Volume-09-Design Guidelines For Electrical Wiring Installations
Volume-09-Design Guidelines For Electrical Wiring Installations
Volume-09-Design Guidelines For Electrical Wiring Installations
ii
PREFACE
As per instructions of Railway Board, CAMTECH, Gwalior has done detail study on safety in low
voltage electrical installations by referring various Indian Standards on the subject and with the help of
experts in this domain.
On the basis of various Indian standards, CAMTECH, Gwalior has already prepared & published eight
volumes under the series “Safety in Electrical Low Voltage Installations”.
This volume-9 on “Design Guidelines for Electrical Wiring Installations ” under the document series
“Safety in Electrical Low Voltage Installations” has been prepared, which gives complete information
regarding Electrical installation from origin of installation to final circuit.
This volume gives detail information of distribution boards, protective devices i.e. MCB/RCCB,
switchboards, cabling/wiring work etc. This volume also consists of detail information of earthing
system in an electrical installation.
This volume also contains design figures and DO’s and Don’t of various electrical installations, which
will also be useful for electrical engineers and technicians while working on electrical wiring
installations.
Technological up-gradation & learning is a continuous process. Please feel free to write to us for any
addition/ modification in this booklet. We shall highly appreciate your contribution in this direction.
LIST OF TABLE
Table 1: Estimated standing leakage current for electrical & electronics appliances: ...................... 4
Table 2: Determination of Load of Lighting Points ......................................................................... 9
Table 3: Determination of Load of Power Points............................................................................ 9
Table 4: Minimum Nominal Cross-Sectional Area of Conductors and MCB for Standard Circuits in
non-residential buildings ............................................................................................... 10
Table 5: Recommended Minimum Nominal Cross-sectional Areas of Conductor for Residential
Building ........................................................................................................................ 11
Table 6: Stranded Conductors for Single Core and Multicore Cables (Class 2) ............................. 13
Table 7: Maximum Operating Temperature for Types of Insulation of Cables................................ 18
Table 8: Maximum Number of PVC Insulated 650/1100 V grade Aluminum / Copper Conductor
conforming to IS 694: 1990 .......................................................................................... 20
Table 9: Minimum Cross-Sectional Area of Protective Conductors (Table 14 of IS 732:2019) ...... 24
Table 10: Size of GI Protective Conductor for 16Sqmm & 10Sq.mm Aluminum & Copper Cable .... 25
Table 11: Maximum Earth fault/ Short circuit Loop Impedance Values for Tripping of MCB’s under
Earth Fault/ Short Circuit ............................................................................................... 26
Table 12: Correction Factor for Ambient Air Temperatures Other Than 30 °C to be applied to the
Current-Carrying Capacities for Cables in the Air ........................................................... 32
Table 13: Correction Factors for Ambient Ground Temperatures Other Than 20 °C to be applied to
the Current-Carrying Capacities for Cables in Ducts in the Ground ................................. 33
Table 14: Reduction Factors for One Circuit or One Multi-core Cable or for a Group of more than One
Circuit, or more than one multi-core cable ..................................................................... 33
vi
Table 15: Current-Carrying Capacity (in Amperes) of PVC and XLPE cable .................................... 35
Table 16: Reduction factor in D1/D2 installation ........................................................................... 36
Table 17: Dimension of Non-Metallic Conduits (PVC) ................................................................... 37
Table 18: Dimensions of Single Core Non-Sheathed Cables with Rigid Conductor Class 1 or Class 2
.................................................................................................................................... 37
Table 19: Values of k1 for Conductors ......................................................................................... 38
Table 20: Values of k2 for Insulated Protective Conductors not Incorporated in Cables and not
Bunched with other cables ............................................................................................ 38
Table 21: Values of k2 for Bare Protective Conductors in Contact with Cable Covering but not
Bunched with other Cables ........................................................................................... 39
Table 22: Values of k2 for Insulated Protective Conductors as a core Incorporated in a Cable or
Bunched with other cables or Insulated Conductors ....................................................... 39
Table 23: Values of k2 Protective Conductors as a Metallic Layer if a Cable, for example, Armour,
Metallic sheath, Concentric conductor, etc. ................................................................... 39
Table 24: Values of k2 for Bare Conductors where there is no risk of damage to any neighbouring
material by the temperature indicated ............................................................................ 40
ISSUE OF CORRECTION SLIP
The correction slips to be issued in future for this handbook will be numbered as follows:
Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).
Sr. No. Date of Issue Page no. & Item no. modified Remarks
viii
DISCLAIMER
It is clarified that the information given in this booklet does not supersede
any existing provisions of Indian Standards (IS) on the subject, related
matters, and other existing provisions laid down by the Railway Board,
RDSO. This is not a statuary document and instructions given are for the
purpose of guidance only. If at any point contradiction is observed, then
Indian Standards, regulations issued by Government bodies, Railway
Board/RDSO guidelines shall be referred.
OBJECTIVE OF PUBLICATION
To prepare guidelines which can educate the Indian Railway (IR) engineers
and technicians dealing with low voltage electrical installations and other IR
officials about various provisions given in IS standards pertaining to IS 3043-
2018, IS 732:2019.
SAFETY IN ELECTRICAL LOW VOLTAGE INSTALLATIONS
iv. FDB (Final Distribution Board) is from where Final Circuits are going to loads/ switch
boards.
v. The circuit which is connected to single-way of switch board/sub-switch board or
fuse/MCB distribution board for supplying current to one or more load point known as
final circuit General Point.
1.6 RCCB
1.6.1 Applicability/use
(Ref:- Para 6.7.5.3 of Section 9 of Part-I NEC:023)
Provision of RCCBs (Current operated RCD) with sensitivity of 30mA shall be made for all
household and similar installations for load of 1kW and above, with voltage levels up to 440 V
and 125 A.
1.6.2 Locations/Sectionalizing
(Ref:- Para 6.7.5.4 of Section 9 of Part-I NEC:023)
Provision of RCCBs shall be made at suitable locations within wiring installations such that in
case of fault, supply of only that particular section of wiring installation is affected and
investigation to clear the fault is restricted to limited section making procedure faster and
easier.
Table 1:Estimated standing leakage current for electrical & electronics appliances:
The estimated continuous leakage current of a computer is approximately 2 mA. This leakage
current is very weak and therefore not dangerous. The sum of all the continuous leakage
currents can cause nuisance tripping (as it is not related to a hazardous situation).
To avoid this risk, a continuous leakage current of less than 30% of the sensitivity of the RCCB
is recommended, i.e. 10 mA for a 30 mA RCCB.This gives an order of magnitude of a
maximum of 5/6 computers or other devices downstream of a 30 mA residual current device
to restrict maximum leakage current to 30% of the sensitivity of the RCCB.
Proper sectionalizing is necessary to avoid false tripping. Where RCCBs are installed in series,
discrimination shall be such that nearest RCCs shall trip first. To achieve such condition, S
type RCCBs with time delay setting may be used instead increasing the rating of RCCB.
1.7.1 Introduction
During the selection of size of cable/wire from MDB to DB or DB to FDB or FDB to
Load/Circuit, following conditions should be satisfied for protection against overload
𝑰𝑩 ≤ 𝑰𝒏 ≤ 𝑰𝒛
𝑰𝟐 ≤ 𝟏. 𝟒𝟓 × 𝑰𝒛
Where,
In = The rated current of the protective device which are protecting the cable/wire. For
adjustable protective devices, the rated current Inis the current setting selected.
Iz = The continuous current-carrying capacity of the cable after applying all reducing
factor i.e. ambient temperature, Grouping, Installation method.
I2 = The current ensuring effective operation in the conventional time of the protective
device
Note:-Where sustained over currents less than 𝑰𝟐 occur. In such cases, consideration
should be given to selecting a cable with a larger cross-sectional area.
Example
(1) Selection of size of cable & rating of MCB for Final Circuit
Total connected load is 8A for a circuit. Size of wire & Rating of MCB to be define with
following condition:-
a. The outgoing 2 core PVC insulated wire is to be to be laid in conduit in masonry of
building.
b. 2 No. equally loaded additional circuits with this circuit are also laid in same
conduit..
c. Ambient temperature 35°C is considered
Case (A):- This MCB is connected to fixed load like lighting load.
Case (B) :- This MCB is connected to variable overload may be exist like power point
First a comprehensive schematic diagram for each building is to be prepared, starting from
MDB, DB & FDB etc. and the manner in which they are connected. This will include essential,
non-essential and UPS systems. Sizes of interconnecting main/sub-main Conductors shall be
indicated.
1.8.2 Marking of Distribution Board
Each Distribution board shall be marked indicating rating of each incoming/outgoing switch
and the details of load/area it feeds. Detail/size of incoming and outgoing Conductor also shall
be marked indicating from where the incoming Conductor has originated. Power/light DBs shall
be marked ‘P’ and ‘L’ respectively.
Format of Labelling:
Where:
G. C1, 2, 3, … H. Final circuits originating from Final Distribution Boards (FDBs)
I. X1, 2, 3, … J. Distribution circuits originating from Main Distribution Boards (MDBs),
Distribution Boards (DBs)
K. I/C L. Incoming circuit to MDB, DB, FDB with a space prior to it
M. O/G N. Outgoing circuit from MDB, DB with a space prior to it
Example:
i At MDB, for outgoing circuit X1 which is connected to DB1 will be named as DB1X1 O/G
ii At DB1 for incoming circuit from X1 circuit of MDB will be named as MDBX1 I/C
iii At DB1 for outgoing circuit X1 which is connected to FDB1 will be named as FDB1X1
O/G
iv At FDB1 for incoming circuit from X1 circuit of DB1 will be named as DB1X1 I/C
v At FDB1 for outgoing circuit C1which is connected to switch board1 will be named as
C1 (Location name)
vi At switch board1 for incoming circuit from C1 circuit of FDB1 will be named as FDB1C1
CHAPTER 2 WIRING
1 Light point* 50 W
2 Fan point 75 W
3 Power outlet 6A 100 W
NOTES
1* Light point may be utilized for a conventional incandescent lamp/tube light with ballast or
single/group of LED lighting fixtures.
2 Fan shall include all types/sweeps/exhaust.
3 If actual rating of appliance is known, it may be taken into consideration subject to
envisaged changes.
g) Toaster/kettle 800
h) Air fryer 1500
i) Kitchen exhaust hood 350
4 Other
a) A.C 1TR/1.5 TR/2 TR 1250/1500/2000
b) Room heater 1000
c) Computer 150
d) TV 100
e) Iron 800
f) EV charging 1000-3000
NOTES
1) Actual requirement may be checked with OEM.
If loads values are not specified than following ratings may be assumed.
Note : B type of MCB to be used by default, unless until specified for C type of MCB.
# This rating is considering overload requirement of the circuits having 6/16 A socket
provided in them.
Mains/sub-mains for total connected load > 7 kW and < 10 10 mm2/4 mm2 or 6
kW mm2 (4 + E)*
* For 3-ph supply and load un-balance within 10 percent use 4 mm2, if load un-balance
likely to exceed, use 6 mm2 (4+E)
Neutral : Black
Earth : Green & Yellow
Table 6: Stranded Conductors for Single Core and Multicore Cables (Class 2)
(Clause 6.2.3, 6.3.3 and 7.3.1)
While selecting conductor for size less than or equal to 16 sq.mm, copper conductor of Class
1 or Class 2 is recommended.
(vii) No part of exposed live part of conductor, solid or stranded (stripped off insulation)
shall remain open outside the area of terminal;
(viii) Cross sectional area of conductor used for inter connections within board shall not be
less than cross sectional area of circuit mains.
(ix) Within switch-board, there shall not be any joints except at terminals.
(x) A low voltage circuit shall be separated from an extra-low voltage circuit.
(xi) Fire alarm and emergency lighting circuits shall be segregated from all other
Conductors and from each other.
(xii) Location of general light and fan switch boards in residential building shall be
positioned close to door frame and on opposite side of hinged edge of door, so that a
person while entering can have immediate access to switch board. If a room has two
doors; lighting control shall be provided on switch boards located near both doors. For
the purpose use of two way switches may be made.
i) When wiring Conductors are to pass through a wall, these shall be taken through a
protection (steel/ PVC) pipe or porcelain tube of suitable size such that they pass through in
a straight line without twist or cross in them on either porcelain, PVC or other approved
material.
ii) All floor openings for carrying any wiring shall be suitably sealed after installation.
2.7.2 Joints in Wiring
(Ref: Para 3.8 of CPWD General Specification Part-I)
i) No bare conductor in phase and/or neutral or twisted joints in phase, neutral, and/ or
protective conductors in wiring shall be permitted.
ii) There shall be no joints in the through-runs of Conductors. If the length of final circuit or
sub-main is more than the length of a standard coil, thus necessitating a through joint,
such joints shall be made by means of approved mechanical connectors in suitable
junction boxes.
iii) Termination of multi-stranded conductors shall be done using suitable crimping type
thimbles.
Wall Thickness
Walls shall be of sufficient thickness to accommodate concealed boxes/switch
boards/distribution boxes so that installation of boxes do not affect strength of wall.
Additional strengthening shall be considered, if necessary.
NOTE — For example, for 100 mm wall, it is not possible to accommodate boxes of depth
60 mm each back-to-back. Under such cases, staggering may solve problem to certain
extent.
I. The third pin shall be connected to earth through protective conductor. 2 pin or 5 pin
sockets shall not be permitted to be used.
II. Conductors connecting electrical appliances with socket outlets shall be of flexible type
with an protective conductor for connection to the earth terminal of plug and the metallic
body of the electrical appliance.
III. Sockets for the power outlets of rating above 1KW shall be of industrial type with
associated plug top and controlling MCB.
IV. Where specified, shutter type (interlocking type) of sockets shall be used.
V. Every socket outlet shall be controlled by a switch or MCB, as specified i.e. no direct
socket is permitted. The control switch/MCB shall be connected on the ‘live’ side of the
line.
VI. 6A and 16A socket outlets shall be installed at the following positions, unless otherwise
specified.
a) Non-residential buildings
6A Socket – 110 cm above floor level.
16A Socket – 23/110 cm above floor level.
b) Kitchen – 23 cm above working platform and away from the likely positions of stove
and sink.
c) Bathroom –
6A socket outlet: Socket outlet for portable appliances like hair dryer, shaver etc. to be
provided adjacent to wash basin/ mirror at 110 cm height above floor level.
d) Rooms in residences –
6A Socket – 70 cm above floor level.
6A socket outlet: for other locations, 23 cm/110 cm above floor level, or any other
level in special cases as desired by the Engineer-in-charge.
e) 16A Socket – 23 cm/110 cm above floor level, or any other level in special cases as
desired by the Engineer-in-charge.
Unless and otherwise specified, the control switches for the 6A and 16A socket outlets shall
be kept along with the socket outlets.
2.9 CONDUIT
2.9.1 Fill factor or space factor
(Ref:- Para 7.2.2.4 of Section 22 of NEC:2023)
Fill factor or space factor is one of the important points strictly to be observed for appropriate
heat dissipation and maintaining temperature within limit for Conductors in enclosures.
NOTE —It shall be noted that number of wires drawn through conduits when exceed allowable
limit, the excess heat generated starts deteriorating insulation very fast leading to
failure and create short circuit. Such work is not easily traceable in external visual
inspection and difficult to correct after the work is complete.
2.9.2 Size of Conduit
(Ref:- Para 5.9.3.6 of Section 9 of NEC:2023)
Size of conduit shall be decided on the basis of number of conductors which can be easily and
safely drawn within, without exceeding the limit of temperature rise (as per below table) at full
load under normal conditions and under that respective situation.
manufacturer.
For deciding the size of conduit following parameters to be considered like
1. Inside cross-sectional area of conduit
During the checking of size of conduit for number of cables, inside cross-sectional area of
conduit is also important factor. If between pull boxes, for every two deviations in direction
of up to 90 degree, area of conduit shall be considered less by 15 percent. There shall be
no further deviation.
Upper part of figure shows 90° bend and lower part of figure shows four bends each of
45° aggregating to 180°.
2. Cross-sectional area of cables (calculated from the maximum overall diameter including
insulation)
3. Number of cables.
Fill factor shall not exceed values as given below:
a) One conductor 53 percent
b) Two conductors 31 percent
c) Three or more Conductors 40 percent
To find suitable Size of Heavy PVC conduit for number of cables references may be taken
from Table 11 & 12 under Annex II.
2.9.2.1 Example: To find suitable Size of Heavy PVC conduit for:
Number of cables (stranded):
I. 2*1.5 Sq.mm (2 run)
II. 2* 4.0 Sq.mm (1 run)
III. 1* 1.5 Sq.mm (1 run)
Number of bends 2 Nos. of 90°
Cross sectional area of cables from Table 16 of Annex 3
S.N. Class Size of conductor Area of Conductor Number of cable
1 2 1.5 Sq.mm 8.55 Sq.mm 5
2 2 4 Sq.mm 16.62 Sq.mm 2
Checking of the nearest and next cross sectional area of conduit from Table 15 of Annex 3
Table 8: Maximum Number of PVC Insulated 650/1100 V grade Aluminum / Copper Conductor
conforming to IS 694: 1990
(Ref: Table 4.1 of CPWD General Specification Part-I)
Note:
(i) The above table shows the maximum capacity of conduits for a simultaneous drawing in
of Conductors.
(ii) The columns headed ‘S’ apply to runs of conduits which have distance not exceeding4.25
m between draw in boxes and which do not deflect from the straight by an angle of more
than 15 degrees. The columns headed ‘B’ apply to runs of conduit, which deflect from the
straight by an angle of more than 15 degrees.
(iii) Conduit sizes are the nominal external diameters.
CHAPTER 3 EARTHING
3.1 INTRODUCTION
A sample schematic Diagram For an Installation has been shown .In this installation incoming
supply from source is coming at incoming of MDB in the installation. Supply is going MDB to
DB & DB to FDB through conductor. Final Circuit is connected from FDB to Load or Switch
Board.
(ii) Earthing conductor’s cross-sectional area shall be not less than 6 mm2 for copper or
50 mm2 for steel when in air.
(iii) Where a bare earthing conductor is buried in the soil, its dimen sions and
characteristics shall also be in accordance with the minimum size required
for earth electrode embedded in soil or concrete
(iv) Aluminium conductors shall not be used as earthing conductors.
Where
k1 = is the value of k for the line conductor selected from Tables 58 to Table 62 of IS 732:
2019 as applicable, according to the materials of the conductor and insulation;
k2 = is the value of k for the protective conductor, selected from Tables 58 to Table 62 of IS
732: 2019 as applicable.
1) For a PEN conductor, the reduction of the cross-sectional area is permitted only in
accordance with the rules for sizing of the neutral conductor
Cross sectional Area of protective conductor for Final or Standard Circuit already
given in table-2.
3.6.3 Example
Table 10: Size of GI Protective Conductor for 16Sqmm & 10Sq.mm Aluminum & Copper Cable
S.N. Type of Cross- Minimum Cross Section Area of Protective Conductor sq.mm Reference
cable sectional
Area of If the
If the Minimum Cross Section Area of Protective
Phase protective
protective Conductor If the protective conductor is
Cable conductor
conductor not of the same material as the line
is of the
is not of conductor
same
the same
material
material
as the line
as the line
conductor
conductor
PVC/XLPE (Sq.mm) Type of K1K2 K1/K2 Formula for Value of Minimum
Copper/ Protective Area of GI Area of Size of
Aluminum Conductor (Sq.mm) GI GI wire
(Sq.mm) (In mm)
1 PVC 10 10 Sq.mm 11558 1.98 (K1/K2)x10 19.83 4.88 Table-
insulated PVC Bare GI 58
copper insulated wire in
Cable copper Contact
Cable with
Cable
Covering
2 XLPE 16 16 Sq.mm but not 9450 1.88 (K1/K2)x16 30.08 6.40 Table-
insulated XLPE Bunched 58
Aluminium insulated with Other
Cable Aluminium Cables
Cable
3 PVC 25 16 Sq.mm GI armour 11551 2.25 (K1/K2)x16 36.08 7.01 Table-
insulated PVC 61
copper insulated
Cable copper
Cable
4 XLPE 35 16 Sq.mm GI armour 9446 2.04 (K1/K2)x16 32.70 6.40 Table-
insulated XLPE 61
Aluminium insulated
Cable Aluminium
Cable
3.6.4 Connection of Protective Conductor
(i) All protective conductors of Final circuit (FDB to Load or switch board) to be connected
at Sub MET of FDB.
(ii) All protective conductors from DB to FDBs to be connected at Sub MET of DB and
each FDB.
(iii) All protective conductors from MDB to DBs to be connected at MET of MDB and sub
MET of each FDB.
