Detailed Project Report on AERIAL BUNDLED CONDUCTOR (ABC) CABLE

ABC CABLE FACTORY
[CODE NO. 2022] 

The aerial bundled conductor (ABC) cables are overhead power lines. These cables are known to use phase conductors that are highly insulated. These conductors are bundled together with a kind of neural conductor. The ABC cables have a kind of traditional design and are considered to be unappealing. When there is high wind and other external forces, there could be a short circuit using these cables. There are resultant sparks that lead to occurrence of bushfires in dry climatic conditions. 

It is important to understand the potential advantages as well as disadvantages associated with the use of ABC cables. Let us start making a note of the potential disadvantages. These cables have simpler installation and are more aesthetically appealing. There is no trimming needed for installation of these cables. These cables can stand in much proximity to buildings and tress and do not generate any kind of sparks when touched. These cables are known to be more aesthetically appealing. These cables require less maintenance and need inspections of lines. These cables have improved reliability in comparison with overhead systems and underground systems as well. 

Let us make a note of potential disadvantages of these cables. There is an additional cost applicable for the cable itself. The insulation tends to degrade due to sun exposure as the insulation in between the wires is shielded from the sun. There are shorter spans and more poles that are much because of increase weight. There could be failures associated with the use of these cables due to erosion, punctures and electrical tracking. 

It needs to be well noted that these ABC cables have been brought into the Australian power systems since 1983. However, it is unfortunate to note that the in few of the bushfire prone areas, the installations of ABC cables leads to creation of fires – at points where the cables are damaged or degraded. At various places, the ABC cables are being replaced with underground cables due to high failure rates. These cables are known to have life expectancy of just 10 years. Historically, it should be noted well that the low voltage ABC lines were installed in 1981 in the rural distribution network of Ireland. 

It is worthwhile to note the potential advantages as well as disadvantages of resorting to ABC cables. These cables are known to be more aesthetically appealing. Little to no trimming is required for using up these cables. These cables have the ease of erection and stringing, need less construction resources and are less labor intensive. These cables can be installed in a narrow right of way. These cables depict much safety for linepersons, when working with live conductors. These cables require less inspection of lines and less maintenance. At times, when there is increased sun exposure, the insulation amidst the wires gets shielded from the sun. The installations need much longer repair times and require more specialize and bigger equipments of repair. The failure modes of these wires is well mentioned before. 

COST ESTIMATION (US$ DOLLAR)

Plant Capacity                                             205.36 KM/day
Land & Building (18,000 Sq.Mtr)                US$ 19.75  Lacs
Plant & Machinery                                      US$  9.78   Lacs
W.C. for 2 Months                                      US$.2.11   Cr
Total Capital Investment                              US$  2.42  Cr
Rate of Return                                            35%
Break Even Point                                         35%

•    INTRODUCTION    
•    ADVANTAGES    
•    DISADVANTAGES    
•    USES AND APPLICATION    
•    MARKET POSITION    
•    THE SWOT ANALYSIS:    
•    MARKET STUDY AND PLANT CAPACITY    
•    US DEMAND TO RISE 5.8% ANNUALLY THROUGH 2017    
•    MARKET STUDY AND PLANT CAPACITY IN NAMBIA    
•    MANUFACTURERS/SUPPLIERS ABC CABLES    
•    MANUFACTURING PROCESS OF ABC CONDUCTOR    
•    CONSTRUCTION    
•    MATERIAL    
•    PROCESS    
•    STRANDING    
•    INSULATION    
•    DEGASSING    
•    QUALITY CONTROL    
•    PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS    
•    TENSILE TEST OF CONDUCTORS    
•    APPARATUS REQUIRED FOR TENSILE TEST    
•    METHOD OF TENSILE TEST OF CONDUCTORS    
•    PROCEDURE    
•    PERSULPHATE TEST OF CONDUCTOR    
•    WHY COPPER WIRES ARE TINNED?    
•    METHODS    
•    WRAPPING TEST FOR CONDUCTORS
•    PROCEDURE    
•    PROCESS FLOW CHART FOR ABC CONDUCTOR    
•    PLANT LAYOUT    
•    SUPPLIERS OF PLANT MACHINERY    
•    CHINA SUPPLIERS OF ABC CABLE MAKING MACHINE    
•    SUPPLIERS XLPE RXTRUSION LINE    
•    SUPPLIERS OF CABLE LAYING UP MACHINE    
•    SUPPLIERS OF RAW MATERIALS    
•    SUPPLIERS OF ALUMINIUM CONDUCTOR    
•    SUPPLIERS OF XLPE COMPOUND    
    
                
APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET