Download Low Voltage Aerial Bundled Cable Manual Prepared by

Low Voltage Aerial
Bundled Cable Manual
Prepared by
Safety and Health
Corporate Services and Company Secretary
May 2014
CS10 # 2369224
HORIZON POWER
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Date:
May 2014
Name:
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Position:
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Date:
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Document Title: Low Voltage Aerial Bundled Cable Manual
CS10 # 2369224
© Horizon Power
Issue Date: May 2014
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HORIZON POWER
Important Notice to Users
This manual has been developed for use by Horizon Power employees’ and Service
Providers engaged to perform Low Voltage Aerial Bundled Cable work on Horizon
Power Electrical Networks.
It is issued by as a controlled document by Horizon Power to Horizon Power employees’
and Service Providers on the condition that it will only be used whilst undertaking Low
Voltage Aerial Bundled Cable work on Horizon Power electricity distribution network.
Low Voltage Aerial Bundled Cable work will only be performed by individuals who are
appropriately trained and qualified in accordance with accepted standards within
Horizon Power. This Manual is not intended, and should not in any way be relied upon,
as a substitute for such training.
Copyright 2014
Copyright is owned by Horizon Power.
Horizon Power (ACN 57 955 011 697).
All rights reserved. No part of this work may be reproduced or copied in any form or by
any means (graphic, electronic, taping or information retrieval system) without the
written permission of the copyright owner.
Document Title: Low Voltage Aerial Bundled Cable Manual
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Table of Contents
Page i
Table of Contents
Section
1
INTRODUCTION .................................................................................................. 1-1
1.1
1.2
1.3
1.4
1.5
1.6
2
Summary ..................................................................................................................... 1-1
Overseas Usage .......................................................................................................... 1-1
Experience and Advantages ........................................................................................ 1-1
Cable Description ........................................................................................................ 1-2
Conductors .................................................................................................................. 1-2
Working Tensions ........................................................................................................ 1-2
CABLE IDENTIFICATION ................................................................................... 2-1
2.1
3
Core Identification ........................................................................................................ 2-1
POLE HARDWARE ............................................................................................. 3-1
3.1
3.2
3.3
4
Universal Bracket for Concrete/Wood Poles ................................................................ 3-1
Mounting Bracket for Universal Bracket on a Concrete Pole ........................................ 3-1
Clamps and Hanger ..................................................................................................... 3-2
STRINGING EQUIPMENT ................................................................................... 4-1
4.1
4.2
4.3
4.4
4.5
4.6
5
Pilot Rope .................................................................................................................... 4-1
Swivel .......................................................................................................................... 4-2
Cable Stockings ........................................................................................................... 4-2
Cumalong .................................................................................................................... 4-3
Dynamometer .............................................................................................................. 4-3
Pullifts (Crankers) ........................................................................................................ 4-4
STRINGING METHOD ......................................................................................... 5-1
5.1
5.2
5.3
5.3.1
5.3.2
5.3.3
5.4
5.4.1
5.4.2
5.5
5.6
5.6.1
5.7
5.7.1
5.7.2
5.7.3
6
Page Number
Installation Method ....................................................................................................... 5-1
Manpower .................................................................................................................... 5-1
Tools and Equipment ................................................................................................... 5-1
Pulling Equipment ........................................................................................................ 5-1
Stringing Equipment .................................................................................................... 5-2
Intermediate and Termination Equipment .................................................................... 5-2
Position of Pulling Equipment ...................................................................................... 5-2
Self Loading Cable Recovery Trailer ............................................................................ 5-2
Winch .......................................................................................................................... 5-3
Positioning of Stringing Blocks ..................................................................................... 5-4
Installation of Pilot Rope .............................................................................................. 5-6
Stocking Attachment .................................................................................................... 5-6
Tensioning and Terminating Cable .............................................................................. 5-6
Using a Capstan Winch with Brake Drum Stand .......................................................... 5-6
Using a Hydraulic Winch with a Self Loading Cable Recovery Trailer .......................... 5-7
Forces ......................................................................................................................... 5-8
ELECTRICAL CONNECTIONS ........................................................................... 6-1
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Insulation Piercing Connectors (IPC’s) ........................................................................ 6-1
IPC Design .................................................................................................................. 6-1
Current Rating ............................................................................................................. 6-1
Service Disconnection ................................................................................................. 6-1
Tapping ....................................................................................................................... 6-1
Cable Separation......................................................................................................... 6-1
Phase Balancing ......................................................................................................... 6-4
End Cap ...................................................................................................................... 6-4
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
7
IMPORTANT POINTS .......................................................................................... 7-1
7.1
7.2
7.3
7.4
8
Cable Description and Identification ............................................................................ 7-1
Stringing Equipment .................................................................................................... 7-1
Stringing Method ......................................................................................................... 7-1
Electrical Connections ................................................................................................. 7-2
TREE CLEARANCE FOR AERIAL BUNDLED CABLE ...................................... 8-1
8.1
8.2
8.3
8.3.1
8.3.2
8.3.3
9
Table of Contents
Page ii
Clearance Zone ........................................................................................................... 8-1
Inspection Zone ........................................................................................................... 8-1
Assessing How Much Needs to be Pruned within the Clearance Zone ........................ 8-1
Basic Clearance .......................................................................................................... 8-1
Tree Growth and Regrowth ......................................................................................... 8-1
Overhanging Branches ................................................................................................ 8-1
TECHNICAL DATA .............................................................................................. 9-1
9.1
9.2
Minimum Spacing Between Circuits for Undercrossings .............................................. 9-2
Baulk Installation Details ............................................................................................. 9-8
10
