PIJF Cables Ukb

8/11/2019 PIJF Cables Ukb

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Armoured PIJF Cable


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Unarmoured PIJF Cable


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Cross section


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Cable Layering


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2400 Pair


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Conductor: Solid annealed copperith conductor sizes of 0.4 & 0.6mm.

Insulation: Colored high molecular weight solid High Density Polyethylene.

Color Coding: Cables are fully color coded in accordance with PIC even count color code.

Twining/pairing: Two colored insulated conductors are uniformly twisted together to form apair. Varying lay length is designed to minimize the cross talk and capacitance unbalance.

Stranding / Cabling: Twisted pairs are assembled into unit of 25 pairs. When desired for lay-upreason, the units are divided into two or more sub-units, which are bind with durably coloredpolyethylene tapes to form a compact and circular cable.

Filling Compound: The water resistant filling compound is applied to the air space within thecable core.

Core Covering: A non-hygroscopic and dielectric Polyester Tape and Water Blocking Tape areapplied helically having a suitable overlap.

Flooding Compound: Sufficient flooding compound is applied between the core wrap andshield.

Moisture Barrier Inner Sheath: An aluminum tape with co-polymer coating is applied over thecable core and then sheathed with black polyethylene compound.

Jacket: Black High Molecular weight low density polyethylene compound. Identification: A plastic tape, duly marked with the manufacturers name, year of manufacture

and cable size, if required, is placed under the core covering. Alternatively, thesse details maybe printed on the outer jacket of cable.


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CONDUCTOR

Pairing and Overlay

Unit Formation

Core wrappings

Filling compound SCREEN

SHEATH

ARMOURING


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Pairing and Overlay

Two insulated conductors shall be twisted

together with uniform lay to form a pair.

The length of the lay of any pair shall be

different from that of adjacent pairs. Thelay of various pairs shall be so chosen as

to satisfy the capacitance unbalance

requirements and cross-task requirement.


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SCREEN

An aluminum tape coated with

polythene / copolymer on both sides

shall be applied over the cable core

with a minimum overlap of 6 mm for allsizes of cables


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CODE FOR WIRE

IDENTIFICATION

Primary colors For 1st wire in a pair

White

RedBlack

Yellow

S d l F 2 d i i


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Secondary colors For 2nd wire in

a pair and binder tape of unit in

50pr/100pr unit Blue

Orange

Green

Brown

Slate/Gray


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CODE FOR TAPE OR BINDER

FOR UNIT IDENTIFICATION

Unit Colour

1 Blue

2 Orange 3 Green

4 Brown

5 Slate/Gray


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Super Units

200 & 400 pair cable su of 50 paiirs

Above 400 pairs su of 100 pairs


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Identification of super units

Position of the layer Colour

First (Marker) Red

Itermediate White

Last (Reference) Black

The numbering of the units will be clockwise


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CABLE LAYING

Receipt, storage, handling andtransport of cable

Surveying and selection of routes,

trenching and layingJointing of cables and termination

Preparation of cable plan, cablediagram and other relevant records

Acceptance testing


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SURVEYING THE SELECTION OF

ROUTE : The routes should be as short as practicable provided other requirements

viz., future requirements and expansion of other services are take in toconsideration. Normally the cable should be laid along road and railwaytracks.

(b) Corrosive soil should be avoided. If unavoidable measures likecovering

the cable with sand or drawing the cable through non-reactive duct shouldbe adopted.

(c) Opening of expensive pavements and roads should be avoided.

(d) The consideration should be given to the existence, alternation and

growth of other services.

(e) While surveying along a new road under construction or newly

developed area, proper coordination should be maintained with otherunderground services like water, electricity, sewage, gas etc.


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DEPENDING UPON THE ROUTESELECTED, PERMISSION FOR

DIGGING TRENCHES ARE TO BE

TAKEN FROM THE RELEVANTAUTHORITIES


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AT THE TIME OF TRENCHING

OPERATION CO-ORDINATION

WITH THE FOLLOWING AUTHORITIES

ARE TO BE MAINTAINED:-

(1)Electric supply.

(2) Water supple.

(3) Gas pipeline.

