Armoured PIJF Cable

Unarmoured PIJF Cable

Cross section
Cable pair identification
50 pair

SU-Super unit
10 pr unit * 5 SU
2
nd
wire: BL-O-GR-BR-SL
1
st
wire: White-Red-Black-
Yellow

Upto 50 pair one spare pair
100 pr-2 spares
Spares outside unit
Cable Layering
2400 Pair
Conductor: Solid annealed copperith conductor sizes of 0.4 & 0.6mm.
Insulation: Colored high molecular weight solid High Density Polyethylene.
Color Coding: Cables are fully color coded in accordance with PIC even count color code.
Twining/pairing: Two colored insulated conductors are uniformly twisted together to form a
pair. Varying lay length is designed to minimize the cross talk and capacitance unbalance.
Stranding / Cabling: Twisted pairs are assembled into unit of 25 pairs. When desired for lay-up
reason, the units are divided into two or more sub-units, which are bind with durably colored
polyethylene tapes to form a compact and circular cable.
Filling Compound: The water resistant filling compound is applied to the air space within the
cable core.
Core Covering: A non-hygroscopic and dielectric Polyester Tape and Water Blocking Tape are
applied helically having a suitable overlap.
Flooding Compound: Sufficient flooding compound is applied between the core wrap and
shield.
Moisture Barrier Inner Sheath: An aluminum tape with co-polymer coating is applied over the
cable core and then sheathed with black polyethylene compound.
Jacket: Black High Molecular weight low density polyethylene compound.
Identification: A plastic tape, duly marked with the manufacturers name, year of manufacture
and cable size, if required, is placed under the core covering. Alternatively, thesse details may
be printed on the outer jacket of cable.

CONDUCTOR
Pairing and Overlay
Unit Formation
Core wrappings
Filling compound
SCREEN
SHEATH
ARMOURING
Pairing and Overlay
Two insulated conductors shall be twisted
together with uniform lay to form a pair.
The length of the lay of any pair shall be
different from that of adjacent pairs. The
lay of various pairs shall be so chosen as
to satisfy the capacitance unbalance
requirements and cross-task requirement.
SCREEN
An aluminum tape coated with
polythene / copolymer on both sides
shall be applied over the cable core
with a minimum overlap of 6 mm for all
sizes of cables
CODE FOR WIRE
IDENTIFICATION
Primary colors For 1st wire in a pair
White
Red
Black
Yellow

Secondary colors For 2nd wire in
a pair and binder tape of unit in
50pr/100pr unit
Blue

Orange

Green

Brown

Slate/Gray
CODE FOR TAPE OR BINDER
FOR UNIT IDENTIFICATION
Unit Colour
1 Blue
2 Orange
3 Green
4 Brown
5 Slate/Gray
Super Units
200 & 400 pair cable su of 50 paiirs

Above 400 pairs su of 100 pairs
Identification of super units
Position of the layer Colour

First (Marker) Red
Itermediate White
Last (Reference) Black

The numbering of the units will be clock
wise

CABLE LAYING
Receipt, storage, handling and
transport of cable
Surveying and selection of routes,
trenching and laying
Jointing of cables and termination
Preparation of cable plan, cable
diagram and other relevant records
Acceptance testing
SURVEYING THE SELECTION OF
ROUTE :
The routes should be as short as practicable provided other requirements
viz., future requirements and expansion of other services are take in to
consideration. Normally the cable should be laid along road and railway
tracks.
(b) Corrosive soil should be avoided. If unavoidable measures like
covering
the cable with sand or drawing the cable through non-reactive duct should
be adopted.
(c) Opening of expensive pavements and roads should be avoided.
(d) The consideration should be given to the existence, alternation and
growth of other services.
(e) While surveying along a new road under construction or newly
developed area, proper coordination should be maintained with other
underground services like water, electricity, sewage, gas etc.
DEPENDING UPON THE ROUTE
SELECTED, PERMISSION FOR
DIGGING TRENCHES ARE TO BE
TAKEN FROM THE RELEVANT
AUTHORITIES
AT THE TIME OF TRENCHING
OPERATION CO-ORDINATION
WITH THE FOLLOWING AUTHORITIES
ARE TO BE MAINTAINED:-
(1)Electric supply.
(2) Water supple.
(3) Gas pipeline.
(4) Sewage system.


