Underground Cable System

Design Manual

June 2012
Asset Management Department, TNB Distribution Division
Page | i

CHAPTER 3

CABLE LAYING SPECIFICATIONS

Underground Cable System Design Manual

3.2

Distribution Division

Laying Cables in Pipes / Ducts

Although direct buried method is preferred by TNB but sometimes cable

needs to be laid in pipes or ducts especially in situation where direct
buried method is not suitable.
Situations where pipes/ducts are required:
a)
Road crossing
b)
Highway crossing
c)
Railways crossing
d)
Monsoon drain crossing
e)
Culvert crossing
f)
River crossing
The common methods used by TNB for crossings are:
a)
Pipes or ducts installation via open cut
b)
Horizontal Directional Drilling (HDD) / trenchless
c)
Laid in G.I. pipe above ground
d)
Cable bridge
When parallel circuits are to be installed in the same trench, a minimum
distance of at least two (2) cable diameters should be maintained.
Whenever pipe/ducts are installed at road crossings for cable laying,
additional pipes/ducts may be laid for future use. Where more than one
length of pipe is used, suitable pipe joints/adapters shall be used around
each joint.
The three types of pipes used by TNB are:
a)
High Density Polyethylene (HDPE)
o
Corrugated single wall and double wall
o
Grade PN10
b)
PVC Class B with SIRIM approved label
c)
Galvanised Iron (G.I.) Pipes

Page | 75

CHAPTER 3
Distribution Division

CABLE LAYING SPECIFICATIONS

Underground Cable System Design Manual

A summary of specific applications for different pipes is shown in

Table 3-2.

3.2.1 Types of Pipes

3.2.1.1

High Density Polyethylene (HDPE)

Double Wall Corrugated HDPE

Where pipes/ducts are required for road crossing, Double Wall
Corrugated HDPE pipes may be used if encased in concrete.

Figure 3-7: Double Wall HDPE Corrugated Pipe

When cables are to be laid in HDPE pipes, one 150 mm diameter HDPE
Pipe/duct is required for each single core, three core and four core XLPE
cable and one 100 mm diameter HDPE pipe/duct for each pilot cable or
fibre optic cable.
The HDPE pipes shall be able to be connected by pipe connection means
of double connection sleeves or equivalent connection accessories
manufactured with the same material and shall be of sand proof or
water proof (special case). The HDPE pipe shall comply to TNB technical
8
specification for HDPE pipes .

Technical Specifications, Single & Double Wall High Density

Polyethylene (HDPE) Corrugated Pipe, 7 April 2000.

Page | 76

CHAPTER 3

CABLE LAYING SPECIFICATIONS

Underground Cable System Design Manual

Distribution Division

HDPE Grade PN10

HDPE pipe of grade PN10 is used as duct sleeve in HDD installations.

Figure 3-8: HDPE grade PN10

3.2.1.2

PVC Pipe Class B

PVC pipe Class B is used as protective sleeve for road crossings with
concrete encasement. It is also used as a protective sleeve for cables
installed on cable bridges. The Class B PVC pipe should have the SIRIM
approved label.

Figure 3-9: Class B PVC ducts

Page | 77

CHAPTER 3
Distribution Division

3.2.1.3

CABLE LAYING SPECIFICATIONS

Underground Cable System Design Manual

Galvanised Iron (G.I.) Pipes

G.I. pipes are used as a protective sleeve for all crossings.

Only used for 3 core and 4 core cables, and single core cables laid in
trefoil.
Cannot be used for single core cables laid singularly (alone) due to
9
induced and circulating eddy currents in the G.I. pipes .
Sizes:
o 150 mm diameter for power cables
o 100 mm diameter for communication cables

HDPE
pipes

G.I. pipes

Roadside
drain
Figure 3-10: Underground electrical ducts crossing a roadside drain

Pekeliling Pengurus Besar Kanan (Kejuruteraan) Bil. A17/2008- Larangan Merentang

Kabel 1 Teras dalam Paip Besi GI

Page | 78

CHAPTER 3

CABLE LAYING SPECIFICATIONS

Underground Cable System Design Manual

Distribution Division

3.2.2 Sizes and Usage of Pipe/Ducts

TNB uses various types of pipes/ducts for cable laying and crossing. The
standard size for pipes/ducts approved for each usage is as show in
Table 3-2.
Table 3-2: Summary of pipes/ducts usage and sizes
Type of Pipe/Ducts

Diameter (mm)

Usage

HDPE double wall

corrugated
HDPE double wall
corrugated
HDPE PN10

100, 150

Paved and unpaved roads not to

be used for bridge crossing
Communication cable ducting

100, 150

HDD for crossings

G.I. pipes

100, 150
450

All crossings
Crossings culverts for one circuit
1C cable in HDPE pipes
Crossings culverts for two circuits
1C cable in HDPE pipes
Bridge Crossing
Paved and unpaved roads

50

914
PVC Class B

100, 150

Monsoon Drain & Culvert Crossings

For single core XLPE cable crossing on top of monsoon drain and culvert,
G.I. pipes of 450 mm/914 mm diameter shall be used for each circuit,
enclosing three 150mm diameter Double Wall HDPE Corrugated Pipe
duct for every three single core XLPE cables and one 100 mm diameter
Single or Double Wall HDPE Corrugated Pipe duct for pilot cable or fibre
optic cable. Similarly for two circuits and above, two and more 450 mm
10
diameter G.I. pipes shall be used .

10

P&PA Specifications

Page | 79