DESCRIPTION ST/08B

CABLES AND OVERHEAD LINES DURATION

SHORT: 2 DAYS

CONTENT

OVERHEAD LINES
1. Different types of O.H. wires and where used.

2. Post , parts of post and paying of wires.

3. Jointing of overhead wires-different joints.

4. Testing of O.H. linesfaults, fault localisation and rectification

CABLES
5. Different cables used in S&T and cable laying procedure
6. Cable Jointing, Protection in jointing and connecting
Materials

7. Periodical tests on cables, fault localisation and rectification Page

8. Termination of S&T cables

9. Colour code scheme in telecom cables identifying pairs

10. Study of jelly filled cable,

11. Normal joint, loading coil joint, capacitance joint and T-joint
and joint practices

12. Cable used in exchange inside / outside and their periodical

testing.

13. Soldering
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OVER HEAD
INTRODUCTION

For Transmission of electrical energy from one point to the other distant point, to established
communication, one of the modes is to use mettalic conductors. They are called Transmission
Lines. Overhead lines are such types of transmission lines.

1) Different types of overhead wires and where used.

Overhead lines can not be worked in those sections of Railways where the track is
electrified, due to inductive interference.
Types of overhead wires used are
i) Galvanised Iron wire i.e. GI wires.
ii) Aluminium conductor steel Reinforced wire i.e. ACSR wires.

i) GI wires :- It is a iron wire protected from corrosion by depositing a thin film of zinc
over it. The different size of wires are used for diffent purpose.
a) 42.5 Kg/Km) For local telephone
28.4 Kg/Km )
b) 85.25 Kg/Km for Block circuit
c) 170.5 Kg/Km for telegraph circuit.
ii) ACSR :- It is not a single solid wire. It consists of a six nos alluminium wires(Strands)
twisted together along a central Steel wire which forms the core of the conductor.
Size Loop Resistance
6/1/1.5 5.62 Ohms/Km
6/1/1.96 3.28 Ohm/Km.
6/1/2.11 3.00 Ohm/Km
It is used for trunk and control lines.

2) POST, Parts of post and paying of wires

Rail Post:- The rails to be used may either MG(12 m) or BG (13 m) released rails, and
may be flat footed rail or bull headed.

PARTS OF POST:
1) Porcelain Insulator:- Supports the line wire on its neck groove and insulates it
from the stalk.
2) Stalk:- Supports the insulator regidly and holds it at a fixed vertical distance
from the bracket.
3) Bracket or cross arm:- Supports the stalk and also maintains the horizontal
distance between wires and pairs.
4) U-back :- Fits the cross arm to the post rigidly.
5) Distance piece :- Packs the gap between the head of the post and the cross arm
at the right angle to the transmission wires.
6) Ties or Tie Bars :- Maintain the vertical separation at cross arms.
7) Struts :- Keep the ties in correct position.
8) Stay shackle :- Links the stay with the cross-arm.
9) Stay clamp :- Links the stay with the body of the post.
10) Straining screw :- Adjusts the tension of the stay.
11) Stay wire :- Connects the straining screw with the stay rod.
12) Stay rod :- Connects the stay wires with the mush-room anchor.
13) Mush-room anchor :- Anchor bottom end of the stay in the ground.
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14) Thimble:- Prevent the rubbing of stay wire at the point of attachment.
15) Stay or Guy :- Keeps the post vertical.
16) Base plate :- Prevents the sinking of the post.
17) Lightning spike :- Provide a discharge path for lightning through the post to the
ground.
18) Number plate :- Shows the number of the post.
19) Concrete Base :- This gives extra strength specially in the water logged areas.
20) Strut support :- The attachment of struts to the post.
21) Paying of wires : Paying is the operation in which the bundles of GI wire
( 1 Coil = 1000 metres) or ACSR wire reeled on wooden
drums( 5 to 20 Km).
Special care is to be taken while paying of wires to avoid damage from rubbing
against the bottoms of the wooden drum or any projection on the buttons etc.
3. Jointing of overhead wires different joints
A. Galvanised Iron wires :

The joints made with GI wire are classified as

i) Britannia joint and ii) Twist joint.

i) Britannia joint : This joint made with GI wires of 3.55 mm dia and above . The
two ends of the GI wires are kept overlapped and a GI binding wire is used to
bind the two wire.
ii) Twist joint : The twist joint is adopted for thinner GI wires, less than 3.55 mm
dia. In this the two ends of the two wires are twisted directly without using a
binding wire.
B. Alluminium Conductor Steel Reinforce wire.

The joint made with ACSR are classified as

i) Tensioned joint and ii) Non tensioned joint.

i) Tensioned joint : this joint will be under the tension of span wire and are to be
located atleast 5 meters away from the insulator. Three types of tensional joints are
a) Twist sleeve joint : The free ends at the ACSRT wires to be jointed are inserted from
opposite direction into a pair of oval shaped alluminium tubes, called sleeves, and
then twisted by sleeve twister.
b) Compression joint (Single sleeve ) : Only one aluminium sleeve of circular cross-
section whose dia is slightly more than the wire is used.
The two ends of the wires to be jointed are inserted from opposite directions so that
two ends will be at centre of the sleeve and compressed tool at every 3 mm.
c) Compression joint (Separate sleeve) : A small steel sleeve is used for jointing the
inner steel wires and a separate aluminium sleeve for overall joint of the ACSR
conductor, first the steel wires are jointed.
iii) Non Tensioned joint : Non-tensioned joint are these which do not carry the
tension of the wires. In these joints, mechanical strength of the joint is not
important but electrical continuity is the main criterion.
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4. Testing of OH lines faults, fault localisation and rectification

Testing of OH wires : O.H lines are periodically tested once in 3 months. The
following tests are conducted.
A) Insulation Test : It is to measure the insulation resistance between the two
limbs L1 and L2 (cross insulation ) and each limb to earth and thereby to assess
of leakage.
The testing is done with the help of Insulation megger at early morning when
leakage is maximum.

