Unit 4 : OVERHEAD DISTRIBUTION LINES

Q1) Estimate the main material requirement for a 600m, 415/240V, 3 phase line with 4
wires in vertical configuration. The line emanate from substation to feed a load of
30kW. Consider span between two poles as 60 meter.( S-22, 6M)
Ans:Data Given:
Total length of line = 600 m
Length of span between two poles = 60 m
600
No. of poles required = 60 + 1=11

Main Material requirement:

1) Poles: Pre-stressed Concrete (PSC / PCC) Poles (8 m) = 11 nos.
2) Conductor: ACSR conductor (6/1 x 2.59 mm) is usually used for LT lines. The length of
Conductor required = 4 conductors/line x Line length + 5% for sag and wastage
4 𝑥 600 𝑥 105
= = 2520m =2.52 km
100

3) GI wire for earthwire: usually 8 SWG GI wire is used.

Length of GI wire required =600 X 105% =630 M
GI wire of 8 SWG weighs 0.131kg/m, hence the required GI wire = 0.131 X 630 kg
= 82.53 = 83 kg
4) LT shackle Insulators: These are required 4 nos. per pole
Total shackle insulators required =4 X 11 = 44
5) Earth knobs: It is required one per pole for carrying earth wire,
Total earth knob requirement = 11 nos.
6) D-clamps for Shackle insulators: It is required for each shackle insulator.
No. of D-clamps required = 44 nos.
7) Guysets: It is required one for each end pole and two for the pole at cut-points (Cut-point
pole usually marked after five spans). Here since the no. of poles are 11, we can make only
one cut-point at sixth pole. So the no. of guysets required = 1+2+1 = 4 nos.
8) Earthing sets: Every fifth LT pole is to be earthed. The end poles are also earthed. So the
total requirement of earthing sets = 3
9) Aluminium Binding Wire / tape: It is usually assumed as 1kg per km length of line. So
approximately we can assume requirement as 1 kg.
Q2) Estimate the mash material required for a 750 m, 415/240 V three phase line with
four wire in vertical configuration. The line emanate from substation to feed a load of
30 kW.
Take the span between two poles as 50 m. The size of conductor is ACSR 6/1 x 2.599mp.
Plan of overhead line is in Figure No. 3.( W-23, 6M)

1) Poles: Pre-stressed Concrete (PSC / PCC) Poles (8 m) = 15nos.