CABLE JOINTING .......................................................................................... 10-1
10.1
10.2
Joint Layout ............................................................................................................... 10-1
Joint Preparation ....................................................................................................... 10-1
11
CABLE REPAIRS ........................................................................................... 11-1
11.1
11.2
Cable Repair Kit ........................................................................................................ 11-1
Cable Repair Instructions .......................................................................................... 11-1
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List of Figures and Tables
Page ii i
List of Figures
Figure 1 – Cable Identification ....................................................................................... 2-1
Figure 2 – Universal Bracket ......................................................................................... 3-1
Figure 3 – Hooked Bracket ............................................................................................ 3-1
Figure 4 – Termination Clamp ....................................................................................... 3-2
Figure 5 – Suspension Clamp ....................................................................................... 3-2
Figure 6 – Angle Yoke ................................................................................................... 3-2
Figure 7 – Stringing Equipment ..................................................................................... 4-1
Figure 8 – Swivel ........................................................................................................... 4-2
Figure 9 – Single Eye Stocking used in LV ABC Stringing ............................................. 4-2
Figure 10 – Cumalong ................................................................................................... 4-3
Figure 11 – Dynamometer ............................................................................................. 4-3
Figure 12 – Web strap ratchet hoist ............................................................................... 4-4
Figure 13 – Self Loading Cable Recovery Trailer .......................................................... 5-3
Figure 14 – Winch working position ............................................................................... 5-3
Figure 15 – Position of Stringing Blocks ........................................................................ 5-4
Figure 16 – Angle of Deviation 26-50° ........................................................................... 5-5
Figure 17 – Stocking Attachment for Pilot Rope ............................................................ 5-6
Figure 18 – Components of IPC before and after clamping ........................................... 6-2
Figure 19 – Clamp (A) ................................................................................................... 6-2
Figure 20 – Clamp (B) ................................................................................................... 6-3
Figure 21 – Clamp (C) ................................................................................................... 6-3
Figure 22 – End Cap ..................................................................................................... 6-5
Figure 23 – Tree Clearance for ABC ............................................................................. 8-2
Figure 24 – Ground Clearance for ABC ......................................................................... 9-1
Figure 25 – Min Spacing between Circuits for Undercrossings ...................................... 9-2
Figure 26 – Min Vertical In-span Separation C .............................................................. 9-3
Figure 27 – Pole Footing with Bolted Baulk ................................................................... 9-8
Figure 28 – Joint Layout .............................................................................................. 10-1
Figure 29 – Joint Preparation ...................................................................................... 10-1
Figure 30 –Cable Repairs - 1....................................................................................... 11-1
Figure 31 –Cable Repairs - 2....................................................................................... 11-2
Figure 32 –Cable Repairs - 3....................................................................................... 11-2
Figure 33 –Cable Repairs - 4....................................................................................... 11-3
Figure 34 –Cable Repairs - 5....................................................................................... 11-3
Figure 35 –Cable Repairs - 6....................................................................................... 11-4
Figure 36 –Cable Repairs - 7....................................................................................... 11-4
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List of Figures and Tables
Page i v
List of Tables
Table 1 – Universal Bracket details ................................................................................3-1
Table 2 – Hooked Bracket details ..................................................................................3-1
Table 3 – Clamps and Hanger details ............................................................................3-2
Table 4 – Stringing Equipment details ............................................................................4-1
Table 5 – Pilot Rope details ...........................................................................................4-2
Table 6 – Swivel details .................................................................................................4-2
Table 7 – Cable Stocking details ....................................................................................4-2
Table 8 – Cumalong details ...........................................................................................4-3
Table 9 – Dynamometer details .....................................................................................4-4
Table 10 – Pullifts details ...............................................................................................4-4
Table 11 – Stringing block details ..................................................................................5-4
Table 12 – Angle of Deviation 26-50° details..................................................................5-5
Table 13 – Forces ..........................................................................................................5-8
Table 14 – IPC clamps (A) detailed ................................................................................6-2
Table 15 – IPC clamps (B) detailed ................................................................................6-3
Table 16 – IPC clamps (C) detailed................................................................................6-4
Table 17 – End Cap details ............................................................................................6-5
Table 18 – Min Spacing between Circuits for Under Crossings ......................................9-2
Table 19 – Minimum Vertical In-span Separation C .......................................................9-3
Table 20 – Joining Sleeve details.................................................................................10-2
Table 21 – Minor Repair Kit details ..............................................................................11-4
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1 INTRODUCTION
Aerial Bundled Cable for Low Voltage Distribution
1.1
Summary
The use of Low Voltage Aerial Bundled Cable (LV ABC) is expected to dramatically
increase in Australia. Compared with conventional bare conductor overhead systems,
overseas experience show that LV ABC promises to be cheaper, safer, more reliable,
require less tree clearing and pruning and so be more aesthetic, be less labour
intensive, require less maintenance and eliminate bushfires being initiated by conductor
clashing.
1.2
Overseas Usage
LV ABC is used on every continent and in a total of approximately 80 countries.
In France, Electricite’ de France (EDF) first used a form of LV ABC in the mid-1950’s.
From 1966 EDF have used aluminium conductor and from 1977 XLPE insulation has
been used. In France, approximately 142,000 km of LB ABC is erected, and each year
EDF remove 7000 km of bare conductor and replace it with LV ABC. In 1984, Bundled
Cable, used on the facades of buildings and strung between poles, comprised 27% of
France’s Low Voltage aerial network.
In Scandinavia LV ABC has been used since 1960’s and approximately 150,000 km has
been installed in Finland and in 1984 it comprised 75% of Finland’s Low Voltage aerial
network. In Sweden LV ABC has been used since the mid-1960’s and approximately
60,000 km was in service in 1984 when it comprised 40% of Sweden’s Low Voltage
aerial network.
In Ireland, approximately 6,000 km has been installed since 1980.
In Britain, a very small quantity of cable has been used, mainly in the East Midlands
Electricity Board for undereaves wiring.
1.3
Experience and Advantages
The extensive experience overseas indicates the following advantages:

Reduced cost for new work. Savings of at least 10% have been achieved in
authorities that have adopted LV ABC in significant quantity.

Significantly improved safety for linespersons, particularly when working on live
conductors.

Significant reduction in the amount of tree clearing and pruning necessary. This
reduces tree pruning costs and because the appearance of lines is improved,
electricity authorities get fewer objections from customers. In the SECV, the area of
clearance space required around LV ABC is approximately 10% of the area of the
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clearance space required around bare LV Conductors. In France, where LV ABC
has been used tree cutting has been reduced by a third.

Bushfires cannot be initiated from clashing conductors.

Reduced maintenance. In France, line inspection has been halved; de-energising of
the network for work in proximity has been practically eliminated; phase-to-earth
faults eradicated (incidents due to wind represent 40% of outages with bare
conductors); repair of suspension points eradicated and lightning damage
considerably reduced.

Less construction resources required due to quicker and easier erection.

Reduced clearances. Overseas authorities have reduced minimum ground
clearances and the clearance between LV ABC and buildings.

Improved reliability in comparison with both bare conductor overhead systems and
underground systems. Insulated conductors prevent accidental contact and supply
can be maintained temporarily in the event of a suspension system collapse.
1.4
Cable Description
The cable consists of four cores, each comprising a cross linked polyethylene (XLPE)
insulated aluminium conductor, twisted together to form a bundle. Electrical connections
are made by the use of insulation piercing connectors and the cable is supported at
intermediate poles and strain poles with easy to install mechanical fittings. The electrical
and mechanical characteristics of the cable are similar to existing bare conductors.
1.5
Conductors
The conductors used for all the cores are of stranded hard drawn aluminium which are
partially compacted, these may be sized 25, 35, 50, 70, 95 or 150 mm 2.
1.6
Working Tensions
A bundle consisting of four laid-up conductors gives ABC a very high ultimate tensile
strength (UTS), for example on the basis of 170 N/mm2 a 4 x 95 mm2 bundle has a UTS
of 65 kN. Although, in theory, it would be possible to use this high UTS to design for
reduced sages and/or longer spans, this is not necessarily economic or desirable for the
following reasons:
1.
Adoption of high tensions automatically increases the loading at angle and
terminal poles and their associated stays, thus increasing their size. This is
particularly relevant to LV distribution systems in the UK which incorporate a high
percentage of angle and terminal poles and where, because of wayleave
difficulties and the need to make service connections, spans greater than 60 m are
not usual.
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2.
SECTION 1
Page 1 - 3
In order to fit connectors to the tensioned conductors it is necessary to open up
the bundle. This clearly becomes more difficult as the tension increases and hence
a lower tension is desirable. Similarly, during the installation of lines, erection at
high tensions is more difficult and to some extent less safe.
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2 CABLE IDENTIFICATION
Figure 1 – Cable Identification
2.1
Core Identification
Conductors must be readily identifiable, particularly in poor light, and there is a special
need to distinguish between the phase and neutral conductors. The phase conductors
are identified by prominent longitudinal ribs on the core insulation, one, two or three ribs
to distinguish between the three phases. The neutral has a minimum of sixteen low
profile, longitudinal ribs equally spaced around the circumference of the core, these
serving to ensure that the neutral can be identified at all times by sight and touch
irrespective of the position of the neutral in the lay of the bundle.
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3 POLE HARDWARE
3.1
Universal Bracket for Concrete/Wood Poles
Figure 2 – Universal Bracket
Stock No.
Application
Safe Working Load (kg)
CB 3020
LV ABC
1.8 kN
Table 1 – Universal Bracket details
3.2
Mounting Bracket for Universal Bracket on a Concrete Pole
Figure 3 – Hooked Bracket
Stock No.
Application
Safe Working Load (kg)
CB 0287
Attachment of universal
bracket to concrete pole
1.8 kN
Table 2 – Hooked Bracket details
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3.3
Clamps and Hanger
Figure 4 – Termination Clamp
Figure 5 – Suspension Clamp
Figure 6 – Angle Yoke
Stock No.
Application
Safe Working Load (kg)
CC 0100
Termination Clamp
95 mm LV ABC
CC 0101
CC 0090
Suspension Clamp
Angle Yoke
SWL (kN)
2
15 kN
2
22kN
2
12kN
95 mm LV ABC
95 mm LV ABC
Table 3 – Clamps and Hanger details
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4 STRINGING EQUIPMENT
Figure 7 – Stringing Equipment
Stock No.
Description
Application
CB 3020
Universal Bracket
4 x 95 mm LV ABC
2
4 x 150 mm LV ABC
CB 3023
Single Stringing
Block Adaptor
4 x 150 mm LV ABC
2
4 x 150 mm LV ABC
SWL (Kg)
2
1.8 kN
2
3 kN
Table 4 – Stringing Equipment details
4.1
Pilot Rope
Multi-filament polyester pulling ropes are available for use, details are shown in Table 5
below. The rope is used to pull the cable from its drum into its final position.
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Stock No.
Description
Application
Non stock Purchase
Requisition Required
14 mm Polyester
14 mm Polyester
4 x 95 mm LV ABC
2
4 x 150 mm LV ABC
2
SWL (kN)
27.4 kN
27.4 kN
Table 5 – Pilot Rope details
4.2
Swivel
The swivel must be used as a link between the pulling rope and the conductor stocking.
Apart from providing this link the swivel relieves torsion (twisting) stress that usually
exists between the pulling rope and conductor bundle.
Figure 8 – Swivel
Stock No.
Application
CZ 0389
4 x 95 mm LV ABC
2
4 x 150 mm LV ABC
SWL (kN)
2
20 kN
Table 6 – Swivel details
4.3
Cable Stockings
A synthetic stocking is available for use with the ABC. Details of cable stocking
available are shown in Table 7 below.
Figure 9 – Single Eye Stocking used in LV ABC Stringing
Stock No.
Application
CC 0073
4 x 95 mm LV ABC
CC 0078
SWL (kN)
2
10 kN
2
4 x 150 mm LV ABC
25 kN
Table 7 – Cable Stocking details
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4.4
Cumalong
Figure 10 – Cumalong
Stock No.
Application
CC 0071
4 x 95 mm LV ABC
2
4 x 150 mm LV ABC
SWL (kN)
2
8 kN
Table 8 – Cumalong details
4.5
Dynamometer
Installed between Pull-lift and Chain or sling the dynamometer measures the working
load tension applied to the cable.
Figure 11 – Dynamometer
Stock No.
Application
SWL (kN)
Non stock Purchase
Requisition Required
LV ABC
10 kN (1000 kg)
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Table 9 – Dynamometer details
4.6
Pullifts (Crankers)
Different types of ratchet chain lever or web strap hoists are available for pulling ABC to
designated load tension. (Figure 12 shows a web strap ratchet hoist).
Figure 12 – Web strap ratchet hoist
Stock No.
Application
SWL (kN)
Non stock Purchase
Requisition Required
LV ABC
10 kN (1000 kg)
Table 10 – Pull-lift details
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5 STRINGING METHOD
5.1
Installation Method
ABC shall be installed using the ‘slack tension’ method. This method is used to
safeguard the cable against damage, such as abrasion, by maintaining round or other
obstruction clearances during stringing.
The only exception to using the ‘slack tension’ method occurs when there is sufficient
manpower to ensure that the cable is not dragging along the ground or damaged by
sharp objects.
5.2
Manpower
The minimum number of Linespersons required to string and tension ABC for a new
construction is three. When replacing existing aerial conductors with ABC (retro-fit), the
minimum number of linespersons required is four.
The Linesperson in Charge shall:
1.
Brief the gang on the proposed job.
2.
Allocate specific duties to each member of the gang.
3.
Nominate or act as an observer who shall observe the work at all times to ensure
that it is carried out in a safe manner.
5.3
Tools and Equipment
5.3.1
Tools

