Estimating and Costing electrical

wiring
Objective
• To know about the following concepts
• Indian Electricity Rules(1956)
• Selection of wiring and its types
• Selection of protective gear (MCCB, MCB, ELCB etc.)
• Condition and requirements for all domestic, commercial and
industrial installation steps
• Electric Shock: Methods of cure, artificial respiration procedure,
precautions against shock
• Installation & testing of 11 kV/ 33 kV lines and cables
• Estimation and wiring calculation
THE INDIAN ELECTRICITY RULES, 1956
Indian electricity rules have been framed to
• Safeguard consumers of electrical energy from shock
• Minimize fire risk
• Ensure satisfactory operation of equipment and apparatus
Objective
• To quote the relevant Indian Electricity rules for a given Electrical
installation
• Interpret the electricity rules (1956) in respect of lighting and power
installation
• Indian Electricity rule. [Link]
Rule 1 : Provide short title and Commencement
Rule 2 : Provide Definitions of different electrical components
Rule 3 : Describe Authorization
Rule 4 : Describe Qualifications of Inspector
Rule 5 : Incudes Entry and inspection by Inspector to an installation
Rule 6 : Procedure to give an Appeal to inspector/ Govt against an order served
Rule 7: Amount of fees in respect of the service of testing and inspection of an
installation
Rule 8 : Incidence of fees recoverable in case of any dispute
Rule 9 : Describe the submission of test records by the installer to the Authority
Rule 10: Submission of list of consumers by the installer to the authority
Rule 11 to 28 : Procedure to apply for a licence to the authority.
Rule29 to 46 : Pertains to General safety Requirement for installation of Electrical
system.
Rule 47 to 59 : Pertains to General Conditions relating to supply and use of electrical
Energy
Rule 60 to 62 :Electric supply lines, systems and apparatus for low and Medium voltage
Rule 63 to 73 : Dealt with Electric supply lines, System and Apparatus for High and
Extra High Voltage
Rule 74 to 93 : Dealt with Overhead line, Underground cables and Generating stations.
Rule 94 to 108: dealt with Electric traction
Rule 109 to 132 : Additional precautions to be adapted in Mines and Oilfields.
Rule 133 to 143 : Miscellaneous
Rules related to electrical installations & wirings..
Rule 2 (ap): supplier” means a licensee, a non-licensee or any other supplier of energy,
including the Government.

Rule 2 (aq) : switch” means a manually operated device for opening and closing or for
changing the connection of a circuit.

Rule 2 (aqa): switchboard” means an assembly including the switchgear for the control
of electrical circuits, electric connections and the supporting frame.

Rule 2 (ar): switchgear” shall denote switches, circuit breakers, cut-outs and other
apparatus used for the operation, regulation and control of circuits.

Rule 2 (as): system” means an electrical system in which all the conductors and
apparatus are electrically connected to a common source of electric supply.

