PROJECT TITLE : 3X800MW‐ PVUNL PATRATU TPP PH‐1 EPC PACKAGE 

OWNER : NTPC LTD
REVIEW OF : CABLE ERECTION PHILOSOPHY

S.No Document No. Description NTPC Comments BHEL Reply  NTPC Comments BHEL Reply  NTPC Comments BHEL Reply  NTPC Comments BHEL Reply 
SH. No‐2, Sl. No‐1.5: Exclusions to be deleted. This document is for PEM scope areas, for other areas  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or  separate document/ drawings shall be submitted by 
1 CABLE ERECTION PHILOSOPHY respective BHEL units. ‐ ‐ ‐ ‐
PE–DC–434–507–E004

SH. No‐2, Sl. No‐2.1: "be cables shall generally" to be  Noted and incorporated in the revised drawing.  No comments Issue Closed

9585‐001‐215‐PVE‐U‐004 or  deleted 
2 CABLE ERECTION PHILOSOPHY ‐ ‐ ‐ ‐
PE–DC–434–507–E004

Sh. No‐2, Sl. No‐2.2, "Cable trays may be oriented  Pls. note Cable Trays may be oriented vertically in many  No comments Issue Closed

vertically….." to be deleted.  areas due to space constraits like Cable Vault cross trays, 
9585‐001‐215‐PVE‐U‐004 or  risers, TG Hall A‐Row, C‐Row Walkway, 0.0 m & 9.0 m etc. 
3 CABLE ERECTION PHILOSOPHY The same is standard practice in all the projects of BHEL  ‐ ‐ ‐ ‐
PE–DC–434–507–E004
and NTPC. Kindly accept the same.

Sh. No‐2, Sl. No‐2.3, "In corrosive areas where  Noted and incorporated in the revised drawing.  No comments Issue Closed

9585‐001‐215‐PVE‐U‐004 or  corrosive chemicals are likely to be handled, cable 
4 CABLE ERECTION PHILOSOPHY trays and supporting structure shall be epoxy painted."  ‐ ‐ ‐ ‐
PE–DC–434–507–E004
to be added.
Sh. No‐2, Sl. No‐2.4, IS 1079 to be incorporated. Noted and incorporated in the revised drawing.  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or 
5 CABLE ERECTION PHILOSOPHY ‐ ‐ ‐ ‐
PE–DC–434–507–E004

Sh. No‐3, Sl. No‐2.4, Cantilever Arms size in trays &  Pls. note that as per Specification Cantilever arms of  Kindly provide as per Tech Spec Pls. note 150mm cable trays shall be  kindly provide cantilever arms as per tech  Noted and incorporated in the revised  No comments Issue Closed

Trenches for 150mm Trays  320mm, 620mm & 720mm are mentioned generally but not  required for cabling in auxllliary routes  specs document.
9585‐001‐215‐PVE‐U‐004 or  specifically for 150mm Trays. However for 150mm tray  in various areas for which cantilever arm 
6 CABLE ERECTION PHILOSOPHY Cantilever arm of 170mm shall be required. The same has  of 320mm is not suitable. Thus please 
PE–DC–434–507–E004
been provided in various NTPC projects. Kindly accept the  accept cantilever arm of 170 mm also..
same.

Sh. No‐4, Sl. No‐2.9, "However, wherever layout  Noted and incorporated in the revised drawing.  No comments Issue Closed

constraints do not permit this spacing….." shall be 
9585‐001‐215‐PVE‐U‐004 or  deleted
7 CABLE ERECTION PHILOSOPHY ‐ ‐ ‐ ‐
PE–DC–434–507–E004

Sh.no‐4, Sl. No‐2.11, "Cable tray support shall be  Noted and incorporated in the revised drawing.  No comments Issue Closed

9585‐001‐215‐PVE‐U‐004 or  designed for loading as per technical specifications…" 
8 CABLE ERECTION PHILOSOPHY shall be incorporated ‐ ‐ ‐ ‐
PE–DC–434–507–E004

Sh.no‐5, Sl. No‐2.13 & 2.14:  to be deleted. Please note these are standard practice of BHEL and same  for installation of cable tray and support  Cl. No. 2.13 is for laying of cable trays  kindly refer to clause no :‐ 4.00.00 of Sub  Noted and clause deleted in the revised  No comments Issue Closed

are followed in NTPC projects like Northe Karanpura. Kindly  system, The contractor shall fix the  along building steel structures, where  Section B‐09, part‐B of for technical  drawing.
accept the same. brackets/clamps/insert plates using anchor  anchor fastner is not applicable. Thus  specification for installation of cable tray 
fasteners. For brick wall suitable anchor  same is retained. Kindly accept. & support system and same to be 
9585‐001‐215‐PVE‐U‐004 or  fasteners shall be used adopted/indicated here.
9 CABLE ERECTION PHILOSOPHY
PE–DC–434–507–E004