The acceptable value is minimum 8 M Ohms/Km is in dry weather and 1.6 M

Ohms/Km in wet weather.
If the value is sub-standard , the line is to be inspected to
i) Replace the partially broken or cracked insulator.
ii) Cut the tree branches touching the wires.
iii) Clean the insulator, if necessary.
B) Conduction (Loop resistance ) test : It is to measure the loop resistance between
two lines L1 L2 and also L1 to Earth and L2 to Earth.
The testing is done with the help of a Bridge Megger at Mid-day when resistance is
maximum.
The acceptable value is maximum 5% may be tolerated in excess at the standard
value. If the loop resistance is very high, check
i) Wire joints
ii) P.G Clamps
iii) Pothead connectors.
iv) Sag
v) Broken strands of ACSR.
vi) Fuses, lightning arrestors. Etc.
C) Transmission loss test : It is to measure the attenuation loss offered by the line at
various spot.
The testing is done with the help of a TMs (Transmission Measuring Set ). Oscillator
and a dB meter preferably at the early morning.
The accepting value is maximum one dB for the total length may be tolerated.
If the value is found to be excess check for
i) Joints
ii) Pot head insulator
iii) P.G Clamp Joints etc.

Faults & Faulty Localisation

Some common types of faults are :

i) Loop or twist : The two limbs of the line L1 and L2 may got twisted due to
over sagging or shorted by stray wire etc.
Symptoms:- The line will be salient but the station upto which loop is occurred
can be contracted No communication with the station is available beyond the
loop from control office.
ii) Earth fault : Both the lines or one of them get earthen partially heavy
hum,i.e. inductive noise is available.
Cracking noise is available due to intermittently earthed.
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iii) Contact fault : One wire of one circuit touches the wire of another circuit
like section control wire touching block or telegraph line.
Symptoms : When the circuit comes in contact with Block lines, Block beats and feeble
speech will be heard on the circuit.
iv) Break fault : Speech and ringing will be normal upto the point of disconnection and
beyond this point the station will be out off.
Symptoms: The station upto which Break fault occurred ringing impulses will sound
from control station.

Rectification of faults :
As soon as a fault localised and the Block Section is identified, the JE Gr.II
(Tele) of that sub-section is to be informed immediately. The concerned like man is to be
ordered at once to proceed into the faulty section. He is to be given the following
information.
i) Name of the circuit (Section control, Block cct etc.)
ii) Block Section that is faulty.
iii) Time of interruption
iv) Available trains for him to proceed to the nearest Block station if possible.
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C A B L E

Introduction : Cable can be defined as, while a number of insulated electrical conductors bunched into a
compact form by providing mechanical protection and electrical insulation is generally called cable.
Cable can be taken under ground, under water (Submarine cable) Overhead(Aerial or
Field Service) and drag the wall of building (Indoor cable). The underground type of cables can be further
classified into signal, communication and power cables as used by Railways.
The communication type of underground cables again comprises of cables used for
telephone purposes and for train control in R.E.Area.

1. DIFFERENT CABLES USED IN TELECOM CIRCUIT AND LAYING PROCEDURE:

VARIOUS TYPES OF TELEPHONE UNDERGROUND CABLES :-
The underground telephone cables for telephone connections can be used in both R.E.
and Non-R.E. area.
Types of U/G Telephone Cables:
i) PCUT Paper Core Unit Twin. ii)PCQT Paper Core Quad Trunk.
ii) PCQL Paper Core Quad Local. iv) Multiple twin cables v)Poly AL Cable
Polyethylene Aluminium Moisture Barrier. Vi) PJ - Petroleum Jelly Filled
Cable.
Construction of PCUT cable :
1. Conductor : A uniform solid annealed copper wire of nearly circular cross section.
2. conductor Insulation : A chemically neutral paper tape is wrapped helically round
the annealed copper conductor. This paper tape encloses air around the wire,
separates the conductor from the other cconductor carries the coloured marking rings
and counting of wires and pairs.
3. Pairs : Two insulated conductors as above are twisted about the common axis. Each
pair takes one telephone circuit.
4. Layers : The twisted pairs are arranged in concentric layers.
5. Units : A 50 pair or 100 pair cable will have all the pair as one unit and this single
unit itself forms the core of the cable. Each layer in the unit is tied with a cotton
thread called Interlayer Binders. Each unit is tied with a colour cotton thread binder.
In each layer the first unit will have Orange binder & last unit will have green binder.
This binder helps in the identification of various UNITS in each layer of the given
cable (Paper type is also used instead of cotton thread). In that case the paper type
carries the number of the unit. Then the entire cone is wrapped with insulating paper.
Paper wrapping - Minimum two layers of paper is wrapped, Brown paper with red
rings indicates that the sheath is lead alloy but not pure lead.
Sheath - A metallic sheath of lead - Antimony alloy is extended over the core. The
sheath provides.
i) Mechanical protection to the cores, ii) Screening against induced voltage iii) Moisture
proof and water tight arrangement to the core, iv) A barrier for the insects and v) also
reduce the impact due to lightning on the cable.
Impregnated paper - Minimum two layers of paper impregnated with an insulating
compound are applied over the sheath .
Impregnated Jute: Two layers of impregnated jute are applied over the impregnated
paper. (The above impregnated paper and jute form into BEDDING).
Armouring - Two layers of galvanised mild steel tape are applied . The second layer
covers the gaps left by the first layer.
Serving Two layers of impregnated jute are applied over the steel tape are applied over
the steel tape armour. Then the cable is white washed so that it does not stick to the other
coils when the cable is reeled over wooden drums.
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PCQT CABLE : R.E.TELECOM. CABLE.