(4) Sewage system.


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TRENCHING :

Trenching should be such that the top of thecable should not be less than

60 cms. from the soil surface.

(b) The alignment should be straight at least 50m at a stretch.

(c) It should be at least 0.3m away from theboundary walls.

(d) The depth of the trench should be 1.2 m. (e) The width of the trench should be between

30 cm and 40 cm minimum


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(i) A separation of 0.6 m (relaxable upto 0.2m)should be maintained while cable laid parallel toelectric cables.

(ii) Parallelism exceeding 0.8 km with 11KV andabove should be referred to PTCC

(iii) At the crossing with electric cables, thetelephone cable should be laid solid in between

for 90 cm on either side. Cross-trenches (trialpits are to be made if records for existingservices


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The min. bending diameter for armouredcables should be 15 times of the

diameter of the cable


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ROAD CROSSING

Cable should be laid through G.I. pipes ofsuitable sizes.

(b) The depth of the pipe from the surface

of the road should be 1m and with a slightslope to pass away water.

(c) The number of pipes laid at a time

should be sufficient to cater to therequirements for 20 years.

(d) No jointing in the middle of the road

GUIDELINES FOR LAYING OF


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GUIDELINES FOR LAYING OF

CABLES ALONG NATIONAL

HIGH WAYS Permission from the Chief Engineer PWD is to be taken.

(b) The cables should be laid at distance not less than457 cm from the Centerline of the road on formation.

(c) The depth of the cable from the soil surface shouldnot be less than 120 cm.

(d) While laying along grove or avenue, dueconsideration to save the cable from the clutches of theroots are envisaged


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Along over bridges culverts &

Flyover

A culvert should be paid by a concrete

channel of 12 depth below the bed of the

culvert to correspond to the footpath

alignment so that all the cables can bedrawn through this opening


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In order to lay the cable across small

bridges with piers the piers should be

extended beyond the width of the road so

that pipe for cables may be securelyclamped on the piers


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In case of long bridges and fly over in

cities, liaison should be kept with proper

authorities to ensure that suitable

arrangements are provided for layingcables. the present practice is to have a

concrete channel 20 to 30 cm in depth 90

cm in width along the footpath withremovable covers


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ALONG RAILWAYS

Side of the track will be selected by DET inconsultation with proper Railway authority e.g.either Divisional Operating superintendent ordistrict Engineer, if the alignment falls within 3

to 5.5 meters from the centre line of anyRailway Track.

Excavation and reinstatement for anyunderground cable within 3 meters of thecentre of any Railway track or any attachmentto any Railway structure should be attended bythe Railway staff at the cost of DOT.


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RAILWAY CROSSING

Railway track should be crossed by G.I. pipes

of 75 mm dia.

Minimum depth of the GI pipe from below the

rail level should be 1.25 meters. The length of the pipe should be sufficiently

long so that work on telecom alignment can be

carried out without any hindrance to the

railway traffic. This should extend at least 4.5

meters from the center of the last track.


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LAYING METHOD OF THE

CABLE

Laying direct in the

ground

laying solid drawing through

duct or duct laying

Digging the trench as perstandard The digging may bedone manually or be thrustboring or by other mechanical

means. Preparation of a bedding 5 cm

high of soft soil (sieved earth)free from stones and corrosive

elements. Thorough checking of cablewhich is to be laid.

Paying out the cable in thetrench


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CABLE


ground


duct or duct laying

As a protective measure a row

of bricks

(length wise or width wise

depending upon the number ofcables) or stone slabs are to be

placed along with cable

alignment. The modern practice

is to lay a plastic tape with name

of the Department printed on it

at about 30 cms above and

along with cable alignment


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CABLE


ground


duct or duct laying

As a protective measure a row

of bricks

(length wise or width wise

depending upon the number ofcables) or stone slabs are to be

placed along with cable

alignment. The modern practice

is to lay a plastic tape with name

of the Department printed on it

at about 30 cms above and

along with cable alignment


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DIRECT LAYING

Digging the trench as per standard Thedigging may be done manually or be thrustboring or by other mechanical means.