Rule 2 (av): Voltage “means Potential difference between any two conductors or
between any part of either conductor and the earth which can be measured by means of
voltmeter and said to be
Low voltage : Where the voltage does not exceed 250 V under normal condition.
Medium voltage : Where the voltage does not exceed 650 V under normal condition .
High voltage : Where the voltage does not exceed 33 KV under normal condition .
Extra High voltage : Where the voltage exceeds 33 KV under normal conditions
Rule 29: Construction, installation, protection, operation and maintenance of electric
supply lines and apparatus-
1. All electric supply lines and apparatus shall be of sufficient ratings for power, insulation
and estimated fault current and of sufficient mechanical strength, for the duty which they
may be required to perform under the environmental conditions of installation, and shall
be constructed, installed, protected, worked and maintained in such a manner as to
ensure safety of human beings, animals and property.
2. The relevant code of practice of the Bureau of Indian Standards (BIS) including National
Electrical Code (IEC) if any may be followed to carry out the purposes of this rule and
in the event of any inconsistency, the provisions of these rules shall prevail.
3. The material and apparatus used shall conform to the relevant specifications of the BIS
where such specifications have already been laid down.
Rule 30: Service Lines and apparatus on consumer premises.
1. The supplier shall ensure that all electric supply lines, wires, fittings and apparatus
belonging to him or under his control, which are on a consumer's premises are in safe
condition.
2. Service lines placed by the supplier on the premises of a consumer which are
underground or which are accessible shall be so insulated and protected by the supplier
as to be secured under all ordinary conditions against electrical, mechanical, chemical or
other injury to the insulation.
3. The consumer shall, as far as circumstances permit, take precautions for the safe custody
of the equipment on his premises belonging to the supplier.
4. The consumer shall also ensure that the installation under his control is maintained in a
safe condition.
Rule 31: Cut-out on consumer’s premises:
1. The supplier shall provide a suitable cut-out in each conductor of every service line
other than an earthed or earthed neutral conductor. Where more than one consumer is
supplied through a common service line, each such consumer shall be provided with an
independent cut-out at the point of junction to the common service.
2. Every electric supply line other than the earthed or earthed neutral conductor of any
system or the earthed external conductor of a concentric cable shall be protected by a
suitable cut-out by its owner.
Rule 41: Distinction of different circuits:
1. The owner of every generating station, sub-station, junction-box or pillar in which there
are any circuits or apparatus, whether intended for operation at different voltages or at
the same voltage, shall ensure by means of indication of a permanent nature that the
respective circuits are readily distinguishable from one another.
Rule 46: Periodical inspections and testing of consumer’s installation:
1. Where an installation is already connected to the supply system of the supplier, every
such installation shall be periodically inspected and tested at intervals not exceeding
five years by the Inspector.
2. Where the supplier is directed by the Central or the State Government, as the case may
be, to inspect and test the installation he shall report on the condition of the installation
to the consumer concerned in a form approved by the Inspector and shall submit a copy
of such report to the Inspector.
3. The fees for such inspection and test shall be determined by the Central or the State
Government, as the case may be, in the case of each class of consumers and shall be
payable by the consumer in advance.
Rule 47: Testing of consumer’s installation:
1. Upon receipt of an application for a new or additional supply of energy and before
connecting the supply or reconnecting the same after a period of six months, the supplier
shall inspect and test the applicant's installation.
2. If as a result of such inspection and test., the supplier is satisfied that the installation is
likely to constitute danger, he shall serve on the applicant a notice in writing requiring
him to make such modifications as are necessary to render the installation safe.
Rule 48: Precautions against leakage before connection:
1. All the electrical equipments shall have the “ IR” values as stipulated in the relevant
Indian Standards before energisation of an installation or apparatus.
2. At a pressure of 500 V DC applied between each live conductor and earth for a period of
one minute the insulation resistance of low voltage and medium voltage equipments
shall be at least 1 Mega ohm or as specified in the relevant Indian Standard.
3. At a pressure of 2.5 KV DC applied between each live conductor and earth for a period
of one minute, the insulation resistance of high voltage equipments shall be at least 5
Mega ohm or as specified by in the relevant Indian Standard.
Rule 50: Supply and use of energy:
1. A linked switch with fuse(s) or a circuit breaker by low and medium voltage consumers.
2. A linked switch with fuse(s) or a circuit breaker by HV consumers having aggregate
installed transformer/apparatus capacity up to 1000 KVA to be supplied at voltage upto
11 KV and 2500 KVA at higher voltages(not exceeding 33KV).
3. A circuit breaker by HV consumers having an aggregate installed transformer/apparatus
capacity above 1000 KVA and supplied at 11 KV and above 2500 KVA supplied at
higher voltages (not exceeding 33KV)
Rule 54. Declared voltage of supply to consumer:
A supplier shall not permit the voltage at the point of commencement of supply to vary
from the declared voltage
• In the case of low or medium voltage, by more than 6 per cent, or in the case of high
voltage, by more than 6 per cent on the higher side or by more than 9 percent on the
lower side, or in the case of extra-high voltage, by more than 10 per cent on the higher
side or by more than 12.5 per cent on the lower side.
Rule 55. Declared frequency of supply to consumer:
• Except with the written consent of the consumer or with the previous sanction of the
State Government a supplier shall not permit the frequency of an alternating current
supply to vary from the declared frequency by more than 3 per cent.
Rule 56. Sealing of meters and cut-outs:
1. A supplier may affix one or more seals to any cut-out and to any meter, maximum
demand indicator, or other apparatus placed upon a consumer’ s premises in
accordance with section 26, and no person other than the supplier shall break any such
seal.
2. The consumer shall use all reasonable means in his power to ensure that no such seal is
broken otherwise than by the supplier.
Rule 58: Point of commencement of supply:
• The point of commencement of supply of energy to a consumer shall be deemed to be
the point at the incoming terminal of the cut-outs installed by the consumer under rule
50
Rule 61. Connection with earth.
The provisions shall apply to the connection with earth of systems at low voltage in cases
where the voltage normally exceeds 125 volts and of systems at medium voltage:

1. Neutral conductor of a 3 phase, 4 wire system and the middle conductor of a 2 phase, 3
wire system shall be earthed by not less than two separate and distinct connections with
a minimum of two different earth electrodes or such large number as may be necessary
to bring the earth resistance to a satisfactory value both at the generating station and at
the sub-station. The earth electrodes so provided, may be inter-connected to reduce
earth resistance.
2. In the case of a system comprising electric supply lines having concentric cables, the
external conductor of such cables shall be earthed by two separate and distinct
connections with earth.
3. The connection with earth may include a link by means of which the connection may be
temporarily interrupted for the purpose of testing or for locating a fault.
4. The frame of every generator, stationary motor, portable motor, and the metallic
parts(not intended as conductors) of all transformers and any other apparatus used for
regulating or controlling energy and all medium voltage energy consuming apparatus
shall be earthed by the owner by two separate and distinct connections with earth.
5. All metal casings or metallic coverings containing or protecting any electric supply-line
or apparatus shall be connected with earth and shall be so joined and connected across
all junction boxes and other openings as to make good mechanical and electrical
connection throughout their whole length
Rule 61 A. Earth leakage protective device:
The supply of Energy to every electrical installation other than low voltage installation
below 5 KW and those low voltage installations which do not attract provisions of section
30 of the Indian Electricity Act,1910, shall be controlled by an earth leakage protective
device so as to disconnect the supply instantly on the occurrence of earth fault or leakage of
current
Rule 77: Clearance above ground of the lowest conductor:
1. The conductor of an overhead line, Including service lines, erected across a street shall not
be at a height less than
a. for low and medium voltage lines : 5.8 meters
b. for high voltage lines : 6.1 meters
2. The conductor of an overhead line, including service lines erected along a street shall
not be at a height less than
a. for low and medium voltage lines : 5.5 meters
b. for high voltage lines : 5.8 meters
3. The conductor of an overhead line including service lines, erected elsewhere than along or
across any street shall be at a height less than –
a. for low, medium and high voltages lines upto 11 KV, if bare: 4.6 metres
b. for high voltage lines above 11 KV: 5.2 metres
4. For extra-high voltage lines the clearance above ground shall not be less than 5.2 metres
plus 0.3 metre for every 33 KV or part thereof by which the voltage of the line exceeds 33
KV Provided that the minimum clearance along or across any street shall not be less than
6.1 metres.
Rule 79. Clearance from buildings of low and medium voltage lines and service lines-
1. Where a low or medium voltage, overhead line passes above or adjacent to or terminates
on any building, the following minimum clearances from any accessible point, on the
basis of maximum sag
a. when the line passes above the building a vertical clearance of 2.5 metres from the
highest point.
b. when the line passes adjacent to the building a horizontal clearance of 1.2 metres from
the nearest point.
2. Any conductor so situated as to have a clearance less than that specified in sub-rule(1)
shall be adequately insulated and shall be attached at suitable intervals to a bare earthed
bearer wire having a breaking strength of not less than 350 kg.
3. The horizontal clearance shall be measured when the line is at a maximum deflection
from the vertical due to wind pressure.
80. Clearances from buildings of high and extra-high voltage lines-
1. Where a high or extra-high voltage overhead line passes above or adjacent to any
building or part of a building the following minimum clearances from any accessible
point on the basis of maximum sag
a. for high voltage lines upto and including 33 KV: 3.7 metres