In R.E area main and derivation cables are used for train control communication
purposes. The main cable runs from one end of the section to the other and along the
track. The derivation cable is used en-route to the various utilisation points like way
stations, Signal cabins switching posts, feeding posts, etc., The main cable carries
aluminium sheath and it is a long distance cable. The derivation cable carries lead sheath
and it is a short length of cable. The size of the derivation cable will also be generally
small. But, the other features are same for both.
Construction of R.E. Cable (PCQT):
Conductor : Each conductor is of Plain annealed high conductivity copper with circular
cross section.
Conductor Insulation : It consists of paper insulated and Polyethylene (PET) insulated
conductors. For paper-insulated conductors, first the copper conductor is given a helical
whipping of paper string and then an insulating paper lap is applied over the paper string.
The insulating paper carries the coloured rings for identification purpose. This is called
Air spaced Dry Core. This improves insulation.
Polyethylene insulated conductors carry soiled colours with Nylon coating. The Nylon
Coating prevents the PET from softening due to heat at the time of jointing and
manufacturing.
QUADS : Four conductors insulated with paper are twisted together uniformly around a
paper string (axis) to from a Star Quad.
The PET Quad consists of Polyethylene string at the centre (axis). Each quad is provided
with helical cotton whipping around it is keep the four conductors of quad intact and to
facilitate the identification and counting of layers and quads.
Core : It is formed of all the quads arranged in concentric layers. Each layer is helical
wrapped with a insulating paper. Then its centered core is given at least four overall
helical wrappings of insulating papers. A metalised paper tape is applied to drain away
the heat to protect the PET from heat at the time of plumbing.
Sheath : The case furnished as above is extended with the sheath 99.55% aluminium is
used for main cable sheaths for better screening ability. All sheath is first given a primar
wash and then an anticorrosive compound is applied over it . A part from screening,
moisture (and insect) barrier for the core.
Bedding : Over the sheath, PVC jacket and impregnated paper are applied for main Al-
sheathed cables. For derivation cables anti-corrosive paper and layers of jute are provided
as bedding. Since lead is less prone to corrosion.
Armouring : Galvanised steel type is applied helically over the bedding in two layers,
the second layer covering the gaps left by the first layer. A layer of anti corrosive
compound is also applied on the steel tape armoring.
Jacking : Black PVC overall jacket doped with 2% carbon(to prevent ultra violet
radiation hazards) is applied over steel tape armour. The PVC can also be doped with
suitable or rodent repellant difficult. The PJ cable has also get the Poly-Al moisture
barrier, polyethylene sheath and jacket. But the colour code is different.
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Laying of Telecom. Cable

Life and performance of a telecommunication cable depend to large extent on the
care taken in installation of the cable and its jointing.

Testing of cable before Laying

Before the cable is laid, visual inspection of cable shall be made and it shall be
tested for insulation and continuity of the cores.
Bending and armouring shall also be inspected to see that there has been no
damage during transit or in storage.
Before the cable is unwinding from the drum, its insulation must be measured
after removing the end seals. No cable having insulation lower than that specification
shall be laid.
Paying Out Cables:
For paying out cables, drums shall be mounted on cable wheels. The drum on the
wheel shall be brought to one end of the trench and the end of the cable freed and laid in
the trench. The cable wheel shall then be drawn along the track.
A party of labourers shall follow the drum and guide the cable from the read into
the trench carefully so that the cable is not damaged or bent unduly.
In case where the wheels are not available, the drum shall be mounted on an axle
at one end of the trench and cable laid out and carried by labourers.
In no case, shall the drum be reeled off on to the road for laying the cable and the
cable dragged on the ground for laying purposes.
It should be ensured that no kink is formed while laying out the cable.
In no case shall the cable drum be laid flat on the ground and cable unrolled from
the drum by twisting the cable. This procedure may cause permanent damage to the
cable.

LAYING OF CABLES
Cables shall be laid generally as per standard instructions. Special precautions
shall be taken in the station, yards etc. where a number of other utilities may be existing
and may be detailed in joint circular issued by the Civil Engineering, Signalling and
Electrical department (Where applicable) of the Railway.
The width of the cable trench shall normally be 0.5 meters. The bottom of the
cable trench shall be leveled and get rid of any sharp materials. In the bottom of the
trench previously leveled. In the soft ground, the cable shall be laid at the bottom of the
trench previously leveled. In the rocky ground the cable shall be laid on a layer on a layer
of sand or shifted earth of 0.05 m. thickness previously deposited at the bottom of the
trench. To both the above cases, the cable shall be covered with a layer of sand or shifted
earth of 0.10-meter thickness.
The cable laid parallel to the track and between home signals of a station shall be
laid at the depth of 1 meter. Cable laid across the track shall be 1 meter below the rail
flanges. Cable laid beyond the home signals in a yard, automatic signal area or IBH or
Level Crossing Gates must be at a depth of 1.2 meters. All station yards, which are theft
prone, the cable shall be laid at cable crossing.
When a cable has to cross the track, it should be ensured that :
i) The cable crosses the track at right angles,
ii) The cable does not cross the track under 10 meters from the centre of the
nearest track.
iii) Within the station limits, the trenches shall preferably be dug at a
distance of not less than 3 meters from the centre of the track, width of
the trench being inside the 3 meters distance.
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iv) At the end of the main cable of the extra loop length of 6 to 8 meters
shall be kept.
It is desirable that the excavation of the trenches is not done in long lengths does not
remain uncovered overnight. It is preferable that trenches are dug, cables laid and
refilling done on the same day.
The inspecting official, who supervises the excavation works, shall have the
shorting materials ready in hand so that in banks where ashes or loose materials are
encountered, shoring can be adopted.
Back filling of the trenches should be done properly, rammed and consolidated.
During excavation, the earth of the trenches shall not thrown on the ballast. The
earth shall be thrown by the side of the trenches away from the track.
In places where cables are to laid close to the track, though preliminary after
digging upto 0.5 m. may be done, excavation to the full depth should be done only just
before laying the cables in the presence of an official from Engineering department.
The work shall be personally supervised at site personally be an official of the
Signal and Telecommunication Department below the rank of a Telecom. Inspector.

