TCE CONSULTING ENGINEERS LIMITED

TCE. M6-EL-CT-6107

SECTION: TITLE

SHEET i OF iii

SELECTION OF CABLE CARRIER SYSTEM

DESIGN GUIDE FOR

SELECTION OF
CABLE CARRIER SYSTEM

FILE NAME

REV.NO

M6-EL-6107-R0

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20-03-2003
FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED

TCE. M6-EL-CT-6107

SELECTION OF CABLE CARRIER SYSTEM

SECTION: CONTENTS

SHEET

ii OF iii

CONTENTS
SL. NO.

TITLE

SHEET NO.

1.0

SCOPE

2.0

RECOMMENDATIONS

2.1

For Power plants

2.2

For Industrial Plants

2.3

For Chemical Plants

3.0

OUTDOOR APPLICATIONS

3.1

Direct burial

3.2

Trenches

3.3

Tunnel

3.4

Duct Banks

3.5

Overhead racks

4.0

INDOOR APPLICATIONS

4.1

Trenches

4.2

Conduits

4.3

Cable trays

5.0

SUMMARY

APPENDIX-1 COMPARATIVE TABLE OF CABLE CARRIER

SYSTEMS

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SECTION:REV.STATUSS

SHEET iii OF iii

REVISION STATUS SHEET

REV.NO.

R0

DATE

DESCRIPTION

20-03-2003

Document No. changed from

TCE.M6-EL-CT-G-CA-6107 to
TCE.M6-EL-CT-6107, new
Revision number indicated &
Generally revised.

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1.0

SCOPE

1.1

This guide indicates the various types of cabling systems and

selection criteria for the same.

1.2

The choice of cable carrier would depend on following factors :

2.0

(a)

Type of application(Indoor / Outdoor)

(b)

Material and installation cost.

(c)

Environment factors like chemical concentrations attack by

rodents/termites.

(d)

Ground water level and drainage systems for water, oil or

other fluids.

(e)

Access for maintenance, installation of additional cables,

movement of vehicles and equipment.

(f)

Good appearance consistent with personnel safety and

cost.

(g)

Specific requirements, if any, of the client.

(h)

Matching with existing requirements.

RECOMMENDATIONS
Following methods of cable laying are recommended based on
discussions in subsequent paras 3.0, 4.0 & 5.0.

2.1

For Power Plants

(a)

Outdoors :
(i)

Switchyard Trenches

(ii)

Transformer yard Trenches

(iii)

Boiler areas Main routes: Tunnels/OH cable racks

with trenches/conduits to branch-off connections.
Cable routes from TG to boiler platforms should be
in OH cable trays at suitable elevations and
supported by structural members bridging Turbine
building and boiler.

(iv)

Boiler platforms Cable trays mounted in vertical

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(b)

2.2

SECTION:WRITE-UP

(v)

Outlying Areas Overhead(OH) racks. To the extent

possible, pipe racks will be used for supporting the
cable trays. For remote outlying areas, directly
buried cables could be considered.

(vi)

Coal Handling Area Cable trays with cables in

vertical formation, run along the conveyor structures
and tunnel enclosure walls, overhead racks and duct
banks for small distance.

(vii)

Road/rail crossings hume pipes encased in

concrete.

Indoors :
(i)

T.G. Building cable trays, conduits/floor chases for

branch-off connections. For details refer to design
guide GA Turbine Building Space Reservation for
Cable Carriers & Bus Ducts TCE.M6-EL-PJ-GSG-6601. It may be noted that floor chases will be
possible only on the ground floor.

(ii)

Utilities and Offsite Buildings Trenches for

switchgear/MCC if the same is located at ground
floor. In case the switchgear/MCC is located in
upper floor OH cable trays shall be provided. In the
plant area or pump house area conduit
embedments/floor chases shall be provided for
equipments from the main cable trays. In case of no
separate room for switchgear/MCC in off site
buildings, and the switchgear/MCC is located in
pump house only, it is preferable to have cable entry
to switchgear/MCC from top.

For Industrial Plants

(a)

Outdoors :
(i)

Substation / Switchyard / Transformer yard trenches

(ii)

Outlying areas overhead racks/trenches/ directly

buried if the area is small.

(iii)

Road / rail crossings hume pipes encased in

concrete.
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(b)

2.3

SECTION:WRITE-UP

Indoors :
(i)

Process plant and utilities buildings with only ground

floor trenches, only if there is no process fluid
spillage expected, otherwise overhead cable trays
to be provided with top entry MCCs. Conduits/floor
chases for branch off connections.

(ii)

Conveyor Belts Cable trays in

configuration run along conveyor structures.

