Acknowledgement
Page | i
Foreword
VP Distribution Division, Hj. Hussin Othman
Page | iii
Contents
Chapter 1:
1.1
1.2
1.3
Requirements
1.4
1.5
Chapter 2:
2.1
Issues to Consider
2.2
10
2.3
10
2.4
Use of Ducts
12
2.5
Cable Formation
13
2.5.1
13
2.5.2
14
2.5.3
16
2.5.4
17
2.5.5
Link Box
18
2.5.6
20
Reference Conditions
21
2.6
Chapter 3:
Page | iv
Introduction
22
3.1
22
3.2
Culvert Dimensions
23
Contents
3.3
Cable Arrangement
26
3.3.1
28
3.3.2
29
3.3.3
Arrangement of Joints
30
3.4
Trench Design
31
3.4.1
32
3.4.2
Road Crossings
33
3.4.3
34
3.4.4
Joint Pit
36
3.4.5
36
3.5
37
3.6
39
Chapter 4:
44
4.1
Duct Banks
44
4.2
46
4.3
Cable Arrangement
51
4.4
Duct Design
52
4.4.1
52
4.4.2
Road Crossings
53
4.4.3
54
4.4.4
Sand Bags
57
4.4.5
58
4.4.6
60
4.5
61
4.6
66
Appendix
67
Glossary of Terms
68
References
70
Page | v
List of Tables
Page | vi
Page 10
Page 26
Page 27
Page 47
Page 47
Page 67
Chapter 1: Introduction
1.1
Page | 1
Page | 2
Introduction
Page | 3
1.2
New growth areas can have even more stringent requirements for
utility installations. The local authority and/or developer may impose
several conditions that require more sophisticated cable trenching and
installation practices. Some of these conditions include:
x
x
x
dE
mechanized excavators for cable trenching.
The developer provides the infrastructure for cable laying.
All cable installation and maintenance work may only use manual
labour or small machines which do not damage the road surface or
pavement.
No possibility of accidental third party digging leading to
breakdowns
Page | 4
Introduction
1.3
Page | 5
Page | 6
Introduction
1.4
Turf and
decorative trees
Local drainage
Sand-filled
reinforced
concrete trench
Page | 7
1.5
Page | 8
Criteria
Issues to Consider
Slab marker
Culvert
Page | 9
2.2
11 kV 3C 240 mm
Air
Air + duct
Sand
Sand + duct
420 A
335 A
289 A
243 A
638 A
418 A
453 A
363 A
777 A
500 A
516 A
424 A
11 kV 1C 500 mm
Trefoil formation
2
33 kV 1C 630 mm
Trefoil formation
2.3
x
x
Page | 10
Ground Level
x
x
Page | 11
2.4
x
x
x
x
x
Use of Ducts
As mentioned above, heat generated by the cable needs to be
conducted through the layers of soil to the ground surface.
When cables are laid in ducts for a considerable distance, the
ducts become a barrier to heat conduction
An additional de-rating factor needs to be introduced when cables
are laid in ducts.
If use of ducts is unavoidable, they should be used in duct banks,
or installed with suitable mechanical protection.
The ducts should be clean and smooth to reduce damage during
cable installation.
Service pits
Pavement
Service pit
covers
Ducts in a bank
Page | 12
2.5
Cable Formation
When more than one cable is laid in the same trench, the cable
formation becomes very important. Cables in the same trench will
affect each other in the form of mutual heating. For single core (1C)
cables, there will also be induced voltages due to different phases of
the same circuit, or cables of different circuits. 1C Cables are either
laid single layer flat-spaced or in trefoil formation, while three core
(3C) cables are always in single layer.
2.5.1
x
x
x
x
3-core cables
Trench walls
Page | 13
x
x
x
x
Single-core cables
Trench walls
Page | 14
x
x
Cable ties
1000mm
Figure 12: Trefoil formation of 3 single core cables held together with
cable tie at every one meter interval
Page | 15
To limit the sheath voltage, all single core cables in a circuit need to be
cross-bonded every 1 kilometre (1 minor). Cross bond connections are
made in a link box as shown in Subsection 2.5.5.
