2–2004 Guide for Field Testing of Shielded Power Cable
Systems Using Very Low Frequency (VLF) describes the methods and practices to
be used in the application of very low frequency (VLF) high voltage excitation
for field testing of shielded power cable systems.

IEEE Standard 400.2 states that for withstand testing, the test object must
withstand a specified voltage applied across the insulation for a specified period
of time without breakdown of the insulation. The magnitude of the withstand
voltage is usually greater than that of the applied voltage. If the cable insulation
is sufficiently degraded, a breakdown can occur. The cable system may be
repaired and the insulation retested until it passes the withstand test.

IEEE Standard 400.2 further states that diagnostic testing allows the
determination of the relative amount of degradation of a cable system section and
establishes, by comparison with accumulated data, whether a cable system section
is likely to continue to perform properly in service.

Diagnostic tests may be nondestructive and are usually performed at lower

voltages than withstand tests. However, when the cable system insulation is in an
advanced condition of degradation, the diagnostic tests can cause breakdown
before the test can be terminated.

131
 Figure 6.3: VLF Test Set

In compliance with PEA operating procedures, all cables after installation and having passed
all commissioning tests, are required to be energized at rated voltage U0/U for a period of 24
hours prior to taking load. This is to test the cable’s reliability and to ensure that the cable is
safe for service in the power distribution system.

6.5. Sample Documents

A sample document for recording field test results for MV and HV cables is attached below for
reference.

132
 Table 6.4: PEA field testing template

References:
1. IEC 60840:2004 Power cables with extruded insulation and their accessories for rated voltages
above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) – Test methods and requirements
2. IEC 60502-2:2005 Power cables with extruded insulation and their accessories for rated
voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) – Part 2: Cables for rated
voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)
3. IEC 60502-4:2005 Power cables with extruded insulation and their accessories for rated
voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) – Part 4: Test requirements on
accessories for cables with rated voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)
4. PEA - Field Test Procedure

133
Chapter 7
Operation and Maintenance

1. Introduction

Upon commissioning of the underground cable into service with PEA Distribution Network,
PEA will monitor its performance and conduct the required maintenance on it throughout its
service life.

The following types of maintenance are done on the cable:

1.1. Preventive

This is planned and carried out at predetermined intervals to detect incipient faults.
This type of maintenance involves routine diagnostic tests and repair or part
replacement of cable, terminations & splices when faults are detected.

1.2. Corrective

This is done after a fault has occurred. It involves diagnostic tests to detect type of
fault and its location, repairs to cables, terminations & splices and re-commissioning
tests.

1.3 Condition Based

Condition-based maintenance (CBM), shortly described, is maintenance when the need arises.
This maintenance is performed after one or more indicators show that the equipment is going
to fail or performance of the equipment is deteriorating.

2. Operation

The load capacity or ampacity of underground power cable is governed by the temperature
rise within the cable and its surroundings. The maximum permissible service temperature of
XLPE cable is limited by the temperature of its conductor which is 90°C.

There are four main factors that have an impact on the ampacity rating of underground cable.
These are:

2.1. Ambient temperature – temperature of air or ground. High ambient temperature will
reduce the cable current carrying capacity.

2.2. Cable design and construction – thermal resistances and losses of the cable
construction materials. Thick insulation will give rise to higher temperature rises
compared to thinner insulation. Single-core cables have higher ampacity compared to
three-core cables.

134
2.3. Condition of installation – in air, direct buried or in ducts and depth at which cable is
buried. Vertically installed cables have 5% less current carrying capacity compared to
cables that are installed horizontally.

2.4. Effects from neighboring cables – induced heating from neighboring cable circuits.
The recommended distances between cable circuits if not maintained will result in
reduced ampacity.

The ampacity of underground cable can be calculated as guided by IEC 60287-1, IEC 60287-
2 and IEC 60287-3.

The load capacity or ampacity of cables shall be determined during the planning stage. This
helps to identify possible network constraints or ‘bottle neck’ conditions that may occur
during peak demand hours.

The cable ampacity rating information shall be made available to the Network Manager or
Control Engineer upon commissioning of the cable. The Network Manager or Control
Engineer is then able to monitor the maximum load current such that it does not exceed the
maximum ampacity rating of the cable. This action also helps to extend the service life of the
cable beyond its design life of 20 to 25 years.

