INTRODUCTION TO

DESIGN, CONSTRUCTION
PRACTICE AND
APPLICATION OF HT ABC
(AERIAL BUNCHED CABLE)

Presented by,
1. Sri. R. Krishnakumar, AEE, SSSD, Palakkad
2. Sri. Deepak T., AE, TC Section, Kanjikode
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Contents
• Introduction to ABC (Aerial Bunched Cables)
• Advantages of ABC
• Constructional features of ABC
• Design of ABC
• Points to be noted during installation.
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Introduction to ABC
• ABC is simply XLPE insulated power cables twisted
around bare messenger wire and are strung directly to
distribution poles.
XLPE
insulated Al
conductors

High tensile,
Stranded bare
(galvanized
steel/aluminium
alloy)
messenger wire
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Introduction to ABC
• In places where there is high congestion of utilities
underground, UGC will not be feasible.

• In places where the ground strata is very hard, trenching or

HDD will be very expensive and hence UGC will not be
economically feasible

• Where there is possibility of frequent underground

activities for road expansion works, water pipeline works and
communication cable works etc, the possibility of damages to
the UG cable is higher and this will increase the future
maintenance and replacement of the cable and hence will
lead to higher life cycle cost in the case of UG cable.
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Introduction to ABC
• ABC is a cable with earthed metallic screen. Hence no
electrical statutory clearance required, only working
clearance is required. Hence ABC is more suitable in
cases where sufficient clearance cannot be maintained
from buildings, structures, trees etc

• In locations where there is chance for tree falling on

lines, ABC installations can be designed so that the
clamps break without causing damage to cables or poles.
In the case of covered conductors, there is chance of
breaking conductors or poles and hence ABC is preferred
in such locations
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Introduction to ABC
• ABC has the limitation of fault carrying capacity of the
copper screen where as covered conductor do not have.
Hence failure chances are higher for ABC installed at
locations with high fault levels. This is an advantage for
covered conductor over ABC near EHT substations of
high fault levels.
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Advantages of ABC
• Multiple circuits of Power and Telephone cables could be strung
in the same set of poles and can be run concurrently with
existing overhead bare conductor without any interference.

• High capacitance and low inductance leads to low impedance of

lines.

• Lower voltage drop and high current capacity provides better

voltage regulations.

• Cheaper compared to underground (UG) cabling.

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Constructional features of ABC

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Constructional features of ABC

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Constructional features of ABC

• XLPE:
• XLPE or Cross-linked polyethylene is a thermoset
insulation material. Crosslinking polymers is a process
which changes the molecular structure of the polymer
chains so that they are more tightly bound together and
this crosslinking is done either by chemical means or
physical means. Chemical crosslinking involves the
addition of chemicals or initiators such as silane or
peroxide to generate free radicals which form the
crosslinking. Physical crosslinking involves subjecting
the polymer to a high energy source such as high-energy
electron or microwave radiation.
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Constructional features of ABC

• Water swellable tapes with TR-XLPE increases life
span. Metal moisture barrier such as lead sheath will also
increase the life span.
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Constructional features of ABC

• PRINCIPAL PARAMETERS:
• Conductor: Round, Stranded and compacted aluminium
conductor as per IS:8130/84
• . The stranded conductor shall be clean and uniform size
and shape and its surface shall be free from sharp edges.
• H2/H4 GRADE ALUMINIUM.
• Not more than two joints shall be allowed in any of the
wires forming every complete length of conductor and no
joint shall be within 300 mm. of any other joint in the same
layer. Joints shall be braced, silver soldered by gas
welded. No joint shall be made in the conductor, once it
has been stranded.
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Constructional features of ABC

• Conductor Screen: Extruded semi-conducting compound
generally as per IS:7098(Pt-2)/85/IEC : 60502(PT-2) 2005.
Conductor screening shall be non-metallic and shall consist of a
layer of extruded semiconducting cross linked polyethylene
compound of thickness not less than 0.5mm.

