Transmission and Distribution Of Power

For 2nd Year 4 sem EE

Underground Cables

Types of underground cables

By Robert Pradhan,
Lecturer in Electrical Dept.
Darjeeling Polytechnic, Kurseong.

Underground Cable – Introduction and Construction

An underground cable essentially consists of one or more conductors covered with suitable insulation and
surrounded by some protective layer. Normally, electric power can either be transmitted using over head lines
or underground cables. But the use underground cable offers a variety of advantages. Some of
the advantages are listed below.
• It is less liable to damage during storm or bad whether condition.

• Offers low maintenance cost.

1. Less voltage drop during normal operating condition and less chance of fault.
But the main disadvantage of underground cable is its cost of installation. For higher voltage the cost of cable
increases due to greater requirement of insulation as compared to overhead lines. Therefore, it is installed in
area or localities where overhead lines cannot be installed.
Requirements of Underground Cable
There are various types of cable available but the choice of particular type depends on the operating voltage and
service requirement. However, a cable must fulfill some of the basic requirement. Those requirements are as
follows:
1. The conductor used in underground cable shall be tinned copper or aluminum conductor of high
conductivity. Stranding is very important to provide flexibility and increase current carrying capacity.
▪ The size of conductor shall be sufficient enough to carry load current without heating and appreciable
voltage drop. The voltage drop shall be within the permissible range.
▪ The cable must have proper thickness of insulation to provide high degree of safety and reliability at
operating voltage.
▪ It must have been provided with suitable mechanical protection to withstand rough handling during lying
of cable.
▪ The material used in the manufacture of cable should be such that there is complete chemical and
physical stability throughout.
Construction of Underground Cable
An underground cable consists of conductor, insulation, sheath, bedding, Armour and serving. Figure below
shows the construction of 3 core cable.

Conductor > Insulation > Metallic Sheath > Bedding > Armour > Serving

Cores or Conductors
The number of core or conductors in a cable depends upon its use. For example, a three core cable is used
for three phase system. The conductors are made of tinned copper or aluminum and are stranded to provide
flexibility.

Insulation
A suitable thickness of insulation is provided on each core or conductor so that the conductors of underground
cable may withstand the operating or designed voltage. The thickness of insulation on the core increases as the
operating or design voltage is increased. Normally the insulation materials are made of impregnated paper,
varnish cambric or rubber mineral compound.

Metallic Sheath
Metallic sheath surrounds the insulation on the core. It is provided to protect the insulation from moisture, gases,
oil, liquids etc. present in the soil and atmosphere. It is normally made of lead or aluminum.
Bedding
Bedding surrounds the sheath. It is made of fibrous materials like jute or hessian tape. The purpose of bedding
is to protect the sheath from mechanical injury due to armouring. You can think it like a shock absorber.

Armouring
Armouring is provided over the bedding to protect the cable from mechanical injury during its handling and lying.
It consists of one or two layers of galvanized steel wire or steel tape. In some cable, armouring is not provided.

Serving
To protect the armouring from atmospheric condition, a layer of fibrous material like jute is applied on the
armouring. This layer is called serving.
Thus, we observe that the main working part of underground cable are core / conductor and Sheath. Other parts
of cable, just protect the conductor and sheath from mechanical injury or chemical attack. This does not mean
that, they are not important. Bedding, Armouring and Servings are very important parts of cable else cable won’t
work as its insulation will degrade.

Classification of underground cables

The classification of Underground cables can be done on the basis of several criteria. Various aspects are taken
into account while classification and these include:

• Number of conductors in the cable

• Voltage rating of the cable
• Construction of cable
• Type and thickness of insulation used
• Installation and Laying of the cables

Classification based upon number of conductors in the cable

1.Single core cable

2.Three core cable

Typically, an Underground cable has either one, three or four cores. These cables are of course, constructed
accordingly.

Underground cables are usually employed to deliver 3 phase power. A 3 cored cable is preferred up to 66 kV.
Beyond that, insulation required for the cable is too much. For higher voltages, 3 cored constructions become
too bulky, and hence, even with some limitations we employ single cored cables

Classification based upon voltage rating of the cable

1.Low tension cables: These have a maximum voltage handling capacity of 1000 V (1 kV)

2. High tension cables: These have a maximum voltage handling capacity of 11 kV.
3. Super tension cables: These have a maximum voltage handling capacity of 33 kV.
4. Extra high tension cables: These have a maximum voltage handling capacity of 66 kV.
5. Extra super voltage cables: These are used for applications with voltage requirement above 132 kV.
Classification based upon construction of the cable

1. Belted cable
In such cables, the conductors (usually three) are bunched together and then bounded with an insulating paper
‘belt’. In such cables, each conductor is insulated using paper impregnated with a suitable dielectric. The gaps
between the conductors and the insulating paper belt are filled with a fibrous dielectric material such as Jute or
Hessian. This provides flexibility as well as a circular shape. As we discussed earlier (in Construction of Cables),
the jute layer is then covered by a metallic sheath and armouring for protection. One particular speciality of this
cable is that its shape may not be perfectly circular. It is kept non-circular to use the available space more
effectively.