Sh.no‐4, Sl. No‐2.14, for installation of cable tray and  Not required in view of above reply at Sl. No 9. Kindly provide as per Tech Spec Incorporated in the revised drawing. No comments Issue Closed

support system, The contractor shall fix the 
9585‐001‐215‐PVE‐U‐004 or  brackets/clamps/insert plates using anchor fasteners. 
Digitally signed
10
PE–DC–434–507–E004
CABLE ERECTION PHILOSOPHY
For brick wall suitable anchor fasteners shall be used. Signature Not by RVerified
‐
K Niranjan
‐

Sh.no‐4, Sl. No‐2.16, "All openings shall be sealed with  All openings shall be sealed with fire sealing compound 
Date: 2018.12.21
Since this is an EPC project, hence water  Pls. note as per Cl. No.4.02.01 of B‐09  Pls. note as per Cl. No.4.02.01 of B‐09  Pls. note as per the specification all  Different voltage  Noted and incorporated 
fire sealing compound which is also continuously  however, waterproofing is not under preview of this  proofing to be ensured  by BHEL and same  Section Vi Part‐B of Tech Spec "All  10:43:10 IST
Section Vi Part‐B of Tech Spec "All  opening for conduit installations shall be  grade cables shall be  in the revised document.
waterproof" to be incorporated. document. to be indicated here openings in the floor/roof/wall / cable  openings in the floor/roof/wall / cable  sealed and made water proof. Thus cl.  laid in separate 
tunnel/cable trenches tunnel/cable trenchesReason: CAT I
No.3.14 is retained as such in the revised  conduits.
9585‐001‐215‐PVE‐U‐004 or 
11
PE–DC–434–507–E004
CABLE ERECTION PHILOSOPHY made for conduit installation shall be 
sealed and made water proof by the 
Location:
made for conduit installation/ cable tray 
installation shall be sealed and made 
document.

NTPCEOC
Contractor". The same is incorporated in  water proof by the Contractor". The same 
the revised drawing in Cl. no.3.14 is incorporated in the revised drawing in 
Cl. no.3.14
Sh.no‐4, Sl. No‐2.16, "The cable entry and exit from  Minimum height shall be 0.5m from FFL have been  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or  switchgear room/pump houses/building may  retained. In case required, higher elevation opening shall be 
12 CABLE ERECTION PHILOSOPHY preferably be taken from 1.5 mtr (minimum) above  taken.  ‐ ‐ ‐ ‐
PE–DC–434–507–E004
FGL to avoid water ingress in cable trenches" to be 
i t d
Sh.no‐5, Sl. No‐3.3, "Cable tray routing points shall be  Noted and incorporated in the revised drawing.  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or  located where they are readily visible and not 
13 CABLE ERECTION PHILOSOPHY concealed  by equipment, fire proofing or other  ‐ ‐ ‐ ‐
PE–DC–434–507–E004
materials" to be incorporated.

1 of 3
 REVIEW OF : CABLE ERECTION PHILOSOPHY

S.No Document No. Description NTPC Comments BHEL Reply  NTPC Comments BHEL Reply  NTPC Comments BHEL Reply  NTPC Comments BHEL Reply 
Sh.no‐5, Sl. No‐3.3, "kindly clarify the basis of selecting  Please note these are standard practice of BHEL and same  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or  these cable sizes" to be incorporated. are followed in NTPC projects like Northe Karanpura. Kindly 
14 CABLE ERECTION PHILOSOPHY accept the same. ‐ ‐ ‐ ‐
PE–DC–434–507–E004

Sh.no‐5, Sl. No‐3.11, "separator may be provided' to  sparator is not required, cable will be tied to maintain  practically it is difficult to maintain the req  Noted and incorporated in the revised 

be incorporated. 100mm (min) gap. spacing, hence either separator to be  drawing.
9585‐001‐215‐PVE‐U‐004 or  provided or control and instrumentation 
15 CABLE ERECTION PHILOSOPHY ‐ ‐ ‐ ‐
PE–DC–434–507–E004 cables to be laid in separate cable tray

Sh.no‐7, Sl. No‐3.13, "indicate conduit support with  Conduit shall be part of station lighting system & same shall  these points to be taken care in station  Noted. The same shall be taken care in 

9585‐001‐215‐PVE‐U‐004 or  spacing between supports" to be incorporated be indicated separately. lighting document. kindly ensure  Station Lighting document furnished 
16 CABLE ERECTION PHILOSOPHY saperately
PE–DC–434–507–E004

Sh.no‐7, Sl. No‐3.13, "Flexible steel conduits shall be  Flexible steel conduit shall be part of station lighting system 
9585‐001‐215‐PVE‐U‐004 or  water proof and dust proof made of heat resistant  & same shall be indicated separately.
17 CABLE ERECTION PHILOSOPHY lead coated steel" to be incorporated.
PE–DC–434–507–E004 ‐ ‐ ‐ ‐

Sh. No‐7, Sl. No‐3.13, "All below ground conduits  Conduit shall be part of station lighting system & same shall 
which are directly buried and all above ground conduit  be indicated separately.
9585‐001‐215‐PVE‐U‐004 or  shall be of rigid steel. Both fittings and conduits shall 
18 CABLE ERECTION PHILOSOPHY
PE–DC–434–507–E004 be hot dip galvanized" to be incorporated