(iv) Protective Conductor from body of MDB,DB & FDB to be connected MET & sub MET of
respectively MDB/DB/FDB
(v) Earthing conductor to be connected
The tripping of MCB during short circuit/Earth fault depend on the value of Loop Impedance
encountered by the fault current. The relation between tripping current (It) of MCB and the
maximum earth fault/short circuit loop impedance (Zs) of the concern circuit are as below:
2 𝑈
Zs≤ 3 ( 𝐼 0 )
𝑡
The maximum fault loop impedance in (Ω) of the concern circuit. Its comprising:
a) The source,
Zs
b) The line conductor up to the point of the earth fault/short circuit, and
c) The protective conductor between the point of the fault and the source;
The current in amperes (Amp.) causing the automatic operation of the disconnecting
It
device (MCB) within the time (0.1 sec)
U0 The nominal A.C. or D.C. line to earth voltage in volts (V).
Table 11: Maximum Earth fault/ Short circuit Loop Impedance Values for Tripping of MCB’s
under Earth Fault/ Short Circuit
Type MCB 6 10 16 20 25 32 40 50 63 80 100 125
of rating
MCB in Amps
B Zs(In
Ohms)
5.11 3.07 1.92 1.53 1.23 0.96 0.77 0.61 0.49 0.38 0.31 0.25
=(2/3x
(U0/ It)
C Zs(In
Ohms)
2.56 1.53 0.96 0.77 0.61 0.48 0.38 0.31 0.24 0.19 0.15 0.12
=(2/3x
(U0/It)
D Zs(In
Ohms)
1.28 0.77 0.48 0.38 0.31 0.24 0.19 0.15 0.12 0.10 0.08 0.06
=(2/3x
(U0/ It)
(i) Every sub-main will have protective conductor that run along with sub-main wiring. In
case of 3- phase sub-main wiring to the final equipment, two protective conductors shall
be provided to make connection to protective equipotential bonding.
(ii) Every circuit will have its protective conductor running along with circuit wiring. In case of
3-phase circuit to final equipment, two protective conductors shall be provided.
(iii) Looping of earth is allowed only in case of point wiring for light fittings and sockets.
Looping is not allowed for wiring in the final circuits for electronic installations such as
computers and equipment with SMPS power supply.
(iv) When 2/3 power outlets are looped to one circuit, earth looping of these outlets is
permissible.
Detail of Do’s and Don’ts for supply and installation of MDB (Main Distribution Board),DB
(Distribution Board),FDB (Final Distribution Board),Final Circuit & Conduit are as below:
Do’s Don’ts
rating of incoming MCB of FDB. 5. Cable to be provided with suitable
glands.
5. Neutral wire conductor to be connected to
neutral bus bar of FDB. 6. Twisted joints for making multiple
neutral or earth outgoing should not
6. Proper labelling should be done in FDB.
be done.
7. 30 mA RCCB to be provided for shock
7. Cable connected to Switchgear shall
protection. 30 mA suitable rating RCBO can
not be stressed condition.
be provided in place of MCB & RCCB.
8. If outgoing circuits are more, then
sectionization of circuits may be done and
30 mA RCCB may be provided for each
section to avoid nuisance tripping due to
inherent leakage current in electrical
equipment.
9. Gasket should be provided in FDB.
10. Phase link for outgoing MCBs to be
provided in FDB
11. As per requirement spare MCB to be
provided.
12. Incoming & outgoing protective earth
conductors shall be connected to Earth bus
bar of FDB
Do’s Don’ts
1. Class 2 copper conductor is recommended 1. 2pin/plate ceiling rose should not
for fixed wiring. be used instead 3 pin/plate
2. Colour coding to be ensured. For Phase - 2. Don’t use higher rating 16/ 20A C
Red, Neutral - Black, PE – Green-Yellow. type MCB for lighting & power
3. General height of switch board should be circuits
reachable and 1.2 m above ground level. 3. Don’t use 5 pin& 2 pin sockets.
4. Separate neutral and protective earth 4. Don’t terminate conductors without
conductor to be used from FDB (From thimbles.
Neutral & Earth Busbar)
5. Rating of MCB should be as per connected
load.
6. Rating of MCB & size of line wire should be
properly coordinated for overload protection.
7. Size of protective earth wire should be same
as per Line wire.