b. for extra-high voltage lines: 3.7 metres plus 0.30 metre for every additional 33 KV
2. The horizontal clearance between the nearest conductor and any part of such building
Shall
a. for high voltage lines upto and including 11 KV: 1.2 metres
b. for high voltage lines above 11 KV and up to 33 KV: 2.0 metres
c. for extra-high voltage lines: 2.0 metres plus 0.30 metre for every additional 33 KV
ELECTRICAL WIRING AND ESTIMATION
References :
Indian Electricity Rule 1956
Indian Electricity act, 1910
The Electricity (supply) act, 1948
Electricity Regulations 1994
IEC 60364:2003 Standard: Electrical Installations of Buildings
Code of practice for selection, installation of Switchgear, IS:10118
Power transformer, IS 2026: 2011
Distribution Transformer, IS 1180: 1989
Code of Practice for Electrical Wiring installations, IS : 732-1989
Code of Practice for fire safety of building (General) Electrical Installation, IS : 1646
PVC insulated cables, IS 694 : 1990
PVC insulated heavy duty cables, IS : 1554
Armoured cables, IS 7098
High Voltage Switchgear, IS: 3072
High Voltage Cable, IS:1255 and IS:692
Medium Voltage Switchgear, IS: 13947
Low Voltage Switchgear, IS 8623, IS 13947, IEC-439-1, IEC-947-1, IEC-529 etc.
Distribution boards, MCB, Isolators, IS 375, Is 2147, IS:2675, IS:8828, IS:2607, IS:9926 etc.
Code of practice for Earthing: IS 3043
Code of practice for the protection of buildings against lightning, IS 2309 , IS:5216
Electricity Supply Specifications
Electricity supply for domestic consumers, according to IEC 60038 standards, meets the
following specifications: -
i. Single phase supply with nominal voltage of 230V, range +10%, -6%;
ii. Three phase supply with nominal voltage of 400V, range +10%, -6%;
iii. Permitted frequency is 50Hz 1%;
iv. Earthing system type (TT System)
Planning of Electrical Wiring
1. Determining Consumer Load Requirements: With the aid of the building floor
plans, the installation requirements such as the proposed load, placement of
electrical equipment and installation design plans can be determined.
2. Calculating Maximum Load Demand: The estimate of the maximum load
demand is for determining the specifications of the wiring equipment such as the
cables and accessories and subsequently to prepare the electrical installation plans.
Diversity factors may be taken into account. The maximum current demand
calculations for each circuit must be prepared. These details will show the current
requirements, in amperes, for each phase and also assist in determining the cable
sizes.
3. Preparation of the Plans, Drawings and Specifications
WIRING AND ITS TYPES
Points to be considered for selection of wiring:
Initial cost : It should be economical.
Durability : It must be able to withstand wear and tear due to weather.
Safety from fire : It should be free from risk of fire as far as possible.
Mechanical Protection : It must provide good mechanical protection to the cables.
Permanency : The wiring must not be affected by the action of weather, fumes, dampness,
chemicals etc.,
Appearance : It is an architectural point of view.
Accessibility : It should be easy to extend or repair the wiring.
Life : The System adopted should have good life.
Maintenance Cost : It should be low.
Wiring system:
1. Tree system of wiring : Branch circuits are tapped from the main circuit at
required points. Disadvantages: Due to Large no. of joints faults may occur at
joints. Considerable voltage drop in the entire system. Locating the faults is
difficult and appearance is not good. Rarely used nowadays.
2. Distribution system of wiring : In this system, Mains are taken to
distribution boards. Separate branch circuit are taken from the DB.
Advantages: No joints, Each circuit can be disconnected from the mains
without affecting other circuits. All the points remain at same voltage level.
Each circuit is protected independently with MCB, RCCB etc. Widely used.
Different Types of wiring Used for Domestic Installation
1. TRS/PVC Sheathed Batten Wiring
2. Wooden/PVC casing and Capping Wiring
3. Metal/Lead Sheathed Wiring
4. Cleat Wiring
5. Conduit Wiring

