25-06-2020

Wiring ,Cabling , IR Testing Megger.

in Solar Plants
• of The device enable us to measure electrical leakage in wire, results
are very reliable as we shall be passing electric current through device
while we are testing. The equipment basically uses for verifying the
BY electrical insulation level of any device such as motors, cables,
generators, windings, etc
Piyush Kumar Singh • Megohmmeter (famous as Megger*) is an electrical instrument used to
Dy.Director//NPTI//NANGAL measure the electrical resistance of insulators. Very often a megger is
used to check the insulation of cable jackets, motors, and other high
voltage (HV) equipment to ensure the safety of equipment.
• During its working, the object under test is connected with the probes
(terminals) of megger and voltages are generated, usually, these
voltages are between 1kV – 5kV. The resistance of the object is
measured, A high resistance value such as 50 MΩ or higher indicates
that object is properly insulated. A small value or zero indicates that
object is not safe and it is short

Pre-Insulated Terminals
Ring Terminals
FEATURES

■■ Pre-insulated halogen free ring type terminal with funnel entry

Part number Colour Hole Size Conductor Size
POWER CABLE
RF-M Red 3, 3.5, 4, 5, 6, 8, 10, 12mm 0.25-1.5mm2

BF-M Blue 3, 3.5, 4, 5, 6, 8, 10, 12mm 1.5-2.5mm2

GF-M Ye llow 3.5, 4, 5, 6, 8, 10, 12mm 4-6mm2

Butt Connectors
FEATURES

■■ Pre-insulated straight connectors with funnel entry

Part Colour Conductor Size number

PL03-M Red 0.25-1.5mm2

PL06-M Blue 1.5-2.5mm2

PL1-M Ye llow 4-6mm2

Pin Terminals
FEATURES

■■ Pre insulated halogen free pin type terminal with funnel entry
Part number Colour Pin Length Conductor Size

RF-P Red 8, 10, 12mm 0.25-1.5mm2

BF-P Blue 8, 10, 12mm 1.5-2.5mm2

GF-P Ye llow 10, 12, 14mm 4-6mm2

Cable Lugs & Connectors
Blade Terminals
FEATURES

■■ Pre insulated halogen free blade type terminal with funnel entry
Part number Colour Blade Length Conductor Size

RF-PP Red 13, 17mm 0.25-1.5mm2

BF-PP Blue 13, 17mm 1.5-2.5mm2

GF-PP Ye llow 13, 17mm 4-6mm2

Also available in this range are Fork terminals, maleand female disconnect andend sleeves.

20 www.jointingtech.co.uk

1

POWER CABLE
POWER CABLE
POWER CABLES
• Usually the operating voltage decides the
type of insulation & cable.
• The various type of cables depending upon
the voltage for which they are designed are
as under:
1. Low Tension – up to 1,100 V
2. High Tension – up to 11 kV
3. Medium High Tension – up to 33 kV
4. Extra High Tension – up to 400 kV
25-06-2020
POWER CABLE
• A power cable is an assembly of two or
more electrical conductors, usually held
together with an overall sheath. The
assembly is used for transmission &
distribution of electrical power. Power
cables may be installed as
permanent wiring within
• buildings,
• buried in the ground,
• Run through trench or duct,
• run overhead, or exposed.
WHY POWER CABLES?
• In very congested areas where the overhead
system of bare conductors for transmission &
distribution of electrical power becomes
impracticable on account of safety
regulations.
• The type of cable to be used at a particular
location is determined by the mechanical
considerations and the voltage at which it is
required to operate.
POWER CABLE
• Flexible power cables are used for
portable devices, mobile tools and
machinery.
• Modern power cables come in a variety
of sizes, materials, and types, each
particularly adapted to its uses.
• Large single insulated conductors are
also sometimes called power cables.
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 25-06-2020

POWER CABLE POWER CABLE

The construction and material are determined
• Cables consist of three major by three main factors:
components: • Working voltage: determining the thickness of
1. Conductor, the insulation;
2. Insulation, • Current-carrying capacity: determining the
cross-sectional size of the conductor(s);
3. Protective Jacket
• Environmental conditions: such as
The makeup of individual cables varies temperature, water, chemical or sunlight
according to application. exposure and mechanical impact,
determining the form and composition of the
outer cable jacket.