• Conductor Insulation: Tripple Extruded cross-linked Polyethylene

generally as per IS:7098(Pt-2)/85 – nominal insulation thickness
8.8 mm. The insulation shall be chemically cross linked poly
ethylene confirming to the physical, electrical and aging
properties as required in the specification. Cross-linking may be
done by exposure to peroxide with nitrogen curing CCV line
method with intention to ensure lowest tree formation. Only
natural unfilled compound shall be used for insulation.
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Comparison of process
VCV CCV
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ECCENTRICITY

Eccentricity shall not be exceed 15%

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Constructional features of ABC

• Insulation Nonmettalic Screen: Layer of Extruded semi-
conducting compound of thickness not less than 0.6mm
confirming to IS:7098(Pt-2)/85.

• Insulation Metallic Screen: The metallic –non magnetic

part shall be applied over the individual core. Copper tape
of adequate thickness should be able to withstand short
circuit current of 10KA for 1 sec.

(Ensure water tight construction to meet longitudinal water

blocking)
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Constructional features of ABC

• Conductor Outer Sheath: Extruded black polyethylene
compound type ST-3 in compliance with IEC-502 for 3 Core
Aerial Bunched Cable. The colour of the outer sheath shall be
black and shall UV rays resistant. The average thickness of the
sheath shall not be fall below the standard value (ts) specified in
the IS when measured as laid in IS 7098 pt(2)/1985. Nominal
Thickness not less than 2.2 mm.

• Messenger: Stranded and compacted all aluminium alloy (AAA)

conductor to IS:398(Pt- IV)/79 to serve the purpose of neutral in
the network and also to carry the weight of the entire Aerial
Bunched Cable under suspension on overhead lines. There shall
not be joints in any wire of the stranded messenger conductor
except those made in the base rod or wire before final drawing.
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Constructional features of ABC

• Messenger Insulaton: Extruded weather resistant black
cross-polyethylene of nominal thickness not less than
1.4mm. Rated voltage of insulation : 1.1 KV

• Minimum Bending Radius: 20D (D- Diameter of the cable)

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Design of ABC
• Main points to be considered while preparing technical
spec:

• Desired fault level for conductor.

• Desired fault level for metallic sheath (for 33kV – 8.2kA for
1 sec may be considered)
• Overlap for metallic sheath should be atleast 20%.
• Span should not be more than 30 meters.
• TR-XLPE with water swellable tapes are ideal for our
state.
• Ampacity rating should be analysed.
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Design of ABC
• Electrical stress at conductor
screen:
33kV HT-ABC: 3X300 + 300

Radius of conductor: 9.77mm

Thickness of insulation: 8.8mm

Therefore Radius of Insulation

Screen : 18.5mm

Hence Electrical stress at conductor

screen:

Er =19.075 ÷ (9.77×loge(18.5/9.77));
= 3.05kV/mm
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Design of ABC
• Electrical stress at Insulation
screen:
33kV HT-ABC: 3X300 + 300

Radius of conductor: 9.77mm

Thickness of insulation: 8.8mm

Therefore Radius of Insulation

Screen : 18.5mm

Hence Electrical stress at Insulation

screen:

Er =19.075 ÷ (18.5×loge(18.5/9.77));
= 1.615 kV/mm
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GTP
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TEST ON ABC
Routine Test
a. Conductor resistance Test
b. Partial Discharge Test
c. High Voltage test
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Single point Bonding of cable

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Single point bonding with SVL

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Selection and application of AB Cable

• The AB Cable is well suited for HT Spur and Fag end lines
• If AB Cable is used in Middle/ starting of the Line following
points should be taken care
• LA Should be installed both ends to divert the surge on the
conductor
• Select the size of the conductor higher than the bare conductor for
proper dissipation of heat.
• Thickness of Metallic sheath to cater the fault current
• Proper bonding of metallic sheath to be ensured
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Points to be noted
• Quality of material and workmanship are very critical incase of
ABC.

• Any damage in the outer sheath may lead to moisture ingress and
failure of the cable.

• The thickness of the Metallic screen should be designed

considering the desired fault level of the upstream substation. The
overlap of the metallic tape should not be less than 20%.