3. Preventive Maintenance
This is to be done every year for the duration of the cable service life. The following
diagnostic tests forms part of the annual preventive maintenance program:

3.1. Infra-red Thermographic Scans of all electrical joints. Mitigative action taken is
dependent upon the scan results but typically the following is recommended:

3.1.1. Temperature T < 30°C, continue with normal maintenance plan.

3.1.2. 300C ≤ Temperature T < 60°C, repeat maintenance within 1 month.
3.1.3. Temperature T ≥ 60°C, repeat maintenance within 1 week.

Conditions 3.1.1 and 3.1.2 are normally associated with poor electrical contact.
Immediate action can be taken to clean & re-torque the joint and re-scan to check if
temperature is within normal limits.

3.2. Visual inspection of joints & splices, physical check on integrity and condition of
ground connection.

3.3. Clean the termination joint outer surface of all dust and contaminant deposits.

3.4. Conduct contact resistant test for all electrical connections - the value must be less
than75 micro Ohm at 100A DC test current.

3.5. As a safety measure, conduct an insulation resistance test (Megger test) before re-
commissioning the cable.

135
If any incipient faults are detected during preventive maintenance tests, these must be repaired
or the deteriorated components replaced before re-commissioning the cable.

4. Corrective Maintenance
This is done whenever there is a fault on the cable. The fault maybe initiated by either
deterioration of the cable insulation, termination or splice, natural disasters like floods or
damaged by a third party. The following steps below are recommended to be part of
corrective maintenance procedure:
4.1. Physical inspection of the cable route to look for possible damage to cable due to
roadworks or digging by contractors.

4.2. Collect as much pre-fault and post-fault data for the cable feeder. This data is analyzed
to determine the most probable cause of failure. Cause of cable failures can typically be
categorized into three main types:

4.2.1. Workmanship – improper handling of cable during transportation,

installation and jointing may result in potential failures after commissioning.
4.2.2. Manufacturing defects – mishandling during manufacturing or use of sub-
standard materials can result in defects being introduced into the cable or
delivery of inferior quality cable.
4.2.3. Operation – frequent overloading and improper operation or operation that
deviates from Standard Operating Procedure (SOP) can result in damage to
the cable.

For 4.2.1 and 4.2.2, we have to audit the system to see if there are other feeders that has
cable from the same manufacturer or cable installed by the same contractor to determine
if similar problem can re-occur on other feeders. For 4.2.3, re-fresher training and
issuance of advisory guidelines will help to reduce failures due to improper operation.

4.3. Once the fault in the cable or joints has been identified, it shall be repaired as soon as
possible to prevent further ingress of moisture into the cable through the faulty part.

4.4. To ensure that the fault has been addressed, re-testing after repairs is done. Insulation
resistance test (Megger test), HV AC Short-time Withstand test (Hi-Pot test) and
energizing the cable without load to its rated voltage for 24 hours, are some of the tests
normally done.

4.5. Monitoring the performance of the cable feeder after re-enegization.

5. Condition Based Maintenance

Condition assessment of power equipment provides knowledge about the initial condition of
the equipment immediately after commissioning as well as the actual condition of the
equipment after several years of service. The follow-up maintenance and time interval for
maintenance of the equipment is then based on this assessment of its condition. This
methodology is known as Condition Based Maintenance (CBM).

136
The measurement of Partial Discharge (PD) is an accepted tool for Condition Based
Maintenance of power cables. Partial Discharges can occur at voids, gaps and similar defects
in power cable. PD detection and monitoring is of vital importance. If allowed to continue,
partial discharge will erode the insulation, usually forming an electrical tree which eventually
will result in complete breakdown and failure of the cable insulation.

PEA uses Oscillating Wave Test System (OWTS) for CBM of underground and submarine
cables. OWTS is able to identify, evaluate, and locate partial discharge (PD) faults in cable
insulation, joints, and terminations.

PD Mapping is used to locate PD along the cable section under test. The PD fault position
can be determined by analyzing the time delay of the different PD pulses arising from
propagation and reflection. It utilises the well-known principle of Time Domain
Reflectometry (TDR) to perform an accurate fault location.

Two parameters, amplitude of PD and Partial Discharge Inception voltage (PDIV), are used to
decide on the follow-up maintenance actions by PEA. PDIV is the voltage level at which PD
pulses are first initiated. Table 7.1 below summarises the recommended maintenance actions
for differing values of PDIV.

PDIV PD Recommended
Values Amplitude Maintenance Action
PDV  Uo  500 pC Replace cable or joint
PDV  Uo 250 - 499 pC Repeat test after 3 months
PDV  Uo 100 - 249 pC Repeat test after 6 months
PDV  Uo < 100 pC Repeat test after 1 year
PDV  Uo - Repeat test after 1 year.