TRENCHING :
Trenching should be such that the top of the
cable should not be less than
60 cms. from the soil surface.
(b) The alignment should be straight at least 50
m at a stretch.
(c) It should be at least 0.3m away from the
boundary walls.
(d) The depth of the trench should be 1.2 m.
(e) The width of the trench should be between
30 cm and 40 cm minimum
(i) A separation of 0.6 m (relaxable upto 0.2m)
should be maintained while cable laid parallel to
electric cables.

(ii) Parallelism exceeding 0.8 km with 11KV and
above should be referred to PTCC
(iii) At the crossing with electric cables, the
telephone cable should be laid solid in between
for 90 cm on either side. Cross-trenches (trial
pits are to be made if records for existing
services
The min. bending diameter for armoured
cables should be 15 times of the
diameter of the cable
ROAD CROSSING
Cable should be laid through G.I. pipes of
suitable sizes.
(b) The depth of the pipe from the surface
of the road should be 1m and with a slight
slope to pass away water.
(c) The number of pipes laid at a time
should be sufficient to cater to the
requirements for 20 years.
(d) No jointing in the middle of the road
GUIDELINES FOR LAYING OF
CABLES ALONG NATIONAL
HIGH WAYS
Permission from the Chief Engineer PWD is to be taken.

(b) The cables should be laid at distance not less than
457 cm from the Centerline of the road on formation.

(c) The depth of the cable from the soil surface should
not be less than 120 cm.

(d) While laying along grove or avenue, due
consideration to save the cable from the clutches of the
roots are envisaged
Along over bridges culverts &
Fly over
A culvert should be paid by a concrete
channel of 12 depth below the bed of the
culvert to correspond to the footpath
alignment so that all the cables can be
drawn through this opening
In order to lay the cable across small
bridges with piers the piers should be
extended beyond the width of the road so
that pipe for cables may be securely
clamped on the piers
In case of long bridges and fly over in
cities, liaison should be kept with proper
authorities to ensure that suitable
arrangements are provided for laying
cables. the present practice is to have a
concrete channel 20 to 30 cm in depth 90
cm in width along the footpath with
removable covers
ALONG RAILWAYS
Side of the track will be selected by DET in
consultation with proper Railway authority e.g.
either Divisional Operating superintendent or
district Engineer, if the alignment falls within 3
to 5.5 meters from the centre line of any
Railway Track.
Excavation and reinstatement for any
underground cable within 3 meters of the
centre of any Railway track or any attachment
to any Railway structure should be attended by
the Railway staff at the cost of DOT.
RAILWAY CROSSING
Railway track should be crossed by G.I. pipes
of 75 mm dia.
Minimum depth of the GI pipe from below the
rail level should be 1.25 meters.
The length of the pipe should be sufficiently
long so that work on telecom alignment can be
carried out without any hindrance to the
railway traffic. This should extend at least 4.5
meters from the center of the last track.
LAYING METHOD OF THE
CABLE
Laying direct in the
ground
laying solid
drawing through
duct or duct laying
Digging the trench as per
standard The digging may be
done manually or be thrust
boring or by other mechanical
means.
Preparation of a bedding 5 cm
high of soft soil (sieved earth)
free from stones and corrosive
elements.
Thorough checking of cable
which is to be laid.
Paying out the cable in the
trench
LAYING METHOD OF THE
CABLE
Laying direct in the
ground
laying solid
drawing through
duct or duct laying
As a protective measure a row
of bricks
(length wise or width wise
depending upon the number of
cables) or stone slabs are to be
placed along with cable
alignment. The modern practice
is to lay a plastic tape with name
of the Department printed on it
at about 30 cms above and
along with cable alignment
LAYING METHOD OF THE
CABLE
Laying direct in the
ground
laying solid
drawing through
duct or duct laying
As a protective measure a row
of bricks
(length wise or width wise
depending upon the number of
cables) or stone slabs are to be
placed along with cable
alignment. The modern practice
is to lay a plastic tape with name
of the Department printed on it
at about 30 cms above and
along with cable alignment
DIRECT LAYING
Digging the trench as per standard The
digging may be done manually or be thrust
boring or by other mechanical means.
Preparation of a bedding 5 cm high of
soft soil (sieved earth) free from stones
and corrosive elements.
Thorough checking of cable which is to
be laid.
Paying out the cable in the trench
Precautions at the time of paying
There should not be any twist in the cable and
there should not be heavy strain (specially in
the case of un armoured cable)
Laying should be as far as practicable
straight and along one side of the bed of the
trench .
If more than one cable are to be laid at a
time, there must not be any criss-cross of the
cables.
Warning Bricks or tapes
As a protective measure a row of bricks
(length wise or width wise depending upon
the number of cables) or stone slabs are
to be placed along with cable alignment.
The modern practice is to lay a plastic
tape with name of the Department printed
on it at about 30 cms above and along
with cable alignment
Preparation of diagrams &
records
All the diagrams relating to the cable
alignment viz. line diagram for primary
secondary and distribution side, cable
plan for primary secondary and distribution
side, records for Pillars and DPs etc. are
to be prepared.
JOINTING ACTIVITY