95 ABC Stripper
(Stock # NT 0443)

150 ABC Stripper
(Stock # NT 0444)

ABC Spanner
(Stock # NT 0310)

ABC Cable Cutters
(Stock # NT 0065)

Pull lifts (Crankers)

Dynamometer

Cumalong
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5.3.2
Pulling Equipment

Self loading Cable Recovery Trailer

Winch and Pilot Rope

Stocking and Swivel

Hand Held Transceivers
5.3.3
Stringing Equipment

Stringing blocks

Single Stringing Block Adapter

Double Stringing Block Adapter
5.3.4
Intermediate and Termination Equipment

Chain, Nylon Fibre Sling

Strain Clamps

Suspension Clamps

Angle Yoke

Universal Bracket
5.4
Position of Pulling Equipment
5.4.1
Self Loading Cable Recovery Trailer
The drum shall be loaded such that the cable is fed from the bottom of the drum. When
positioning the brake Drum Stand, make sure that:

The distance from the pole should not be less than the height of the pole.

It is positioned to one side of the poles alignment, so that the ABC does not rub
against the pole.
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Figure 13 – Self Loading Cable Recovery Trailer
5.4.2
Winch
Locate the winch in a suitable working position.
The winch should be placed beyond the final pole position at a distance not less than
the height of the pole and offset from the poles alignment.
Figure 14 – Winch working position
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5.5
Positioning of Stringing Blocks
The following guidelines are to be used when using the Stringing Blocks for in-line
situations and angles encountered between 0 and 50°.
Figure 15 – Position of Stringing Blocks
Stock No.
Description
Application
SWL (Kg)
CB 3023
Single Stringing
Block Adaptor
LV ABC Stringing
0-25°
3 kN
Table 11 – Stringing block details
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Figure 16 – Angle of Deviation 26-50°
Note I:
The use of two stringing blocks allows easy adaption of the suspension claps.
Note II:
The 12 mm holes in the base of the stringing blocks allows the adaption of a 10 m rod of
adjustable length to spread the stringing blocks apart during stringing and clamping.
When an angle of more than 50° is encountered, the pole construction must change to
a double termination, where two eyebolts and two strain clamps are to be used.
Stock No.
Description
Application
SWL (Kg)
CB 3024
Double Stringing
Block Adaptor
LV ABC Stringing
26-50°
3 kN
Table 12 – Angle of Deviation 26-50° details
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5.6
Installation of Pilot Rope
After each pole has been dressed with the appropriate mounting hardware, attach the
stringing blocks. Ensure that the pilot rope passes over/under any obstructions, existing
conductors etc in the positions which the ABC must occupy.
5.6.1
Stocking Attachment
When attaching the pilot rope to the nylon stocking, ensure that the swivel is located
between both as sign in Figure 17 below.
Figure 17 – Stocking Attachment for Pilot Rope
Note:
1.
Cable ends should be staggered at approximately 25 mm intervals before attachment of stocking.
2.
Do not apply electrical or other insulation tape to the ABC underneath the stocking.
3.
Apply approximately 25 mm of insulation tape over the stocking about 25 mm from the end.
4.
Using 12.70 mm (½”) Band-it, clamp the stocking over the insulation tape, and then completely
cover the Band-it with insulation tape.
5.
Ensure there is a smooth transition from pilot rope to cable to prevent jamming when passing
through stringing blocks.
6.
Check the integrity of stocking and that the swivel is free to rotate.
5.7
Tensioning and Terminating Cable
As the cable is not to be allowed to drop onto or drag along the ground or over any
obstacle, it must be pulled through using the ‘slack tension’ method. This means the
braking mechanism on the brake drum should be adjusted to maintain required
clearances.
5.7.1
Using a Capstan Winch with Brake Drum Stand
After the end of the ABC on the drum has been checked to be secure, make three and a
half turns on the capstan, engage the capstan, then take the slack up to the pilot rope
gradually adjusting the brake on the brake drum to maintain clearances.
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The observer shall monitor the progress of the stocking/swivel joint through each
stringing pulley. The cable/brake drum operator shall observe the cable on the drum,
but must inform the winch operator by transceiver to stop when only four turns remain
on the cable drum.
When the cable is approximately four metres from the final termination pole, apply more
brake tension to the brake drum to take up excess cable sag. Ensure excessive tension
is not applied to cable drum brake. Continue to pull cable through the stringing pulleys
until the required amount of cable has passed through the final stringing pulley.
Terminate the cable at the winch end first with the pull lift and cumalong to remove the
tension from the winch. Using the pull lift, cumalong, chain and dynamometer, tension
the ABC at the brake drum end according to the correct tension charts and terminate
using the strain clamp. Make sure that, when the ABC is served at the termination pole,
the remainder is LOWERED to the ground.
5.7.2
Using a Hydraulic Winch with a Self Loading Cable Recovery Trailer
After the end of the ABC on the drum has been checked to be secure, engage the
winch, then take the slack up in the pilot rope gradually adjusting the brake on the brake
drum to maintain clearances.
The observer shall monitor the progress of the stocking/swivel joint through each
stringing pulley. The cable/brake drum operator shall observe the cable on the drum,
but must inform the winch operator by transceiver to stop when only four turns remain
on the cable drum.
After the required amount of cable has past through the last stringing block on the
termination pole, the winching ceases.
Terminate the cable at the winch end first with the pull lift and cumalong to remove the
tension from the winch. Take up the excess slack by rewinding the ABC back on the self
loading trainer. Using the pull lift, cumalong, chain and dynamometer, tension the ABC
according to the correct tension charts and terminate using the strain clamp. Make sure
that, when the ABC is severed at the termination pole, the remainder is LOWERED to
the ground.
Note:
The cable should be secured to the suspension clamps in descending order of
line angle deviation. That is, poles with the largest angle of deviation should
be clamped in first.
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5.7.3
Forces
Pounds (lbf)
0
100
200
225
250
275
300
325
350
375
400
425
450
475
500
525
550
575
600
625
650
675
700
725
750
775
800