Sh. No‐7, Sl. No‐3.14, "Different voltage grade cable  Please note these are standard practice of BHEL and same  This may be included as per specifications  Pls. note as per cl. No.3.04.01 of B‐09  the referred clause is about pipe. Pls. note there is no specific clause  No comments Issue Closed

shall be laid in separate conduits. Conduits shall be  are followed in NTPC projects like Northe Karanpura. Kindly  requirement Section Vi Part‐B of Tech Spec "The size  hence kindly add note as mentioned in  referring to filling criteria of conduit in the 
sized so that conduit fill shall not exceed the  accept the same. of the pipe first submission specification. Kindly accept the cl. No.3.14 
9585‐001‐215‐PVE‐U‐004 or  following:‐ shall be selected on the basis of  which is again retained in the revised 
19 CABLE ERECTION PHILOSOPHY
PE–DC–434–507–E004 one cable :40% maximum 40% fill criteria". In view of  document.
two cable:31% the same cl. No. 3.14 is retained. Kindly 
three cables and more:40%" accept.
SH. No‐8: Sl.no‐3.23, "Where there is a considerable  Noted and incorporated in the revised drawing. However,  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or  risk of steam, hot oil or mechanical damage cable  cable routing shall be avoided from such areas.
20 CABLE ERECTION PHILOSOPHY routes shall be protected by barriers or enclosures" to  ‐ ‐ ‐ ‐
PE–DC–434–507–E004
be incorporated. 
SH. No‐8: Sl.no‐4.1, "joints shall be avoided" to be  Noted. Genrally joints are avoided, however if exceptionally  There shall not be any joint in the cable  Incorporated in the revised drawing.
9585‐001‐215‐PVE‐U‐004 or  incorporated.  any need arises same shall be provided not less than 250m  where cable application length is less than 
21 CABLE ERECTION PHILOSOPHY length. The same is also acceptable in NTPC North  the standard drum length. ‐ ‐ ‐ ‐
PE–DC–434–507–E004
Karanpura project. Pls. accept the same.
SH. No‐8: Sl.no‐4.8, "with PVC tapes/ nylon" to be  Noted and incorporated in the revised drawing.  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or  deleted and "clamps and ties " to be incorporated.
22 CABLE ERECTION PHILOSOPHY ‐ ‐ ‐ ‐
PE–DC–434–507–E004

SH. No‐8: Sl.no‐4.11, "The cable lugs for control cables  Noted and incorporated in the revised drawing.  No comments Issue Closed

9585‐001‐215‐PVE‐U‐004 or  shall be provided with insulating sleeve " to be 
23 CABLE ERECTION PHILOSOPHY incorporated. ‐ ‐ ‐ ‐
PE–DC–434–507–E004

SH. No‐8: Sl.no‐4.12, "or when a joint is necessitated  Pls. refer BHEL reply above at sl. No. 21. There shall not be any joint in the cable  Incorporated in cl. 4.1.

9585‐001‐215‐PVE‐U‐004 or  due to site constraints " to be deleted. where cable application length is less than 
24 CABLE ERECTION PHILOSOPHY the standard drum length. ‐ ‐ ‐ ‐
PE–DC–434–507–E004

SH. No‐8: Sl.no‐4.12, "Mounting arrangement of cable  In cable slit & in case of buried cables, cable trays are not  Comments may be read as :‐ Incorporated in the revised drawing.

tray supports, cable laying arrangement in cable slit  required, thus mounting arrangement is not applicable.  1. Mounting arrangement of cable tray 
and buried cable trench for cables to be indicated " to  supports to be indicated.
9585‐001‐215‐PVE‐U‐004 or  be incorporated. 2. cable laying arrangement in cable slit 
25 CABLE ERECTION PHILOSOPHY ‐ ‐ ‐ ‐
PE–DC–434–507–E004 and buried cable trench for cables to be 
indicated.

SH. no‐10: Sl. no 3.18, Please add As such fire incident in outdoor pipe  this is as per clause no:‐4.04.14 of B‐09  The clause added is in line with clause no:‐ kindly provide as per  Noted and incorporated 

Interplant cables of station auxiliaries and  cum cable rack is not envisaged.  chapter of Part‐B of technical  4.04.14 of B‐09 chapter of Part‐B of  clause no:‐4.04.14 of  in the revised document.
unit critical drives shall be segregated in  However, following is incorporated in  specifications. kindly add the same  technical specifications. However, further  B‐09 chapter of Part‐B 
such a way that not more than half of the  revised document: clarity is provided. Thus no change in this  of technical 
drives are lost in case of single incident of  "In interplant cable trays station  clause is required. specifications.
fire. Power and control cables for AC drives  auxiliaries & unit critical drives shall be 
and corresponding emergency AC or DC  segregated in Left Hand Side and Right 
9585‐001‐215‐PVE‐U‐004 or 
CABLE ERECTION PHILOSOPHY drives shall be laid in segregated routes.  Hand Side cable trays. Whereever both 
PE–DC–434–507–E004
Cable routes for one set of auxiliaries of  side cable trays are not available, such 
same unit shall be segregated from the  cables shall be laid in separate vertical 
other set. trays. This philosophy shall be applied 
for power & control cable for AC drives 
and corresponding emergency AC or DC 
drives."

