Aerial Bunched Cables

Contents

Introduction - Oman Cables Industry (SAOG)........................................................................................... 3

Aerial Bunch Cables................................................................................................................................. 4
Constructional Drawing ............................................................................................................................ 8
MV Aerial Bunch Cable......................................................................................................................... 8
Overhead Conductor - Aerial Bunch Cable ........................................................................................... 8

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 Aerial Bunched Cables
Introduction - Oman Cables Industry (SAOG)
Oman Cables Industry (SAOG) was established in 1984 and started commercial production of building
Wires in 1987. Setting a 10 year target period to manufacture L.V. Power Cables, Control Cables, Low
Smoke Flame Retarding (LSF/FRLS) Cables, Over Head Line Conductors and Flexible Cables for both
domestic and export markets, OCI was able to fulfill the mission in merely 8 years. Today, OCI is the
largest cable manufacturer in Sultanate of Oman. Beside local sales, OCI exports to all the GCC
countries, the Middle East, the Far East, Vietnam, Yemen, U.K., Pakistan, etc.

The company’s reputation, manufacturing capabilities, quality and reliability bagged it large orders from
world renowned EPC contractors like Snamprogetti – Italy, Snamprogetti – France, Chiyoda-Foster –
Japan/U.K. OCI, in a short span of time, has successfully made its mark in 4 continents of the world
against tough international competition. OCI products are also approved and registered with Department
of Electrical Services, Ministry of Development, Negara, Brunei Darussalam.

Located in Rusayl, the Sultanate’s largest industrial complex, the company is equipped with ultra-modern
Plant & Machinery. OCI gives you a choice in wires, cables and conductors as per British standards, IEC
specification, MEW-UAE, WED-Abudhabi, DEWA-Dubai, MEW Bahrain, Ministry of Defence and to other
national and international standards. In 1994 the company was accredited with the ISO 9002 certification
in remarkably short period of 6 months in line with OCI’s proven capability to meet it’s challenges. Added
to it, OCI is now accredited with the ISO 9001- design capabilities certification, which further bears
testimony to OCI’s consistency in Quality Management. The company is also a proud recipient of His
Majesty’s trophy for the Best Industry Award in the year 1991, 1992, 1996 and 1997 – a unique award for
it’s achievements. Certificate of Honour for excellence in the year 1993, 1994, 1995, 1998, 1999 to 2000
were further awarded to OCI’s success. The company continues to enjoy the position of the top ten best
performing companies in the Sultanate since and has shown a steep rise in growth. This demonstrates
the confidence the customer has reposed in OCI. The company draws strength from its highly
experienced staff, design & project management resources and stringent Quality Assurance procedures
to deliver total commitment to quality, reliability, safety and customer satisfaction.

OCI’s performance has attracted world renowned ‘DRAKA HOLDINGS NV’ – The Netherlands, one of
the largest ‘Special Cables’ manufacturing group in the world to participate in it’s equity. With technical
know-how and support of Draka Holdings, OCI is capable of displaying better growth and fostering
customer satisfaction. As an affiliate of Draka Holding Organisation with operations in Europe, United
States and the Far East, OCI is ideally positioned to service customers on both the national and global
front. OCI offers combine unrivalled experience and a vast product range developed with the support,
strength and resources of one of the world’s most significant cable companies.

In the year 1999, OCI has successfully launched and started delivering solutions to the Instrumentation
cables. Keeping in line with this success, the company has ventured into other hi-tech products, viz.,
special cables, Oil & Gas cables, etc., to its existing line of products. OCI is humbly proud of its efforts
and success and believes success is not a destination but a journey. It will strive further to achieve even
higher pinnacles of success and continue to offer better service and satisfaction to its distributors and
end users.

In this brochure we give details of Aerial Bunch Cables.

OCI prides on its ability to offer products to each customer specific needs quickly, efficiently and with an
assurance of product quality.

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 Aerial Bunched Cables
Aerial Bunch Cables
Aerial Bunch Cables are basically a compromise construction between Power cables and Overhead
conductors. Though the concept is not very new, but of late its use is increasing all over the world.

The basic construction is as follows:-

3 power cores consisting of standard aluminium conductors, insulated

with XLPE insulation
+
One sheath lighting aluminium conductor with XLPE insulation (optional)
+
One messenger Al-alloy conductor (bare or covered)

The messenger conductor can be of galvanised steel wire also.

The purpose of messenger wire is

a) It acts as load bearing wire.
b) It acts as earth or neutral conductor. Typical Aerial
Bunch Cables

Advantages of Aerial Bunch Cables are as follows:-

a) These are cheaper than power cables.
b) Cores being insulated, the chances of power thefts are eliminated.
c) Cores being insulated, the chances of faults due to falling of trees or birds are eliminated.
d) These can be laid in places where, due to lack of space, power cables cannot be laid.
e) Insulation also helps to prevent corrosion of conductor.
f) Cables are also safe for crossing of telecommunication lines.

As these are laid on poles aluminium conductor with maximum size of 95 sq mm are normally used.

Due to above mentioned advantages these types of cables are gradually getting widespread acceptance,
specifically in developing countries.