Table 7.1: Recommended Maintenance for differing values of PDIV

[Note: Uo is the nominal operating voltage of the cable under test]

Figure 7.1 show a typical set-up for OWTS and Figure 7.2 shows an example of PD Mapping
result.

Figure 7.1: OWTS test set for medium voltage system

137
Figure 7.2: An example of PD Mapping result

138
 Figure 7.3: PEA’s XLPE Power Cable Preventive Maintenance Test Form

Reference:
1. PEA Maintenance Plan

139
Appendix I
1. Construction of MV Underground Cable
These specifications cover 22 kV and 33kV single-core MV underground power cables of
copper conductor, cross-linked polyethylene (XLPE) insulation, copper wire screen and
polyethylene (PE) sheath.
The cable shall be manufactured and tested in accordance with the latest edition of IEC
60228, IEC 60502, and IEC 60811, unless otherwise specified in these specifications.

The underground power cables shall be designed, constructed and installed for operation
under the following conditions:

 System voltage: 3-phase, 22 kV and 33 kV

 Rated frequency: 50 Hz
 Conductor temperature:
a) for normal operation: 90°C continuously
b) for emergency overload condition: 130°C
c) for short-circuit condition: 250°C

The structure of 22kV and 33 kV MV underground cable is as shown in Figure 1. The

construction of the underground power cables shall be according to technical data in Table 1
and Table 2.

1 – Copper conductor
2 – Conductor semi-conducting screen
3 – XLPE insulation
4 – Insulation semi-conducting screen
5 – Metallic screen
6 – Inner bedding with water blocking
7 – Protective outer PE jacket

Figure 1.0: Typical construction of MV Underground Cable

140
Nominal cross-sectional area
35 50 95 120 185 240 400 500
of conductor (mm2)
Min. number of wires in
6 6 15 18 30 34 53 53
conductor

Diameter of conductor +
6.95 8.33 11.45 12.95 15.98 18.47 23.39 26.67
1% (mm)

Thickness of conductor
0.5
screen, approx. (mm)

Thickness of insulation
5.5
(mm)

Diameter over insulation,

19.0 20.5 23.5 25 28 30.5 35.5 39.0
approx. (mm)

Thickness of insulation
0.5
screen, approx. (mm)
Total cross-sectional area
of copper wire screen, 10 10 10 10 25 25 25 25
minimum (mm2)
Number of wire screen,
20 20 20 20 30 30 30 30
minimum

Thickness of non-metallic
1.8 1.8 1.9 2.0 2.1 2.2 2.4 2.6
sheath (mm)

Overall diameter, approx.

28 30 33 34 38 42 48 52
(mm)

Max. D.C. resistance of

0.524 0.387 0.193 0.153 0.0991 0.0754 0.0470 0.0366
conductor at 20 °C (Ω/km)

Table 1: Technical Data for typical 22kV MV XLPE Underground Cable

141
Nominal cross-sectional area of
50 95 120 185 240 400 500
conductor (mm2)
Min. number of wires in
15 18 30 30 34 53 53
conductor

Diameter of conductor + 1%
8.33 11.45 12.95 15.98 18.47 23.39 26.67
(mm)

Thickness of conductor screen,

0.5
approx. (mm)

Thickness of insulation (mm) 8.0

Diameter over insulation,

25.5 28.5 30.0 33.0 35.5 40.5 44.0
approx. (mm)

Thickness of insulation screen,

0.5
approx. (mm)
Total cross-sectional area of
copper wire screen, minimum 10 10 10 25 25 25 25
(mm2)
Number of wire screen,
20 20 20 30 30 30 30
minimum

Thickness of non-metallic
2.0 2.1 2.2 2.3 2.4 2.6 2.7
sheath (mm)

Overall diameter, approx. (mm) 35 38 40 44 47 55 58

Max. D.C. resistance of

0.387 0.193 0.153 0.0991 0.0754 0.0470 0.0366
conductor at 20 °C (Ω/km)

Table 2: Technical Data for typical 33kV MV XLPE Underground Cable

142
The constructional elements of MV underground cable are explained below:

a) Conductor

The conductor is of plain annealed copper compact round concentric stranded wire complying
with IEC 60228. The conductor is designed to carry currents under normal, overload and
short-circuit operating conditions.

b) Conductor Screen

Placed over the conductor, is an ultra-smooth XLPE semi-conductive layer. It functions to

smooth the electric field at the interface between the conductor and XLPE insulation.

c) Insulation

The XLPE insulation insulates the conductor when working at its rated voltage from the
screen that is at earth potential. The thickness of XLPE insulation must be based on its ability
to withstand lightening impulse voltage as well as operating voltage throughout its expected
life.