(iii)

Main substation switchgear building trenches.

vertical

For Chemical Plants

(a)

(b)

Outdoors :
(i)

Substation / Switchyard / Transformer yard trenches

(ii)

Outlaying areas cable trays run along pipe racks/

trenches. For direct burial, check for any chemical
effluents in the soil.

(iii)

Road / rail crossings hume pipes encased in

concrete

Indoors :
(i)

Process Plant and Utilities Buildings with only ground

floor - trenches, only if there is no process chemical
spillage expected otherwise overhead cable trays to
be provided with top entry MCCs. Conduits for
branch-off connections.

(ii)

Conveyor belts cable trays in vertical configuration

run along conveyor structures.

(iii)

Main substation switchgear building trenches.

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OUTDOOR APPLICATIONS
Outdoor cabling would be required for equipment like
transformers, circuit breakers, isolators, current and potential
devices, outdoor control cabinets, instrumentation devices,
outdoor motors, outdoor lighting and tie-cables from main
switchgear building to off-site services plant building.

3.1

Direct Burial

3.1.1

In this method the cables are laid in excavated earth with a

layer of sand below and above the cables and protective covers
to prevent mechanical damage. The excavation is then back filled.
For details of buried cables refer drawing TCE.M2-EL-CT-S-2045
sh. 1 and 2.

3.1.2

This system is low in cost. However, damage to cables is more

difficult to locate and repair than in other methods of cable
installation and it does not lend itself to changes/additions. Also it
should be checked whether any chemicals in the soil will have a
deleterious effect on the cable insulation. Direct burial method is
used generally for short lengths of cables or when only a few
cables are required to be laid outdoors and a permanent trench
may not be justified.

3.2

Trenches

3.2.1

In trench systems the cables are laid either on MS carrier

arms or prefabricated/site fabricated cable trays supported from
MS sections or supported from walls of built-up concrete trenches
below grade. Trenches are provided with removable covers which
may be used as walkways. Concrete covers shall be used for
outdoor area and chequered plates shall be used indoor area.
Trench system is used when large number of cables have to be
laid for a group of equipment in a specific area. The main run of
trench should be suitably laid out centrally through the group of
equipment with smaller branch off trenches or short runs of
conduits or directly buried cables branching off to individual
equipment.

3.2.2

This system makes for easy maintenance, additions and

alterations.

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3.2.3

Trenches must be specifically cleared of interference with other

services like cooling water mains, equipment foundations, traffic
and equipment movement and drainage system. Trenches are
generally used in switchyard and transformer yards, switchgear/
MCC room/control room of various pump houses where the same
are placed on the ground floor.

3.2.4

Trenches shall be avoided in places where there are possibilities

of collection of hazardous liquids such as fuel oil or combustible
material such as coal dust or chemicals from the consideration of
outbreak of fire or chemical reaction with cable sheath / insulation
However in refineries trenches are completely filled with sand.

3.2.5

Trenches are also not preferred in the project sites with shallow
ground water levels due to the problems associated with water
seepage through trench walls.

3.2.6

In indoor applications, floor chases / short shallow cable trenches

(branch - offs) are closed with lean concrete.

3.3

Tunnel

3.3.1

In tunnel systems the cables are laid like in a trench, the difference
being a closed roof and an adequate depth for walk-through. This
system is higher in cost than trenches. However,
it has the advantage of having capacity of running large number of
cables, good physical protection and minimum interference to
traffic/heavy equipment movement and drainage. Where heavy
vehicular movement is envisaged and plant drainage crosses the
tunnel, the tunnel shall have to be lowered by atleast 1000 mm
from the grade level. The ground water level should be checked to
preclude any seepage/flooding in seasons of heavy rainfall .

3.3.2

Adequate ventilation and lighting arrangement should be provided

for in the tunnel.

3.3.3

Cable tunnels are generally used in boiler area where fairly long
lengths of large numbers of cables are to be laid under paved
ground and accessibility for movement and maintenance of heavy
equipment is required. They are also used for underground hydro
power station.

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3.4

Duct-Banks

3.4.1

In this system, (i.e. conduit systems of steel, Hume pipes, HDPE

pipes encased in concrete) cables are pulled through conduits/
pipes which are arranged in rows underground and encased in
concrete. This arrangement requires manholes located at
reasonable pulling lengths of 15 to 20 metres. Additions/changes
are difficult in this system and number of spare pipes must be
provided for at time of installation. It may be noted that cables
cannot be easily added in partially filled conduit/pipes. Duct banks
shall be straight runs and manholes shall be provided at every 15
m of straight run and wherever duct bank changes direction.