2. CABLE JOINTING, PROTECTION IN JOINTING AND CONNECTING

MATERIAL.TELEPHONE CABLE JOINTING
Jointing procedure for the lead sheathed PCUT Telephone cable:

The standard drum length of cable manufactured by M/S Hindustan Cable Limited is of
500 mts. Or 1000 mts., depending on the size of cable . So, when more than above length is
required, two drum lengths of cables are to be jointed, this type of joint is Straight Through
Joint. But in telephone cables, it is commonly called as Cable Joint.
Cable Jointing Pit :- At the site of cable jointing, a pit is to be dug up, the dimentions of
which can be 1.2m x 0.8m x 0.8m, and a tent is to be taken to prevent entry of water into the pit
in the event of rain etc.
Preparation of Lead Sleeve : This is a cylindrical pipe of Lead which is placed at the joint of
inter connection of the two ends of the cable as an extra piece. This serves as a metal cover over
the jointed open core. As per P&T standard size of Lead sleeve for commonly used cable size are
given below :-

No. of pairs in the cable Lead Sleeve (Length x internal dia) in mm.
6 Ibs / mile 10 Ibs / mile 20 Ibs / mile
10 152 x 19.1 152 x 19.1 305 x 25.4
20 305 x 25.4 305 x 25.4 305 x 38.1
50 305 x 38.1 305 x 38.1 381 x 50.8
100 381 x 50.8 381 x 50.8 457 x 63.5

A lead sleeve of length as shown above, is prepared out of lead steel if ready-made one is
not available. For the correct size of the lead steel is cut and it is made into a cylindrical tube. The
meeting edges are thoroughly cleaned with thick knife and it is neatly wiped with plumbing metal
using a little tallow (flux). Then it is inserted into an iron rod (or crow bar) and it is neatly dressed
with wooden mallet. The final shape should be inform in cross-section and free from bends. The
dia meter of this Lead Sleeves will always be larger than the diameter of the joint. A vent hole is
made at the centre of the lead sleeve by making a V-Cut.
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Preparation of Cable: The two cables to be jointed are made straight and over lapped. Then
leaving an overlapped. Then leaving an overlap of one and half times the length of the lead sleeve
to be used for jointing, the extra length of cable is cut.

Preparation of ends of Cable :-

1) On one end of the cable, a binding is done with a thin G.I wire at a length equal to one and
half times the length of Lead Sleeve to be used.
2) Then the jute serving is removed upto the point of binding by cutting it with a knife and
hammer.
3) Now, a second G.I binding is provided over the steel tape armouring (50 mm) away from the
first binding.
4) The double steel tape armouring is cut by a Hacksaw and removed one by one by cutting
pliers. (Care should be taken not to damage the inner Lead sheath).
5) Then the two layers of jute bedding and paper are removed by hand after slightly warning
with a kerosene blow lamp and cutting with a knife (This flame should not be burn the core
insulation ).
6) Lead sheath is cleaned with cotton waste moistened with a little kerosene.
7) After that all the tools used so far and the hands are cleaned thoroughly.
8) Now the lead sheath of the cable is cut by a hacksaw leaving 3 (75 mm) from the second
binding core should be taken not to damage the core while cutting the sheath .
In the same way the end of the other cable is also prepared.
Insertion of Lead Sleeve :- The prepared Lead Sleeve is now inserted into one end of the cable
before the conductor jointing is commenced.

Jointing of Conductor : A twin knot is made over the core insulation paper away from the
mouth of the lead sheath.
Then similar Twin knots are made for every layer. They keep the pairs in correct position while
jointing the individual conductors.
Now the two ends are kept face-to-face leaving some space between them. This space is called
Jointing Space.
This jointing space for commonly used cables is as given below : (as per P & T standard0
Length of Lead Sleeve Jointing Space
152 mm 100mm
305 mm 230 mm
381 mm 305 mm
457 mm 381 mm
Before commencing the jointing of copper conductors of the cable is to be tested to know the
condition of the cable.
Jointing Operation : the jointing operation is started with zero layer with marker pair. Paper
sleeve is inserted is one of the conductors before jointing.
First both the conductors are twisted twice alongwith paper insulation. Then the paper insulation
is carefully removed with a side cutter and again the bare copper wire is evenly twisted for a
length of about 1 (25 mm) and rest is trimmed off with a pair of nippers. Then the twisted
portion is bent on the side opposite to the paper sleeve and the paper sleeve is drawn over so that
the base portion of the twist is completely covered. The paper sleeve for the next pair is insulated
on the other side to reduce the bulging at the centre.
Soldering The tip is soldered for conductor gauges more than 6 Ibs/mile. The tip is also
soldered when conductors of different gauges are jointed.
Lacing :The complete joint is laced with twin to reduce bulging and to hold all the pairs in a grip.
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Heating : The above jointed portion is heated by charcoal flame to remove the inner moisture
(Do not use naked flame).
Wrapping of paper :Paper is wrapped over the joint to protect the conductors from heat which
will be applied during plumbing.
Plumbing : Now the lead sleeve which was inserted on one side of the cable drum over the joint
and it is dressed with a wooden mallet on the ends to taper the either ends to grip the sheath of the
cable (Keep the vent hole on the top).
Both the ends of cable sheath and the sleeve ends are cleaned with a shave hook and tallow is
applied to prevent any oxidation. The plumbing metal is melted in an iron ladle and poured on
one side of the dressed sleeve and the same is neatly wiped all over the end by a wiping pad. A
mirror can be use to see the bottom portion of the joint. Now, tallow is applied which cools the
joint. Similarly, the other end also wiped. Lastly the vent hole enables the inner gasses to escape
at the time of plumbing.

Straight through joint Box :- The above is kept in a straight through joint box for protection and
is fitted properly. Then bitumen compound is filled inside the box. If the G.I box is not available,
a brick chamber is to be made and the joint is secured in that and bitumen is filled completely to
make it moisture proof.
Earthing : An earth is used to connect armour for electrical continuity.

Note :-
1) In one end of the cable, the pairs appear in clockwise direction. This end is called A end
and a red band is provided at this end.
2) At every straight through joint, the A-end should meet the E-end to avoid cross-connection of
pairs. So, at the time of cable drum length faces the E-end of subsequent drum length.