POWER CABLE POWER CABLE

Cables for direct burial or for exposed
installations may also include metal
armour in the form of wires spiraled
around the cable, or a corrugated tape
wrapped around it. The armour may be
made of steel or aluminum, and
although connected to earth ground is
not intended to carry current during
normal operation.
• Power cables use stranded copper or
aluminum conductors, although small power
cables may use solid conductors. The cable
may include non-insulated conductors used
for the circuit neutral or for ground (earth)
connection.
• The overall assembly may be round or flat.
Non-conducting filler strands may be added
to the assembly to maintain its shape. The
cables may have a plastic or metal sheath
enclosing all the conductors.

POWER CABLE POWER CABLE

• The materials for the sheath will be • Cables intended for underground use
selected for resistance to water, or direct burial in earth will have heavy
oil, sunlight, underground plastic or metal, most
often lead sheaths or may require
conditions, chemical vapors, special direct-buried construction.
impact, or high temperatures. When cables are exposed to
Cable materials may be specified mechanical impact damage, they may
not to produce large amounts of protected with flexible steel tape or wire
smoke if burnt. armor, which may also be covered by a
water resistant jacket.

3

POWER CABLES
Power Cables (3 / 3½ / 4 / 5 CORE up to 630 SQ. MM
AND 3.8 / 6.6 kV) and SINGLE CORE up to 1000 SQ.
MM as per IS:1554 (Part-I) / IS:7098 (Part-I) / BS / IEC
SELECTION OF POWER CABLES
Possible overloading duration & magnitude
Route length and voltage drop
Mode of installation considering installation
environment such as ambient & ground
temperature, chemical & physical properties
of the soil
Flame retardant properties
Plant safety requirements
PVC CABLES
CONDUCTOR:
The most acceptable metals for conductors
are copper and aluminium due to their higher
conductivity and ductility.
As copper has got higher affinity for sulphur,
it corrodes in the atmosphere where sulphur
fumes are present. In these conditions tinned
copper should be used. Aluminium oxide film
which is always present on Aluminium
conductor surface acts as barrier and it
protects the aluminium conductor from
corrosion in fumes laden atmosphere.
25-06-2020
SELECTION OF POWER CABLES
Power cables are generally selected
considering the application. However,
following factors are important for selection
of suitable cable construction required to
transport electrical energy from one end to
the other.
Maximum operating voltage
Insulation level
Frequency
Load to be carried
PVC CABLES
PVC insulated LT Heavy Duty cables
are made as per IS-1554 (Part I) 1988.
The cables are suitable for use on AC
single phase or three phase (earthed or
unearthed) systems for rated voltage up
to and including 1100 volts. These
cables can be used on DC systems for
rated voltage up to and including 1500
volts to earth.
PVC CABLES
• CONDUCTOR CONSTRUCTION
The most economical construction for conductor is
solid conductor i.e. conductor is made of one single
wire. As the area of conductor increase, solid
conductor becomes more stiff and hence difficult to
handle. In this case stranded construction is adopted.
Here the conductor is made of number of strands.
The strands are arranged in spiral layers in
1+6+12+18+…….. formations. This construction
provides more flexibility. Where crimping of lugs are
required, the conductor has to be of stranded
construction only.
Formula for total number of strands = 1+3n(n+1)
where n is no. of layers
4

PVC CABLES
• CONDUCTOR CONSTRUCTION
To economize in insulating material, weight
and overall diameter, shaped conductors are
employed in bigger sized cables. Here the
stranded conductor is shaped in to a segment
of a circle so that when all the cores are laid,
they form a complete circle.
IS-1554 permits solid conductor construction
up to 10 sq. mm in Aluminium and up to 6 sq.
mm in copper. It permits the use of shaped
conductors for sizes from 16 sq. mm
onwards.
PVC CABLES
• INNER SHEATH:
• Inner sheath is provided over the laid up
cores. It is provided to give circular
shape to the cable and it provides
bedding for the armouring.
• I.S. 1554 permits following two methods
of applying the inner sheath of any
thermoplastic material i.e. PVC,
Polyethylene, etc.
PVC CABLES
• b) TAPPED INNER SHEATH: Here the inner
sheath is provided by wrapping a
thermoplastic tape over the laid up cores. It is
generally employed in cables having sector
shaped cored i.e. multi core cables of 16 sq.
mm and above. This method saves a process
and hence manufacturers always provide this
type of inners heath unless the purchase
specifications ask for extruded inner sheath.
25-06-2020
PVC CABLES
• INSULATION
• The PVC covering over conductor is called insulation
and is provided by extrusion process only. The
insulated conductor is called core.
• IS-1554 permits two types of PVC insulation as
follows :
• 1) Insulation with TYPE A PVC compound as per I.S.
5831 which is suitable for 70 deg.C continuous
operation.
• 2) Insulation with TYPE C PVC compound as per I.S.
5831 which is suitable for 85 deg.C continuous
operation.
PVC CABLES
• a) EXTRUDED INNER SHEATH: Here the
inner sheath is provided by extrusion of
Thermoplastic over the laid up cores. This
type of the inner sheath is generally provided
in cables having round cores i.e in control
cables and in power cables up to 10 sq. mm
size. This type of the inner sheath also acts
as a water barrier between cores and outer
sheath. In case of a puncture in the outer
sheath the water can not reach to the cores
and hence we recommend that cables for
outdoor underground uses should have
extruded inner sheath.
PVC CABLES
• ARMOURING
• In case of armoured cables, generally
galvanized steel wire/strip armouring is
provided over the inner sheath in multi-
core cables and over the insulation in
single core cables. It provides
mechanical protection to inside cores and
it carries earth return current in case of a
short circuit of a core with armour.
5