• Insufficient overlap of the metallic screen may result in electrical

discontinuity which will lead to corona discharge and burning of
insulation. Hence extreme care should be taken while drawing the
cable, so no appreciable stress is developed in the metallic screen.
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Points to be noted
• Earthing practices employed have very high implications
on the life of the installation.

• Jointing and termination are highly skilled jobs. Any

lapse may lead to premature failure. While doing straight
joints it should be ensured that no sharp edges are
present which may lead to failure of joint.

• Poor handling of the cable may affect various layers

very badly and lead to premature failure
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Points to be noted
• Loading and unloading of drums to be done with care so
that the cable do not sustain any stress or damage.

• During storage it should be ensured that there are no

holes in the outer coverage which may allow rats etc
going inside and damaging the outer sheath. Damaged
outer sheath will allow water ingress and subsequent
failure of the cable.

• Taking out the cable from the drum should be done with
the help of jack or turn table.
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Points to be noted

• While drawing the cable, it should be ensured that it is not

rubbing on the ground or any hard surface.

• Before installation of the cable, nylon roller should be

fixed on all poles and cable should be passed through the
rollers. The groove depth of the roller should be minimum
two times the diameter of the cable. It should be ensured
that the roller turns at angle points so that the cable do
not slip out of the groove or rub on the sides of the roller.
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Points to be noted
• While drawing the cable, it should be ensured that the cable
do not rub on poles, structures, trees .etc

• Cable should not be bent more than the bending radius

allowed. Sharp bending may cause damages in the
insulation and copper screen.

• Cable/cable loops should be tied using plastic cable ties only.

Never use metallic wires. This may cause heavy induced
current in the binding wire during external earth fault beyond
the point due to unbalance current in the cable and
subsequent melting of the binding wire and damage in the
outersheath of the cable.
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Points to be noted
• At angle points, two tension clamps should be fixed. One
suspension clamp should be fixed in the same level on
the pole using same steel strap.

• The cable should be, as far as possible, towards road

facing side of the pole. This is to avoid rubbing of the
cable on tree falling etc. The breaking strength of the
clamps will be so designed that it breaks and the cable
comes down without causing damage to poles in case of
tree falling etc.
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Points to be noted
• It is always better to change the other already existing
overhead HT or LT lines to ABC while installing new HT-
ABC. In case any HT-OH above the HT-ABC is inevitable,
the HT-ABC shall be installed on cantilever channels. This
is to avoid flashing of the HT-ABC in case live HT-OH line
falls on it. The copper screen beneath the outer sheath
will be at earth potential and the outer sheath has an
insulation of about 1.1kV only. Installation on cantilever
channels is also applicable in case of LT lines below. This
is to avoid rubbing on cross arms where there is
possibility of cable coming down on tree falling etc.
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Points to be noted
• Continuity of copper screen should be ensured by testing
before installation and before commissioning.

• Metal parts of the clamps should be earthed on all poles.

• Cable termination is a skilled job and should be done very

carefully following the instruction by the KSEBL. When a
particular layer is being cut, it should be ensured that the
layer beneath it is not injured. Otherwise this will lead to
subsequent failures after energisation.
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Points to be noted
• Straight joints other than T-joint with MVT, shall be made
with bolted joints of two and termination kit mounted on
the pole.

• Small damages or scratches, if any, in the outer sheath of

the cable can be sealed with high voltage heat shrinkable
tape.

• The copper screen shall never be earthed at more than

one point. This may cause external fault current taking a
path through the copper screen and damage it.
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Points to be noted
• Messenger shall be earthed at both ends. At joints, the
two messengers shall be brought down and be connected
to one pipe earth.

• HT-ABC failures are due to either poor quality of materials

or poor workmanship.
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Pulling of A B Cable
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Anchoring Clamp
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Suspension Clamp
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Break observed in metallic

sheath after the failure of
straight joint
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Observed the melting

of outer jacket it may
due to break in the
metallic sheath or
misaligned overlap
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Thank you