825
850
875
900
925
950
976
1000
1025
1050
1075
1100
1125
1150
1175
1200
1300
1400
1500
1600
1700
1800
Kilograms (kgf)
Newtons (N)
Kilo Newtons (kN)
0
45.9
90.7
101.9
113.1
124.4
135.6
147.8
159.0
170.2
181.4
192.6
203.9
215.1
227.3
238.5
249.7
261.0
272.2
283.4
294.6
305.8
317.0
329.3
340.5
351.7
362.9
374.1
385.3
396.5
407.7
420.0
431.2
442.4
453.6
464.8
476.1
487.3
498.5
509.7
521.9
533.1
544.3
590.2
635.1
680.9
725.8
771.7
815.5
0
450
890
1000
1110
1220
1330
1450
1560
1670
1780
1890
2000
2110
2230
2340
2450
2560
2670
2780
2890
3000
3110
3230
3340
3450
3560
3670
3780
3890
4000
4120
4230
4340
4450
4560
4670
4780
4890
5000
5120
5230
5340
5790
6230
6680
7120
7570
8000
0
.45
.89
1.00
1.11
1.22
1.33
1.45
1.56
1.67
1.78
1.89
2.00
2.11
2.23
2.34
2.45
2.56
2.67
2.78
2.89
3.00
3.11
3.23
3.34
3.45
3.56
3.67
3.78
3.89
4.00
4.12
4.23
4.34
4.45
4.56
4.67
4.78
4.89
5.00
5.12
5.23
5.34
5.79
6.23
6.68
7.12
7.57
8.00
Table 13 – Forces
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6 ELECTRICAL CONNECTIONS
6.1
Insulation Piercing Connectors (IPC’s)
Insulation Piercing Connectors are required for all electrical connections to the main
Aerial Bundled Cable. Cable ties should be used, and applied to secure the tapping
conductors to the conductor being tapped. The application of the electrical connection to
the ABC shall not impair the environmental protection afforded by the insulation.
The IPC’s provide a simultaneous connection between insulated cores either main
conductor to main conductor, or main conductor to service cable.
Note:
6.2
IPC’s are NOT designed to make or break a load
IPC Design
No insulation is to be stripped from the main conductor or service cores. The design of
the IPC is such that connection is make by piercing teeth being forced into the main
conductor/s or service cables when tension is applied to the insulated shearhead bolt.
Once the insulated bolt head has sheared off, remove the remainder of the shearhead
so that moisture will not be trapped around the bolt head.
6.3
Current Rating
Insulation Piercing Connectors are rated at the current carrying capacity of the largest
nominal size of conductor that is allowable for a particular connector, plus 20%.
6.4
Service Disconnection
Where a service or main conductor is to be disconnected from a main cable the IPC
must not be removed because of the risk of moisture penetrating the cable. Instead,
approximately 100 mm of the disconnected cable should be left in the IPC, bent
downwards to avoid moisture entering the IPC, then sealed correctly.
6.5
Tapping
When tapping either main cable to main cable or services to main cable, it very
important that the neutral insulation piercing connector is positioned furthest away from
the pole. The reason for this is that if the service cable or ABC was to break away, the
neutral would be the last to pull apart.
6.6
Cable Separation
A cable separation tool facilitates the adaption of IPC’s, and can easily be used to
separate conductors. By no means must any substitute be used, i.e. screwdriver,
spanner etc. Check that the bold ends of the IPC’s are not touching the other cores of
the ABC when the separating tools are removed.
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Figure 18 – Components of IPC before and after clamping
Figure 18 shows the components of the IPC before and after clamping. Although the
IPC has a neoprene seal around each set of clamping teeth to prevent water from
penetrating the joint, it must not be clamped in a vertical position.
Care must be taken to ensure the correct IPC is used for each installation. The IPC’s
before are suited to four different applications and must not be used otherwise.
(A)
Double bolt clamp to be used on ABC to ABC, or ABC to XLPE or PVC covered
aluminium or copper mains. The range of conductor size for both sides of the IPC
is 35-95 mm2 (CC 0080) and 50-185 mm2 / 50-150 mm2 (CC 0081). This clamp is
not to be used on bare conductors.
Figure 19 – Clamp (A)
Stock No.
Description
Application
CC 0080
Double Bolt Insulation
Piercing Connector
35-95 mm / 35-95 mm
CC 0081
Double Bolt Insulation
Piercing Connector
50-185 mm / 50-150 mm
2
2
2
2
Table 14 – IPC clamps (A) detailed
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(B)
Single bolt clamp suitable for use on 95 mm2 ABC to 6-35 mm2 aluminium/copper
service cables. This clamp is not to be used on bare conductors.
Figure 20 – Clamp (B)
Stock No.
Description
Application
CC 0082
Single Bolt Insulation
Piercing Connector
95 mm / 6-35 mm
CC 0085
Double Bolt Insulation
Piercing Connector
150 mm / 6-35 mm
2
2
2
2
Table 15 – IPC clamps (B) detailed
(C)
Double bolt clamp suitable for use on 95 mm2 ABC to 50-150 mm2 bare
aluminium conductor and 150 mm2 ABC to 50-150 mm2 bare aluminium
conductor.
Figure 21 – Clamp (C)
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Stock No.
Description
Application
CC 0084
Double Bolt Insulation
Piercing Connector
95 mm / 50-150 mm
CC 0089
Double Bolt Insulation
Piercing Connector
150 mm / 50-150 mm
2
2
2
2
Table 16 – IPC clamps (C) detailed
6.7
Phase Balancing
Method to be used to ensure correct phase balancing for single phase connections.
Step 1. Add the numbers in the house number.
Step 2. Divide this number by three, and if:
(a) it is divisible without a remainder, it is connected to the red phase.
(b) with a remainder of 1, it is connected to the white phase.
(c) with a remainder of 2, it is connected to the blue phase.
Example:
House numbers:
Note:
56 = blue phase
57 = red phase
58 = white phase
If a house number 1 or 2 are found, treat these numbers as remainders
That is:
house number 1 = white phase
house number 2 = blue phase
In the case of a duplex, with separate services and sharing the same house number,
connect one half of the duplex to a different phase.
That is:
6.8
house number 35a and 35b
35a = blue phase
35b = red or white phase
End Cap
The other type of Eng Cap which is available does not permanently adhere to the ends
of the cores of the ABC as does the Live End Seal Cap. The End Cap is smaller and
does not require a mastic strip for the End Cap to adhere to, but is simply pushed onto
the end of the core.
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When completely pressed onto the cores, the End Cap provides a permanent watertight
seal because of the circular ribs inside the cap. The End Cap, if used as a temporary
seal, can easily be removed and re-used again.
Figure 22 – End Cap
Stock No.
Description
Application
CJ 0063
End Cap
95 mm
CJ 0062
End Cap
150 mm
2
2
Table 17 – End Cap details
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HORIZON POWER
7 IMPORTANT POINTS
7.1
Cable Description and Identification