PVC CABLES
• As per I.S. 1554 (Part I) 1988, round wire
armouring is provided in cable, where
calculated diameter under armour is upto
13 mm. Above this the armouring is
either with round wire or strip of size 4
mm x 0.80 mm. As strip construction is
economical, the manufacturers always
provide steel strip armouring unless wire
armouring is specially specified.
PVC CABLES
• It permits the following types of outer
sheath PVC compounds:
• 1) Outer sheath with type ST1 PVC
compound as per IS-5831, which is
suitable for 70 deg.C continuous
operation.
• 2) Outer sheath with Type ST2 PVC
compound as per IS-5831, which is
suitable for 85 deg.C continuous
operation.
PVC CABLES
• Moreover, due to the burning of PVC a dense
corrosive smoke is emitted which makes fire
fighting very difficult, due to poor visibility and
toxic nature of the smoke. HCL content of the
smoke, not only damages other costly
equipment lying nearby, but also penetrates
the RCC and corrodes the
reinforcement. Due to this there is an
extensive damage to the property.
25-06-2020
PVC CABLES
• OUTER SHEATH
• The PVC covering on armouring in case
of armoured cables and over the inner
sheath in case of unarmoured cables is
called outer sheath.
• I.S. 1554 specifies nominal and minimum
thicknesses of outer sheath for
unarmoured cables and only minimum
thickness of outer sheath for armoured
cables.
PVC CABLES
• PVC has got fire retardant properties due to
its halogen content. The fire in the cable gets
extinguished immediately on removal of the
fire source.
• In the modern Power, Chemical, Fertilizer and
Cement Plants many PVC cables are
bunched in the cable shaft or on cable trays.
In case of fire in these cables, the fire
becomes self sustaining.
PVC CABLES
• To overcome these deficiencies FRLS i.e.
Fire Retardant Low Smoke PVC was
developed.
• If required, we can provide Fire Retardant
Low Smoke (FRLS) PVC Inner sheath and /
or outer sheath. This PVC compound, apart
from meeting the requirements of Type ST2
steel as per IS-5831, has got better fire retardant
properties and it emits lower smoke and acid
fumes when it catches fire.
6

CONTROL CABLES
Control Cables (any size and any no. of Cores)
as per IS:1554 (Part-I) / IS:7098 (Part-I) / BS / IEC
XLPE CABLES
• CROSS-LINKED POLYETHYLENE (XLPE):
XLPE means cross-linked polyethylene or
vulcanized polyethylene. The basic material is
low density polyethylene. Polyethylene is a
thermoplastic material consisting of long
chain of hydrocarbon molecules. At elevated
temperatures these molecules tend to move
relative to one another so that the material
becomes increasingly deformable and will
eventually melt at the temperature around
110oC.
XLPE CABLES
ADVANTAGES OF XPLE CABLES OVER PVC
CABLES
(A) TECHNICAL:
1.Higher current rating, higher short Circuit Rating
2.Higher insulation resistance - 1000 times more than
PVC cables
3.Better Resistance to Surge currents
4.Low Dielectric Losses
5.Better resistance to chemicals and corrosion
6.Longer Service life
7.Comparatively higher cable operating temperature
90°C and short circuit temperature 250°C.
25-06-2020
COLOUR CODING
The following colour code is used for identification:
• Single Core : Red, Black, Yellow, Blue or natural
• Two Cores : Red and Black
• Three Cores : Red, Yellow and Blue
• Three & Half : Red, Yellow, Blue and Reduced
neutral Black
• Four Core : Red, Yellow, Blue and Black
• Five Core : Red, Yellow, Blue, Black, and Grey
• Six Cores : Two adjacent cores. Blue and Yellow
(Counting and direction core) and remaining
Grey in each layer OR by printing numbers on
each core
XLPE CABLES
• By means of process similar to the vulcanization of
rubber the polyethylene molecules can be cross-
linked. The process of cross-linking or vulcanization
consists of producing chemical bonds at interval
between the long molecular chain to give a “ladder”
effect which prevents slippage between molecules.
As a result of cross-linking the material becomes heat
resistant and does not soften at higher temperatures.
Further it has better resistance to stress cracking and
good resistance to ageing in hot air. With the change
of structure there is no adverse effect on electrical
properties.
XLPE CABLES
ADVANTAGES OF XPLE CABLES OVER
PVC CABLES
(B) COMMERCIAL:
1.Lower laying cost because of comparatively
smaller diameter of cable and lighter weight
2.Requiring less size of cable trays / supports
3.One size lower cable can be used as
compared to PVC insulated cable.
4.Density of XLPE is lower than PVC.
5.For longer cable length voltage drop shall
be considerably low.
7

