UNIT 4

SERVICE CONNECTION, INSPECTION AND

TESTING OF INSTALLATION:
Concept of service connection, Types of service connection and
their features, Method of installation of service connection,
Estimates of underground and overhead service connections,
Inspection of internal wiring installations, Inspection of new
installations, Testing of installations, Testing of wiring installations,
Reason for excess recording of energy consumption by energy
meter.
 Concept of service connection

• Service connection is the overhead or under ground

cable connecting the supplier’s distributor line (in the
ploe) to the consumer’s wiring (in the meter board).
• It means of providing electric power supply from the
eisting pole up to the meter board.
Types of service connection and their features

There are two types of service mains

1) Overhead service connection
2) Under ground service connection.
Overhead service connection are easy to errect, cheap and fault
location with correction is ve easy. In case of additional power
requirement only cable can be replaced which causes economy

Underground service connection are having long life with safety. They
have good appearance and is not affected by atmosphere &
lightening surges.
 Method of Installation of overhead Service Connection
THE FIGURE SHOWS THE OVERHEAD SERVICE CONNECTION FOR TAPPING A
SINGLE-PHASE POWER SUPPLY. TOP MOST WIRE (1) WHICH TAKES
MECHANICAL LOAD IS CALLED MESSENGER WIRE. THIS MESSENGER WIRE
ED TO THE SUPPORTING PIPE (4) IN ONE SIDE AND TO THE POLE(6) ON THE
OTHER SIDE. THE MESSENGER WIRE ROKEN AT BOTH ENDS BY MEANS OF
I.1KV BREAK INSULATOR(8).TO THIS MESSENGER WIRE REEL INSULATORS
ARE SUSPENDED THROUGH WHICH DOUBLE SHEATHED PVC CABLES (3) ARE
DRAWN. FINALLY THE CABLES ARE EN TO THE METER BOARD (7) THROUGH
SERVICE PIPE(5).THE SERVICE PIPE IS FIXED TO THE SUPPORT PIPE BY ANS
OF CLAMPS .IF THE HORIZONTAL DISTANCE BETWEEN POLE AND SUPPORT
PIPE IS MORE THAN 15 M ,THEN ORDER TO MAINTAIN SUPPORT PIPE
VERTICALLY A STAY IS REQUIRED TO THE PIPE(USUALLY CALLED HALF POLE)
CH IS TO BE BROKEN AT THE MIDDLE BY MEANS OF 1.1 BREAK KV BREAK
INSULATOR IS TO BE PROVIDED. RTHING IS TO BE PROVIDED TO THE METER
WITH 8 SWG G.I. WIRE.
SECIFICATIONS OF MATERIAL USED IN OVERHEAD SERVICE
CONNECTION
1) MESSENGER WIRE: 10 SWG G.I WIRE.
2) SUPPORT PIPE : 40 MM DIAMETER 2.95 MM THICK G.I PIPE 1.8 M LONG FOR
SINGLE PHASE OR 50 MM DIAMETER AND 2.95 MM THICK G.I PIPE 1.8M LONG
FOR 3 PHASE INSTALLATION.
3) SERVICE PIPE :P.V.C PIPE 2MM THICK OF APPROPRIATE DIAMETER
DEPENDING ON THE SIZE AND THE NUMBER OF CABLES TO BE TAKEN BY THE
PIPE. USUALLY 2M IN LENGTH WITH 3 NUMBERS OF BENDS OF THE SAME
DIAMETER.
4J BREAK INSULATOR : 1.1 K.V PORCELAIN BREAK INSULATOR.
5) SERVICE CABLES :DOUBLE SHEATHED PVC ALUMINUM CABLES OF
APPROPRIATE SQUARE MM CROSS SECTION DEPENDING ON THE LOAD AND
250V GRADE IN CASE OF SINGLE PHASE AND 500V GRADE IN CASE OF 3 PHASE
SUPPLY.THE STANDARD CROSS SECTION OF ALUMINUM IN SQUARE MM ARE
2.5,4,6,10,16,25,35,50,70,95, 120,150,185 AND 240 IN THE CABLES.
6} METER BOARD :For single phase power connection
teak wood back covered meter board 305 x 305 x 65mm
made out of 15mm thick plank for front and 12mm plank
for the back with 40 x 20 mm batten around (using fixing
screws in front).
For three phase power connection the back covered (box
type) board size is 500 x 500 x 65 mm teak wood with 2
coats of high grade varnish with front plank of 15mm and
back plank of 12mm thick.
7) EARTHING: 40mm diameter G.I pipe 2.95 mm thick,
2.5M long 12.5 mm holes drilled at an interval of 300mm.
The whole pit of 340mm diameter is to be filled with coal
and salt.
8} EARTH WIRE : It is 8 SWG. G.I wire, for connecting
meter body to earth pipe.
9) FUSE UNIT : Porcelain fuse unit of required current
rating and voltage grade
 METHOD OF INSTALLATION OF U.G. SERVICE
CONNECTION
• Generally the under-ground cable system is preferred to that of over-head
service system srticularly in cosmopolitan cities like Bangalore, Mysore,
Mangalore, Hubli etc.,
• The figure 16. shows the usual U.G. service connection of sufficient
current capacity and of required cords. The
• U.G.cable (1) from the Meter Board (6) is taken to ground through G.I pipe
using bends. In the ground sually trench laying is done in case of no
obstruction.
• However in case of road crossing etc, in the round also the cable is taken
through G.I. pipe (2) using bends from where it is connected pot head (4)
of suitable current range.
• After this pot head, the supply is linked to thi double sheathed cables (5)
which are flexible.
• For a single phase twin core U.G. c; phase either 4 core or 3 and half core
U.G. cable is used. Always we are select in U.G. cable .
• The fixation of these steel armouring in a concentric way without affe,
called BONDING
 Different Methods of Laying UG Cable Are