There are some limitations of such construction. Since the electric field is tangential, the insulation provided is
stressed. As a result, the dielectric strength falls over time. Hence, such construction isn’t preferred for voltage
levels above 11 kV.

2. Screened cable
Further divided as H-type and S.L. - type cables.

▪ H-Type Cables: It was first designed by M. Hochstadter. The three cores are individually insulated with paper
and then covered by a metallic screen / cover. These metallic covers are perforated. As a result, such
 construction allows the three metallic screens to touch each other. These three metallic covers are then
grouped together in a metallic tape usually made of copper. A lead sheath surrounds this construction. The
metallic covers and the sheath are grounded.

The obvious advantage is the electric stresses are radial, not tangential and hence of lesser magnitudes.
Also, the metallic covers improve the heat dissipation.

▪ S.L Type Cables: It is similar to the H type cables, with the difference that each of the three cores has its
own lead sheath. With this provision, the need for the overall sheath used previously is eliminated. The
advantage of such a construction is that the chances of a core-to-core breakdown are greatly minimized.
Also, the flexibility of the cable is improved.

The limitations are severe. Such construction is limited for voltages up to 66kV only. The individual sheaths
are thinner, and if there are constructional defects, moisture may enter the cable and reduce its dielectric
strength.

▪ H.S.L. Type Cables: This type of cable is combination of H type and S.L. type cable. In these cables each
core is insulated with impregnated paper and provided with seperate lead sheaths.

3. Pressure cables
For voltages beyond 66 kV, the electrostatic stresses in the cables exceed the acceptable values and solid
cables become unreliable. This occurs mainly because voids are created when voltages exceed 66 kV. Hence,
instead of solid cables, we use Pressure cables. Typically, such cables are either oil filled or gas filled.
▪ Oil Filled Cables: Oil is circulated under suitable pressure through ducts provided for such purpose. This oil
supply and pressure are maintained through reservoirs kept at proper distances. The oil used is the same
that is employed for impregnation of paper insulators.
▪ Gas Filled Cables: Pressurized gas (usually dry nitrogen) is circulated around cables in an air-tight steel pipe.
Such cables are cable of carrying higher values of load current and can operate at higher values of voltage.
But the overall cost is more.

Classification based upon insulation of the cable

Various insulating materials used in cable construction are Rubber, Paper, PVC, XLPE (Cross linked Polyethene)
etc. Such classification is based upon operating temperature limitations. Following are some insulating materials
used and their maximum operating temperatures.
 Insulation material Max. operating
temperature

PVC TYPE A 75°C

PVC TYPE B 85°C

PVC TYPE C 85°C

XLPE 90°C

RUBBER 90°C

RUBBER – EPR IE-2, 150°C

EPR IE-3, EPR IE-4,
SILICON IE-5

Classification based upon installation and laying of the cable

▪ Direct Buried: As the name suggests, the conductors are buried underground in a trench without additional
accessories. Sometimes cooling pipes are added if required. Once the cables are installed, there’s no visible
sign above the ground.
▪ Trough: Concrete troughs are dug and cables are installed in them. They’re visible on the surface.
Maintenance is easier.
▪ Tunnels: Sometimes, tunnels are dug up for this purpose. Such construction is mainly employed if a river
needs to be crossed or if the intended power distribution is to a major city. Maintenance and future expansion
is easier, but initial cost is higher.
▪ Gas Insulated Lines: This is a relatively new technology. For cables operating at higher voltages and currents,
and handling high power, such gas insulated line construction is safer. It is being employed nowadays for
advanced projects.

Underground cables are, of course, meant to be installed or laid under the ground. The reliability of
underground cable network highly depends upon proper laying of cables, quality of cable joints and branch
connections etc. There are three main methods of laying underground cables, which are - (i) direct laying, (ii)
draw-in system and (iii) solid system. These three methods are explained below with their advantages and
drawbacks.
Direct laying of underground cables
This method is the most popular as it is simple and cheap. The cables to be laid using this method must have
the serving of bituminised paper and hessian tape so as to provide protection against corrosion and electrolysis.
The direct laying procedure is as follows.

Laying procedure

• A trench of about 1.5 meters deep and 45 cm wide is dug.

• Then the trench is covered with a 10 cm thick layer of fine sand.
• The cable is laid over the sand bed. The sand bed protects the cable from the moisture from the ground.
• Then the laid cable is again covered with a layer of sand of about 10 cm thick.
• When multiple cables are to be laid in the same trench, a horizontal or verticle spacing of about 30 cm is
provided to reduce the effect of mutual heating. Spacing between the cables also ensures a fault occurring
on one cable does not damage the adjacent cable.
• The trench is then covered with bricks and soil to protect the cable from mechanical injury.