CABLE CODE
The following codes are used for designating the cables as per
IS:1554/ Part-I / 1988 / IS:7098-Part:I
CONSTITUENT
• COPPER CONDUCTOR
• ALUMINIUM CONDUCTOR
• PVC INSULATION
• XLPE INSULATION
• STEEL ROUND WIRE ARMOUR
• STEEL FLAT STRIP ARMOUR
• STEEL DOUBLE ROUND WIRE ARMOUR
• STEEL DOUBLE FLAT STRIP ARMOUR
• NON MAGNETIC (AI) ROUND WIRE ARMOUR
• NON MAGNETIC (AI) FLAT STRIP ARMOUR
• PVC OUTER SHEATH
CABLE CODE
• 4 core x 4.0 sq. mm AYWY: Aluminium
conductor, PVC insulated, laid up, inner
sheathed, G.I. wire armoured and PVC
sheathed cable having 4 cores of 4.0 sq. mm
conductor size.
• 3 ½ core x 50 sq. mm AYFY: Aluminium
conductor, PVC insulated, laid up, inner
sheathed, Steel strip armoured and PVC
sheathed cable having 3 cores of 50 sq. mm
and 1 core of 25 sq. mm conductor size.
POWER CABLE
• Take weight of a small conductor
piece and measure its weight in
grams. Then find out the weight of
the conductor in gms per meter
length. Divide it by 2.7 in case of
Aluminium and by 8.9 in case of
copper. It will give the area of the
conductor in sq. mm.
25-06-2020
CABLE CODE
• YWY means Copper conductor, PVC insulated, round
CODE LETTER wire armoured and PVC sheathed cable.
-
A • AYFY means Aluminium conductor, PVC insulated,
Y steel strip armoured and PVC sheathed cable.
2X
W
• FOR EXAMPLE
F • 3 Core x 2.50 sq. mm YWY : Plain Copper conductor,
WW PVC insulated, laid up, Inner sheathed, G.I. wire
FF armoured and PVC sheathed cable having 3 cores of
Wa
2.50 sq. mm conductor size.
Fa
Y
POWER CABLE
• The best way to check the length of the
supplied cable is by resistance method.
Take the resistance of the full drum and
divide the reading by the resistance of 1
mtr. length.
• To decide the size of the conductor,
particularly that of the sector shaped
conductor, we recommend the following
method:
POWER CABLE
• HANDLING AND LAYING OF CABLES
• Cables are costly capital items. They are arteries and
veins of the plant and any blockade in the same will
paralyze the complete plant. Unfortunately very little
attention is paid in handling and installing the Cables.
Generally the work is entrusted to unskilled labourers
and they may damage the cable in handling and
laying. This damage may not be noticed while
charging the cable but when water comes in to contact
with this Cable, it shows a fault. In this case the blame
comes on cables.
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 25-06-2020

POWER CABLE POWER CABLE

• Therefore, special attention should be paid in handling
and laying the cables. If they are laid properly, they
will give trouble free service for years to come.
• Some recommendations about the handling and
laying of CABLES :
• If possible the cables should be unloaded by a crane
or a fork lift. If the same is not available, the drums
should be rolled down from the truck to a inclined
plane or should be dropped from the truck on scrap
truck tyres or on sand. In the last case the cable drum
may get damaged, if proper care is not taken.
• The wood of the drum deteriorates fast
if the drums are kept in sunlight or in
moist atmosphere. The drums should be
stored in covered godown having a
concrete flooring.
• On receipt of the drums, the cables
should be meggered with a 500/1000
volts megger.