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 REVIEW OF : CABLE ERECTION PHILOSOPHY

S.No Document No. Description NTPC Comments BHEL Reply  NTPC Comments BHEL Reply  NTPC Comments BHEL Reply  NTPC Comments BHEL Reply 
SH. no‐11: Sl. no 4.11, All tools required for  Noted and confirmed.
9585‐001‐215‐PVE‐U‐004 or 
CABLE ERECTION PHILOSOPHY termination shall conform to DIN standard. ‐ ‐ ‐ ‐
PE–DC–434–507–E004
Bending chart table applicable shall be  Pls. note that bending radii data of each  No comments Issue Closed
indicated cable shall be furnished during detailed 
9585‐001‐215‐PVE‐U‐004 or  engineering in each datasheet of cable 
CABLE ERECTION PHILOSOPHY
PE–DC–434–507–E004 furnished by cable manufacturers. Kindly 
accept cl. No.3.1 retained in the revised 
specification.
All the mounting arrangement shall be as  Pls. note mounting arrangement details  No comments Issue Closed
9585‐001‐215‐PVE‐U‐004 or 
CABLE ERECTION PHILOSOPHY per technical specifications. kindly confirm are prepared in line with Technical 
PE–DC–434–507–E004
specification. Any specific issue may pls. be 
NTPC document no.  Noted and incorporated 
9585‐001‐215‐PVE‐U‐004 or  to be indicated for  in the revised document.
CABLE ERECTION PHILOSOPHY
PE–DC–434–507–E004 reference documents

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 3X800 MW PVUNL PATRATU TPP DOCUMENT NO.
PHASE-1 EPC PACKAGE PE–DC–434–507–E004
Rev No: 03
CABLE ERECTION PHILOSOPHY Date: 29.11.2018
SHEET 2 of 10

1.0 Scope
1.1 This document is intended to cover the aspects of cable raceway design and installation,
Laying and termination of various types of cables for the project.

1.2 Design calculations for cable sizing and selection are covered in a separate document.

1.3 Latest revisions of all drawings / documents shall be referred.

1.4 Reference standard

i) IS: 1255 (Code of practice for installation and maintenance of power cables).

1.5 Exclusions: The following areas / systems are excluded from the scope of this
Document.

a) Switchyard.
b) Ash handling plant.
c) Coal handling plant.
d) ESP Integral cabling.
e) Steam generator integral cabling.
f) Turbine and generator integral cabling.
g) FGD system integral cabling.

2.0 Cable Raceway System

2.1 Cables shall generally be laid in galvanised MS cable trays in multi-tier arrangement. The
trays shall in turn be supported on flexible cable tray support systems in TG Building, cable
vaults, along structural members/ concrete surfaces inside plant buildings, cable trenches
below switchboards/ MCCs in auxiliary plant buildings, and interconnecting pipe-cum-cable
trestles. The trays shall be fixed to supports by means of bolting. Clamping of trays to the
cantilever arms shall be resorted to where due to fabrication mismatches, there are
misalignments between the respective locations of holes in trays and the cantilever arms.

2.2 Cable trays shall be oriented horizontally in all areas, except in areas subject to coal dust or
ash deposition (such as boiler platforms, raceways along C-row of Main Power House area,
interconnecting overhead cable tray paths between boiler area and ESP area, etc.). Cable
trays may be oriented vertically in other areas also if so required due to reasons such as
space restriction, accessibility, plant aesthetics, operational clearances, etc. as per approved
layout drawings. Branching of cables from main route shall be done through cable
trench/slit/cable troughs.

2.3 Cable trays shall have standard width of 150mm, 300mm & 600mm and standard lengths of
2.5m. Minimum thickness of mild steel sheets used for fabrication of cable trays shall be 2mm.
Minimum thickness of side coupler pate shall be 3 mm. Cable trays shall be ladder type for
power and control cables, while perforated type cable trays shall be used for instrumentation
cables. In corrosive areas where corrosive chemicals are likely to be handled, cable trays and
supporting structure shall be epoxy painted.

2.4 Main support channel and cantilever arms shall be fabricated out of minimum 2.5mm thick
rolled steel sheet conforming to IS 1079. Cantilever arms for various cable tray sizes shall be
as follows:
 3X800 MW PVUNL PATRATU TPP DOCUMENT NO.
PHASE-1 EPC PACKAGE PE–DC–434–507–E004
Rev No: 03
CABLE ERECTION PHILOSOPHY Date: 29.11.2018
SHEET 3 of 10

S. No. Cable tray Width Cantilever Arm size for Cantilever Arm size for
overhead trays trays in trench

a) 150 mm 320 mm 320 mm

b) 300 mm 320 mm 320 mm

c) 600 mm 620 mm 750 mm

2.5 Cable trays shall be ladder/perforated type as specified complete with matching fittings (like
brackets, elbows, bends, tees, crosses, etc.) accessories (like side coupler plates, etc. and
hardware (like bolts, nuts, washers, G.I. strap, hook etc.) as required. Cable trays, fittings and
accessories shall be fabricated out of rolled mild steel sheets free from flaws such as
laminations, rolling marks, pitting etc. These (including hardware) shall be hot dip galvanized
as per relevant IS.