Induced sheath voltage occurs due to induction across cables carrying
current. This only occurs in single core cables as three-core cables
cancel out the effect due to internally connected copper tape screens.
The induced voltage is directly proportional to the length of the cable
and the maximum voltage allowed by TNB Distribution Division is 50V.
A graph of this relationship is shown in Figure 14.
To keep the induced voltage below 50V, the sheath must be crossbonded at every 1 kilometre (1 minor) and cross-bonded with earthing
at every 3 kilometres (1 major).
X Bond Joint
ST Joint
500m
500m
1000m = 1 minor
X Bond Joint
ST Joint
ST Joint
500m
500m
1000m = 1 minor
500m
X Bond Joint
& earth
500m
1000m = 1 minor
3 minor = 1 major
Figure 13: Diagram of a major span
(3km, 3 minors, 1 cross-bond at each one km joint)
Page | 16
(1,000 m)
X bond joint
(1,000 m)
X bond joint
with earthing
(1,000 m)
X bond joint
Sheath
core
Sheath
Voltage
Major
Minor
Minor
Minor
Max Voltage
= 50V
Distance
Figure 14: To keep the induced voltage below 50V, the sheath must be
cross-bonded at every 1 kilometre (1 minor) and cross-bonded
with earthing at every 3 kilometres (1 major)
2.5.4
Service pit design shall take into consideration the required bending
radius of the largest possible cable size to be laid.
According to the BICC Electric Cables Handbook, the nominal bending
radius for XLPE 33kV cables is 15 times the cable diameter. To simplify
the calculations for all cable types a general rule is derived from this
value.
The rule of thumb to calculate the bending radius of distribution cables
is:
Bending radius = 15 x cable diameter
Page | 17
Link Box
All link boxes must be precisely and clearly labelled with circuit number
and feeder names.
The link box shall be installed near the trench above ground level so
that it can be easily located during breakdowns and also for ease of
maintenance.
Cable sizes for connection of sheath to link box are as below:
x
x
Link box
Connecting
cable to link box
Joints
Figure 15: Typical link box location next to a reinforced concrete trench
Page | 18
Figure 16: Typical example of 11kV, 6+1 Link box. A 70mm Cu PVC/PVC
cable is used to connect sheath to the link box
Figure 17: Typical example of 33kV, 6+1 Link box. A 300mm Cu PVC/PVC
cable is used to connect sheath to the link box
Page | 19
nPVC Cable Slabs are used as visual warning indicators, while at the
same time providing mechanical protection for underground cables in
the event of accidental or unauthorized excavation/digging work.
x
x
x
x
The Cable Slabs are buried below the ground level and above
the underground cables.
Cable slabs will be placed at the Slab Marker Level which is
visible at the wall of the culvert. Diagrams for the installation
location are shown in Chapter 3.
Nylon cable ties are used to lock/tie together a string of nPVC
cable slabs.
nPVC cable slab dimensions are 1000mm (ln.) x 250mm (wd.)
x 4.5mm (th.), red in colour.
Page | 20
2.6
Reference Conditions
Having regard to all that has been discussed above, this Manual has
been designed with the following conditions in mind:
1.
dE
normal mechanized excavators for cable trenching.
2.
3.
4.
5.
h h
topsoil of 100mm on top of it. No sealant to be used between
hp out.
6.
7.
Page | 21
Chapter 3:
3.1
Reinforced
concrete culvert
Washed river sand
Cable slabs
MV 3 core cables
Page | 22
3.2
Culvert Dimensions
Length:
Internal Depth:
Internal Width:
Thickness:
x
x
x
Material:
Reinforcement:
Loading criteria:
Markings:
1000 mm
600 mm
600, 1200, 1500 mm
1000 mm (used in Medini)
70, 95, 100 mm
80 mm (used in Medini)
Concrete characteristic strength of 30 MPa
Design to the requirements of BS 8110 : 1997
Live load of 10KPa or special design for
other loading conditions.