POWER CABLE PVC CABLE

I.S. 1554 does not mention the minimum megger values of the PVC cables. The Table

• Please note that megger value decreases below gives the minimum megger values of the PVC cables as per B.S. 6346-1989

with increase in the length, temperature and MINIMUM INSULATION RESISTANCE VALUES

size of the cables. NOMINAL CROSS SECTIONAL AREA OF

CONDUCTOR SQ.MM
INSULATION RESISTANCE IN MEGA OHM/
KILOMETRE AT 20 DEG.C 650/1100 VOLTS

• Before meggering, both the ends of the 1.50 10

2.50 9
cables should be opened out and cleaned to 4.00 8

remove dust or metal particles. After the test, 6.00 7

the core should be shorted to discharge the 10.00

16.00
7
6
cable, otherwise charged cores may give a 25.00 5

shock to a person who may handle it 35.00 5

50.00 5
subsequently. 70.00 5
95.00 & above 5

PVC CABLE PVC CABLE

• As PVC cables have got higher capacitance, while
meggering, a high charging current will flow initially
and hence the megger will show a lesser reading. As
per International specifications the reading after one
minute of continuous meggering should be taken.
• It is observed that some electricians check the cables
by giving one phase to one of the cores of the cable
and check the other cores by a tester for a possible
leakage.
• This is a wrong method as other cores will show an
induced voltage when tested with a tester due to
capacitance between the cores, which is quite high in
case of PVC cables. Capacitance also increases with
increase in temperature, length and size of the cable.
• When laying the cables the drums must be rotated in
the direction marked on the drums.
• If they are rotated in the reverse direction, the
winding will become loose.
• Always use jacks to raise the cable drum and then
pull the cable from the drum. It is observed that some
times due to non availability of jacks, people turn the
cable drum on flange side and then unwind the cable.
This gives one twist to the cable per turn unwound
and due to this the armour comes out damaging the
outer sheath and forms a bulge.

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 25-06-2020

PVC CABLE PVC CABLE

• Where the cables are crossing the roads, the
same should be laid in concrete ducts. Care
should be taken to see that the sharp edges
of concrete ducts do not damage the cables
when the same are being pulled. Rollers must
be provided when longer lengths are being
laid, to avoid any damage to the sheath.
• The cables with extruded inner sheath must
be used when the same are laid in ground.
• When cables are laid in ground, sand bedding
must be provided below the cable and it
should also be covered by sand and over the
sand a brick layer should be provided.
• Sharp bends should be avoided while laying
the cables. We recommend a minimum
bending radius of 12 x D Cables. (D is the
overall diameter of the cable).

HT CABLES
• For circuits operating at or above 2,000
volts between conductors, a conductive
shield may surround each insulated
conductor. This equalizes electrical
stress on the cable insulation. The
individual conductor shields of a cable
are connected to earth ground at the
ends of the cable, and at locations along
the length if voltage rise
A high voltage cable designed for 400 kV. Large center conductor carries
during faults would be dangerous.
the current, smaller conductors on the outside act as a shield to equalize
the voltage stress in the thick polyethylene insulation layer.

HT CABLES HT CABLES
• Cables for power distribution of 10kV or • Modern high voltage cables use polymers or
higher may be insulated with oil and polyethylene, including (XLPE) for insulation.
paper, and are run in a rigid steel pipe, They require special techniques for jointing and
semi-rigid aluminum or lead sheath. For terminating.
higher voltages the oil may be kept • Many multi-conductor cables have a bare or
under pressure to prevent formation of insulated grounding or bonding wire which is for
voids that would allow partial- connection to earth ground. The grounding
discharges within the cable insulation. conductor connects equipment enclosures to
ground for protection from electric shock.