2) Conductor: ACSR conductor (6/1 x 2.59 mm) is usually used for LT lines. The length of
conductor required = 4 conductors/line x Line length + 5% for sag and wastage
= 4*750*105/100=3150mm =3.15km
3) GI wire for earthwire: usually 8 SWG GI wire is used. Length of GI wire required =
GI wire of 8 SWG weighs 0.131kg/m, hence the required GI wire =750*105/100
=787.5*0.131kg/mm =103.63kg
4) LT shackle Insulators: These are required 4 nos. per pole ;Total shackle insulators
required
= 15*4=60nos
5) Earth knobs: It is required one per pole for carrying earth wire, Total earth knob
requirement = 15 nos.
6) D-clamps for Shackle insulators: It is required for each shackle insulator. No. of D-
clamps
required =60 nos.
7) Guysets: It is required one for each end pole and two for the pole at cut-points (Cut-point
pole usually marked after five spans). Here since the no. of poles are 15, we can make only
one cut-point at sixth pole. So the no. of guysets required = 1+1+1 = 3 nos.
8) Earthing sets: Every fifth LT pole is to be earthed. The end poles are also earthed. So the
total requirement of earthing sets = 3
9) Aluminium Binding Wire / tape: It is usually assumed as 1kg per km length of line
so approximately we can assume requirement as 1kg.
Q3) Estimate the main material required for a 2km overhead line to extend from
existing line. Assume a span of 50m (S-22, 6 M)
Assuming LT line (3 phase 4 wire):
Total length of line = 2m = 2000m
Span between two poles = 50m
No. of poles required= (2000/50) + 1= 40+1 = 41 (if tap is take from existing pole it is 40)
Insulators:
Assuming vertical configuration, 3 phase 4 wire
LT shackle insulators for the poles (4 for each pole) = 4 x 41=164
Earth knobs for carrying the earth wire = 41
D clamps made from MS flats of suitable sizes
Conductor
Length of AAC Ant conductor (phase conductor) = (3x2000)+5% for sagging and wastage
=(3x2000x105/100)=6300m=6.3km
Length of AAC Gnat conductor (neutral conductor) = (2000)+5% for sagging and wastage
=(2000x105/100)=2100m=2.1km
Length of No.8 SWG GI wire Taking its weight approximately as 100 kg per km.
=2km x 105/100 = 2.1km
Weight of No.8 SWG GI wire=2.1x100=210 kg including guarding
Miscellaneous
Guysets complete (one for end pole and 2 for every 5th pole)=1+(2x7) =15
Guywire 7/20 SWG = 35kg (lumpsum)
LT Earthing sets (every 5th pole is earthed) = 8
Aluminium binding wire and binding tape = 2kg each
Sr no. Description of material Quantity Unit
1 PCC poles, 8m or 7m long 41 No
2 Phase Conductor 6.3 Km
3 Neutral conductor 2.1 Km
4 LT shackle insulator 164 No
5 8 SWG GI wire 210 Kg
6 Guy set 15 Set
7 Guy wire 35 Kg
8 D clamps 35 kg
9 Earth knobs 41 No
10 Earthing set 08 Set
11 Aluminium binding wire 02 Kg
12 Aluminium binding tape 02 Kg
13 Bolts and nuts 60 kg
14 Aluminium paint 02 Liter
15 sundries lumpsum lumpsum
Q4) State the methods of laying underground cables and write the list of material
required for laying underground cable. ( S-22, 2M)
Ans: Methods of laying underground cables:
i) Direct Laying (Cables buried directly underground)
ii) Draw-in-system
iii) Solid system
List of material required for laying underground cable:
1) Sand
2) Bricks
3) China clay
4) Bitumen compound
5) Conduits, ducts or tubes made of either iron, clay or cement concrete
Q5) State the purpose of guarding wire used in distribution lines
Ans: Purpose of guarding wire used in distribution lines:
Guarding wire is used to protect the personnel, lines or equipment in the event of fault. When
distribution line conductor snaps (brakes down) during abnormal weather conditions such as
heavy rains, storms and lightning, the live conductor touches the guard wire, which is
earthed.
Thus snapping of conductor creates earth fault, causing fuse to blow or protective relay
operate and disconnect the faulty line from supply. Thus snapped conductor becomes dead
and no harm can occur even if somebody touches such conduct.
Q6) List four factors determining selection of HT power cables. ( W-22, 2M)
Ans: Factors Determining Selection of HT Power Cables:
1. Current carrying capacity.
2. Voltage regulation.
3. Short circuit rating
4. Cable construction.
5. Cable shield requirement
Q7) Write any two factors for selection of LT (415) power cable.( S-24, 2M)
1. Current carrying capacity
2. Voltage regulation
3. Short circuit ratio
4. Load Capacity
Q8) List any eight electrical equipment required in HT (11kv) substation.( W-22, 4 M,
S-24, 4 M)
Ans: Electrical Equipment Required in HT (11kv) Substation:
i) Busbar: - Bus bar is common conductor to which incoming & outgoing lines are
connected. It is generally made from ACSR conductor. Cross section of conductor depends
on current. In Substation, there are three bus bar:
1) Incoming bus bar (33kV/66kV)
2) Station bus bar (11 kV) 3) Outgoing bus bar (11kV)
ii) Power Transformer:- Its function is to step down the incoming voltage (Secondary
transmission) to outgoing voltage (Primary distribution) without change in frequency.
iii) Auxiliary Transformer: - Its function is to step down the input voltage (11 kV) to
distribution voltage (3-ph, 4wire, 440V) to give supply to control room, area lighting, staff
quarters etc.
iv) Lighting Arrester: - It is provided for protection of substation, transformer against
lightning stroke.
v) Earth switch: - It is used for safety purpose. It is closed during maintenance to discharge
capacitor.
vi) Isolator: - Its function is to isolate the circuit whenever required. e.g at the time of
maintenance.
vii) Circuit Breaker: - It is protective device. It open or break the circuit whenever there is
fault & protect the equipment.
viii) Relay: It senses the fault & gives signal to tripping circuit of C.B to open.
ix) Instrumental Transformer (CT & PT):- C.T & P.T are used for measurement of
electrical quantities and also for protection purpose.
x) Horn Gap Fuse: - It is provided to primary side of transformer for protection against
over current.
xi) Control Room: - It is constructed near to switchyard in which control panel is installed
from which various circuits are controlled by operator.
xii) Control Panel: - Control panel consists of different types of relays to detect different
types of faults.
xiii) PLCC (Power Line Carrier Communication):- It is used for direct communication
between substations to generating station also between two major substations. For this
purpose same transmission line carries communication signal.
xiv) Series Reactor: - To limit the short circuit current.
xv) Shunt Reactor: - It draws lagging KVAR to control voltage of transmission line.
xvi) Series Capacitor: - It supplies reactive power in KVAR
xvii) Shunt Capacitor: - For power factor improvement
Q9) Draw the single line diagram of HT (11kV) substation ( S-22, 4 M)
Ans: Single Line Diagram of HT (11kV) Substation:

Q10) Distinguish between overhead and underground distribution line .( W-22, 4M S-

24, 4M)
Ans:
Sr no. Basis Overhead distribution Underground
line distribution line

1 Public safety Less More

2 Initial cost Less More
3 Flexibility More Less
4 Chances of faults More Less
5 Appearance Poor Good
6 Fault location and Easy to detect and repairs Difficult to detect and
repairs repairs

7 Useful life Less More

8 Maintenance cost More Less
OR

Q11) State the different methods of cable termination for HT/ LT (11KV/ 415V) line.
Explain any one method in details.(W-22,S-24 4M, 6M)
OR
Explain with suitable example selection procedure of power cables in HT -distribution
including their termination of cables underground cabling.( S-23, 4M)
Factors determining selection of HT power cables
1. Current carrying capacity
2. Voltage regulation
3. Short circuit rating
4. Cable construction
5. Cable shield requiremenT
Methods of Cable Termination For HT (11KV) Line:
1. Heat Shrink
2. Lug Termination
3. Claw type termination
4. Spade termination
5. Crimping
1) Heat shrink:
Heat shrink cable terminations can be used for LV-MV-HV power cables present indoors
and outdoors. Indoors, these cable terminations connect to substation switchgear,
transformers and insulated cable boxes. Outdoors, they are used in overhead and
underground distribution lines.

 High-quality heat shrink cable terminations have excellent strength

 They are highly resistant to chemicals, solvents, and extreme temperatures
 Highly quality cable terminations do not crack, melt or get displaced when applied
properly
 The flexibility of heat shrink cable terminations allow them to be used in cases where
cables have to be bundled together.
2) Lug Termination:
 Strip conductor to insertion depth
 Conductor ends must be cleaned before termination
 Insert conductor fully into cable lug or ferrule
 Using the appropriate crimping tool crimp lug onto conductor
Lug is used to terminate stranded conductors only. It is made of tinned copper tubing pressed
into different shapes and sizes, and is crimped onto the conductor. Hand crimping tools
usually accommodate several lug sizes in a fixed head, which is obtainable with indent, oval,
hexagon crimp type dies. For larger lugs, hydraulic crimping machines with capacities from
5 tons upwards are used.
3) Claw type termination:
Prysmian Claw Cleats (Aluminium Cable Clamps) are two piece, single fixing LUL
approved cable cleats providing cable support and protection against all weather conditions
in industrial or outdoor areas with operating temperatures -60°C to +105°C.
Prysmian claw cable cleats with single bolt fixing are suitable for supporting cables with
10mm to 51mm outer sheath diameter forming part of the Prysmian BICON range of way
cable cleats.
Epoxy coated claw cleats are available for heavy industrial and hazardous area locations
where higher levels of corrosion protection is required.