8. Plug Socket outlet boards shall be located as
near as possible from the location of
4.1.5 CONDUITS
Do’s Don’ts
1. Within conduit system, there shall be
1. Fixing of conduit on surface may be done with
no sharp edges, burrs or surface
saddle/saddle with spacer/clips.
projections which may damage
2. Size of conduit shall be decided on the basis of insulated conductor/cable or inflict
number of cables which can be easily and injury to the installer or user
safely drawn within, without exceeding the limit
of temperature rise 2. Don’t use of metal conduits as earth
continuity conductor shall not be
permitted in general.
Annexure 1
Table 12: Correction Factor for Ambient Air Temperatures Other Than 30 °C to be applied to the
Current-Carrying Capacities for Cables in the Air
Insulation
Mineral 1)
Ambient
Temperature °C PVC XLPE and EPR PVC Covered or Bare not Exposed to
Bare and Exposed Touch 105 °C
to Touch 70 °C
(1) (2) (3) (4) (5)
10 1.22 1.15 1.26 1.14
15 1.17 1.12 1.20 1.11
20 1.12 1.08 1.14 1.07
25 1.06 1.04 1.07 1.04
30 1.00 1.00 1.00 1.00
35 0.94 0.96 0.93 0.96
40 0.87 0.91 0.85 0.92
45 0.79 0.87 0.78 0.88
50 0.71 0.82 0.67 0.84
55 0.61 0.76 0.57 0.80
60 0.50 0.71 0.45 0.75
65 – 0.65 – 0.70
70 – 0.58 – 0.65
75 – 0.50 – 0.60
80 – 0.41 – 0.54
85 – – – 0.47
90 – – – 0.40
95 – – – 0.32
1)
For higher ambient temperatures, consult the manufacturer
Table 13: Correction Factors for Ambient Ground Temperatures Other Than 20 °C to be applied to
the Current-Carrying Capacities for Cables in Ducts in the Ground
Table 14: Reduction Factors for One Circuit or One Multi-core Cable or for a Group of more than One
Circuit, or more than one multi-core cable
(Ref: Table 36 of IS 732:2019)
To be Used
Arrangement Number of Circuits or Multi-core Cables with
Item (Cables Current-
Touching) Carrying
Capacities,
Reference
1 2 3 4 5 6 7 8 9 12 16 20
1 Bunched in air, 1.0 0.8 0.70 0.65 0.60 0.5 0.54 0.52 0.50 0.4 0.41 0.38 Tables 21
on a surface, 0 0 7 5 to 32
embedded or Methods A
enclosed to F
2 Single layer 1.0 0.8 0.79 0.75 0.73 0.7 0.72 0.71 0.70
on wall, floor 0 5 2
No further Tables 21
or to 26
unperforated reduction
Annexure 2
Table 15: Current-Carrying Capacity (in Amperes) of PVC and XLPE cable
(Normative)
(Ref: Table 41 of Annex-T of IS 732:2019)
Reference Number of Loaded Conductors and Types of Insulations
methods in
Table 20 of
IS:732:2019
16 41 43 48 53 58 61 66 73 77 84 91 --
25 53 57 63 70 73 78 83 90 97 101 108 121
35 -- -- -- 86 90 96 103 112 120 126 135 150
50 -- -- -- 104 110 117 125 136 146 154 164 184
70 -- -- -- 133 140 150 160 174 187 198 211 237
95 -- -- -- 161 170 183 195 211 227 241 257 289
120 -- -- -- 186 197 212 226 245 263 280 300 337
150 -- -- -- -- 226 245 261 283 304 324 346 389
185 -- -- -- -- 256 280 298 323 347 371 397 447
240 -- -- -- -- 300 330 352 382 409 439 470 530
Note: (i)The appropriate table of current carrying capacity given in Annexure S of IS-732:2019 should be
consulted to determine the range of conductor sizes for which the above current carrying capacities are
applicable, for each installation method.
(ii) For the time being, this Annex relates to non armoured cables and insulated conductors having a nominal
voltage not exceeding 1 kV a.c. or 1.5 kV d.c. This Annex may be applied for armoured multi-core cables
but does not apply to armoured single-core cables.