Sand Bed and nPVC Slab Level Marker (Red)
Slab level
marker
Sand bed
level marker
Figure 20: Detail of 600 mm wide culvert with sand bed marker for typical
Reinforced Concrete Trench
Page | 23
Slab level
marker
Sand bed
level marker
Page | 24
Slab level
marker
Sand bed
level marker
Figure 23: Detail of culverts used with fixed thickness of 80mm used in the
Medini site in Nusajaya, Johor
Page | 25
3.3
Cable Arrangement
cable
area
2
(mm )
cable
diameter
(mm)
600
mm
1000
mm
1200
mm
11kV 3-core
240
70
2
5
6
single layer
11kV single-core
500
54.4
2
4
5
trefoil
33kV single-core
3
4
630
71.4
1
trefoil
* Detailed variations in cable laying options are shown in Appendix A.
Page | 26
1500
mm
7
6
5
Maximum number of
circuit (total)
11kV 3C
2
240mm
11kV 1C
2
500mm
33kV 1C
2
630mm
220 A
330 A
390 A
230 A
340 A
410 A
240 A
370 A
430 A
260 A
400 A
470 A
300 A
420 A
500 A
* Use this table together with Appendix A for other variations of cable mix.
Example:
If 2 cables of 33kV 1C, 3 cables of 11kV 1C and 1 cable of 11kV 3C to be
2
installed inside 1500mm trench, so the loadings for each cable are:
Total number of circuits is: 2 + 3 + 1 = 6
Using Table 3 for maximum number of 6 circuits, the ampacity for each
cable is:
1.
2.
3.
Page | 27
Cable slabs
3C cable
Page | 28
Cable slabs
1C cables in trefoil
Page | 29
Arrangement of Joints
Trench
Local soil
Page | 30
Turf
3.4
Trench Design
The culvert shall be installed with a clearance of 100mm from the top
of the culvert for topsoil and turfing as shown in Figure 28.
Page | 31
100mm
Culvert
Native Soil
Top Soil
Figure 28: Turf, topsoil, washed river sand and culvert in a cable trench
3.4.1
Turf
Road
Cable
trench
Figure 29: Location of cable trench along roadside should be placed to avoid
intrusion of other utilities such as drainage
Page | 32
Road Crossings
Road
Ducting
Concrete encased duct
Local drainage
Figure 30: PVC ducts may need to go through or around other local utility
trenches such as drainage or telecommunication lines
Page | 33
Page | 34
PPU
Ducts to PPU
Service pits
Concrete trench
Figure 33: Typical service pit, trench and duct bank connections for
Main Distribution Substations (PPU)
PMU
Ducts to PMU
Service pits
Concrete trench
Figure 34: Typical service pit, trench and duct bank connections for
Main Intake Substations (PMU)
Page | 35
Joint Pit
3.4.5
Link box
Concrete slab
Connecting cables
to link box
Joints
Figure 35: Typical installation of a link box on a 50mm thick concrete slab
next to the cable joint
Page | 36
3.5
2) Install the culvert evenly and at the same level. Sealants are NOT
to be used to allow rainwater to seep out.
Page | 37
Turf
Topsoil
Washed river
sand
Native soil
Page | 38
3.6
The sand and topsoil needs to be stacked neatly beside the trench
during cable installation. When laying cables, the topsoil and washed
river sand must be removed from the trench by using handheld tools
or a small mechanised excavating machine as below.
Page | 39
2) Remove the washed river sand until the sand bed level marker is
seen (about 500 mm deep).
Page | 40
4) Backfill with washed river sand until the slab level marker.
Page | 41
Cable slabs
Slab level marker
6) Backfill the washed river sand until level. Any shortfall of washed
river sand must be topped up.
Page | 42
8) A TNB Cable Route Marker will be installed every 50m. The marker
will be in the form of a concrete slab installed on the turfing.
