CEEAMA-TECHNICAL-PAPER-2018 by Sunil Vora
CEEAMA-TECHNICAL-PAPER-2018 by Sunil Vora
CEEAMA-TECHNICAL-PAPER-2018 by Sunil Vora
Sunil G. Vora
CEEAMA LFM 105
Sunelec Infra LLP, Palghar
E-mail : [email protected]
Preamble :
Distribution of electricity requires the use of conductors in various forms i.e. cables, wires, bus-
bars etc. The most common types of cables are: insulated, flexible, armoured, shielded,
braided etc. One of the newer variants is the “Bundled Cable” where 3 fully insulated
conductors are bunched together with a bare conductor to form a cable suitable for hanging
from poles. This configuration helps to achieve flexibility as well as maintain insulation and
isolation from nearby conductors & structures.
These range of cables are known by the self-descriptive name “Aerial Bunch Cable” and come
in both Low Tension and High Tension varieties. (LT- ABC, HT- ABC)
ABC combines the advantages of underground armoured cables and overhead bare
conductors. Let us now see how we can use the properties of HT- ABC to solve some common
problems faced by Discoms in Urban, Rural as well as Industrial Areas
Why ABC ?
ABC are suitable for distribution of power in highly congested urban areas and as well as rural
areas. The major advantages of ABC are :
In urban areas, the narrow gaps between buildings do not provide sufficient bare conductor
clearance. Here ABC can be an ideal replacement
ABC can be laid without cutting or trimming any trees as no fault is caused by passing ABC
thru branches
Due to completely insulated construction, it is a deterrent for pilferage of power
Stray leakages being less, overall power loss is also less in ABC
Right of Way (ROW) issues are avoided due to use of existing poles to lay new feeders
The safety afforded to Linemen climbing poles to attend to faults is much higher with ABC
when compared to bare conductor
Bird faults are eliminated in case of ABC
High winds can cause bare conductors to touch resulting in line faults which are not
applicable to ABC
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Upto 6 ABC cables can be laid on 1 pole which is remarkable as space for new lines is
always scarce in urban areas
Faults on ABC are visible and fault location can be faster than underground cables
In MIDC or Municipal areas, road cutting charges are phenomenally high for underground
cables
Background :
MIDC Tarapur is a major Industrial Area near Boisar on the Western Railway track. Since it
was set up in the 1980’s, the area is now home to 1500+ small, medium and large industries.
MSETCL & MSEDCL have set up 3 EHV stations and 7 peripheral 33kV Sub-stations.
HT Consumers are connected to the grid at 11kV, 33kV & 132kV levels while LT consumers
are fed from numerous 11kV Distribution Transformer Centres (DTC) in the area.
Over 50 feeders are emanating from various 132/33kV/11kV & 33kV/11kV sub-stations. As a
result, the area is criss-crossed with overhead lines of all voltages and types. Additionally, the
ground is crowded with HT cables, Telephone cables, Gas lines & Water pipe lines. Road and
Drainage work is continually ongoing and underground cables are repeatedly damaged with
resultant outages of power supply. Hence, an alternative way of accommodating new feeders
while maintaining safety and reliability is the need of the hour. At the same time, Industries are
becoming power intensive and contract demands above 1 MVA are now common. MSEDCL
allows 11kV consumers with loads above 1.5 MVA to opt for Express Feeder which involve
laying a separate dedicated line from the sub-station
Case Study :
Two existing industries in MIDC Tarapur were expanding and required Contract Demand of
2 MVA ( ~ 100A load at 11kV ). The additional load was not feasible on the existing feeders
having 0.1 ACSR conductor, as the ampere load was > 300A. Over 25 consumers were
already connected on the same feeder and clients were facing interruption whenever a fault
occurred in any of the premises. Frequent and prolonged use of DG set was affecting overall
power cost. As a result, clients decided to opt for Express Feeder. The distance of these
industries were 1.5kM and 1 kM respectively from the nearest MSEDCL 33kV/11kV sub-
stations. The options of laying a new express feeder were :
1. Underground Cable (many gate & road crossings)
2. Overhead Line using Bare conductor (insufficient clearance for erecting new feeder)
3. Overhead Line using ABC
Annexure A shows the cost comparative for all 3 options
After careful consideration of the merits and demerits, we opted for Express Feeder via ABC.
The work was done under supervision of MSEDCL under DDF scheme.
Vendors were identified and orders were placed. Tarapur being a highly polluted area, hot dip
galvanized (HDG) poles and pole fittings were used for long life. In the initial stage, the handling
of ABC drum was difficult but soon the knack of paying out the ABC using mobile cranes
(hydra) was learnt. Laying upto 15 spans per day (0.4 km) was achieved after initial trial period.
Adjusting equal sag in all spans demands considerable skill and continuous monitoring is
required to ensure an aesthetically decent finish.
For the uptake and downtake, normal armoured HT cables with end termination kits were used.
Lightning arresters were installed at sending end as well as receiving end.
The 1st Express Feeder using HT ABC was commissioned in January 2017 and the 2nd in July
2017. A new industry used HT ABC to take 1.5MVA connection via Express Feeder by using
the existing poles on which ABC was laid earlier and was commissioned in October 2017.