Some Common Wrong Practices
and Their Remedies.
Crossing Water Pipes
Crossing Culverts

Crossing 11KV Electric Cables
In respect of parallelism, it is advisable to take
the telecom cable with maximum horizontal
clearance as far as practicable but not less than
0.6 meters
Absence of sheath continuity and armour
continuity in Telecom cable and its improper
earthing in the vicinity of power cable will result
in AC induction and consequent impairment of
the telecom circuits

When the power parallelism is more than
0.8 kms the cable route should be referred
to Power Telecom Co-ordination
Committee (PTCC) for recommendation of
protection measures
. In case of crossings, care should be taken see
that telecom cable crosses at right angles and at
a vertical clearance preferably of 0.6 meters but
not less than 0.3 meters at any point. When the
specified clearances cannot be maintained, it is
preferable to lay the telecom cable through
cement concrete pipes for a length of 1 meter on
either side of power cable at the crossing and
seal the mouths at both ends.
CABLE JOINTING
STRAIGHT JOINT

BRANCH JOINT

ARRANGEMENTS TO BE MADE
BEFORE THE START OF JOINTING
CONDUCTOR JOINTING
CONVENTIONAL METHOD :-Twist Joint

USING CONNECTORS

DIFFERENT JOINTING
PROCEDURES IN TELECOM
CABLES
LEAD SLEEVE JOINTS
AUXILIARY LEAD SLEEVE SEAL
(ALSS) JOINT.
JOINTING OF JELLY FILLED CABLES
USINGT THERMOSHRINKING
TECHNIQUE
PROCEDURE FOR JOINTING J.F.
CABLE USING XAGA
TECHNIQUE
Cable Marking
Armour removing
Conductor Jointing
Filling of Compound
Metal Canister
Cable Preparation
Thermo shrinking
Armour Continuity Completed


Kit Selection
TSF 1 10/6.5, 20/6.5
TSF2 50/6.5
TSF3 100/6.5
TSF4 200,300, 400/6.5
TSF5 600, 800/6.5
TSF 6 1000 ,1200/6.5
When cables to be jointed are of same
pair found on both sides, use the kit
indicated in the kit selection chart


b)When one cable is larger in pair count
than the other, the kit indicated against
the smaller one is to be used, e.g. to join a
100 pair cable to a 20 pair cable, TST
1 is to be used.
. The sum of the diameters of all the cables on
the branch side plus the thickness of branch
clips should not exceed the maximum splice
bundle diameter indicated in the kit selection
chart.
Condition 2. If any side contains only one
cable, the diameter of the single cable should
not fall below the minimum cable diameter
indicated in the kit selection chart.

Kit Selection
TSF 1
TSF2
TSF4
TSF5
TSF 6
Kit Selection
TSF 1
TSF2
TSF4
TSF5
TSF 6
10/6.5, 20/6.5
Kit Selection
TSF 1
TSF2
TSF4
TSF5
TSF 6
18/6.5, 28/6.5
Kit Selection
TSF 1
TSF2
TSF4
TSF5
TSF 6
10/6.5, 20/6.5
Kit Selection
TSF 1
TSF2
TSF4
TSF5
TSF 6
10/6.5, 20/6.5
Kit Selection
TSF 1
TSF2
TSF4
TSF5
TSF 6
10/6.5, 20/6.5