10

HT CABLES
• Electrical power cables are often
installed in raceways,
including electrical conduit and cable
trays, which may contain one or more
conductors.
• A hybrid cable can include conductors
for control signals or may also
include optical fibers for data.
INDIAN STANDARDS
IS-6474:1984 Polyethylene insulation &
sheath of electric cables
IS-8130:1984 Conductors for insulated
electric cables and flexible cords
IS-3975:1988 Mild steel wires, formed wires and
tapes for armouring of cables
International Standards
• IEC 228 Conductors of insulated cables. Guide to the
dimensional limits of circular conductors.
• IEC 331 Fire resisting characteristics of electric
cables.
• IEC 332 - 3 Tests on electric cables under fire conditions.
Part 3: Tests on bunched wires or cables.
• IEC 502 Extruded solid dielectric insulated power
cables for rated voltages from 1kV to 30 kV.
• IEC 754 - 1 Test on gases evolved during combustion of
materials from cables. Part 1: Determination
of the amount of halogen acid gas evolved
during combustion of polymeric material
taken from cables.
• IEC 811 Pts 1 through 5 Common test methods for insulating
and sheathing materials of electric
cables.
25-06-2020
INDIAN STANDARDS
IS-1554 Part-1 PVC insulated Cables
IS-5831:1984 PVC insulation & sheath of
electric cables
IS-7098 Part-1 Cross linked polyethylene (XLPE)
insulated PVC sheathed cables (for
working voltage upto & including
1100 V)
IS-10810:1984 Methods of test for cables
Indian Standards
• IS- 7098 Part-1 Cross linked polyethylene insulated
PVC sheathed cables (for working
voltage upto & including 1100 V)
• IS 1554 Part-1 PVC insulated Cables
• IS- 6474: 1984 Polyethylene insulation & sheath of
electric cables.
• IS- 5831: 1984 PVC insulation & sheath of electric
cables.
• IS- 10810: 1984 Methods of test for cables.
• IS- 8130: 1984 Conductors for insulated electric
cables and flexible cords.
• IS- 3975: 1988 Mild steel wires, formed wires and
tapes for armouring of cables.
International Standards
• IEC 885 Pts 1 through 3 Electric test methods for electric
cables.
• IEC 304 Standard colours for insulation for
low frequency cables and wires.
• IEC 227 01-1 through 6 PVC insulated cables of rated
voltages up to and including
450/750 V.
• IEC 1034 Pts 1 & 2 Measurement of smoke density of
electric cables burning under
defined conditions.
• IEC 28 International Standard of
Resistance for Copper
• IEC 60840 Tests on extruded power cables
• IEC 60502-1 Power cable with extruded
insulation.
11

STANDARD TECHNICAL REQUIREMENT
• FOR XLPE HT POWER CABLE
• All cables should be suitable for high ambient, high
humid tropical Indian Climatic conditions. Cables
should be designed to withstand the mechanical,
electrical and thermal stresses under the unforeseen
steady state and transient conditions and should be
suitable for proposed method of installation.
• Conductor should be of uniform, of good quality, free
from defects Aluminium copper.
• Insulation should be Cross Linked Polyethylene
(XLPE) .
STANDARD TECHNICAL REQUIREMENT
• Inner sheath - All armoured and multi-core un-
armoured cables shall have distinct extruded inner
PVC sheath of black colour.
• Armouring - Material for armour for Single Core Cable
should be Aluminium wire. For Multi-core cable it
should be GS wire/flat. Armouring should be as per
relevant IS and it shall have minimum 90% coverage.
• Outer Sheath – It should be of black colour PVC (type
ST2 as per IS 5831) with Cable size and Voltage
grade embossed on it. Sequential marking should be
at every 1 (one ) meter distance. Word "FRLS" shall
also be embossed on it at every 5 (Five ) meter
distance.
25-06-2020
STANDARD TECHNICAL REQUIREMENT
• For 33 kV and 11 kV cables, conductor screen and
insulation screen both should be extruded, semi-
conducting compound and shall be applied along with
XLPE insulation in a single operation by triple
extrusion process. Method of curing for 33 kV cable
should be "Dry curing/ gas curing " only, whereas for
11kV and 3.3 kV cables it should be "Dry curing/ gas
curing / Steam curing".
• Cable should be provided with copper metallic screen
suitable for carrying earth fault current as stipulated in
Clause-1.2 of Section 1. For single core armoured
cables the armouring shall constitute the metallic part
of the screening.
STANDARD TECHNICAL REQUIREMENT
• FRLS Properties - All cable shall be Flame Retardant,
Low Smoke (FRLS) type. Outer sheath shall have the
following properties –
• Acid Gas Generation – Max 20% ( as per IEC 754-1)
• Smoke density rating: 60% (As per ASTM D 2843)
• Flammability test - As per Swedish chimney test F3
as per SEN 4241475
• As per IEC 332 part-3 (Category B) Minimum bending
radius shall be 10 D
12
 25-06-2020