The insulation shall be of dry-cured XLPE compound with a thickness to meet dimensional,
electrical and physical requirements specified. The compound shall be of high quality heat,
moisture, ozone and corona resistant. This insulation shall be suitable for operation in wet or
dry locations at conductor temperature not exceeding 90°C for normal condition, 130°C for
emergency overload conditions and 250°C for short circuit conditions.

d) Insulation Screen

This is similar to the conductor screen and is placed over the XLPE insulation. It ensures
close contact between the semi-conductive layer and the XLPE insulation. It prevents
concentration of electric filed at the interface between the XLPE insulation and the semi-
conducting screen.

It shall consist of either a semiconducting tape or a layer of extruded semi-conducting

compound, or combination of these materials. The extruded semiconducting compound shall
be a thermosetting or thermosetting compound that is firmly and totally bonded to the
insulation.

e) Metallic Screen

The metallic screen is a concentric layer of copper wires. The metallic screen is electrically
continuous and bonded together throughout the cable route with copper contact tape. It is
grounded at least at one point along the cable route.

Its function is to drain the capacitive, induced and short-circuit currents to ground.

143
f) Inner Bedding with Water-blocking

An inner bedding of thermosetting plastic compound with water blocking is applied over the
metallic screen to provide a continuous longitudinal water-tight barrier throughout the cable
length. It also provides good adhesion to the outer PE protective sheath and helps to limit the
unavoidable shrinking of the outer PE sheath. It also acts as an additional barrier against
ingress of moisture from minor damage to the outer sheath.

g) Protective Outer PE Jacket

This outer protective jacket is made of Polyethylene (PE) and is typically black in color. It
protects the metallic components of the screen from contact with ground, humidity and
corrosion. It is also able to withstand mechanical stresses during installation and service, and
other risk such as termites and chemical spills.

2. Construction of 115 kV Underground Cable

These specifications cover 115kV single-core HV underground power cables of copper
conductor, cross-linked polyethylene (XLPE) insulation, copper wire screen and polyethylene
(PE) sheath. The cable shall be manufactured and tested in accordance with the latest edition
of IEC 60228, IEC 60811 and IEC 60840, unless otherwise specified in this specification.

The underground power cable shall be designed, constructed and installed for operation under
the following conditions:
 System voltage: 3-phase, 115kV, solidly grounded neutral
 Rated frequency: 50 Hz
 Conductor temperature:
a) for normal operation: 90 °C continuously
b) for emergency overload condition: 130 °C
c) for short-circuit condition: 250 °C
The structure of 115 kV HV underground cable is as shown in Figure 2. The construction of
the underground power cables shall be according to technical data in Table 3.

1 – Copper conductor
2 – Inner semi-conducting layer
3 – XLPE insulation
4 – Outer extruded semi-conducting layer
5 – Water blocking tape
6 – Copper wire screen with spiral binder tape
7 – Inner Bedding with Water blocking
8 – Metallic moisture barrier tape
9 – Protective outer PE jacket

Figure 2: Typical construction of 115kV Underground Cable

144
 Description Unit Data
Material - Copper
Nominal cross-sectional area mm2 800
Circular compact
Conductor Shape -
stranded
Diameter of conductor mm 34.0 ± 1%
DC resistance at 20 °C (Max.) Ω/km 0.0221
Conductor Screen Thickness (Approx.) mm 1.0
Material - XLPE
Insulation Thickness mm 16.0
Thickness, at any place (Min.) mm 14.4
Insulation Screen Thickness (Approx.) mm 1.0
Synthetic Water
Thickness (Approx.) mm 0.5
Blocking Layer
Copper Wire Total cross-sectional area (Min.) mm2 95
Screen Number of wire (Min.) - 50
Synthetic Water
Blocking & Thickness (Approx.) mm 1.0
Cushioning Tape
Aluminum Tape Thickness (Nominal) - 0.19
as Radial
Thickness at any place (Min.) mm 0.17
Water barrier
Material - PE
Thickness excluding rib
Sheath Ribbed type mm 3.5
(Nominal)
Thickness at any place (Min.) mm 3.0
Table 3: Technical Data for a typical 115 kV XLPE Underground Cable

The constructional elements of 115kV underground cable are explained below:

a. Conductor

The conductor is of plain annealed copper compact round concentric stranded wire complying
with IEC 60228. The conductor is designed to carry currents under normal, overload and
short-circuit operating conditions.

b. Conductor Screen

Placed over the conductor, is an ultra-smooth XLPE semi-conductive layer. It functions to

smooth the electric field at the interface between the conductor and XLPE insulation.

c. Insulation

The XLPE insulation insulates the conductor when working at its rated voltage from the
screen that is at earth potential. The thickness of XLPE insulation must be based on its ability
145
to withstand lightening impulse voltage as well as operating voltage throughout its expected
life.