Page | 43
Chapter 4: Duct
4.1
Bank Design
Duct Banks
Page | 44
Pavement
Duct bank
Native soil
Figure 38: A 4 x 3 duct bank with one circuit of single-core cables, six threecore cables, and a fibre/pilot cable as installed in Medini, Nusajaya
Page | 45
4.2
Figure 39 shows the standard 950mm wide duct bank. Reinforced duct
banks will have three layers for flat formation and two layers for trefoil
formation, and the number of ducts laid in a single layer depends on
the trench width.
Trefoil duct banks are also specified and are shown in Figure 43
through to Figure 46.
Page | 46
carrying capacity. Table 5 shows a guideline to calculate cable
ampacities based on different number of circuits in a duct bank.
Table 5: Ampacity of each cable based on total number of circuits in a bank
Maximum number
11kV 3C
11kV 1C
33kV 1C
2
2
2
of circuit (total)
240mm
500mm
630mm
10
200 A
380 A
430 A
9
210 A
390 A
450 A
8
220 A
400 A
460 A
7
230 A
410 A
470 A
6
240 A
430 A
490 A
5
250 A
460 A
530 A
4
260 A
500 A
570 A
3
280 A
520 A
600 A
2
310 A
550 A
640 A
Page | 47
Page | 48
Communications
duct
Communications
duct
Page | 49
Communications
duct
Page | 50
4.3
Cable Arrangement
Each duct can only accommodate one power cable as shown in Figure
47 and Figure 48. Communication cables may share a single duct.
The fibre/pilot cable for communications shall be placed at the lowest
duct, furthest away from the road so that power cables can be
installed at the upper ducts for better ampacity.
If ducts are installed in trefoil formation, the cables will have to follow
the duct formation.
Page | 51
4.4
Duct Design
4.4.1
Road
Pavement
Duct bank
Scupper pipe
Local drainage
Figure 49: Location of a duct bank along a road or drainage
Page | 52
Road Crossings
Road
Pavement
Ducting
Concrete encased duct
Local drainage
Figure 50: Ducts for road crossings must be encased in 50mm thick concrete
to withstand heavy road conditions
Page | 53
Service pits are used for pulling, bending and jointing of cables.
Service pits need to be made available at every 25 meter intervals
along the length of the duct banks. Cable joints and duct bank tee-offs
are made in these service pits.
These pits are filled with nylon sand bags and covered with concrete
slabs. Sandbags assist in arc-quenching and are detailed out in
Subsection 4.4.4.
Specifications of the service pits are as follows:
x
x
x
x
x
Page | 54
Standard service pit no branch-off, used for jointing, crossbonding and earthing.
T-junction service pit single branch-off
Cross-junction service pit multiple branch-off
Figure 52: Standard service pit, usually as location for cable joints
Figure 53: Service pit with a T-junction connection, usually for branching off
into substations or road crossings
Page | 55
Figure 54: Service pit with a cross-junction connection, usually for branching
off into several locations at the same place
Page | 56
Sand Bags
Nylon material
Not heavier than 10kg once filled with sand
Figure 56: Service pits must be filled with sandbags to assist in arc quenching
Page | 57
The service pits shall be covered with concrete slabs with the following
dimensions as shown in Figure 57.
Service Pit Cover / Concrete Slab Dimensions
x Thickness:
50 mm
x Length:
1000 mm per slab
x Width:
According to duct bank width
Figure 57: Dimensions of three 1500 mm wide concrete slabs to form the
service pit cover
Figure 58: Service pit cover sitting on the sides of the service pit
Page | 58
Page | 59
Connecting cable
to link box
Link box
Joint
Figure 62: Typical link box embedded in the ducting concrete for duct banks
Page | 60
4.5
Page | 61
Duct
Page | 62
7) Repeat the process for the following layers, one layer at a time.
Page | 63
Page | 64
Page | 65
4.6
Cable laying and maintenance work will be done in the duct banks via
service pits. Cables can be laid according to site requirements into any
available ducts.
Note that the communication cables will utilize the lowest duct,
furthest away from the road.
Please refer to Section 4.3 for diagrams of cable arrangement for duct
banks.