3. PERIODICAL TESTS ON CABLES, FAULTS, FAULT-LOCALISATION AND

RECTIFICATION
The instruction deals with the periodical Tests of cable :
SCHEDULE OF TESTS: - PERIODICITY

1. Transmission loss test (Repeater to Repeater) Monthly

2. Insulation test (Repeater to cable Hut)
i) Between conductors of untapped quads
ii) Between conductors and earth Monthly
3. Loop resistance of untapped quad
(Repeater to cable Hut) Monthly
4. Measurement of Signalling voltage at input and output of repeater. Monthly
5. Input and Output level of Repeater station . Monthly
6. Measurement of Cross talk (RPTR to RPTR) Quarterly
i) Near End
ii) Far End
7. Measurement of noise on cable Yearly

PROCUDURE OF TESTING
a. Transmission loss test (Repeater to Repeater)
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Feed a tone of 0 dB at 800 Hz to the cable pair under measurement. Measure the
attenuation of the measuring end by keeping the switch of the TMS Kit in Trans(Loss)
position. The transmission loss should be 0.25 dB/Km (for loaded RE Cable).
b. Insulation resistance :
The insulation resistance should be measured by a 100V Megger only between
conductors of pairs of untapped quads and between each limb and earth. The insulation
resistance should not be less than 625 Meg Ohms/Km of each conductor is at 16 degree
centigrade.
During the month from July to October the insulation resistance should be measured
daily on a test quad. This will give a pre warning to the maintenance staff if the insulation
of the cable goes down below the determined value so that immediate action may be
taken before the complete failure of cable.
c. Loop resistance :
The loop resistance measurement should be carried out on untapped quads between
Repeater and cable Hut by a meter of an approved type or by a wheat-stone Bridge.
d. Signalling Voltage:
The signalling voltage should be measured on load by feeding permanent voltage from
Test Room . The input and output voltage of all repeater stations should be measured by a
meter of approved type. The signalling voltage should be measured on all quads having
phantom derivation.
e. Input and Output Levels:
The performance of the cable circuit can be checked by conducting this through test.
Feed a tone of 5 dBm at 800 Hz on Pair 1 from Test room and measure at the input of the
first Repeater station by disconnecting the plug (U links). The reading should be
measured by TMS Kit on Trans position. This will give loss of cable of between
CT/Room and 1st RPTR connect the plug and measure the level at output of repeater
disconnecting between the second & first reading gives the gain of the trans amplifier of
the circuit under test. Put through the plugs and measure the level at the input of the of
the second repeater in the same manner as described earlier. The difference in reading of
3rd. and 2nd gives the loss in cable between first in the second Repeater stations. Likewise,
reading should be taken on all Repeater stations.
For receive pair (Pr.2), the last repeater station will feed a tone and the other repeater
stations will measure as describe.
The above test is to be conducted by keeping the switch of the TMS Kit in Loss position
& all reading should be taken by isolating the plugs.
f. Near End & Far End Cross Talk:
The measurement of cross talk shall be carried out by a cross talk meter. Far end cross
talk level should be better than 65 dB & Near talk level should be better than 61 dB.
i) Near and Far end cross talk should be measured by feeding a tone of 0 dB at
800Hz. On Pr.1 (Disturbing pair) of quad and measuring the talk on Pr.2
(Disturbed pair)at the same station. While conducting test the cable at the other
end should be kept isolated.
ii) To measure far end cross talk a signal of 0dB 800 Hz shall be feed on Pr.1 and
resulting cross talk should be measured on Pr.2 at the far end. While conducting
far end talk, the far end should be terminated by a characteristic impedance.

Noise on Cable:
Interference to speech transmission, is, the psophometric voltage in communication cable
is to be measured by Psophometer. This is to be done by connecting a 600 Ohms
resistance across the telephone circuit. The Psophometer voltage should not exceed
2 mV.
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FAULT LOCALISATION ON COMMUNICATION CABLES :-

Fault occurring in cables which are in use on Lower distribution voltages will be
considered. The common faults which are likely to occur in such cables are:
i. Group Fault : The insulation of the cable may break down causing a flow of current
from the core of the cable to the lead sheath or to the earth. This is called Group Fault.
ii. Short Circuit Fault : If the insulation between the conductors is faulty, a current flows
between them . This is called a Short circuit Fault.
iii. Open circuit Fault : An open circuit fault occurs when a conductor gets between or when
a joint pulls out.

Method used for localisation ground and short circuit faults differ from these used for
localisation open circuit faults.
METHIOD USED FOR LOCALISING GROUND AND SHORT CIRCUIT
FAULTS :
In case of multicore cable it is advisable first of all, to measure insulation resistance of
each core to earth and also between cores. This enables to sort out the core that is earthed
in case of Ground fault, and so sort out the cores that are shorted in case of a Short circuit
fault Loop tests are used for location of Ground and Short circuit faults. These tests can
only be used if a sound cable runs along with the faulty cable of cables.
The Loop tests work on the principle of Whetstone Bridge. The advantage of these tests
is that the resistance of fault is connected in the battery circuit and therefore does not
affect the result. However if the fault resistance is high, the sensitivity is adversely
affected. Murray and Varley Loop tests are generally carried out for localising Ground
and Short circuit faults.

LOCALISATION OF OPEN CIRCUIT FAULTS IN CABLES :

The Localisation of an Open circuit in a cable may be done by a capacitance test. The
principle of this method is based upon the fact that the capacitance of a cable is
proportional to its length. In case the total capacitance measurement is necessary. The
capacitance measurements may be done by any of the Known methods by using Iantys
bridge or using a Ballistic galvanometer.