1) Trench laying 2) Pipe laying 3) Trough wiring.

1) TRENCH LAYING(of Direct-laying System): Inthis method of
laying UG cabl deep, 450 mm wide is dug along the route.
Inside this a brick duct is formed ir is drawn at the center of
this duct around which river sand is filled. Finally the also
closed with brick. The cable indicator should be provided on
top at an inte1 the route.
DUCT OR PIPE LAYING(of Draw in System) : In this method
pipe made up concrete or stone-ware are first laid inthe
ground. Through these ducts the cat type of laying is usually
used in road crossings. Cast iron ducts are used ir along the
bridge & railway crossings etc.
TROUGH WIRING (of solid System): In this method of laying
pits or chanr along the route in which china clay or wood are
laid.The cable is drawn in the tr bitumen compound is filled in
the free space of the trough and finally covered
 SPECIFICATION OF MATERIALS USED
IN U.G. CABLE
1. Under ground cable(l.S 692/1957):
Size of cable In square mm.such as 4, 6, 10, 16, 25, 35, 50, 70, 95, 12 Conductor
material usually aluminium only(since over head lines are of ACS No of cores 2 for
single phase, 3 or 3 112 or 4 for 3 phase. Insulation
PVC sheathed with additional sheathing of either paper i lead alloy.
Voltage grade 1.1 KV class for low and medium voltage. Armouring Steel
wire armoured or tape armoured.
2. POT HEAD:
Voltage grade 1.1KV or 11KV.
Material Cast iron.
Suitable for particular no. of core and size of cable: For ex. 2 core 10 sq mm cc:
3. STONE WARE PIPE (l.S. 1554 OF 1964):
Size : 101.6mm dia.
Length : 61 M.
4. G.I pipe (1.S 1239 of 1964 ):
Dia - 40 mm for 6, 10 and 16 sq.mm cables or 50 mm dia for higher sizes
5. PVC Cables
Size: In sq.mm such as 2,4,6,10,16,25 etc.,
Conductor : Aluminium.
Insulation : PVC
Voltage grade : 1.1 KV
METER BOARD:
300 x 300 x 65 mm box type teak wood varnished board for
single phase or 500 x 500 x 65 mm box type teak wood varnished
for 3-phase.
EARTHING: 40 mm G.I pipe 3 mm thick, 2.5M long, 12.5 mm
wholes drilled at an interval of 300 mm. The whole pit of 340
mm dia. is to be filled with coal and salt.
 ESTIMATE FOR SERVICE MAINS
Estimate for UG Service Mains
lllusrative Example

Q. Prepare a UG service connection to feed power supply to an A.E.H. lnstalltaion having a

lighting load of 1020W and a power load of 3kW for a distance of 1OM.
a) Materials for UG service connection
Length of UG cable = Horizontal distance + looseness + meter side up to ground level +
pole side = 1O + 2 + 3.5 + 4.5 = 20M
Total load current = 4020/230 = 17.5A. therefore 16sqmm Alluminium U.G. cable is to
be used (Taetking a factor of safety three ) 50A iron pot head of single phase (Two
terminal), 250Vg 1Osqmm Alluminium double sheathed PVC cable = 12m for
connecting U.G. cable to pole.
No.of 11.5 x 23 x 7.5cm bricks 1O x 100/23 = 43.47 or say 45
Length of 40mm G.I. pipe = 2.5 x 2M (for both sides of poles) + 2.5M for earthing =
7.5M No. of 60A Fuse unit-3No.
No.of 40mm GI bends 3 and 8 SWG G.I. wire 1Kg 300 X 300 X 65 TW meter board.
Estimate of cost for service connection with UG cable
Clamps & other miscellaneous materials such as coal,salt, bolts, nuts etc.,
 Estimate of cost for service connection with UG cable

SI. Particulars Unit Quantity Rate Cost

No.
Rs.Ps. Rs.Ps.