2.6 Suitable cable tray accessories such as horizontal and vertical bends, crosses, tees, reducers
etc. shall be used in conjunction with straight runs of cable trays wherever required as per
approved layout drawings to ensure a continuous and break-free tray support system for
cables.

Cable tray accessories shall be factory fabricated for use at site as per approved drawing
titled “TYPICAL DETAILS OF CABLE TRAYS AND ACCESSORIES”, (drawing no. 9585-001-
215-PVE-B-003). For specific site requirements (e.g. irregular angle bends such as 30º/60º
bends, etc) as per layout conditions, tray accessories shall be fabricated at site from the
straight length of respective sizes as required. They shall be applied with one coat of red lead
primer, one coat of oil primer followed by two finishing coats of aluminium paint.

2.7 The flexible cable tray support system shall comprise of galvanised MS single channel (C1:
having provision of supporting cable trays on one side) or double channel (C2: having
provision of supporting cable trays on both sides) members as main supports, cantilever
arms, various brackets, clamps, floor plates, all hardware such as lock washers, hexagon
nuts, hexagon head bolt, support hooks, stud nuts, hexagon head screw, channel nut,
channel nut with springs, fixing studs etc.

2.8 The main support and cantilever arms shall be fixed at site using necessary brackets, clamps,
fittings, bolts, nuts and other hardware etc. to form various arrangements required to support
the cable trays. Welding of the components shall not be allowed. However, welding of the
bracket (to which the main support channel is bolted) to the overhead beams, structural steel,
insert plates or reinforcement bars will be permitted. Any cutting or welding of the galvanized
surface shall be brushed and red lead primer, oil primer & aluminium paint shall be applied.
Running lengths of single / double channels shall be cut to required lengths for installation.
Any cutting or welding of galvanised surface shall be brushed and red lead primer, oil primer
& aluminium paint shall be applied.

2.9 Horizontally running cable trays shall be clamped by bolting to cantilever arms at an interval
max of 2000 mm. vertically running cable trays shall be bolted to main support channel by
suitable bracket/clamps on both top and bottom side rails at an interval of 2000 mm. For
vertical cable risers/shafts cable trays shall be supported at an interval of 1000mm. fixing of
cable trays to cantilever arms or main support channel by welding shall not be accepted.
Spacing between cable trays shall normally be kept 300mm for cable laying convenience and
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effective heat dissipation. For installation of cable tray and support system,
brackets/clamps/insert plates using anchor fastener shall be fixed.

2.10 All cable way sections shall have identification, designations as per cable way layout drawings
and painted/ stencilled at each end of cable way and where there is branch connection to
another cable way. Minimum height of letter shall not be less than 75mm. For long lengths of
cable trays, the identification shall be painted at every 10m. Risers shall additionally be
painted / stencilled with identification numbers at every floor.

2.11 The cable trays and supports system shall be type tested, of approved makes, and
conforming to their respective approved drawings. Cable tray support shall be designed for
loading as per technical specifications.

2.12 Cable trays shall be grounded as per the provisions of the approved grounding document for
the project.

2.13 Deleted.

2.14 Deleted.

2.15 Directly buried cables

a) Cable trenches shall be constructed for directly buried cables. Construction of cable
trench for cables shall include excavation, preparation of sieved sand bedding, riddled soil
cover, supply and installation of brick or concrete protective covers, back filling and
compacting, supply and installation of route markers and joint markers. Laying of cables
and providing protective covering shall be as per IS: 1255 and “INSTALLATION DETAILS
OF CABLE TRAYS SUPPORT (Annexure-A).

b) RCC cable route and RCC joint markers shall be provided wherever required. The
voltage grade of the higher voltage cables in route shall be engraved on the marker.
Location of underground cable joints shall be indicated with cable marker with an additional
inscription “Cable Joint”. The marker shall project 150 mm above ground and shall be
spaced at an interval of 30 meters and at every change in direction. They shall be located
on both sides of road crossings and drain crossings. Top of cable marker/joint
marker shall be sloped to avoid accumulation of water/dust on marker.

2.16 For outside cable trench to inside cable trench connection, pipe sleeves in walls as under will
be provided for each cable tray for transiting the cables from one side to the other above the
finished floor level
a) For each 600mm wide tray: 3 nos. 200 diameter PVC pipes.

b) For each 300mm wide tray: 2 nos. 200 diameter PVC pipes.

c) For each 150mm wide tray: 1 no. 200mm diameter PVC pipes.