4. TERMINATION OF CABLE

Pot heading of cable: It is the operation of connecting the terminal end of the underground
telephone cable to PVC switchboard cables. The PVC switchboard cables are then directly
terminated on equipment. First, the conductor of the PVC cable. Then a separate Lead sleeve is
plumbed (after dressing) to the lead sheath of the pot sleeve . the inner space of the pot sleeve is
completely filled with wax to seal against moisture entry. A circular lid of lead is then soldered
on the top end of the sleeve. The PVC cables are taken through the holes in the top lid . This is
indoor type of joint and hence it should not be exposed to outside weather. These pot heads are
fixed vertically on walls or kept inside the cable trench on the floor.
 14

Termination of Cable :- The under ground cables terminated in termination box. There are two
types of boxes:
i) Cable termination box (C.T box)
ii) Protected cable termination box (P.C.T.box), C.T. box is used for indoor
terminations. The conductors of the pairs are terminated and soldered on the tags
provided on the back side of box. The PVC cable is connected to the terminal
provided on the front side of the box. The back portion is completely filled with
bitumen compound to avoid entry of moisture. The C.T. boxes are mounted
vertically on walls. A gland is plumbed to the cable sheath at the entry of the box.
An earth clamp is also provided as shown in fig.6.
P.C.T box is used when over-head lines are connected to underground cable. This

Is meant for outdoor use. Hence it is protected from weather conditions.

Protective devices like fuses etc.,are also provided.

5. COLOUR CODE SCHEME IN TELECOM. CABLES IDENTIFYING

PAIRS AND QUADS
COLOUR CODE (FIG. 2) OF PCUT CABLE IDENTIFYING PAIRS :
Colour Coding Scheme :

i) PCUT Cable : Here to remember marker and layer colour of ODD and EVEN layer
the following may be followed :-

Blue => Layer colour

Orange => Marker colour
B O R G Red => Layer colour
(Blue) (Orange) (Red) (Green) Green=>Marker Colour

ODD Layer EVEN Layer

ii) Polythene insulated cable : The following may be followed to remember colour
code of switch board, jelly filled etc. cables for long duration.

B O G B S this indicate colour code for Main wire

Blue Orange Green Brown Slate

Mate wire for PJ filled cable : W R B Y

(White) (Red) (Black) (Yellow)

Mate wire for SB (Switch Board) Cable : W Y B R P

(white) (Yellow) (Black) (Red) ( Pink)
 15

iii) PCQT cable : In case (i) i.e. in PCQT cable it has been observed that BORG is
followed for layers (ODD and EVEN) but here in case ii) i.e. in PCQT cable colour
code of string (thread) is the striking criteria. In that case, the following order may be
followed for durable remembrance.

Sl Layer Coloured Ring for Coloured Thread for

No. 1st Quad Last Others 1st Quad Last Others
(Marker) Quad(Ref.) (Marker) Quad(Ref.)
1. EVEN RED BLUE Bl. & R W.O W.O W(White)
alternate (White
Orange)
2. ODD RED BLUE -DO- BK,O BK, O BK
(Black,
Orange)

Pictorial Description Of PCQT cable :-

i) Distribution of layers :-

Layer 0 (May be treated as EVEN Layer)

Layer 1 ODD layer.

Layer 2 EVEN Layer

Layer 3 ODD Layer.

ii) Distribution of marker and reference quads :

Sl ITEM FIGURES DEPICTING COLOUR CODE

No.
1. First quad of layer2
(EVEN)(MARKER)
 16

Sl ITEM FIGURES DEPICTING COLOUR CODE

No.
2. Last Quad of layer
3(ODD)(REFERENCE)

3. Fourth Quad of layer

zero
(EVEN)(OTHERS)

In case of 3rd . quad in layer zero the only change will be Blue will be replaced by red colour ring.

In this cable the paper insulation on the conductor carries the coloured rings at
equal lengths throughout the cable as shown in fig. 2 : 1. The pairs twisted (in fig. 2.3)
are arranged into the concentric layers.
i) Pairs in ODD layers carry Blue rings. But first and second pair in each ODD
layer carry ORANGE rings. Out of the two ORANGE ring pairs, single and
double pair is the First one and three and four ring pair is the second one (fig.3).
ii) Pairs in EVEN layers carry RED rings. But first and second pairs in each even
layer carry GREEN rings. Out of the two GREEN ring pairs, single and double
ring pair is first one and three and four ring pair is the second one.
First and second pairs in any layer is called Marker 1 and Marker 2
respectively. Zero layer is the even layer. The above system of identification and
counting of pairswith the help of colour is called colour code or Colour
Scheme

COLOUR CODE SCHEME IN R.E (PCQT) TELECOM. CABLES

IDENTIFYING QUADS AND SPECIFICATION :
The four wires A,B,C,D in a quad carry Blue or Red coloured rings in groups as
shown in fig. 7.
The diagonally opposite wires in a quad form a pair, each concentrically arranged
quad in the core carry overall external cotton thread (whipping) in a helical
 17

manner. The colour of this cotton whipping is white For here and even layers
except the first and last quads in each of the above layers. Black For ODD
layers. For the first and last quads in all ODD and even layers an extra orange
thread is added to the black or white whipping.

Identification of first and last quads in each layer can be done as per the table
shown below :
Quad Zero layer and Even layer Odd layer
Colour of Colour of cotton Colour of Colour of
Rings whipping Rings. cotton
whipping
First quad Red White Red Black
Last quad Blue Orange Black Orange

Different parameters of R.E Cables :

R - Resistance
C - Capacitance
L - Inductance
G - Leakance

6. STUDY OF JELLY FILLED CABLE

Jelly filled cable is an underground cable having polythene as insulation on conductors

and the interspaces between the conductors is fully filled with petroleum jelly. Petroleum jelly
prevents entry of moisture and water inside the core area in the event of any damages to the cable.
The cable is circular in shape through out its length and free from any physical defect.
Jelly filled cable is wound on strong wooden drum. The length of the cable on any drum
is of 500 mtrs. + 10% .

Uses :
In Railway Polyethylene sheathed Jelly filled cable with poly-Al moisture barrier is used
for providing telephone connection to the subscribers and jelly filled quad cable is used for
special purposes in Railway electrified area .
Fault localization is easily possible in Jelly Filled cable as water does not spread into it.