The insulation shall be of dry-cured XLPE compound with a thickness to meet dimensional,
electrical and physical requirements specified. The compound shall be of high quality heat,
moisture, ozone and corona resistant. This insulation shall be suitable for operation in wet or
dry locations at conductor temperature not exceeding 90°C for normal condition, 130°C for
emergency overload conditions and 250°C for short circuit conditions.

d. Insulation Screen

This is similar to the conductor screen and is placed over the XLPE insulation. It ensures
close contact between the semi-conductive layer and the XLPE insulation. It prevents
concentration of electric filed at the interface between the XLPE insulation and the semi-
conducting screen.

It shall consist of either a semiconducting tape or a layer of extruded semi-conducting

compound, or combination of these materials. The extruded semiconducting compound shall
be a thermosetting or thermosetting compound that is firmly and totally bonded to the
insulation.

e. Water Blocking Layer

A water blocking layer is provided under the metallic screen for a continuous longitudinal
watertight barrier throughout the cable length. This layer shall be compatible with other cable
materials and have a non-corrosive effect on adjacent metallic layers.

f. Metallic Screen

The metallic screen is a concentric layer of copper wires. The metallic screen is electrically
continuous and bonded together throughout the cable route with copper contact tape. It is
grounded at least at one point along the cable route.

Its function is to drain the capacitive, induced and short-circuit currents to ground.

g. Inner Bedding with Water-blocking

An inner bedding of thermosetting plastic compound with water blocking is applied over the
metallic screen to provide a continuous longitudinal watertight barrier throughout the cable
length. It also provides good adhesion to the outer PE protective sheath and helps to limit the
unavoidable shrinking of the outer PE sheath. It also acts as an additional barrier against
ingress of moisture from minor damage to the outer sheath.

h. Radial Water Barrier

As additional protection against ingress of moisture and formation of water trees in the
insulation, a water barrier consisting of laminated aluminum tape having average thickness of
at least 0.19 mm and coated on both sides with an ethylene acrylic adhesive copolymer or
polyethylene shall be included under the nonmetallic sheath.

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i. Protective Outer PE Jacket

This outer protective jacket is made of Polyethylene (PE) and is typically black in color. The
sheath shall be of ribbed type having a crest width and depth of 2.5 mm respectively. The
center to center distance between crests shall be 7 mm.
It protects the metallic components of the screen from contact with ground, humidity and
corrosion. It is also able to withstand mechanical stresses during installation and service, and
other risk such as termites and chemical spills.

3. Cable Termination Kits for MV XLPE Cable

Outdoor and indoor cable termination kits for MV XLPE underground cable rated at 22kV and
33kV shall be manufactured and tested to the latest edition of either IEC 60502-4 or IEEE 48
standards.
The cable termination kits shall be suitable for use in a tropical environment and shall
have minimum value of Specific Creepage Distance (SCD) to IEC 60815 of 31mm/kVpp
or Unified Specific Creepage Distance (USCD) of 53.7mm/kVpp to IEC/TS 60815-1:2008
for Very Heavy Polluted Conditions.
The termination shall be made from non-tracking, weather and ultra violet resistant
materials. Stress control shall be either by using molded stress cone, voltage gradient tube
or stress grading pad. Stress control by tapping is not acceptable.
The cable termination shall be designed and manufactured for installation and operation
under the following conditions:

 Altitude : up to 1,500 m above sea level

 Ambient air temperature : 40 °C, maximum
: 35 °C, average on one (1) day
 System voltage : 3-phase, 22 kV & 33 kV, solidly grounded neutral
 Rated frequency : 50 Hz

The cable termination shall conform to the physical dimensions for 22kV and 33kV single-
core XLPE underground cables as shown in Table 4 and Table 5 respectively below.