A typical construction is as given below :-

3 x 95 sq mm Power Cores – Aluminium conductor, XLPE insulated

+
1 x 16 sq mm lighting core – Aluminium conductor, XLPE insulated
+
1 x 95 sq m messenger conductor of aluminium – magnesium –
silicon alloy. 5 cores laid together

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 Aerial Bunched Cables
Technical particulars of the construction are as given below :-
3C x 95 + 95 +16

1. Nominal voltage : 0.6/1.0 KV

2. Standard applicable : IEC 60502 part 1 in general

3. Power core
i) Conductor
a) Material : Aluminium
b) Area-nominal : 95 mm²
c) Diameter : 11.4 mm 15 RBD Wire Drawing Machine
d) Standard : IEC 228/ BS 6360
ii) Insulation
a) Material : XLPE
b) Thickness-nominal : 1.6 mm
c) Diameter over-insulation : 14.8 mm approx.
iii) Core identification : By ridges or by printing core numbers on black cores.

4. Lighting core
i. Conductor
a) Material : Aluminium
b) Area-nominal : 16 mm²
c) Diameter : 5.1 mm
d) Standard : IEC 228/ BS 6360
ii. Insulation
a) Material : Cross linked polyethylene
b) Thickness-nominal : 0.7 mm
c) Core Diameter : 6.5 mm approx.
61 Bobbin Strander
5. Messenger conductor
a) Material : AAAC
b) Area : 95 mm²
c) Diameter : 12.5 mm
d) Standard : DIN 48201 part 6

6. Overall diameter of bundle : 42.1 mm approx.

7. Electrical parameters
i) Max. D.C. Resistance at 20°C
a) Phase conductor : 0.320 ohm/km
b) Lighting conductor : 1.91 ohm/km
c) Messenger conductor : 0.358 ohm/km
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 Aerial Bunched Cables
8. Standard packing length : 500 mtrs

Some countries have started using MV aerial bunch cables as well.

One such typical construction is as given below:-

3 x 95 sq mm Al conductor, Semicon screen, XLPE insulation,

semicon screen, copper taped, PVC sheathed and 1 x 25 sq mm
steel wire, PVC sheath, four cores laid up together – 22 KV (E)
grade.

Technical particulars of the above constructions are as below:-

3C x 95 + 1 x 25

1. Nominal voltage : 12/20 (24 KV)

2. Standard applicable : IEC 60502 part 2 in general

3. Power core
i. Conductor
a) Material : Aluminium
b) Area-nominal : 95 mm²
c) Diameter : 11.4 mm
d) Standard : IEC 228/ BS 6360

120mm/45mm Extruder
ii. Conductor screen
a) Material : Semi conducting XLPE

iii. Insulation
a) Material : HT grade cross linked polyethylene
b) Thickness -nominal : 5.5 mm

iv. Insulation screen

1) Non metallic
a) Material : Semi conducting XLPE

2) Metallic
a) Material : Copper tape

v) Sheath
a) Material : PVC type ST 2
b) Nominal thickness : 1.4 mm
c) Overall diameter of core: 30.0 mm approx.
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 Aerial Bunched Cables
4. Messenger core
i) Conductor
a) Material : Galvanised steel
b) Area : 25 mm²
c) Diameter : 6.4 mm

ii) Insulating sheath

a) Material : PVC
b) Thickness : 1.2 mm
c) Core Diameter : 8.8 mm approx.

5. Overall diameter of bundle : 63.21 mm approx.

6. Electrical parameters
i) Max. D.C. Resistance at 20°C
a) Phase conductor : 0.320 ohm/km
b) Current carrying capacity : 360 Amps

7. Standard packing length : 500 mtrs

5-Core Drum Twister

Brief technical details of some Aerial Bunched cable sizes - as per NFC – 33-209

S.No Description Cable weight Cable dia Current rating

kg/km mm Phase in air Lighting in air
at 30°C (A) at 30°C (A)
1 3Cx35+1Cx16+54.6 780 33 138 83
2 3Cx50+1Cx16+54.6 990 36 168 83
3 3Cx70+1Cx16+54.6 1140 37.5 213 83
4 3Cx95+1Cx16+54.6 1378 44 258 83

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 Aerial Bunched Cables
Constructional Drawing
MV Aerial Bunch Cable
3C x 95 + 1C x 25, 22kV ‘E’
To IEC 60502 Part 2 to the Extent Applicable
Sl.No. Description
1 Conductor – Galvanised Steel Messenger
2 Insulation – PVC
3 Conductor – Aluminium
4 Conductor – Screen
5 Insulation – XLPE
6 Insulation Screen
7 Copper Tape Screen
8 Outer Sheath - PVC

Overhead Conductor - Aerial Bunch Cable

3C x 95 + 95 + 1C x 16
Sl.No. Description
1 Aluminium Conductor (Power)
2 XLPE Insulation
3 Aluminium Conductor (Lighting)
4 Bare ‘Al-Alloy’ Conductor (Messenger)

Quality Assurance Laboratory Finished Goods Storage Yard

Last Revision Date: November 2003 Page 8 of 8