1. TRS/PVC Sheathed Batten Wiring

Key Points:
1. Tough Rubber Sheath (TRS) or PVC insulated wires are used and laid down on the
wooden batten which are fixed on wall or ceiling.
2. To fasten the wires/cables on the batten, tinned brass/iron link clip fixed with small
nails are used.
Advantages:
• Cheap method for small and medium residential premises.
• Easy to locate fault and redress it.
Limitations:
• This method suitable only for dry conditions not suitable for outdoor use.
• Wood batten may catches fire and always is a risk of fire in case of Short Circuit.
• Not recommendable where acids and alkalis are to be present.
2. Wooden/PVC casing and Capping Wiring
Key points:
• suitable for indoor low voltage domestic installation and VIR or PVC Wires are laid in
two or three channels of wooden/PVC casings which are fixed on walls or ceilings.
• It consist of U shaped grooves ,usually two in number.
• Wires are laid in grooves and the casing is covered by rectangular strip of same width,
that is called “CAPPING” and that was fitted by means of screw.
• Capping and casing are made up of TEAK WOOD/PVC

Advantages:
• This system has longer lifespan.
• Capping cover protects the wires by exposing to the weather
• As Phase conductor and neutral conductor are placed separately there is a less chance of
short circuit.
• Repairing and maintenance is easy.
Limitations:
• As Wood is inflammable and there is a risk of fire.
• The wiring is not perfectly damp proof.
• Costlier than TRS/PVC sheathed batten wiring
• The PVC casing capping wiring gives better look than
wooden casing capping wiring
3. Metal/Lead Sheathed Wiring
Key points:
• It is similar to the TRS or PVC sheathed wiring system. Only difference is that The wires
used here are lead or metal sheathed.
• The wires are either two core or three core type.
• The wires run on wooden batten and fixed by link clips..
• An earth wire is solidly connected with the sheath to prevent the lead sheath
becoming electrically alive.
Advantages:
• Suitable to use in places exposed to sun or rain.
• It can be used in damped places by covering the ends.
• It has longer life.
• Protection from fire is good and mechanical protection is high
Limitations:
• In the event of improper earthing or damaged insulation the metal sheath become
alive.
• Not suited where fumes of acid are present
• It is comparatively costly.
4. CLEAT WIRING
Key points:
• It is preferred for firm house and temporary shelters.
• Single core PVC OR VIR Cables are used in this system
• cleats are made up of porcelain/wood and have two parts base or bottom and top
• The base of the cleat is grooved to accommodate the cable on it and top in the axial
direction
• Cleats are fixed on wooden plugs fitted on the wall at regular interval
• Its life time is 5 years approximately .
Advantages:
fault can be easily identify
Expansion of wiring is possible
Materials collected after removal of installation can be used for further wiring
Cheaper
Limitations:
Unsuitable for damp and wet Areas
Poor appearance
Mechanically unprotected
Little safe
5. Conduit Wiring
Key Points:
• An Electrical conduit pipe made of steel/PVC is used to protect and route electrical
wires/cables with PVC insulation.
• Wires are drawn through conduit pipes with the help of fish wire (a steel wire). a no. of
junction boxes and other accessories are also required in this system to facilitate the
drawing of wires
• There are two types of conduit wiring according to conduit pipe installation
1. Surface Conduit Wiring
In this wiring method conduits are fixed on the surface of roof or wall with the help of
saddle screwed to wooden/plastic plugs (gutka). This system is recommended for
workshop and factories, in damp areas as well as fire prone zones, offices & hotels.
2. Concealed Conduit Wiring
In this method conduits are embedded inside the walls or ceilings during the time of
construction. The PVC wires are drawn in to the conduits with the help of GI wires.
Advantages: Limitations:
• It gives very good appearance 1. It is Costly
• Well protected from mechanical injury and fire. 2. Replacement of defective
wire in the conduit not very easy
• No risk of damage the wire insulation 3. Skilled workforce is reqd.
• Provide protection against moisture
• sustainable and long-lasting .
Surface conduit