 Cable cleats suitable for cleating cables with diameters 10 to 51mm

 Claw cleats are manufactured from aluminium alloy
 Can be stacked to a maximum of three on a single fixing
 Can be used for all types of cable routes
 Plain finish – for normal industrial areas or outdoor unpolluted areas
 Epoxy coated versions available for harsher environments
 Packing pieces to be used where required
4) Spade termination
Spade lug terminals are used to dress and terminate a conductor to a termination point or post
with a mechanically secure, "partially captured" connection. The "partially captured" feature
allows the terminal to be removed from a termination post without completely removing the
compression nut (as is required with ring lugs). This security feature may be beneficial in
moderate vibration environments where there is a requirement for the termination to be
disconnected.
5) Crimping
Crimping is a totally different wire termination method. This was used to replace soldering
techniques. In this method, the connection is made using a crimping tool. The insulation of
the conductor is manually un-stripped and it is connected with the contact of the cable
assembly. Though the physical exertion is very high in this type of termination, it also offers
very reliable connectivity.
Q12) State types cables used for distribution line installations ( S-23, 2M)
Distribution line installations utilize various types of cables, each designed for specific
purposes and voltage levels. Here are the commonly used types of cables for distribution
lines:
Overhead Conductors:
1. Bare Conductors
2. Aerial Bundled Conductors (ABC)
Underground Cables:
1. Underground Distribution Cables
2. Underground Residential Distribution (URD) Cables
3. Submarine Cables
Submarine Power Cables:
1. High Voltage Cables
2. High Voltage Power Cables
3. Extra High Voltage (EHV) Cables
4. Fiber Optic Cables
Q13) Draw the neat sketch of 11 KV HT substations and enlist the material required in
the substation ( S-23, S- 24 4M)
A 11 kV High Tension (HT) substation typically consists of various equipment and
materials to facilitate the transmission and distribution of electrical power. Here is a list
of commonly used materials and equipment in an 11 kV HT substation:
1) Transformers
2) Circuit Breakers
3) Isolators
4) Lightning Arresters
5) Busbars
6) Current Transformers (CTs
7) Potential Transformers (PTs
8) Lightning Protection System
9) Control Panels
10) Insulators
11) Surge Arresters
12) Battery and Battery Chargers
13) Earthing System
14) Steel Structures
15) Cables and Conductors
16) Protective Relays and Control Systems

Q14) State the classification of cable on voltage levels( W-23, S-24 2M)
Low tension (L.T.) Cable 0 – 1 kV
High tension (H.T.) Cable 1 – 11 kV
Super tension (S.T.) Cable 11 – 33 kV
Extra high-tension (E.H.T.) Cable 33 – 66KV
E.S.V (extra super voltage) above 132KV
Q15) How insulation resistance is tested between Conductors?( W-23, 4M)
Ans. Testing of Insulation Resistance Between Conductors.
The object of this test is to ensure that the insulation is sound between the conductors so
that there may not be an appreciable leakage between them. In this case the circuit diagram
remains the same, as shown in below Fig.3.b, except that the loop at the main switch is
removed and all the lamps and all metallic connections between the two wires of the
installation are removed from the lamp holders. Rest of all the things remaining the same
i.e, the main switch off, main fuse withdrawn, all other fuses in their positions and all
single pole switches in 'on' position, the terminals of the megger are connected to the two
poles or lines of the installation and insulation resistance is measured between two
conductors (line and neutral conductors). The insulation resistance so measured should not
50 𝑀Ω
be less than𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑢𝑡𝑙𝑒𝑡𝑠

any case the value should not be less than 0.5 M and need not ohm Number of outlets but
in to be more than one Mega ohm.
In case of PVC wires, insulation resistance must be Number of outlets
12.5 𝑀Ω
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑢𝑡𝑙𝑒𝑡𝑠

