ABC CABLE

[EIRI/EDPR/4070] J.C.: 2205XL

INTRODUCTION

An ABC Cable, also known as Aerial Bundled Cable, is an overhead power line.
This cable consists of numerous insulated conductors, bundled and wrapped
together tightly. It also comes along with a bare neutral conductor. The use of
insulation is the ABC cable is in contrast with the traditional transmission cables
that were uninsulated. Additionally, these cables can transmit power in low
voltages.

TYPES OF ABC CABLES:

If we talk about the ABC cable sizes and types, then ABC cables have three
classes. Additionally, each class is available in different sizes that we are going to
discuss below:

• Low Voltage Aerial Bundle Cables:

Low Voltage ABC cables work well for overhead power lines and room entrance.
They can usually bare pressure of 1kv and below. These cables come with a
benefit of the low maintenance cost, installation, and operating cost. The cables
consist of aluminum, copper, or aluminum alloy as a conductor. The standard low
voltage Aerial bundled cables come in: IEC 61089, BS 7870, DIN 48201, ASTM
B399, BS EN50183 and NFC33-209.

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• Medium Voltage Aerial Bundle Cables:

Medium Voltage, Aerial Bundle Cables, are the most effective for power grid
transformation in urban, forest, and coastal areas. It also works great for
overhead power transmission. The system is more efficient, reliable, and
economical. These types of cables have the ability to bare voltage levels of 10kv
and below, 6.35/11kv, 12,7/22 kV, 19/33kv, etc. The conductor used is
aluminum and has a circular shape. The insulation material mostly used is XPLE.
The material used for inner and outer semiconductor is compound, but the
bedding material is semi-conducting. The screen comprises a copper tape or a
copper wire. Moreover, the outer sheath is HDPE. The standard medium-voltage
aerial bundled cables come in: IEC60502, NF C33-209, GB 12527-90 ASTM

• Duplex/Triplex Service Drop Wire:

These duplex or triplex service drop wire has a high tensile strength capability to
carry the load of 120V for overhead service applications. It also uses PVC or XPLE
cable as an insulation material. The main composition is 1350-H19 aluminum,
along with phase conductors twisted concentrically. Its neutral core is made up of
AAC, ACSR, or 6201 aluminum alloy. These duplex services drop wires are
applicable to street lighting, outdoor lighting, and building temporary services.
The conductor temperature of PVC insulated doesn’t exceed 75 degrees. And the
conductor temperature of XPLE insulated doesn’t exceed 90 degrees. The standard
duplex/triplex voltage wire comes in: ASTM B230, B231, B232, and B-399, B498,
ICEA S-76-474.

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ADVANTAGES OF USING ABC CABLES:

ABC Cable Network introduced a number of benefits that you get to avail when
you use ABC cables instead of conventional ones. Here are some of them:

• Increased Safety:

ABC cables are more safe, secure, and reliable than any conventional
transmission lines.

• Low Maintenance Costs:

These cables have low power costs, low installation costs, and, most importantly,
low maintenance. It has all of it. This is why aerial bundle cable has started to
replace the obsolete bare copper and aluminum conductor worldwide.

• Wide Area Coverage:

Unlike traditional uninsulated transmission cables, you can use ABC cables in all
areas. Knowing about ABC cable specifications, it is perfect for areas where the
installation is quite a task. These cables are the best choice for installation in
congested urban areas, where it is very difficult to lay the lines in between the
narrow gaps of buildings. It is totally not possible to install bare conductors there.
They are also quite ideal for places such as hilly areas or dense forest. ABC Cable
Company ensures that they lay power lines there without trimming any trees.

• Secure from Short Circuits:

Moreover, because of its excellent insulation, it reduces the risk of many

accidental electrocutions.

• Affordable Prices:

Additionally, the ABC cable price is quite economical, which makes it more
attractive than other traditional cables.