3.4.2

Like tunnels, this system is good from point of view of physical

protection to cables and minimum interference to movement of
equipment/traffic. As in the case of tunnels, the top of duct bank
shall be lowered wherever heavy vehicular movement is envisaged
and plant drainage crosses.

3.4.3

Since this system is generally the most expensive, requires space

for manholes and more exact estimates of cable requirements for
the area covered by the duct banks and difficulty of making
additions/ changes, it may be generally avoided unless the other
systems are not feasible to install.

3.4.4

For road crossings/rail crossings duct banks are preferred.

3.5

Overhead Racks

3.5.1

In this arrangement the cables are laid in trays or racks supported

from ground mounted structures. Usually pipe structures if any, to
be installed for the area, are additionally designed for providing
racks for cables. Cables should be run above the pipe lines,
especially those which may leak or with a horizontal separation as
a side extension of the pipe structure. In case the cable trays are
run below the pipes the top most tray should be provided with
cover for protection. In semi-outdoor areas like boiler platforms,
vertical cable trays may be supported from columns or flooring
structure.

3.5.2

This system would generally be less costly than below grade

systems. However, interference with equipment access, movement
of traffic, electrical clearances from any live points have to be
taken care of.
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3.5.3

Wherever the overhead cable racks cross roads/rail tracks,

minimum clearance of 6 mtrs. from grade level shall be provided
for movements of vehicles.

4.0

INDOOR APPLICATIONS
Indoor cabling would be required for equipment like
switchboards/switchgears, control relay and instrumentation
panels, indoor motors and indoor transformers if any.

4.1

Trenches

4.1.1

These are cast in - situ concrete floors and covered with

removable covers. Indoor trenches may be used in the ground
floor. Trenches may be run as required if there is no interference
with other equipment, column foundations and grade beams or
trenches may be run only alongside/ under the main switchboards
with conduits embedded in the ground to branch off to other
equipment located in the room.

4.1.2

In this system consideration has to be given to co-ordination with

drainage, foundations and grade beams and requirements of floor
space for maintenance movement of equipment. Trench system
should be avoided if any chemical/fluid spillage or water flooding is
expected. For example, trenches to be avoided in Water
treatment and Fuel oil handling plants or where chemicals exist
which can damage cable sheath / insulation.

4.2

Conduits

4.2.1

Conduit system by itself is expensive when large number of cables

are involved and is not adaptable for additions and changes. It is
extensively used for lighting circuit wiring. For power and control
circuits it is generally used in branch off connections to motor
terminals, push buttons, instrumentation switches like flow,
pressure etc. For these branch off connections the conduits have
to be embedded in the floor before the floors are completed and
as such equipment locations should be fairly accurately indicated
in the general layout drawings. Separate conduits shall be
provided for power, control and instrumentation cables. In this
connection, it may be noted that maximum 52 mm dia conduits can
be embedded in the upper floors with sufficient spacing between
the conduits. These limitations are mainly due to 150 mm
thickness and overall civil requirements of maintaining the floor
slab strength.
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4.3

Cable Trays

4.3.1

This is the commonly used system for indoor installations. It is

generally the least expensive, easy for additions & alterations and
does not interface with drainage and civil foundations. However, it
is more vulnerable to environmental factors. The material/paint
finish of cable trays in chemical corrosive areas should be
selected with care after consultation with the chemical engineer
working on the project.

4.3.2

Cable trays may be supported from ceiling. If a separate cable

vault gallery with a height of about 3 meters is allocated for cabling,
floor mounted cable trays may be used. Otherwise it would be
generally preferable to provide ceiling mounted cable trays to
avoid any interference of movement/access to personnel and
equipment. Cable trays should also be clear of mechanical
services, pipes, ducts etc.

4.3.3

In case top cable entry system is adopted for switchgears / MCCs

/local control panels, adequate steps shall be taken for sealing the
cable entry points in the panels, after the cables are terminated
and for supporting the cable drops from overhead cable tray
system. In addition, it is better to insist on provision of kerb walls
around all pipe / duct openings in floors to avoid any spill water
raining out the switchgear / MCC / control panel or any other
electrical equipment.

5.0

SUMMARY
Appendix-1 is attached herewith giving a comparative table of the
various cable carrier systems discussed above.