Q16) List out the material use for H.T. 11 KV & L.T. 415 V Overhead Line( W-23, 4M
S-24,4M))
Following are the material use for H.T. 11 KV & L.T. 415 V Overhead Line
 Conductors - Solid/ Stranded/Hollow/Bundled.
Material of conductor- Copper, Aluminum, all aluminum or ACSR.
Poles-Tubular steel pole, angle pole, R.C.C. poles
Insulators
Bird guards
Earth wire
Stay assembly
G.I. Clamps
Ant climbing Arrangement
Earthing set
Lightening arrestor
Cross arms

Q17) Draw the single line diagram of L.T. substation (415 V)( W-23, 4M, S-24 4M)
Q18) Explain earthing provision using suitable sketch for HT/LT distribution lines
installation. (S-23, 4M)
For distribution lines such as HT line and LT line, wire earthing is used by low
resistance wire known as the earth wire. This earth wire is connected to Earth
Electrodes, buried in the ground. For this, horizontal trenches are dug, and strip
electrodes get buried inside these trenches. The electrodes are of copper, galvanized iron or
steel.
Q19) Estimate the material required for 2 km, 11 KV overhead line to extend from
existing
line. Assume a span of 50 m.(W-24, 4M)
Considering following factors,
a) Size of Conductor: ACSR 6/1 x 2.59 mm
(b) Tabular pole or supports of 11m. Length
(c) Size of earth wire-Galvanized steel 8 SWG
(d) No. of earthing sets to be installed-3 nos.
Estimated Materials are as follows.
A) Material required for connect 2km overhead line with existing 11 KV line.
MS channel for cross arm 10 cm x 5 cm x 15 mts.- 1 No.
H.T. 11kV disc insulator with complete fitting
H.T. 11kV pin type insulator with pins and nuts to support jumper wires. -3 No.
Stay set with clamp, stay wire, rod bow, nuts, stay plate -2 set
Concreting for stay rod- 2bags
Concreting for existing pole -2bags
Earth wire damp of mild steel- 1No.
Aluminum binding wire for jumpers 1kg.
B) Fittings for H.T. straight line support
Tubular line support pole 11m long- 40 No.s
Foundation with cement concentrating for poles-40 No.
Cross arms for support to main cross arms- 80 No.s
11 kV pin insulator with pin and nuts-120 No.s
Danger board -40 No.s
Earthing wire clamps - 40 No.s
Barbed wire for anti climbing -40kg
Aluminum binding wire- 18 kg.
C) ACSR conductor 6/1 x 2.59 mm length-780 kg.
2000×3=6000 mts.
Sag 1%60 mts.
Total length = 6060 mts.
D) 8 SWG GI earth wire- 60kg.
Length 2000 m.
Sag 2% = 40 m
Total length = 2040 m
E) Material for 3 nos, earthing sets.
Earth plate Gl of 60 cm x 60 cm x 3.8 m thick -3 No.s
Gl earth wire 8 SWG, 10 mts for each set wt. 1 kg each -3 kg.
Gl pipe for earth wire 15 mm diameter (for 3 set)-30m
20 mm Gl pipe-30m
MS nut bolts, salt, charcoal, thimbles, wire mesh, funnel etc. as per earthing estimates.- as
per required
F) Painting for Poles-20 ltr.
G) Transportation charges, loading and unloading the material etc.
H) Labor Charges
11% overhead and supervision charges.