Concealed conduit Steel conduit

House Wiring
Condition for Domestic & Industrial Installation
• Height of switch board must be 1.3m to 1.75m from floor level
• Height of distribution board must be 1.5m to 1.75m from floor level
• The bottom of ceiling fan should have minimum clearance of 2.75m
• All lamp should be filled with a minimum clearance of 2.75m above floor level
• For load above 4kw,3 phase supply must arrange & Load should be equally shared
among the three phases
• In any building light wiring and power wiring should be kept separate
• Maximum load in a light circuit should not be more than 800W or less than 10 nos of
points and maximum one point for a power circuit
• Weatherproof wire for service connection with sufficient current carrying capacity.
• Minimum Cross sectional area of Copper wires 1.5 sqmm for light/fan point, 2.5 sqmm
for light circuit, 4 sqmm for power circuit (AC/ Gyser/Power point), 6sqmm for main
circuit wiring
• Every line or phase/circuit should be protected by suitable ratings fuse/MCB/RCCB
Installation & testing of 11 kV/ 33 kV lines
Materials and Accessories used
1. Poles (Supports) : The poles or supports are classified according to the material
used for it. i. Steel ii. Cement iii. Wood
i. Steel poles are further classified as a) Rail Poles, b) Tubular Poles
ii. Cement poles are further classified as a) R.C.C poles, b) P.S.C. poles
2. Conductors : Aluminium conductors of different types and sizes are used
for drawing overhead lines which are
a) AAC, b) AAAC, c) ACSR
3. Insulators : a) PIN type used in 11 KV line, Disc type used in 33 KV line
and beyond c) Guy Strain Insulators used for guy/stay wires.
4. Guy Assembly : It is needed for dead-end and angular locations to counter
balance the load on the supports due to pulling of the conductors, so that
supports remain straight in vertical position.
5. G.I. Wire : It is used for protective guarding at the crossing of lines with
roads, railway tracks, telecommunication lines, etc.
6. GO Switches : The GO switches are used in electrical lines with voltage of
5 kV to isolate the line. They can be mounted vertically or horizontally.
7. Cross-arms : a) V cross-arms for tangent locations with clamps are widely
used , b) Double-channel cross-arm for tension or cut point locations where
Double Poles are used.
Installation:

1. Survey and Right of Way (ROW) : Initial survey should be carried out for
construction of new lines. During line survey various type of crossings i.e.
highway crossing, railway, river, telephone lines, E.H.V. lines etc. are to be
taken into account.
Before finalising the route, the following parameters should be kept in mind
i. The shortest route possible. Ii. As close as possible to the road for easy
maintenance and approach during the construction. iii. Route should be in the
direction of possible future load. iv. Angle points should be less.
Right of Way: (a) Once the route of the line is fixed approval has to be obtained,
(i) from the railway authorities for railway crossings,
(ii) from the competent forest authorities for routing of the line in forest areas, and
(iii)From the state level Power Tele-communication Coordination
Committee(PTCC).
(b) In addition if urban development, airport and similar other areas fall in the route
of the line, permission has to be obtained from those departments.
(c) Sometimes private gardens/orchards may fall on the route and require tree
cutting. The details of trees are to be marked. Compensation is fixed by
revenue authorities and paid to the owner.
Construction
The construction activity of H.T. lines is divided into the following:
1. Pit marking, pit digging
2. Erection of supports and concreting
3. Providing of guys to supports
4. Mounting cross-arms, pin and insulators, and pin binding
5. Tying and stringing of the conductor
6. Jointing of conductors
7. Sagging and tensioning of conductors
8. Crossings
9. Guarding /Anti -climbing device on poles
10. Earthlings
11. Testing and commissioning
Testing and Commissioning
When the line is ready to energise, it should be thoroughly inspected in respect of
the following.
1. Poles — proper alignment, concerting and muffing.
2. Cross-arms — proper alignment.
3. Binding, clamps and jumpers — To check whether these are in reach.

4. Conductor and ground wire — Proper sag and to check whether there are any
cuts, etc.

5. Guy — To check whether the Guy wire is tight and whether the Guy insulators
are intact.

6. Earthing System: In order to check whether the earthing connections support

and the fittings are intact the following steps should be taken. Measure earth’s
resistance with a earth tester. After the visual inspection is over and satisfied,
the conductor is tested for continuity/ground, by means of a Megaohmmeter or
megger. At the time of testing through the megger, a person should not climb on
the pole or touch the guarding, conductor, guy wire etc.