Preparation of a bedding 5 cm high ofsoft soil (sieved earth) free from stonesand corrosive elements.

Thorough checking of cable which is tobe laid.

Paying out the cable in the trench


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Precautions at the time of paying

There should not be any twist in the cable and

there should not be heavy strain (specially in

the case of un armoured cable)

Laying should be as far as practicablestraight and along one side of the bed of the

trench .

If more than one cable are to be laid at a

time, there must not be any criss-cross of the

cables.


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Warning Bricks or tapes

As a protective measure a row of bricks

(length wise or width wise depending upon

the number of cables) or stone slabs are

to be placed along with cable alignment.

The modern practice is to lay a plastic

tape with name of the Department printed

on it at about 30 cms above and alongwith cable alignment


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Preparation of diagrams &

records

All the diagrams relating to the cable

alignment viz. line diagram for primary

secondary and distribution side, cable

plan for primary secondary and distributionside, records for Pillars and DPs etc. are

to be prepared.


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JOINTING ACTIVITY


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Some Common Wrong Practices

and Their Remedies.

Crossing Water Pipes


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Crossing Culverts


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Crossing 11KV Electric Cables

In respect of parallelism, it is advisable to take

the telecom cable with maximum horizontal

clearance as far as practicable but not less than

0.6 meters Absence of sheath continuity and armour

continuity in Telecom cable and its improper

earthing in the vicinity of power cable will result

in AC induction and consequent impairment ofthe telecom circuits


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. In case of crossings, care should be taken see

that telecom cable crosses at right angles and at

a vertical clearance preferably of 0.6 meters but

not less than 0.3 meters at any point. When thespecified clearances cannot be maintained, it is

preferable to lay the telecom cable through

cement concrete pipes for a length of 1 meter on

either side of power cable at the crossing andseal the mouths at both ends.


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CABLE JOINTING

STRAIGHT JOINT

BRANCH JOINT


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ARRANGEMENTS TO BE MADE

BEFORE THE START OF JOINTING


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DIFFERENT JOINTING

PROCEDURES IN TELECOM

CABLES

LEAD SLEEVE JOINTS

AUXILIARY LEAD SLEEVE SEAL(ALSS) JOINT.

JOINTING OF JELLY FILLED CABLES

USINGT THERMOSHRINKINGTECHNIQUE

PROCEDURE FOR JOINTING J.F.


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PROCEDURE FOR JOINTING J.F.CABLE USING XAGA

TECHNIQUE Cable Marking

Armour removing

Conductor Jointing

Filling of Compound

Metal Canister

Cable Preparation

Thermo shrinking

Armour Continuity Completed


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Kit Selection

TSF 1 10/6.5, 20/6.5

TSF2 50/6.5

TSF3 100/6.5

TSF4 200,300, 400/6.5

TSF5 600, 800/6.5

TSF 6 1000 ,1200/6.5


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When cables to be jointed are of same

pair found on both sides, use the kit

indicated in the kit selection chart

b)When one cable is larger in pair count

than the other, the kit indicated against

the smaller one is to be used, e.g. to join a

100 pair cable to a 20 pair cable, TST1 is to be used.


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. The sum of the diameters of all the cables on

the branch side plus the thickness of branch

clips should not exceed the maximum splice

bundle diameter indicated in the kit selectionchart.

Condition 2. If any side contains only one

cable, the diameter of the single cable should

not fall below the minimum cable diameterindicated in the kit selection chart.


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Kit Selection

TSF 1 TSF2

TSF4

TSF5

TSF 6


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Kit Selection

TSF 1 TSF2

TSF4

TSF5

TSF 6

10/6.5, 20/6.5


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Kit Selection

TSF 1 TSF2

TSF4

TSF5

TSF 6

18/6.5, 28/6.5


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Kit Selection

TSF 1 TSF2

TSF4

TSF5

TSF 6

10/6.5, 20/6.5


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Kit Selection

TSF 1 TSF2

TSF4

TSF5

TSF 6

10/6.5, 20/6.5


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Kit Selection

TSF 1 TSF2

TSF4

TSF5

TSF 6

10/6.5, 20/6.5

PIJF Cables Ukb

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