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• Easy Detection of Faults:

As these cables are visible, so it is quite easy to detect any fault in their system.
Additionally, the problem of water logging is not a problem anymore with ABC
cables. The risk of electricity theft is a major problem in this system, but when
you use ZW cables, you don’t have to worry about it. The company has made it
harder and more obvious to detect.

• Easy Installation:

No crossbars or insulators are required, so the installation has become way easier.

Aerial Bunched Cables (ABC) is a very novel concept for Over Head Power
distribution. When compared to the conventional bare conductor over head
distribution system. ABC provides higher safety and reliability, lower power losses
and ultimate system economy by reducing installation, maintenance and operative
cost. This system is ideal for rural distribution and specially attractive for
installation in difficult terrains such as hilly areas, forest areas, coastal areas etc.

Aerial Bunched Cables is also considered to be the best choice for power
distribution congested urban areas with narrow lanes and by – lanes. In
developing urban complex, Aerial Bunched Cables is the better choice because of
flexibility for rerouting as demanded by changes in urban development plan.

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 CONTENTS

INTRODUCTION
TYPES OF ABC CABLES:
• LOW VOLTAGE AERIAL BUNDLE CABLES:
• MEDIUM VOLTAGE AERIAL BUNDLE CABLES:
• DUPLEX/TRIPLEX SERVICE DROP WIRE:
ADVANTAGES OF USING ABC CABLES:
• INCREASED SAFETY:
• LOW MAINTENANCE COSTS:
• WIDE AREA COVERAGE:
• SECURE FROM SHORT CIRCUITS:
• AFFORDABLE PRICES:
• EASY DETECTION OF FAULTS:
• EASY INSTALLATION:
ADVANTAGES
DISADVANTAGES
USES AND APPLICATION
APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR ABC CABLE
MANUFACTURING PROCESS
CONSTRUCTION
MATERIAL
PROCESS
STRANDING
INSULATION
DEGASSING
QUALITY CONTROL
TESTING OF ELECTRICAL POWER CABLE:
(A) TYPE TEST:
1. TESTS ON PHASE/STREET LIGHT CONDUCTOR:
2. TEST ON MESSENGER CONDUCTOR:
3. PHYSICAL TEST FOR XLPE INSULATION:
4. TEST FOR THICKNESS INSULATION.
5. HIGH VOLTAGE TEST.
(B) ACCEPTANCE TEST:
(C) ROUTINE TEST:
MARKET OVERVIEW
APPLICATIONS:
PLANT LAYOUT

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PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF ABC CABLE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM WIRE
SUPPLIERS OF LUBRICATING OIL
SUPPLIERS OF WOODEN CABLE DRUMS
SUPPLIERS OF XLPE COMPOUND
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF XLPE EXTRUSION LINE
SUPPLIERS OF ANNEALING FURNACES
SUPPLIERS OF TUBULAR STRANDING MACHINE
SUPPLIERS OF POINTING MACHINE

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SUPPLIERS OF BUFFING MACHINE
SUPPLIERS OF ELECTRIC CRANES
SUPPLIERS OF INDUSTRIAL WEIGHING SCALE
SUPPLIERS OF UNIVERSAL TESTING MACHINE
SUPPLIERS OF GALVANOMETER
SUPPLIERS OF MICROMETER
SUPPLIERS OF TORSION TESTING MACHINE
SUPPLIERS OF WRAPPING, BANDING & BUNDLING MACHINES
AND EQUIPMENTS
SUPPLIERS OF HEAT TREATMENT PLANT
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF MEASURING AND TESTING INSTRUMENTS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
CHINA SUPPLIERS OF ALUMINIUM CONDUCTOR MAKING MACHINE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 205.36 KM/Day

Land & Building (18,000 sq.mt.) Rs. 17.14 Cr
Plant & Machinery Rs. 6.83 Cr
Working Capital for 2 Months Rs. 160.65 Cr
Total Capital Investment Rs. 185.21 Cr
Rate of Return 47%
Break Even Point 26%

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