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APPENDIX 1
COMPARATIVE TABLE OF CABLE CARRIER SYSTEMS

SL.
NO

TYPES OF SYSTEMS

DIRECT
BURIAL

TRENCH

TUNNEL

(1)

(2)

(3)

DUCT BANK

CABLE TRAY

(4)

CONDUIT

(5)

(6)

COST

LOW

HIGHER
THAN (1)

HIGHER
THAN (2)

HIGHEST

LOW

HIGHER THAN
(5)

APPLICATION

OUTDOOR

OUTDOOR
/INDOOR AT
GROUND
LEVEL

OUTDOOR

OUTDOOR

INDOOR/
OUTDOOR
WITH
TRAY
COVERS FOR
MECHPROTECTION

INDOOR/
OUTDOOR

(A) TYPICAL

ONLY FOR
SMALL
DISTANCES
SUCH AS
OVER HEAD
RACKS TO
TRANSFORMERS, OFFSITE INTERCONNECT
IONS,
OUTDOOR
MOTORS

SWITCHYARDS,
TRANSFORMER
YARDS,
ELECTRICAL
EQUIP-MENT
AT GROUND
LEVEL
WHERE
UPPER
FLOORS ARE
NOT
AVAILABLE
OR HEAD
ROOM IS NOT
AVAILABLE
FOR TRAYS

BOILER
AREA
WHERE
ACCESS IS
REQD. FOR
MAINTENANCE AND
MOVE-MENT
OF HEAVY
MATERIALS

FOR SHORT
LENGTHS
UNDER
ROADS AND
TRACKS
OTHERWISE
SHOULD BE
AVOIDED
DUE TO
DIFFICULT IN
CONSTRUCTION
AND
CABLING

ON THE
UNDER-SIDE
OF FLOORS/
CEILING OF
BUILDINGS,
VERTICALLY
ON COLUMNS,
ON OUT-DOOR
PIPE RACKS,
UNDER SIDE
OF BOILER
PLATFORMS

EMBEDDED IN
GROUND OR
FLOORS OR
CLEATED ON
WALLS AND
COLUMNS,
USUALLY FOR
BRANCH OFF
CONNE-CTIONS
TO MOTORS,
PBS, I&C FIELD
DEVICS ETC.

ACCESSIBILITY FOR
CABLE
MAINTENANCE,
ADDITIONS,
ALTERATIONS

POOR

GOOD

GOOD

POOR

GOOD

POOR

SAFETY TO CABLES

FAIR, WITH
ROUTE
MARKES TO
WARN AND
PREVENT
PICK AXING
CHEMICALS IF
EXPEC-TED IN
THE SOIL TO
BE CHECKED
FOR DAMAGE
TO
INSULATION

GOOD

GOOD

GOOD

SUSCEPTIBLE
TO RODENTS
ATTACKS

GOOD

EXAMPLE

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APPENDIX 1 (Contd.)

SL.N
O

TYPES OF
SYSTEMS

INTERFER-ENCE
WITH
OTHER
SERVICES

CURRENT
RATING

(a)

PVC CABLES

DIRECT BURIAL

TRENCH

TUNNEL

(1)

(2)

FLEXIBILITY TO
AVOID INTERFERENCE

COMPELTE
LAYOUT TO BE
CO-ORDINA-TED
WITH
FOUNDATIONS,
DRAINAGE,
PIPING AND
TRAFFIC MOVEMENT IF ANY

DUCT BANK

(3)

MAY BE CONSIDERED SAME AS (5)

SAME
AS (2)

CABLE TRAY

(4)

(5)

(b)

- DO -

XLPE CABLES
6.6 kV TO 33kV

-DO-

(6)

TOP LEVEL OF
THE DEPTH TO
BE DESIGNED
TO ALLOW FOR
THE REQUI-RED
MOVE-MENT OF
RAIL/ ROAD
TRAFFIC
AVAILABILTY
OF THE REQD
SPACES FOR
MANHOLES TO
BE CHECKED

TO BE COORDINATED
WITH PIPING,
VENTILATION
AND LIGHTING

5% TO 10%
LESS UPTO 16
SQ.MM 10% TO
20% LESS
ABOVE 16
SQ.MM

5% TO 10%
LESS UPTO 50
SQ.M AND
NOMINALLY
LESS FROM
ABOVE 50
SQ.MM TO 150
SQ.MM, 5%
MORE ABOVE
150 SQ.MM

-DO-

NOMINALLY
LESS UPTO 35
SQ.MM, 5%
MORE ABOVE
35 SQ.MM

- DO -

5 TO 10% MORE
FOR CABLES
UPTO 150
SQ.MM AND 10
TO 15% MORE
FOR CABLES
ABOVE
150Sq.MM

- DO -

(i) 1100V

(ii)UPTO 6.6 kV

CONDUIT

ABOUT
LESS

20%

FLEXIBLITY
TO
AVOID
INTERFERENCE

MAY BE
CONSIDERD
SAME AS (4)

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