The different sizes of cables to be used for various telecommunication circuits are as following
table :
Sr No. Size of conductor Circuit
1 2.81 Kg/Km (10 Ib/mile) Subscriber connections no exceeding 5 Km
2 5.65 Kg/Km (20 Ib/mile) Subscribers connections and different lines 5
to 8 km long.
3 11.26 Kg/Km (40 Ib/mile) Tie lines on more than 8 Km in the same
local area.
 18

4 28.19 Kg/Km (100 Ib/mile) Control cables and long distance trunk circuit
5 Quaded cable, 0.mm copper Telecommunications control circuits in RE
conductor. area

Construction of Jelly Filled cable :

A B C D E F

LEGENDS:

A Polythene outer jacket

B Galvanised steel tape
C Polythene Tape
D Polythene Inner sheath
E Poly-Al-Laminated Tape
F Polythene Insulated Copper Conductor

7. Normal Joint, Loading coil joint, Capacitor joint and T joint and Joint Practice
Joints in R.E. Cable:

Types Spacing
i) Straight through (Normal Joint) (SJ) 457.5 mts.
 19

ii) Loading Coil Joint (LCJ) 1830 mts.

iii) Derivation joint (Transformer Joint) (DJ) Tapping points.
iv) Straight through cum derivation joints (SJ/DJ) 457.5 mts.
v) Capacitor Joint (CJ) 915 mts.

Purpose of the above different joints :-

i) Straight through joint is made to interconnect two successive lengths of cable.

ii) Loading coil joint is made to interpose extra inductance in the form of loading coils in
series with the conductors of VF pair to keep the attenuation low in the VF range and
make the circuit to work as a Low Pass Filter.
iii) Derivation Joint is made to connect the derivation cable with the main cable through
transformers wherever tapping of circuits are required.
iv) Straight through cum Derivation Joint : In case of a derivation joint falling very near to a
normal joint, both the joints are clubbed into single joint.
v) Capacitor Joint is made to connect capacitors in parallel externally to the VF quads for
the purpose of reducing noise and cross talk in the V.F circuits.

Then with a smooth file (without damaging the core ) and removed to twin. Knot is put
on the core 25 mm. Away from the bell mouth of the aluminium sheath.

Insertion of Lead Sheath : A Lead Sleeve with top vent hole to escape hot air and moisture is
prepared and slipped into one end of the cable. For Al sheathed cables only Lead Sleeves are
used, not Al Sleeve.

Layer Separation : The various layer are separated and quad No. Rings are inserted on both
sides.

Testing : The cable is tested with a megger.

Jointing of Quads: The quad conductors are jointed starting from zero layer Marker quad on
both sides as per quad No. rings.

Jonting of PET Quads : The PET conductors are butt jointed by using tinned split copper sleeve.

Bandaging : This splitted joint is laced with cotton twin to keep it intact and compact.

Dressing and Plumbing of Lead Sleeve :- Now the Lead Sleeve is slides. Now the lead sleeve is
slided over the joint with vent hole on top and both ends are dressed taper with a wooden mallet
ends are dressed taper with a wooden mallet to grip the Al sheath. After that both end of the
sleeve are sealed with plumbers metal heated by a white petrol blowlamp.
Bonding wire is connected from armour to armour via Al sheath and Lead Sleeve to maintain
continuity for screening.

Anti-corrosive protection :- Anti-corrosive tape and paint is applied on it.

 20

Straight through joint Box :- The entire portion of jointing placed into a straight through joint
box and filled with bitumen compound.
Precaution :-
1. The pit should protect from entry of water.
2. The joint should be kept horizontal.
3. A end of cable should meet the E end.
4. A heap of mud should be placed over the burried joint to flow water away.
5. Bitumen compound should be cooled before pouring the CI box also with nuts and bolts
of CI box to protect from resting.

Loading Coil Joint :

In a transmission line the attenuation (dB loss) increases with increase of frequency and
decrease of diameter of the conductor. So in underground cables the attenuation is much higher
than that of overhead lines. In case of transmission lines the condition for minimum attenuation is
given by the formula :
LG=CR
Or, L = C R
G

Where R (Resistance ), C (Capacitance) L (Inductance) and G ( Leakance) are the primary

constants of the transmission are the primary of the transmission line.
But in R.E. communication cables with .9 mm, diameter copper conductors by construction the
value of L is very less and C is more due to closer spacing of cable conductors, R is also more
due to thinner conductors and G is very small (in micro Ohm) due to the better insulation. So, to
keep down the attenuation in R.E. communication cable, either we must increase the L and / or
decrease C in order to satisfy less free line condition Viz. LG = CR.
C (Capacitance ) of the cable pair can be decreased only when the pair separation is increased.
This increased the size and cost of the cable. So it is found convenient to increase the L
(inductance) by artificial means, which is termed as LOADING of cables.
Different methods are adopted for loading of cables. One method is to wrap each conductor of the
cable with a wire or tape of soft magnetic material. This is called Continuous Loading and it is
costly, so it is adopted for submarine cables only.
In R.E. cables loading is done by connecting Lumped Impedance (called Loading coil) of 88 mH.
To VF pairs only at regular intervals of 1830 mts. This method is called Lumped Loading.

Requirement of Loading Coils:

They must have 1) Low resistance 2) High insulation, 3) Low capacitance, 4) Smaller size with
higher inductance, 5) Shielding to avoid interference to other coils, 6) Equal electrical effects on
each by of the circuit (Electrical balance to avoid cross talk and 7) Reasonable cost.

Construction of Loading Coil :

The wire is wound on a core of toroidal shape in two exactly equal parts. Each part is inserted in
one conductor of a pair in series so that exactly half the inductance is added 15 each conductor of
the pair. In the latest construction ferrite rings are used as cores. The two parts of the coil should
have balanced electrical properties to avoid Cross talk.
Connection of a Loading Coil :-
The loading coils are connected as shown: -
A A

B B
 21

Loading Coil Loading Coil

To balance the parts of the coil electrically the actual winding is done as shown :-
Note : 1. Only the V.F pairs are loaded in R.E. Communication cable . The Phantom and PET
pairs are not loaded.
2. The local telephone cables are not loaded.
3. The coils are sealed and only the loads will be available outside the box.

DERIVATION JOINTS.
For tapping the required circuits, from the main cable, a derivation cable is not directly connected
to the main cable but it is connected through transformers as shown in fig. So, it is also called as
Transformer Joint. The transformers are used for impedance matching.