Advantages
• Simpler and cheaper than the other two methods

• Heat generated in cables is easily dissipated in the ground.

Disadvantages

2. To install new cables for fulfilling an increased load demand, completely new excavation has to be done
which costs as much as the new installation.
3. Alterations in the cable network are not easy.
4. Maintenance cost is higher.
5. Identifying the location of a fault is difficult.
6. This method can not be used in congested areas such as metro cities where excavation is too expensive.

Draw-in system
In this method, cast iron or concrete pipes or ducts are laid underground with manholes at suitable positions
along the cable route. The cables are then pulled into the pipes from the manholes. Usually, an additional
pipe/duct is also provided along with the three cable ducts for carrying relay protection connections and pilot
wires. Distance between the manholes should be such that pulling in the cables is easier. At corners or while
changing the direction of route, radius of the corners must be longer. The cables that are to be laid in this way
need not be armoured but must be provided with the serving of hessian and jute in order to protect them when
being pulled.

Advantages
• Repairs, additions or alterations to the cable network can be easily made from manholes without re-
excavation.
• In this method, as the cables need not be armoured, the cable jointing procedure becomes simpler.
• Maintenance cost is quite lower.
• Fewer chances of fault occurrence due to the strong mechanical protection provided by the system.

Disadvantages
• The initial cost is very high.
• Due to unfavourable conditions for dissipation of heat, current carrying capacity of the cables is
reduced.

Solid system
In this method, the cable is laid into troughing of cast iron, stoneware, asphalt or treated wood. When the cable
is laid into the position, the troughing is filled with a bituminous of asphaltic compound and then covered over.
Cables to be laid in this manner could be just lead covered as the troughing provides a good mechanical
protection.
This method is very rarely used nowadays as it is more expensive and requires skilled labour and favourable
weather condition.

:HR PVC :

Heat resisting PVC compound has good thermal stability at an accelerated process temperature. The rate of
degradation of HRPVC compound with time under the influence of temperature is less. It has high thermal
stability can withstand high continuous temperature which is an indication of performance of the cable at
normal and elevated temperature in actual usage.
The cables with HR PVC compound can work continuously at an operating temperature of 85 Deg. C. The
usage of HR insulated cables is recommended in humid atmosphere and at places with constant high
temperature than normal temperature. The current rating of the HR insulated cables is higher than the
general PVC insulated cables.

FRLS Compound :
 Fire Accidents in cable galleries and other vulnerable areas like power plants and
industrial complexes and in public places like theatres, hotels and airports, etc. have demonstrated the need
for reliable electrical installation, resistant to fire and ability to operate during a fire without propagating it.
The use of correct electrical installation makes evaluation of buildings easier, minimizes the element of panic
and enables the emergency services do their job efficiently, significantly aiding damage control operations
and reducing loss of life and property.
Electric Cables supplying these circuits must be manufactured and tested for certain standards and
specifications concerning their behaviour in fire. Flame Retardant Low Smoke (FRLS) cables, which are
manufactured using specially developed FRLS compound for sheathing, are resistant to ignition and flame
propagation, and reduce smoke emission and release of acid fumes.

XLPE :

XLPE means cross linked polyethylene or vulcanised polyethylene. The basic material of XLPE is low density
polyethylene. Polyethylene is a thermoplastic material consisting of long chain Hydrocarbon Molecules at
elevated temperature and these molecules tend to move relative to one another so that the material
becomes increasingly diformable and will eventually melt at a temperature of around 110 Deg. C. By means
of process similar to the Vulcanisation of Rubber the PE Molecules can be cross linked. The process of cross
linking or vulcanisation consists of producing chemical bonds at intervals between the long molecular chain
to give a "Ladder" effect which prevents slippage between molecules. As a result of Crosslinking, the material
becomes heat resistance and does not soften at higher temperature. Further it has better resistance to
stress cracking and good resistance to ageing in hot air with the change in structure. There is no adverse
effect on electrical properties. XLPE Cables are excellent in electrical, thermal, mechanical and chemical
properties

De-rating of Cable:
The factor due to which electrical cable lose its current carrying capacity means it can not carry the
amount of current for which it is designed.

Following are the reason of derating factor comes into action

1. Ambient Temperature: If temperature of the environment increases correspondingly cable starts
getting derated due to resistance changes.

2. Air laying/Under ground laying: cable get derated if it laid underground rather than upper ground.

Rating of Cable:

Definition: The current rating of the cable is defined as the maximum current carrying capacity of the power cable under
normal operating condition. The current rating of power cable decided the upper limit of power transfer by a cable. It
mostly depends on the insulation temperature and electrical resistance of the conductor