The trays shall be stopped approximately 200mm short of the wall on both sides and cables
passed through the pipe sleeves as above, the pipe sleeves being aligned horizontally with
the respective cable trays. This method is adopted for smooth passage of cables and effective
sealing of cable openings. All openings shall be sealed with fire sealing compound.

For cable entry to pump house / building, outside cable trays running on walls / structure shall
enter by means of wall opening. Alternatively, cable pull pit shall be provided outside and shall
connect to cable trench inside by means of pipe sleeves as indicated above. The cable entry
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and exit from switchgear room/pump houses/building shall be taken from 0.5 mtr (minimum)
above FFL to avoid water ingress in cable trenches.

Where cables cross roads/ rail tracks, the cables shall be laid in hume pipe /PVC pipe.

2.17 Local cabling in various auxiliary plants or pump houses from the main tray runs to equipment
terminal boxes shall be through notches in floor, which will be filled up with sand and then
provided with lean concrete covering matching with the floor after completion of cable laying.

2.18 Cable troughs shall be used for branching out few cables from main cable route. These shall
be U-shaped, fabricated of mil steel sheets of thickness 2 mm and shall be hot dip galvanized.
Troughs shall be standard width of 50mm & 75 mm with depth of 25 mm

3.0 General Philosophy of Cable Installation

3.1 Cable runs shall be uniformly spaced, properly supported and protected. All bends in runs
shall be as per specification and made with due consideration to avoid sharp bending and
kinking of cable. The bending radius of various types of cables shall not be less than those
specified by cable manufacturers or that specified in IS: 1255 Table 5.

3.2 For the purpose of cable laying, the cables are categorised as under:

a) HT: Power cables of 11KV / 3.3KV grade

b) LT: Power cables of 415KV grade, catering to loads at 415V AC/ 230V AC/ 220V DC /
24V DC

c) Control: Control cables of 1.1KV grade generally carrying control signals at 220V DC /
110V AC.

d) Instrumentation: (Also called screened control cables): Screened cables of cross-

sections 1.5sqmm or lower generally carrying very low voltage very low current
signals.

3.3 All cables shall be provided with identification tags indicating the cable numbers in
accordance with the cable circuit schedule. Cable tags shall be fixed at terminal ends, at tray
intersection / bend and at each side of floor/ wall/ duct crossings etc and at every 20m in
cable trench/tray or buried run. Cable tray routing points shall be located where they are
readily visible and not concealed by equipment, fire proofing or other materials.
Cable tag shall be of 2 mm thick aluminium with number punched on it and securely attached
to the cable by not less than two turns of 20 SWG GI wire conforming to IS:280. Alternatively,
cable tags can be made of nylon, cable marking ties with cable number heat stamped on the
cable tags.
3.4 Single core cables for a. c. three phase circuits, when laid on trays, shall be in trefoil formation
(each trefoil with RYB phases formation), with distance of four times the diameter of cable
between trefoil centrelines. The trefoil formation shall be duly secured to the cable tray by
means of trefoil clamps of nonmagnetic material at every 2000mm interval. All multicore
cables shall be laid touching formation.

3.5 Power and control cables shall be laid on separate tiers. The laying of different voltage grade
cables shall be on different tiers according to the voltage grade of the cables as defined in
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clause 3.2 above. In horizontal tray stacks, H.T. cables shall be laid on top most tier and
cables of subsequent lower voltage grades on lower tiers of trays.

3.6 1100 V grade multi-core power cables carrying continuous current when laid on trays shall be
placed in single layer, touching and clamped by means of cable ties/clamps.
The cable clamps/ties required to clamp multicore cables shall be of SS-316 material, 12mm
wide, polyester coated ladder lock type. The clamps/ties shall have self-locking arrangement
& shall have sufficient strength. The cable clamps/ties shall be supplied in finished individual
pieces of suitable length to meet the site requirements.

Cables of sizes indicated below, shall be clamped individually.

(a) Single core cables : 500 sq mm or higher (when not laid in trefoil
formation- e.g. dc circuits)/ neutral cables)
(b) Multi core cables : 95 sq mm or higher

3.7 Control and instrumentation cables shall be laid in multi layers, but not exceeding three layers
in any section. Special purpose cables (e.g. IPB, WAN etc.) shall be laid as per system
manufacturer/ supplier recommendations with due regard to segregation of routes for
redundant circuits.

3.8 While power, control and instrumentation cables shall generally be laid in separate trays, low
current carrying power cables (valve/ damper actuator power cables) may be laid along with
control cables. In most such cases, the cable sizes shall be 2.5 sq mm; however, in
exceptional cases higher sizes as per approved cable sizing calculations (required due to
voltage drop criterion) may be used.

3.9 Cables shall be placed on trays on the basis of their types and functions as under for
horizontal formations:

a) HT cables: in the top tier(s).

b) LT power cables: in the tray(s) below the HT cable trays.

c) Control cables: in the tray(s) next below to the LT power cable tray(s).

d) Instrumentation cables (screened control cables): in the bottom most perforated

tray(s).

HT Power, LT Power and LT Control/Instrumentation cables shall be separated from each

other by at least 300mm.