TYPE TESTS TYPE TESTS

• e. Physical tests for out sheath
• a. Tests on conductor • i. Tensile strength and elongation at break
• i. Annealing test (for copper) • ii. Ageing in air oven
• ii. Tensile tests (for aluminium) • iii. Hot test
• iii. Wrapping tests (for aluminium) • iv. Shrinkage test
• iv. Resistance test • f. Bleeding and blooming tests (for outer sheath)
• b. Tests for armouring wires/strips • g. Partial discharge test
• c. Test for thickness of insulation and sheath • h. Bending test
• d. Physical tests for insulation • i. Dielectric power factor test
• i. As a function of voltage
• i. Tensile strength and elongation at break
• ii. As a function of temperature
• ii. Ageing in air oven • j. Insulation resistance (volume receptivity) tests
• iii. Hot test • k. Heating cycle test
• iv. Shrinkage test • l. Impulse withstand test
• v. Water absorption (gravimetric) • m. High voltage test
• n. Flammability test

ACCEPTANCE TESTS Routine Tests for Cables

• a. Annealing test (for copper)
• b. Tensile test (for aluminium) • Routine tests:
• c. Wrapping tests (for aluminium)
• d. Conductor resistance test,
• The following shall constitute routine
• e. Test for thickness of insulation tests:
• f. Hot set test for insulation, • a) Conductor resistance test
• g. Tensile strength and elongation at break test for
insulation and sheath • b) Partial discharge test (for screened
• h. Partial discharge test (for screened cables only) cables only) and
• i. High voltage test and
• j. Insulation resistance (volume resistively) test
• c) High voltage tests

SMOKE DENSITY TEST ON FRLS CABLES AS PER ASTM D-2843 SMOKE DENSITY TEST ON FRLS CABLES AS PER ASTM D-2843

Sl.No. TIME OBSERVATION

SMOKE DENSITY TEST 0 0.00 1

100 1 0.25 8
3 Max. Smoke Density
2 0.50 14
90
Rating Observed (%) 44.3
LIGHT ABSORPTION IN %AGE --------->

3 0.75 22
80
72 72
68 4 1.00 28
70 64 Min. Transmission of
5 1.25 33
55 56
Light (%) 55.7
60 6 1.50 39
47 48 7 1.75 40
50 42
39 40 8 2.00 42
40 33
28 9 2.25 47
30 22 10 2.50 48
20 14 11 2.75 55
8
10 12 3.00 56
1
13 3.25 64
0
14 3.50 68
00

25

50

75

00

25

50

75

00

25

50

75

00

25

50

75

00
0.

0.

0.

0.

1.

1.

1.

1.

2.

2.

2.

2.

3.

3.

3.

3.

4.

15 3.75 72
TIME IN MINUTES ------->
16 4.00 72

708

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Oxygen & Temp. Index Test on FRLS Cable as per ASTM D-2863 Oxygen & Temp. Index Test on FRLS Cable as per ASTM D-2863

OXYGEN & TEMPERATURE INDEX

36.0%

35.0% 34.0%
Temp. (Deg.C) % Oxy. Index. Temp. Index
34.0% 33.2%
OXYGEN INDEX(%) -------->

33.0% 32.4%
31.5%
25 34.0% 420 DEG.C
32.0%

31.0%
30.0%

29.0%

28.0% 50 33.2%
27.0%
26.0%

25.0%

24.0%

23.0% 75 32.4%
22.0%

21.0%
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500

TEMPERATURE IN ( Deg.C) ----->

100 31.5%

Wiring Installation – Wire Size Selection

• LSZH – Low Smoke Zero Halogen • Wire is manufactured in sizes according to a
• LSOH - Low Smoke Zero Halogen standard known as the American wire gauge
• FRLS – Flame Retardant Low Smoke (AWG). As shown in Figure 9-115, the wire
diameters become smaller as the gauge
numbers become larger. Typical wire sizes
range from a number 40 to number 0000.

• Outer Sheath Color Coding

• The color of a cable’s outer sheath tells you the gauge of the
wire inside the sheath as well as the amperage rating for the
circuit.
• WHITE = 14-gauge wire, 15-amp circuit
• YELLOW = 12-gauge wire, 20-amp circuit
• ORANGE = 10-gauge wire, 30-amp circuit
• BLACK = 8- or 6-gauge wire, 45- or 60-amp circuits. Check
sheath labeling for gauge and circuit specifics.
• GRAY = Underground cable. Since all UF (underground
feeder) cable is gray, check the