6 36 30 42 36
10 48 40 56 47
16 62 52 73 61
25 80 66 93 78
35 96 80 112 94
50 113 94 132 112
70 140 117 163 138
95 166 138 193 164
120 189 157 220 186
150 213 178 249 210
185 240 200 279 236
240 277 230 322 272
300 313 260 364 308
Annexure 3
Dimension of Non-Metallic Conduits (PVC) & Single Core Non-Sheathed Cables with
Rigid Conductor Class 1 or Class 2
Table 18: Dimensions of Single Core Non-Sheathed Cables with Rigid Conductor Class 1 or
Class 2
(Ref: Table D-4 of Annexure D of Section 9 Part-1 of NEC-2023)
Notes
1 For more information, refer 16.1.2 and 16.1.3 of IS 694:2010.
2 Class 1 is solid conductor and class 2 is stranded conductor, for further details, refer Table
3 of IS 694.
Sr. Nominal Sectional area Class of Thickness Maximum Cross sectional
No. of conductor conductor of insulation overall diameter area of cable
mm2 mm mm mm2
i. 0.5 1 0.6 2.3 4.15
ii. 0.75 1 0.6 2.5 4.91
iii. 1 1 0.6 2.7 5.73
Table 20: Values of k2 for Insulated Protective Conductors not Incorporated in Cables and not
Bunched with other cables
(Ref.: Table 58 of IS 732: 2019)
90°C thermoplastic (PVC) 30 160/ 1401) 143/ 1331) 95/ 881) 52/ 491)
90°C thermosetting (e.g. XLPE and EPR) 30 250 176 116 64
60°C thermosetting ( EPR rubber) 30 200 159 105 58
85°C thermosetting EPR rubber 30 220 166 110 60
185°C thermosetting (silicon rubber) 30 350 201 133 73
1)
The lower value applies to thermoplastic (for example, PVC) insulated conductors of cross-sectional area greater than
300mm2.
2)
Temperature limits for various types of insulation are given in IEC 60724.
3)
For the method of calculating k, see the formula at the beginning of this Annex.
Table 21: Values of k2 for Bare Protective Conductors in Contact with Cable Covering but not
Bunched with other Cables
(Ref.: Table 59 of IS 732: 2019)
Table 22: Values of k2 for Insulated Protective Conductors as a core Incorporated in a Cable or
Bunched with other cables or Insulated Conductors
(Ref.: Table 60 of IS 732: 2019)
70°C thermoplastic (PVC) 70 160/ 1401) 115/ 1031) 76/ 681) 42/ 371)
90°C thermoplastic (PVC) 90 160/ 1401) 100/ 861) 66/ 571) 36/ 311)
90°C thermosetting (e.g. XLPE and EPR) 90 250 143 94 52
60°C thermosetting (rubber) 60 200 141 93 51
85°C thermosetting rubber 85 220 134 89 48
185°C thermosetting (silicon rubber) 180 350 132 87 47
1)
The lower value applies to thermoplastic (for example, PVC) insulated conductors of cross-sectional area greater than
300mm2.
2)
Temperature limits for various types of insulation are given in IEC 60724.
3)
For the method of calculating k, see the formula at the beginning of this Annex.
Table 23: Values of k2 Protective Conductors as a Metallic Layer if a Cable, for example, Armour,
Metallic sheath, Concentric conductor, etc.
(Ref.: Table 61 of IS 732: 2019)
Table 24: Values of k2 for Bare Conductors where there is no risk of damage to any neighbouring
material by the temperature indicated
(Ref.: Table 62 of IS 732: 2019)
Annexure 5
DETAIL WIRING DIAGRAMS FROM MDB TO FINAL CIRCUIT
Description
1 MDB (Main Distribution Board 8 MET (Main Earth Bus Bar)
2 4P Incoming MCCB 9 Incoming 4 Core Cable
3 4P outgoing MCCB 10 Protective Earthing Conductor (Cable Armoured)
4 Phase Bus Bar (Main) 11 Outgoing 4 core Cable
5 Neutral Bus Bar (Main) 12 Protective Earthing Conductor
6 Earth Electrode 13 Gland
7 Earthing Conductor
NOTE
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CONTACT US
https://indianrailways.gov.in/railwayboard/view_section.jsp?lang=0&id=0,1,304,366,538,2713,2718
,2722
E-mail : [email protected]
INDIAN RAILWAYS
Centre for Advanced maintenance TECHnology (CAMTECH), Maharajpura, Gwalior - 474005
50 VOLUME 8: DESIGN GUIDELINES FOR ELECTRICAL WIRING INSTALLATIONS