Thus, 3 consumers with Express Feeder via ABC are working at present in Tarapur MIDC.
No fault has occurred so far and we are monitoring the performance periodically.
Post Script :
In my recent visits to clients in other states, I was pleasantly surprised to learn that in
Telangana, a client with a load of 1200 kVA had an 11kV Express Feeder using HT-ABC since
2015 ! Also another client in Himachal Pradesh was served an estimate for new connection
using ABC ! Similarly, a client in Uttarakhand has a connection using HT-ABC since 8 years !
In Punjab, near Ludhiana, I actually saw a pole carrying 6 feeders of HT ABC . In Sikkim, I saw
HT & LT ABC put to use very effectively thru forest areas. In Gujarat, I saw composite lines
with bare conductor and ABC on the same pole.
It was humbling to know that we are not doing something very innovative but rather, we are
following what other states have already adopted !
Conclusion :
The advantages of using ABC are very clear and selecting the right application is the job of
Electrical Engineers. Human nature is to be suspicious about anything new but after hands-on
experience, we tend to accept it easily. So it is with ABC. After having used in 3 projects in 2 years,
I would now say, using ABC is as easy as saying A.. B.. C.. !
Page 3 of 3
SUNELEC 11kV HT EXPRESS FEEDER COST COMPARATIVE DEC 18
OPTION 1 : UNDERGROUND OPTION 2 : OVERHEAD BARE CONDUCTOR OPTION 3 : OVERHEAD AERIAL BUNCHED CABLE
S.No.
Description Qty. Units Rate Rs. Amt. Rs. Description Qty. Units Rate Rs. Amt. Rs. Description Qty. Rate Rs. Amt. Rs.
3C x 185 sq.mm.
0.1 ACSR (Dog) 3c x 120 sq.mm.
11kV ( E ), XLPE
Conductor / (3 11kV ( E ) HT ABC
Insulated, Al.
1 1000 mts. 1,050 1,050,000 conductors per 3000 mts. 110 330,000 with 95sq.mm. 1000 mts. 600 600,000
conductor, G.I.
running mt. of bare messenger
Round Armoured
line) wire
Cable
200mm dia HDPE
DWC Pipes for (152 x 152) x 12m (100 x 116) x 11m
2 200 mts. 275 55,000 30 nos. 19,000 570,000 60 nos. 12,000 720,000
road / gate long RSJ Poles long RSJ Poles
crossings
150mm dia RCC HDGI Cross Arms, HDGI Cross Arm,
3 Half Round Pipe 700 mts. 150 105,000 Clamps & 2 tons 75,000 150,000 Clamps & 0.75 ton 75,000 56,250
for cable cover Fabrication Fabrication
Cable protection Stay sets & stay Stay sets & stay
4 8000 nos. 5 40,000 1 lot 50,000 50,000 1 lot 50,000 50,000
using red bricks wires wires
Sand bedding & 11kV Polymer
Suspension &
5 covering using dry 15 brass 3,000 45,000 Composite Pin 100 nos. 400 40,000 1 lot 40,000 40,000
Dead end clamps
river sand Insulators
11kV Polymer 1 phase jointing
RCC Cable Route Long Rod kits & Insulator
6 100 nos. 300 30,000 45 nos. 1,000 45,000 1 lot 25,000 25,000
Markers Insulators with Support at Mid
Tension H/W Span
Excavation, 1:4:8 Concreting 1:4:8 Concreting
7 Refilling and 600 cu.mt 500 300,000 of poles, studs, 60 cu.mt 3,000 180,000 of poles, studs, 100 cu.mt 3,000 300,000
levelling stay sets stay sets
Pole erection incl. Pole erection incl.
Cable Laying
8 1000 mts. 150 150,000 excavation, re‐ 30 nos. 3,000 90,000 excavation, re‐ 60 nos. 2,500 150,000
(labour charges)
filling filling
MIDC Road & Gate locati Conductor HT ABC Cable
9 10 15,000 150,000 25 spans 1,500 37,500 1000 mts. 150 150,000
cutting cess ons Stringing hanging
Pole painting, Pole painting,
10 Sundries 1 lot 50,000 50,000 muffing, danger 1 lot 100,000 100,000 muffing, danger 1 lot 100,000 100,000
signs, ACDs signs, ACDs
Say Rs. 20 lacs / km 1,975,000 Say Rs. 16 lacs / km 1,592,500 Say Rs. 22 lacs / km 2,191,250
Note : Common items like LA installation, Cable Jointing for end of feeder connection, Guarding are not considered as they are common to all 3 methods of erection
Sheet 1 of 1
ANNEXURE B
.
Typical configuration of HT ABC – 3 XLPE Insulated Cores with 1 bare ‘Messenger Wire’
A variety of suspension clamps, eye bolts, J hooks, dead end clamps are available for
simple installation of ABC from poles. More customized accessories are still being
developed for fast installation and connections.
ANNEXURE C : ABC INSTALLATION VARIETIES
Fig 1. Mid Span Joint in ABC Feeder Fig 2. 3 Feeders on 1 Pole using ABC
Fig. 5. ABC Cable Passing Thru Trees Fig 6 Excessively Sagging ABC
(Courtesy – Ensto India Pvt. Ltd.)