3.10 For vertical formations, the outermost tray shall be considered as the topmost tray and the
order indicated in clause 3.9 shall be followed. In rare cases, where there is no clear
distinction of bottom/ top trays, the order convenient for linking the horizontal and vertical
formations avoiding criss-crossing, or exit of cables shall be followed.

Typical examples of tray numbering are given overleaf.

3.11 Wherever it is not possible to accommodate cables as per the criteria indicated in the clauses
3.9 & 3.10 (due to layout constraints) for very short field runs, control cables may be laid in
the same tray with the instrumentation cables with clear minimum gap of 100mm/ separator
may be provided between the two types of cables.
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3.12 All cables associated with the unit shall be segregated from cables of other units. Interplant
cables of station auxiliaries shall be laid in such a way that not more than half of the drives are
lost in case of single incident of fire. Power and Control cables for ac drives and
corresponding ac or dc drives shall be laid in segregated routes. Cable route for one set of
auxiliaries of same unit shall be segregated from the other set. Segregation means physical
isolation to prevent fire jumping or minimum one hour fire rating. Cables of unit critical drives
shall be segregated in such a way that not more than half of the drives are lost in case of
single incident of fire. In switchyard, control cables of each bay shall be laid on separate racks
/ trays.

3.13 To facilitate pulling of cables in GI conduits, powdered soft stone, plastic soap or other dry
inert lubricant may be used. However any material harmful to the cable sheaths shall not be
used.

L1 R1 01
L2 R2 02
L3 R3 03

DOUBLE SIDED TRAY SINGLE SIDED TRAY

(HORIZONTAL RUN) (HORIZONTAL RUN)

03
02
01
03 02 01 01 02 03
SINGLE SIDED TRAY SINGLE SIDED TRAY SINGLE SIDED TRAY

(VERTICAL RUN) (VERTICAL RUN) (VERTICAL RUN)

HORIZONTAL TRAY

01
02
03

VERTICAL RISER ALONG WALL

01 02 03

WALL
EXAMPLE OF CHANGE OF NUMBERING SCHEME
FOR ENSURING LEVEL CONTINUITY

3.14 No single core cable shall pass through a GI conduit/ pipe or duct singly except DC single
core cables. AC single core cables shall pass through GI conduit/ pipe in trefoil formation only,
or through PVC pipes. Conduit/pipe occupancy shall not exceed 40% of the conduit/pipe
cross-section area. Pipes / conduits if used in corrosive areas shall have anti-corrosive
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coating both inside & outside. All openings in the floor/roof/wall / cable tunnel/cable trenches
made for conduit installation shall be sealed and made water proof. Different voltage grade
shall be laid in separate conduits.

3.15 Wherever specific cable routes are not shown in cable schedules, cables may be laid through
the shortest route as per the above criteria, as directed by site Engineer.
3.16 Power and control cables shall be secured fixed to trays/support with self-locking type
clamps/ties. For horizontal trays arrangements, multicore power cables and control cables
shall be secured at every five meter interval. For vertical tray arrangement, individual multicore
power cables and control cables individual multicore power cables and control cables shall
be secured at every one meter by nylon cable strap. After completion of cable laying work in
the particular vertical tray, all the control cables shall be binded to trays/supports by aluminium
strips at every five meter interval and at every bend.

3.17 For Cable unloading, pulling etc following guidelines shall be followed in general:

a) Cable drums shall be unloaded, handled and stored in an approved manner on hard and well
drained surface so that they may not sink. In no case shall be drum be stored flat i.e. with flange
horizontal. Rolling of drums shall be avoided as far as possible. For short distances, the drums
may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In
absence of any indication, the drums may be rolled in the same direction as it was rolled during
taking up the cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on
cable wheels and shall be rolled slowly so that cable comes out over the drum and not from
below. All possible care shall be taken during unreeling and laying to avoid damage due to
twist, kink or sharp bends. Cable ends shall be provided with sealed plastic caps to prevent
damage and ingress of moisture.

b) While laying cable, ground rollers shall be used at every 2 meter interval to avoid cable
touching ground. The cables shall be pushed over the rollers by a gang of people positioned in
between the rollers. Cables shall not be pulled from the end without having intermediate
pushing arrangements. Pulling tension shall not exceed the values recommended by cable
manufacturer. Selection of cable drums for each run shall be so planned so as to avoid using
straight through joints. Care should be taken while laying the cables so as to avoid damage to
cables. If any particular cable is damaged, the same shall be repaired or changed to the
satisfaction of Project Manager.

3.18 Two separate cable routes one on each side shall be provided for each boiler unit. Cables
for one set of auxiliaries such as ID, FD, PA fan & half of the coal mills shall be routed in one
route & for other set of auxiliaries through other route. Interplant cables of station auxiliaries and
unit critical drives shall be segregated in such a way that not more than half of the drives are
lost in case of single incident of fire. Power and control cables for AC drives and corresponding
emergency AC or DC drives shall be laid in segregated routes. Cable routes for one set of
auxiliaries of same unit shall be segregated from the other set.