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Nominal cross-sectional 35 50 95 120 185 240 400 500
area of conductor (mm2)
Diameter of conductor ±1%
6.95 8.33 11.45 12.95 15.98 18.47 23.39 26.67
(mm)

Diameter over insulation,

19.0 20.5 23.5 25.0 28.0 30.5 35.5 39.0
approx. (mm)
Total cross-sectional area of
copper wire screen, minimum 10 10 10 10 25 25 25 25
(mm2)
Overall diameter, approx.
28 30 32 34 38 42 48 52
(mm)

Table 4: Physical Dimensions of 22kV Single-core XLPE Underground Cable

Nominal cross-sectional
50 95 120 185 240 400 500 50
area of conductor (mm2)
Diameter of conductor ±1%
8.33 11.45 12.95 15.98 18.47 23.39 26.67 8.33
(mm)

Diameter over insulation,

25.5 28.5 30.0 33.0 35.5 40.5 44.0 25.5
approx. (mm)
Total cross-sectional area of
copper wire screen, minimum 10 10 10 25 25 25 25 10
(mm2)
Overall diameter, approx.
35 38 40 44 47 55 58 35
(mm)

Table 5: Physical Dimensions of 33kV Single-core XLPE Underground Cable

3.1 Outdoor Termination for MV XLPE Cable

The MV outdoor cable termination shall be IEEE 48 Class 1A for use on extruded dielectric
cable. The termination materials shall be either of Silicone or EPDM rubber and can be of
pre-molded slip-on type, pre-molded cold shrinkable or heat shrinkable type.
The termination kit shall be supplied complete with the following accessories:

a. Two-hole NEMA pad, compression type cable terminal lug, made either of tin plated
copper or copper alloy and suitable for connecting to copper conductors of diameters as
specified in Table 4 and Table 5 for 22 kV and 33 kV cables respectively.

The connector shall be furnished with mounting hardware: two (2) bolts, two (2) nuts, two
(2) flat round washers and two (2) spring lock washers of stainless steel.

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b. NEMA type termination mounting bracket, for cross-arm section with dimensions of up to
100 mm x 100 mm to 120 mm x 120 mm complete with carriage bolts of not less than 150
mm long and hot-dip galvanized to ASTM A 153.

c. Clamping device of non-magnetic, corrosion resistant material to clamp the cable and
cable termination on to the mounting bracket.

d. Grounding device and copper braided strip for connecting the metallic screen to earth.

e. Insulating booths for cable protection from exposure to moisture, contamination, corrosion and
other environmental hazards.

f. Cable termination instructions.

3.2 Indoor Termination for MV XLPE Cable

The MV indoor cable termination shall be IEEE 48 Class 1A for use on extruded dielectric
cable. The termination materials shall be either of Silicone or EPDM rubber and can be of
pre-molded slip-on type, pre-molded cold shrinkable or heat shrinkable type.
The termination kit shall be supplied complete with the following accessories:

a. One-hole NEMA pad, compression type cable terminal lug, made either of tin plated
copper or copper alloy and suitable for connecting to copper conductors of diameters as
specified in Table 4 and Table 5 for 22 kV and 33 kV cables respectively.

The connector shall be furnished with mounting hardware: one (1) bolt, one (1) nut, one
(1) flat round washes and one (1) spring lock washer of stainless steel.

b. Grounding device and copper braided strip for connecting the metallic screen to earth.

c. Cable termination instructions.

4. Cable Termination Kits for 115 kV HV XLPE Cable

Termination kits for HV single-core XLPE cable with copper conductor and rated at 115kV
shall be manufactured and tested to the latest edition of either IEC 60840 or IEEE 48 standards.
The cable termination kits shall be suitable for use in a tropical environment and shall have
minimum value of Specific Creepage Distance (SCD) to IEC 60815 of 31mm/kVpp or Unified
Specific Creepage Distance (USCD) of 53.7mm/kVpp to IEC/TS 60815-1:2008 for Very
Heavy Polluted Conditions.

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The cable termination shall be designed and manufactured for installation and operation under
the following conditions:
 Altitude : up to 1,500 m above sea level
 Ambient air temperature : 40°C, maximum
: 35°C, average on one (1) day
 System voltage : 3-phase, 115kV, solidly grounded neutral
 Rated frequency : 50 Hz

The cable termination shall conform to the physical dimensions for 115kV single-core XLPE
underground cable as shown in Table 6 below.