TX

Quad Main Cable

RX

CAPACITOR JOINT (CABLE BALANCING).

During the process of cable manufacture, care is taken to keep the various capacitance
unbalances within close limits. But due to the handling of cable in the process of paying out and
laying the various capacitance unbalances are created. This capacitance, unbalance causes, cross
talk and noise in V.F circuits carried in the cable. In RE communication cable, the capacitance
unbalance exists between:
a) Conductors of a quad and sheath (Earthed). This is called of a Earth Coupling.
b) Conductors of a quad and between adjacent quads. This is called Cross talk coupling.
Cross talk couplings cause cross talk and Earth couplings produce noise in VF circuits. Hence
to limit the cross talk and noise in R.E V.F circuit, the two couplings are measured in the field
after laying the cable by an instrument called CUM set (Capacitance Unbalance Measuring
set)and the measured values are recorded in a tabular form. With the help of these tabulated
readings, the corrective measures are adopted.
4. By transposing the two conductors of a pair where necessary. This is called polingand
Poling is done to reduce Earth coupling.
5. By connecting capacitors externally in shunt. This is done for reducing the cross talk
coupling.
The above operation, by which the capacitance unbalances are brought within the permissible
limits, is termed as Balancing.
Permissible limits of capacitance unbalance for full and half loading sections are 40 PF and
20 PF respectively.
CUM Set :-
Capacitance Unbalance Measuring set is the instrument by which the various capacitance
unbalances of the cable circuits are measured.
The unit basically consists of an oscillator circuit and a calibrated capacitor with the
associated controls to simulate the various circuit configurations of e and k.
 22

The principle of working of this meter is, feeding an audio tone in one side circuit and
monitoring the level of the tone on the affected side circuit. This monitoring is done by a head
phone (or a meter deflection) . The level of the tone is brought to minimum by introducing known
value of capacitance. Thus the amount of unbalance can be directly read on a calibrated variable
capacitor. The conductor across which the external balancing charts or from the Campbell
equation.

4. CABLE USED IN TELEPHONE EXCHANGE INSIDE / OUTSIDE AND THEIR

PERIODICAL TESTING.

INDOOR WIRING CABLES :

i) Cable VIR (Vulcanised India Rubber) braided and compounded single core
copper conductor 250/440 V for indoor wiring of telecommunication circuits.
ii) Cable PVC (Poly Vinyle Chloride) insulated black PVC Sheathed flat twin core
copper conductors, 250/440V
iii) Switch Board Cable: - It is an indoor type of cable used for extending the
connection to various locations in the administrative building or for
interconnection of various stages of equipment in Telephone Exchange, Trunk
Boards, etc. These cables are run along the walls on wooden batten fixed with
link clips. These cables are used previously for wiring manual switchboards,
hence the name. This cable consists of high-grade annealed tinned copper
conductors with PVC insulation and cable is PVC sheathed.
The core is wrapped with a moisture proof tape (Cellulose). The copper
conductors are tinned to avoid oxidation during soldering cables with conductor
diameters of 0.5 mm and 0.6 mm are available Rip cord is a nylon thread. It is
used to cut open the sheath.
iv) FS cable : Field service cable is used for outdoor applications for providing
communication on temporary basis in floods, cyclone, etc. They can be substitute
for over head lines also. The specification of Field Service cable, Single core
twin twisted, size : 7/0.0148(0.375 mm) 250 V /440V grade PVC insulated and
PVC sheathed.

9. SOLDERING :
It is a process of jointing two metal pieces permanently like metal plates, wires
etc.
SOLDERING PROCESS :
Metal pieces are first cleaned with help of sand paper or knives and then heated
at the place to be jointed by the Bit of the soldering Iron. When the place is sufficiently
heated, a little flux is applied so that the moisture or any oil and grease is removed by
chemical action. A little solder is then applied on the place, which melts away and flows
 23

through the entire heated surface. Now the soldering Iron is removed from the jointing
place and the joint is allowed to cool down which will make a strong permanent joint.
RESIN CORED SOLDER.
It is a wire type solders flexible and soft whose inner core is hollow which is
filled with resin powder. The resin power functions as Flux.
FLUX: To remove oxidise layer, any oil, grease etc. Flux is made of rasin, Borax, HCl,
ZnCl2, salamnonial.

DOS & DONTS

Dos

Overhead

1. Periodical Testing should be done within the predetermined time for better maintenance
of Overhead alignment.
2. Lightning spike must be provided in every post.
3. Stay wire must be provided in all posts and should be tightened properly.
4. During power line (LT & HT) crossing standard spacing must be followed and guard
must be provided overhead wires.
5. Specified gap must be maintained for Railway & Road crossing and in congested
localities.
6. Care must be taken for any type of overhead jointing so that high resistance may not
formed. Grease must be applied during jointing.

Cable

1. Keep the proper distance at the time of cable laying alongwith Railway track.
2. Soil depth of cable must be followed as per extend rule.
3. Laying cable should not be exposed without filling of soil and ends of the cable to be
covered with proper Nalco taping.
4. Cable sheath and Armour should be earthed with an interval of one Kilometer.
5. Distance of cable hut should be maintained properly for termination and testing purpose.
6. Insulation of cable should be maintained properly .
7. A lead sleeve with top vent hole to escape hot air and moisture.

Donts
Overhead

1. More than tolerated sag cannot be allowed.

2. Corrosive and edged wires dont use for O/H transmission.
3. No strands of ACSR wire should not be kept. That should be immediately treated.
4. The insulator should not be dirty
5. Joints of ACSR wires should not bend in the process of twisting.
 24

6. Bulging at the centre of the joint not to be formed.

Cable

1. No induced voltage may arise to dangerous values. Precautions to be taken for avoiding
electric shock.
2. Dont mount the drum without cable wheels.
3. Dont expose the cable without filling of soil during laying.
4. width of the cable trench should not be kept below 0.5 meters.
5. Dont keep cable trench at a distance below 3 mtrs. from the centre of the track within
station limits.

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