Each phase of the bundle is embossed with a number i.e. 1 Red, 2 White, 3 Blue, as
well as having the same corresponding number of prominent longitudinal ribs on the
core insulation.

The neutral is fully ribbed around the circumference of the core insulation.
7.2
Stringing Equipment

Make sure that sufficient stringing equipment is available before attempting to string
ABC.

Do not use any substitute stringing equipment other than that equipment which is
mentioned in this booklet.
7.3
Stringing Method

The minimum number of linespersons required to string and tension ABC for a new
construction is three.

The minimum number of linespersons required to string and tension ABC for a retrofit or aerial changeover is four.

When positioning the Brake Drum Stand and the Winch, be sure that their distances
from the poles are not less than the height of the pole.

The Brake Drum Stand and the Winch should be positioned to one side of the poles
alignment to avoid abrasion of the cable against the pole.

When an angle greater than 25° and less than 50° is encountered, an Angle Yoke is
to be used with two suspension clamps.

Do not leave suspension clamps and cable hangers attached to the hook on the
universal bracket when pulling out the cable.

Ensure that the stringing block adaptors are correctly attached to the universal
bracket.

Any angle over 50° is to be double terminated.

It is extremely important for the universal bracket on an angle pole to split (halve) the
angle, this determines the position of the Stringing block(s) for the correct clamping
in procedure.
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SECTION 7
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
If the overall conductoring distance of 95 mm2 ABC is in excess of a full drum
(400 metres), then the person responsible at the brake drum must ensure that no
less than four complete turns (10 metres) remain on the drum whilst paying out
under tension.