Nominal cross-sectional area of conductor mm2 800

Diameter of conductor ±1% mm 34
Thickness of insulation mm 16
Diameter over insulation, approx. mm 68
Total cross-sectional area of copper wire screen, minimum mm2 95
Overall diameter, approx. mm 86

Table 6: Physical Dimensions of 115 kV Single-core XLPE Underground Cable

4.1. Outdoor HV Cable Termination Kit

The housing for this type of termination can be of either porcelain or composite material
suitable for filling with silicone insulating oil. The stress cone shall be preferably of pre-
fabricated and factory-tested Si-rubber.

The termination kit shall be supplied complete with the following accessories:

a. Torque-controlled conductor bolt

b. Fittings made of corrosion resistant alloy
c. Mounting hardware, bolts, nuts washers and spring lock washers of stainless steel
d. Grounding device and copper braided strip for connecting the copper wire screen to
earth
e. Base plate with support insulators to isolate termination from grounded steel support
structure
Special tools (if required) and jointing instructions

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5. Splices for MV XLPE Cable

Splices for MV XLPE single-core underground cable with copper conductor rated at 22kV and
33kV shall be manufactured and tested to the latest edition of either IEC 60502-4 or IEEE 48
standards.

The cable splicing kits shall be suitable for use in a tropical environment and shall be
designed for direct burial installation and operation under the following conditions:

 Altitude : up to 1,500 m above sea level

 Ambient air temperature : 40°C, maximum
: 35°C, average on one (1) day
 System voltage : 3-phase, 22 kV & 33 kV, solidly grounded neutral
 Rated frequency : 50 Hz

The splicing kit shall be of pre-molded slip-on type, pre-molded cold shrinkable or heat
shrinkable type. Splicing method with tape wrapping will not be accepted. Stress control
for the cable shield terminus shall be of either molded stress cone or voltage gradient tube.
Outer covering of splicing kit shall be semi-conductive having grounding eye to provide a
dead front ground shield for the insulation body.
Connectors for grounding of copper screen shall also be provided. The splicing kits shall
be suitable for single-core XLPE cables having overall diameters and copper conductor
diameters as specified in Table 4 and Table 5 for 22 kV and 33 kV cables respectively.
The outer protective jacket shall be of shrinkable tube to seal the splice against ingress of
moisture and for protecting from mechanical damage.
Each splicing kit shall be supplied with a supplementary kit for cross-bonding and
grounding of copper screen to reduce the effect of induced voltages.

6. Splices for 115 kV HV XLPE Cable

Splices for HV XLPE single-core underground cable with copper conductor rated at 115kV shall
be manufactured and tested to the latest edition of either IEC 60840 or IEEE 404 standards.
The cable splicing kits shall be suitable for use in a tropical environment and shall be
designed for installation in manholes where they will be constantly subjected to
immersion by contaminated water.
The cable splices shall be designed and manufactured for installation and operation under
the following conditions:

 Altitude : up to 1,500 m above sea level

 Ambient air temperature : 40 °C, maximum
: 35 °C, average on one (1) day
 System voltage : 3-phase, 115kV, solidly grounded neutral
 Rated frequency : 50 Hz
 BIL : 550kVpeak

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 The splicing kit shall be of pre-molded slip-on type, pre-molded cold shrinkable or heat
shrinkable type. Splicing method with tape wrapping will not be accepted.

Connectors for grounding of copper screen shall be provided. Compression type

connectors suitable for copper conductors shall also be provided. The splicing kits shall
be suitable for single-core XLPE cables having overall diameters and copper conductor
diameters as specified in Table 6 for 115kV rated cables.

The outer protective jacket shall be of shrinkable tube to seal the splice against ingress of
moisture and for protecting from mechanical damage.

Each splicing kit shall be supplied with a supplementary kit for cross-bonding and
grounding of copper screen to reduce the effect of induced voltages.

7. Current Carrying Capacity

The current carrying capacity for various cable circuit arrangements and ambient
conditions under normal operating conditions are given in the tables below:

Table 7.1 Operating condition - installation in ground

152
Table 7.2 Operating condition - installation in air

153
Table 7.3 Load capacity - installed in ground

154
155
156
157
Table 7.4 Load capacity - installed in air

158
159
160
161
8. Single-core Cable Arrangement

If two busbar systems are coupled by a number of single-core cables in parallel, the
inductance of each of the parallel cables should be equal, as far as possible, to ensure equal
sharing of load current between the cables.

This inductance is most unbalanced when cables of one phase are grouped together and
placed side by side next to one another. A preferred arrangement is for the cable of
different phases to be grouped into circuits such that the spacing of each cable is kept
within one circuit.

A fully symmetrical load sharing can be more readily achieved by the use of three-core cables
because here, due to the uniformly laid-up cores, in normal operation there is no inductive
reaction with neighboring cable.