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• Wire Color Coding

• This code is standard for all conductors. The colors you’re
most likely to find in your home are the following:
• BLACK (OR RED) = HOT. Hot wires carry current from
the panel to the device, which could be a switch, receptacle,
light fixture or appliance. There are other colors for hot
wires, but they’re much less common.
• WHITE = NEUTRAL. Neutral wires carry the current back
to the panel, completing the circuit.
• BARE (OR GREEN) = GROUND. In the event of a
ground fault, the ground wire provides a path for the fault
current to return to the panel, opening the breaker or blowing
the fuse, cutting off the flow of electricity.
• Joint Box or Tee or Jointing System
• In this method of wiring, connections to appliances are
made through joints. These joints are made in joint boxes
by means of suitable connectors or joints cutouts. This
method of wiring doesn’t consume too much cables size.
• You might think because this method of wiring doesn’t
require too much cable it is therefore cheaper. It is of
course but the money you saved from buying cables will
be used in buying joint boxes, thus equation is balanced.
This method is suitable for temporary installations and it is
cheap.

LV Lugs Cable Lugs & Connectors

LV Copper Lugs
FEATURES

■■ Designed to be crimped on to a conductor to facilitate the termination of the cable via the
lug hole
■■ Copper lugs are electrolytically tin plated to avoid oxidation
■■ Each terminal has a sight hole for visual inspection of the conductor inserted
■■ 1000V Rated
LV copper tube crimping
lugs
• Loop-in or Looping System Part number

A 03-M
Hole Size

3.5, 4, 5, 6mm
Conductor Size

1.5mm2
Partnumber

A24-M
Hole Size

8,10,12, 14,16,20mm
ConductorSize

120mm2

A 06-M 3.5, 4, 5, 6, 8mm 2.5mm2 A30-M 8,10,12, 14,16,20mm 150mm2

• This method of wiring is universally used in wiring. Lamps and other A 1-M

A 2-M

A 3-M
3.5, 4, 5, 6, 8mm

3, 4, 5, 6, 8,10mm

4, 5, 6, 8,10,12mm
4-6mm2

10mm2

16mm2
A37-M

A48-M

A60-M
8,10,12, 14,16,20mm

10,12, 14,16,20mm

10,12, 14,16,20mm
185mm2

240mm2

300mm2

appliances are connected in parallel so that each of the appliances can A 5-M

A 7-M
4, 5, 6, 8,10,12mm

5, 6, 8,10,12mm
25mm2

35mm2
A80-M

A100-M
12,16,20mm

16, 20mm
400mm2

500mm2

A 10-M 6, 8,10,12, 14,16mm 50mm2 A120-M 16, 20mm 630mm2

be controlled individually. When a connection is required at a light A 14-M

A 19-M
6, 8,10,12, 14,16mm

8,10,12, 14,16, 20mm

70mm2

95mm2
A160-M

A200-M
16, 20mm

16, 20mm
800mm2

1000mm2

or switch, the feed conductor is looped in by bringing it directly to the

LV Narrow Palm Copper Lugs
terminal and then carrying it forward again to the next point to be fed. FEATURES

• The switch and light feeds are carried round the circuit in a series of ■■ Designed to be crimped onto a conductor to facilitate the termination of the cable via the
lug hole in tight spaces and reduced space terminal blocks

loops from one point to another until the last on the circuit is reached. ■■ Copper lugs are electrolytically tin plated to avoid oxidation
■■ Each terminal has a sight hole for visual inspection of the conductor inserted
The phase or line conductors are looped either in switchboard or box LV narrow palm copper ■■ Please refer to our tooling and equipment section on page 212 for dies and tooling
■■ 1000V Rated
and neutrals are looped either in switchboard or from light or fan. Line tube crimping lugs
Part number Palm Width Hole Size ■■ Tested to BS EN 61238 Partnumber
Conductor Size PalmWidth Hole Size ConductorSize

BTN10-M 9m m 5m m 10mm2 BTN95-M 15.5mm 8mm 95mm2

or phase should never be looped from light or fan. BTN16-M

BTN25-M
9m m

9m m
5m m

5m m
16mm2

25mm2
BTN120-M

BTN150-M

BTN185-M
19mm

19mm

24.5mm
8, 10mm

8, 10mm

10mm
120mm2

150mm2

185mm2
BTN35-M 11.5mm 6m m 35mm2

BTN50-M 11.5mm 6m m 50mm2 BTN240-M 31mm 10, 12,16mm 240mm2

BTN70-M 11.5mm 6m m 70mm2 BTN300-M 31mm 10, 12mm 300mm2

www.jointingtech.co.uk 21

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