3.19 Cables shall be laid on cable trays strictly in line with cable schedule.

3.20 For road/rail crossings, buried RCC hume pipes (at a depth of minimum 1000mm) shall be
used. Alternatively, RCC duct banks may also be used as per site condition.

3.21 If required the necessary modification in cable tray layout shall be made at site to suite condition
i.e. to avoid fouling of cable trays with beam, columns, steel structure, pipes etc. with prior
approval from project manager. Wherever accessories like bends, elbow, tees, crosses etc are
required in cable trays installation a pre-fabricated type of accessories in line with technical
specification requirement shall be used.
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3.22 Recommended tightening torque shall be used for dowels and bolts.

3.23 Where there is a considerable risk of steam, hot oil or mechanical damage cable routes shall be
protected by barriers or enclosures

4.0 Cable Termination & Jointing

4.1 Termination and jointing of cables shall conform to the requirements of IS: 1255 and shall be
carried out as per the recommendations of termination and jointing kit supplier. Cable
terminations at various electrical and electronic equipment terminals shall be done as per
approved scheme/ interconnection diagrams. Joints for less than 250m run of cable shall not
be provided. Extra length shall be provided for one LT and two HT joints at a later stage.

4.2 Termination and jointing of HT cables shall be done with pre – moulded type, taped type &
heat shrinkable type termination/ jointing kits of proven design & type tested as per IS :
13573(for above 3.3kV) and IS : 13573 /VDE0278 (for 3.3kV). The kit shall be complete with
tinned copper solderless crimping type cable lugs & ferrule as per DIN standard.

4.3 When the equipment are supplied with undrilled gland plates for cable/ conduit entry into the
equipment, all drilling & cutting on the gland plate and any minor modification work required to
complete the job shall be carried out at site as per cable glanding requirement. A plan showing
the holes for cable entry in the gland plate shall be developed at site in consultation with site
engineer for drilling holes (gas cutting is not allowed). Types of glands to be used are as under.

I. Material: Nickel- Chromium plated brass, heavy duty conforming to BS: 6121
II. Type: Double compression
All cable entry points shall be sealed & made vermin and dust proof. Unused openings shall be
effectively sealed by 2mm thick aluminium sheets.

4.4 Termination of cables shall be done as per termination drawings & interconnection diagrams
furnished. Shorting & looping of cores/ wires at terminals and between the panels if required
shall be carried out as per approved scheme.

4.5 All cable entries in the equipment shall be sealed by cable glands supplied with the equipment.
Any discrepancy in cable glands/ lugs with respect to cable size shall be brought to the notice of
site engineer.

4.6 Adequate length of cables shall be pulled inside the switchboards, control panels, terminal
boxes etc so as to permit neat termination/ dressing of each core/ conductor.

4.7 Power cable terminations shall be carried out in specified manner to avoid strain on the
terminals.

4.8 Control cable cores entering switchboard or control panels shall be neatly bunched and strapped
with cable clamps & ties and suitably supported to keep them in position at the terminal block.
All spare cores shall be neatly dressed and suitably grounded / insulated with blank ferrules.

4.9 Screened control cables of small cross sectional area, (0.5 sq mm) shall be terminated by means
of cage clamp termination system.

4.10 Individual cores of control cables shall have ferrules for identification. Ferrule numbers shall be
provided as per the control schemes and other related documents.
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4.11 Termination of aluminium/ copper conductor cables shall be done by means of suitable tools as
indicated below:

Type of lugs

I. HT Power Cables: As per DIN 46329

II. LT Power Cables: Tinned Copper (solderless crimping type).

III. LT Control Cables: Tinned copper (solderless crimping type).

4.12 Cable joint(s) shall normally be made at an appropriate point (s) in the straight run of cables
only when the length of the run is more than the standard drum length supplied by the cable
manufacturer, or when a joint is necessitated due to site constraints. In such cases, when
jointing is unavoidable, the same shall be made by means of specified cable-jointing kit. Prior
approval of Engineer shall be taken for deciding location of joint.

4.13 Junction boxes may be used, wherever required, for jointing/ marshalling of control and
instrumentation cables.

5.0 Trefoil Clamps

The cable trefoil clamps shall be used for clamping of MV & LV single core cables to be routed
in trefoil formation using trefoil clamps Trefoil clamps for single core cables shall be pressure
die cast aluminium or fibre glass or nylon and shall include necessary fixing accessories like
G.I. nuts, bolts, washers, etc.

6.0 Fire Sealing System

The fire proof cable penetration sealing system shall be of the following types:

a. Type-A: This is either silicone foam system or equivalent foam system or using individual blocks for
each cable along with suitable frame work rated for one hour. This is to be implemented at floor
openings below C&I panels, control panels/Boards etc. In CER & CCR.

b. Type-B: Type-B fire sealing system is any proven fire sealing system rated for one hour. This will
comprises of rest of wall and floor crossing of cable/cable trays, opening below HT/LT
Switchgears/boards other than those covered under Type ‘A.
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