1. 200 x 100 x 75 mm bricks No. 45 3.00 135.00

2. 16sqmmAlluminium twin core steel armoured

UG cable 1.1KV class M
20 80.00 1600.00

3 40mm GI pipe 3mm thick 5M for laying

cable + 2.5M for earthing M 7.5M 140.00 1050.00

4 40mm GI bends 3mm thick No. 3 95.00 285:00

5 1Osq.mmAllumi nium double sheathed PVC cable

250Vg 100M(coil) 12M 1260.00 151.20

6. 6. 60A porcelain fuse unit 250Vg No. 1 145.00 145.00

7. Iron pot headwith 2 terminals 250Vg No. 240.00 240.00

for 16 sqmm UGcable
8. Bitumenous compound KG 20.00 20.00

9. 8SWG GI wire for earthing KG 65.00 65.00

10. 300X300X65mm back coverd meter board No. 200.00 300.00
11. Clamp for holding pot head with pole No. 35.00 35.00
12. Clamp for holding GI pipe with pole No. 2 25.00 50.00
13. Miscellaneous materialas such as screws
coal, salt, bolts, nuts, etc., Lumpsum 138.00
14. Labour charges a) Laying 150.00 300.00

b) Earthing work 50.00

Total 4514.20
Adding 5% for contingencies and unforeseen 225.80
item
Total estimate of cost is Rupees four thousand seven hundred and Grand Rs. 4740.00
forty only) total
 Illustrative Examples for Overhead Service Main
Q: Prepare an estimate for overhead service connection to feed power
supply to a factory of 15H.P. load for a distance of 1OM.
1) Material calculation (for service connection):- 50mm G.I. Pipe 1.8M
Approximate current = 1.6 X 15 = 24A
Giving a factor of safety of 2, the current rating ( to be observed in the
wire table) is 48A. The size of the aluminum cable is 16 sq. mm
Length of each lead = 10 + 3 + 3 + 4 = 20M.
Therefore the total length of cable required = 20 X 4 = 8OM
No. of Break Insulator = 2
No. of reels = 4 (10 + 2) = 48
30mm PVC Pipe 2M & bends 3 Nos. 500X500X65 T.W. M Board -1 No.
40mm G.I. Pipe 2.5m for earthing & 1Kg of 8 SWG G.I. wire. 30A fuse
unit-3Nos. & Misc. materials
SI. Particulars Unit Quantity Rate Cost
No.
Rs.Ps. Rs.Ps.
1 50mm G.I. pipe 3mm thick 1.8m

for supporting M 1.8 250.00 450.00

2 1O SWG G.I. for massanging Kg. 1 68.00 68.00
3 16sq. mm aluminium double 100M
(coil) 80M 1750.00 1400.00
sheathed PVC cable 1.1KV
4 Porcelain reel insulators
15mm dia. Gross 48Nos. 72.00 24.00
5 1.1 KV porcelain Break insulator Nos. 2 5.00 10.00
6 8SWG G.I. wire for earthing Kg. 65.00 65.00
7 30mm PVC pipe 2mm thick for
servicing. 3M 2M 42.00 28.00
(length)
8 PVC Bends suitablefor 30mm pipe No. 3 8.00 24.00
9 500 X 500 X 65mm T.W. back
covered Meter board. No. 1 480.00 480.00
10 40mm G.I. Pipe 3mm thick M 2.5 190.00 475.00
11 30A porcelain fuse unit 500Vg No. 3 60.00 180.00
12 12.5mm dia, 300mm eye bolt
nuts of M.S. No. 2 25.00 50.00
13 Miscellaneous materials such as
binding wire, pole clamp, supporting
clamp, bolt nuts, coal, salt,
cement etc. Lumpsum 146.00
14 Labour charges
a) for servicing Rs. 150/-
b) earth worlk Rs. 75/- 225.00
Tot
3625.00
al
Adding contingencies and unforeseen
181.25
things @ 5%
Grand Total 3806.25
Or say Rs. 3806.00
Estimate of cost for service main is rupees Three thousand eight hundred six only.