Ensure pilot rope passes over under any obstructions when installing into stringing
blocks.

Staggering the ends of the cable 25 mm (approx) before attaching the cable
stocking.

Ensure that the stocking has a band of insulation tape at its end, clamped with
Band-it then covered with insulation tape.

Ensure that the swivel is attached to the stocking to avoid unnecessary twisting of
the pilot rope.

Do not over tension the cable, refer to the appropriate sag and tension charts.

The cable should be clamped, after being tensioned and terminated in descending
order of line deviation.

Observe cable phasing orientation if more than one drum of cable will be used.

Check inside of the ABC drum for nails protruding, splinters of wood, etc, prior to
paying out.

If using the Self Loading Cable Recover Trailer, make sure the cable is payed out
from the bottom of the drum

Make sure that the Stringing blocks on each termination pole during a retro-fit are
suspended with slings so that there is no chance of the block becoming alive during
stringing.

Hand held transceivers must always be used during stringing operations. (Three is
the minimum required.)
7.4
Electrical Connections

Make sure that the correct IPC is used.

Ensure that the correct size of cable is positioned in the appropriate side of the IPC.

Do not allow an IPC to make or break a load.

Do not remove any insulation from cables when a connection is made using an IPC.
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
If using a double insulated cable, the outside sheath of the cable must be removed
prior to attaching an IPC.

Do not exceed the recommended maximum bending radius of ABC.
i.e.
95 mm2 single Core – 95 mm radius
150 mm2 Single Core – 115 mm radius
95 mm2 Bundle – 345 mm radius
150 mm2 Bundle – 410 mm radius

Ensure correct size of ratchet or ring spanner is used to tighten IPC’s.

Do not exert a bending force on the shear head of the IPC.

Remove shear head from IPC when correct tension is attained.

Do not remove an IPC from the ABC once it has been installed.

Do not install an IPC on a vertical core or in a vertical position.

Use the recommended end caps on ABC cores at termination points to stop the
ingress of moisture into the cable.

Allow approximately 80 mm between IPC’s on installation.

Make sure that service cables and tops to the main bundle have drip loops to
prevent water entering the IPC.

Ensure that DIN fuses are positioned in the Ensto fuse tray correctly.

Do not allow the bottom bolt of the Ensto bracket to come into contact with the fuse
tray when closing.

Ensure that the drip loops in the line and load side of the Ensto do not interfere with
the removal/replacement and closing of the fuse tray.

Make sure the neutral connection on the Ensto and Pfisterer are against the pole,

There is no necessity to stagger compression joints at a double termination pole.
(Separate cores only)

When operating the Ensto, ensure that the fuse tray is fully closed.

Ensure tee of cable cores are shaped prior to connecting to the main cable.

If more than one single phase connection is made in a circuit breaker box, ensure
that the house numbers are connected with the lowest house number from the left
hand side when viewing from the front of the box.
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8 TREE CLEARANCE FOR AERIAL BUNDLED CABLE
Aerial Bundled Cable (ABC) avoids many of the risks associated with bare conductors
provided the insulation remains intact. Insulation may be damaged by constantly
rubbing or hitting from objects such as tree branches and buildings.
8.1
Clearance Zone
The clearance zone is a 1 m radius around the low voltage ABC.
8.2
Inspection Zone
The Inspection zone requires any unsound tree timber, inside a 45° angle from both
sides of the base of a pole, to be removed.
8.3
Assessing How Much Needs to be Pruned within the Clearance Zone
8.3.1
Basic Clearance
To minimise the risk of abrasion it will be necessary to remove any branches from within
one metre of the cable that could damage the insulation through tree movement or
growth within the pruning interval.
8.3.2
Tree Growth and Regrowth
Adequate allowance must be made for tree growth or regrowth within the pruning
intervals. Light leafy regrowth, such as that produced by Eucalyptus trees within one
year of cutting, can be left in contact with the ABC. However, it must be cleared before it
becomes firm enough to cause abrasion.
Consideration should be given to training the growth past and around the cable, by
removing only those branches likely to rub against the cable, back to the junction with
another branch or the trunk.
8.3.3
Overhanging Branches
Branches are permitted to overhang ABC provided that clearances specified are
maintained. Obviously unsound branches within the inspection zone should receive
attention.
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Figure 23 – Tree Clearance for ABC
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9 TECHNICAL DATA
Figure 24 – Ground Clearance for ABC
Complies with code of practice for overhead line construction
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9.1
Minimum Spacing Between Circuits for Undercrossings
Figure 25 – Min Spacing between Circuits for Undercrossings
Lower Circuit
Voltage in kV
Upper Circuit
Voltage in kV
Attached to Common
Structure at Point of
Undercrossing A (mm)
Not attached to Common
Structure at Point of
Undercrossing B (mm)
LV ABC
LV
380
600
LV ABC
LV to 11
1200
1200
LV ABC
11 to 33
1200
1200
LV ABC
33 to 66
1800
1800
LV ABC
132
2400
2400
Table 18 – Min Spacing between Circuits for Under Crossings
1.
2.
The spacing shall be maintained with no wind and the upper circuit at the
temperature specified below:

LV minimum design temperature normally 50°C;

Up to 33 kV maximum design temperature normally 65°C; or

Up to 132 kV maximum design temperature normally 85°C.
Lower circuit at 15°.
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Figure 26 – Min Vertical In-span Separation C
Lower Circuit
Voltage in kV
Upper Circuit
Voltage in kV
Minimum Vertical In-span
Separation C (mm)
LV ABC
LV
600
LV ABC
LV to 11
1200
LV ABC
11 to 33
1200
LV ABC
33 to 66
1800
LV ABC
132
2400
Table 19 – Minimum Vertical In-span Separation C
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9.2
Baulk Installation Details
Figure 27 – Pole Footing with Bolted Baulk
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10
CABLE JOINTING
10.1
Joint Layout
Figure 28 – Joint Layout

Ensure phase and neutral are correctly matched and orientated.