The minimum clearance between two circuits of single-core cables should be approximately
twice the axial spacing of individual cable in a circuit. In addition, the sequence of phases
within a circuit is most important.

FLAT formation

da da Dc da da

A B C
C B A
Circuit 1 Circuit 2

TREFOIL formation

A A

da da da da
Dc

da da
B C C B

Circuit 1 Circuit 2

Minimum Clearance between Circuits Dc = 2 [Axial Spacing da]

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Depending on the number of three-phase circuits, the following phase relationships between
circuits is recommended:

ABC CBA ABC CBA

With this type of circuit arrangement, the inductances of each of the paralleled cables in a
phase are approximately equal. The individual inductances of cables in phases A, B and C
are, however, different. This is less of a disadvantage than unequal inductances between the
parallel connected cables in any one phase.

The following arrangement is most unfavorable and not recommended since this will result
not only in unsymmetrical phase inductances between A, B and C but also unbalanced
inductances of the paralleled cables in any phase.

ABC ABC ABC ABC

For installations on racks or cable trays, the cables of the same phase must not be arranged
side by side but on different platforms. Between the racks, a distance of 300mm or more
should be maintained. On each platform, room should be given to allow two different circuits
with opposing phase sequences to be installed.

ABC CBA
BCA ACB
CAB BAC

With this type of arrangement, the inductances of the paralleled cables are reasonably equal.
The inductance of each of the phases, however, is different from one another. This is not so
important since these busbars linking the cable runs are normally short. When only one
circuit is required, the triangular or trefoil arrangement shall be the preferred choice. This
will result in equal inductances between the phases in the circuit.

B
A C

Where several circuits are installed in trefoil formation, it is preferred to rotate the phases in
each circuit as shown below:

B B B B
A C C A A C C A

The trefoil arrangement of several circuits above one another is not recommended since the
inductances of the paralleled cables differs greatly one from another.

When single-core cables are installed in air, attention must be given to ensure adequate
clamping of the cable circuit at equal short intervals to withstand the effects of peak short-
circuit currents. This means they must withstand the stresses produced under short-circuit;
remain in position such that neither the cable nor the clamp is damaged.

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Appendix II
Vietnam
Hanoi Power Corporation (EVNHANOI)

In conjunction with the development of this handbook, the content development team visited Vietnam
to understand the issues and challenges faced by the other LMS utilities in underground power
distribution system design, construction and installation. They met up with Hanoi Power Corporation
to discuss and exchange views, insights and best practices. They also went on visits to project sites in
Hanoi. The team also went to Haiphong where they were taken on site visits by Haiphong Power
Company.

Hanoi is the capital city of Vietnam. EVNHANOI has an ambitious master plan to develop its power
network. By 2015, it expects to convert 40% of overhead lines to underground power distribution
system within the City and 100% in eight urban districts. New 110kV substations are to be
constructed. Voltage levels will be upgraded from 6kV and 10kV to 22kV. The 110kV lines with
conductors ranging from 120mm2 to 185mm2 will be upgraded to either 400mm2 or 1200mm2 copper
cables.

To ensure optimization of its power distribution network, the voltage level in substations will be kept
within declared tolerances and balanced among phases in outgoing feeders so as to avoid overloading
of transformers and lines. New underground and overhead outgoing feeders will also be constructed.

As part of its maintenance strategy, EVNHANOI is planning to deploy new technologies such as
computerized maintenance management systems, software applications and tools for network design
calculations, high-tech equipment and devices for condition monitoring amongst others. EVNHANOI
is also improving systems and processes for a comprehensive multi-level training system,
consolidation of R & D functions and development of manuals to streamline procedures.

The total capital expenditure for this power distribution network rehabilitation and consolidation
program until 2015 is estimated to be more than 19,000 billion Vietnamese Dong (equivalent to about
USD900 million).

The implementation of this program will come with many external and internal challenges.
EVNHANOI has to overcome many obstacles such as lack of clarity in procedures and criteria in
current regulations of the municipalities and City Hall for road excavation works, seasonal
environmental factors such as monsoon rains and floods plus work-site conditions and constraints in
heavily built-up areas and narrow streets.

In addition to these, EVNHANOI also need to build up its capacity and develop its competencies in
advanced testing methodologies, and to acquire appropriate high-technology equipment and testing
devices. There is also a need to focus on Human Resource Development especially for expertise in
underground power distribution system design, construction and installation.

We hope that this handbook will provide solutions to help overcome some of these challenges.

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