Page | 66
Appendix
Appendix A
Table 6: Variations in Reinforced Concrete Trench Cable Laying Options
3C 11kV
240mm2
0
0
1
1
2
600 mm
1C 11kV
500mm2
1
2
0
1
0
1000 mm
3C
1C
1C
11kV 11kV 33kV
0
0
3
0
1
2
0
2
1
0
4
0
1
0
2
1
2
1
1
3
0
2
0
2
2
1
1
2
2
0
3
0
1
3
1
0
5
0
0
1C 33kV
630mm2
1
0
1
0
0
1200 mm
3C
1C
1C
11kV 11kV 33kV
0
0
4
0
1
3
0
5
0
1
3
1
1
4
0
2
1
2
2
2
1
2
3
0
3
0
2
3
1
1
4
1
0
6
0
0
3C
11kV
0
0
0
0
0
0
1
1
1
1
1
2
2
2
2
2
3
3
3
3
4
4
4
5
5
5
6
6
7
1500 mm
1C
11kV
0
1
3
4
5
6
1
2
3
4
5
0
1
2
3
4
0
1
2
4
0
2
3
0
1
2
0
1
0
1C
33kV
5
4
3
2
1
0
4
3
2
1
0
4
3
2
1
0
3
2
1
0
2
1
0
2
1
0
1
0
0
Page | 67
Glossary of Terms
Ampacity
Cable
Cable Slab
Concrete Slab
Cross-bonding
Duct
Duct Bank
Fibre/pilot cable
Flat formation
Joint
Link box
Page | 68
Glossary of Terms
Reinforced Concrete
Sand bedding
Scupper
Service Pit
Sheath
Thermal resistivity
d
Topsoil
Trefoil formation
Page | 69
References
[1] />Electric Cables HandbooktLondon
3rd Edition 1997.
[2] Pekeliling Pengurus Besar Kanan (Pengurusan Aset) Perkhidmatan Dan
Amalan Kejuruteraan, Bil A21/2010, Penggunaan Slab Kabel nPVC Baru
Untuk Menghindar Kerosakan Kabel Bawah Tanah Akibat Korekan Pihak
Ketiga, TNB 4 Oktober 2010.
[3] Pekeliling Pengurus Besar Kanan (Kejuruteraan) Bil A44/2009,
Penggunaan Paip Polyvinyl Chloride (PVC) atau Paip Galvanized Iron (GI)
untuk Rentangan Kabel Baru Di Sepanjang Jambatan/Jejambat (Bridge
Crossing), TNB 26 Oktober 2009.
[4] Edaran Kejuruteraan Bil 60/95, Timbalan Pengurus Besar, Kejuruteraan
(Pembahagian), Laying and Jointing Of Single Core, 500mm2 Aluminium
11Kv AND 22Kv XLPE Cable, 16 Disember 1995.
[5] Edaran Kejuruteraan Bil 49/94, Timbalan Pengurus Besar, Kejuruteraan
(Pembahagian), Mengesan Kerosakan Kabel Voltan Tinggi Satu Teras Yang
Mempunyai Sambungan Jenis Cross Bonding, TNB 10, Februari 1995.
[6] Edaran Kejuruteraan Bil 49/94, Timbalan Pengurus Besar, Kejuruteraan
(Pembahagian), Jarak Optima Untuk Cross Bonding Bagi Kabel 33kV Jenis
XLPE dan Lokasi Yang Paling Sesuai Untuk DK>
Di Tempat-dE:.
[7] Panduan Kejuruteraan Bil 67/2001, Penggunaan Kaedah Merentang Kabel
11kV Bawah Tanah Di Dalam Peparit Kabel Tetap (Berkonkrit), TNB 14
March 2001, KEJ-PEM-01-01-01.
[8] XLPE Insulated Cables Catalogue, Tenaga Cable Industries Sdn Bhd (TCI).
[9] Electropedia: The World's Online Electrotechnical Vocabulary,
Commission Electrotechnique Internationale (IEC), 2011.
Page | 70