Each core must be cut accurately to ensure correct balance of tensions.
Note:
10.2
It is extremely important that, on completion, all four cores will have exactly the
same tension at each compression sleeve.
Joint Preparation
Figure 29 – Joint Preparation
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1.
Mark cable end with tape at half sleeve length.
2.
Strip insulation as shown on drawing.
3.
Insert cable into sleeve ensuring tape mark is within 1-2 mm of full penetration.
4.
Crimp with appropriate die, in sequence starting at number 1.
5.
Do not overlap the crimps.
Stock No.
Description
Application
CJ 0491
Full Tension Sleeve
95 mm / 95 mm
CJ 0490
Full Tension Sleeve
150 mm / 150 mm
2
2
2
2
Table 20 – Joining Sleeve details
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HORIZON POWER
11
CABLE REPAIRS
11.1
Cable Repair Kit
Application – the kit is to be used on 95 mm2 and 150 mm2 cables:
1.
minor cable insulation damage;
2.
where an IPC has to be removed due to mains cable damage; and/or
3.
where an IPC has been removed by mistake.
Contents:

1 off – Sigmaform SGR54 -14 x 250 mm Shrinkaround™ Sleeve.

1 off – Heatproof paper 400 x 220 x 1.6 mm.

1 off – Aluminium oxide abrasive strip 300 x 25 mm.

1 off – TCE cleaning pad.

1 off – Instruction sheet.
11.2
Cable Repair Instructions
Figure 30 –Cable Repairs - 1
Step 1

Separate the damaged cable using the Cable Separation Tool. (The wedge will not
provide adequate separation)

Abrade the cable jacket to be covered CIRCUMFERENTIALLY, with either the
abrasive strip, a file or a carding brush.

Roll the Shrinkaround™ Sleeve tightly to give it a circular shape.
Note:
Emery paper must not be used as it deposits a conductive material on the
cable.
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Figure 31 –Cable Repairs - 2
Step 2

Place the Shrinkaround™ Sleeve around and on the cable so that the sealant side
of sleeve is next to the cable and the contact adhesive of the lower flap is facing up.

Remove the protective release paper from both flaps of the Shrinkaround™
Sleeve. This will expose the surfaces of the contact adhesive.
Figure 32 –Cable Repairs - 3
SIGMAFORM ‘SGR’ Series Shrinkaround™ Sleeve is a heat shrinkable pololefin, split
sleeve. The Shrinkaround™ Sleeve is ‘bonded’ together with contact adhesive to form
a circular tubing over damaged cable sheaths and is especially designed for use on all
cable insulations.
Shrinkaround™ Sleeve provide complete waterproofing, insulation, abrasion and
corrosion resistance under the adverse environmental conditions. Shrinkaround™
Sleeve have excellent electrical properties as well as being highly resistant to moisture,
fungus and weathering.
Note:
Allow 50 mm per end overlap beyond the damaged area.
Document Title: Low Voltage Aerial Bundled Cable Manual
CS10 # 2369224
© Horizon Power
Issue Date: May 2014
User to check printed document is correct
SECTION 11
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HORIZON POWER
Figure 33 –Cable Repairs - 4
Step 3

Align the centre of the top flap over the centre of the lower flap, so that the edge of
the top flap is at the white line of the lower flap.

PRESS DOWN FIRMLY on the centre of the flaps to mate the adhesive surfaces.
Note:
Once the surfaces contact each other, DO NOT try to pull apart or re-align.

Centre the sleeve over the damaged area allowing 50 mm per end overflap. Place
the flap on top of the cable.

Run the hot torch nozzle over the full length over the flap to ensure a good bond
between the flaps.
Figure 34 –Cable Repairs - 5
Step 4

Place a length of heat-proof paper between the core t be repaired and the other
cores. The cable separation tool can be used to hold the paper in place.

Ensure that only the wrap around sleeve is exposed to the flame.

Heat the centre area until it shrinks over the cable and the blue spots turn black.
Then heat the flap until the ‘Sigmaform’ letters become shallow and flatten out.
Document Title: Low Voltage Aerial Bundled Cable Manual
CS10 # 2369224
© Horizon Power
Issue Date: May 2014
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Figure 35 –Cable Repairs - 6
Step 5

Work towards one end, applying heat uniformly and smoothly until all blue spots turn
black. Then apply more heat to the flap area so the ‘Sigmaform’ letters become
shallow and flatten out. Make sure the Mastic is flowing around the end.

Repeat the same procedure on the unshrunk half.
Note:
Ensure that the protective heat-proof paper is in place.
Figure 36 –Cable Repairs - 7
Step 6

Leave completed repair to cool.

Remove Cable Separation Tool and the heat proof paper, and return cable to
original position.
Stock No.
Description
CZ 0600
Minor Repair Kit
Application
For damage of no more than 100 mm
2
2
of insulation on 95 mm / 150 mm
ABC cable.
Table 21 – Minor Repair Kit details
Document Title: Low Voltage Aerial Bundled Cable Manual
CS10 # 2369224
© Horizon Power
Issue Date: May 2014
User to check printed document is correct
SECTION 11
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HORIZON POWER
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Document Title: Low Voltage Aerial Bundled Cable Manual
CS10 # 2369224
© Horizon Power
Issue Date: May 2014
User to check printed document is correct