Kolkata, West Bengal, India 1

Definition of Covered Conductor 
of Covered Conductor

Covered conductors consist of a conductor surrounded by

a covering made of insulating material as protection
against accidental contacts with other covered conductors
and with grounded parts such as tree branches, etc. In
comparison
i with
ith insulated
i l t d conductors,
d t thi covering
this i has
h
reduced properties, but is sufficient to withstand the
phase‐to‐earth
phase to earth voltage temporarily – As BS EN 50397
50397‐1:
1:
2006.

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 Brief of Covered Conductors
• In forestland CCs reduce tree faults. This CC provides insulation that reduces 
p
the chance of flashover when a tree branch falls between conductors. 
• CC also helps with animal faults and allows utilities to use armless designs 
or other tight configurations. 
• CC is available with a variety of covering types. The insulation materials 
polyethylene, XLPE, and EPR are common. 
• From a design and operating viewpoint, CCs must be treated as bare 
conductors according to the National Electrical Safety Code (NESC) (IEEE C2‐
d t di t th N ti l El t i l S f t C d (NESC) (IEEE C2
2000), with the only difference that tighter conductor spacings are allowed. 
• It is also used in Australia to reduce the threat of bush fires.
• E
European experience with CCs suggests that covered‐wire fault rates are 
i ith CC t th t d i f lt t
about 75% less than bare‐wire fault rates. 
• In Finland, fault rates on bare lines are about 3 per 100 km/year on bare and 
1 per 100 km/year on covered wire
1 per 100 km/year on covered wire.

Ref: EA Technology on Covered Conductor System for Distribution

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Covered Conductor System

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 Design requirements for CCs:

• Conductors must be handled with care
• Only accessories designed and approved for the 
O l i d i d d d f th
conductor may be used
• Arc protection devices must be used on lines 
vulnerable to overvoltages
• Substations must have tripping earth‐fault protection 
devices and alarming secondary devices

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 Types of Covered Conductor 
There are three basic types of CC Overhead line systems‐
1.XLPE/HDPE
2.Aerial cable systems
3.Spacer cable concept

•XLPE (cross‐linked polyethylene) /HDPE(high density polyethylene) 
‐Conductor material :Copper, Aluminium or Steel cored aluminium types 
such as ACSR
such as ACSR.
A. Single sheathed
B. Multiple sheathed

•Spacer cable is the three CC phases held in a cradle and supported by a steel 
or alumoweld cable.
‐ Vibration risk are reduced and reliability increased.
Vibration risk are reduced and reliability increased
•Aerial cable is a fully insulated 3‐core cable with an earth screen used for 
overhead applications.

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 Types of Covered Conductor….Continued 

Type Sub types
1 C
1. Covered 
d Several types of single sheath conductors available in UK‐
Several types of single sheath  conductors available in UK
Conductor 1. SAX
− Widely employed for 20 kV 
− Available in 35 to 240 mm2
Available in 35 to 240 mm
− Covered with 2.3 or 3.3 mm XLPE
− Normally 2.5 to 3 % carbon
2.    PAS/BLX
/
− The Al‐alloy conductor is compacted
− Sizes from 35 to 241 mm2
− XLPE is available in nominal thicknesses of 2 to 3 mm.
3.    CC/CCT
− Can have a grey XLPE coating compared with the black XLPE of SAX
conductor.
− CC (2 mm iinsulation)
l ti ) h
has ttended
d d tto b
be used
d ffor rural,
l llong span situations,
it ti
whilst the CCT (originally 2.3 mm insulation) is used for forested terrain.

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 Types of Covered Conductor….Continued 
Type Sub types
2.     Aerial  − Aerial cable, also known as ‘overhead’ or Universal cable, is basically a
cable cable that can be strung overhead and run underground and underwater.
− It obviates the need for OHL/cable junctions and has a very low
susceptibility to lightning.
− lower impedance than bare or CC CC, the voltage drop is lower for an aerial
cable than for other types of CC line and it is possible to increase the
network length between substations by 40-50%
Features :
• Fully shielded three core power cables
• Excellent contact resistance
• Go overhead, underground, underwater
• No cross arms
• No OHL/underground cable junction

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Schematic of Axces ‘Universal’ overhead cable 
 Types of Covered Conductor….Continued 
Type Sub types
3 Spacer cable −
3.  Spacer cable Spacer cable systems are essentially three CC phases in a polymeric
support cradle supported by a ‘messenger’ cable.
•A messenger-supported three layer cable construction in a close triangular
configuration
g
• The mechanical strength to weather severe storms
• The electrical strength to prevent faults due to phase to phase or phase to
ground contact, tree contact or animal contact
• A complete coordinated system including cable, messenger, spacers,
insulators and hardware

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 Reliability:
Aerial Cable

Cost Spacer Cable

Bare Wire
Covered Conductor
Reliability

Fig: Cost vs. Reliability Curve
•From the above cost curve we can see that When constructing parallel 
lines, bare and CC lines cost the same make the CC distribution system
lines, bare and CC lines cost the same make the CC distribution system 
reliable by preventing outages caused by collisions or momentary attack 
with a foreign object.
Failure rate:
Failure rate:
•Bare conductor = 4.5 faults / 100 km
•Covered conductor = 0.9 faults / 100 km
I t ti f l t i it l
•Interruption free electricity supply
•40 % less space than bare lines 

•Ref:
R f EA Technology
T h l on C
Covered
dCConductor
d t S System
t ffor Di
Distribution
t ib ti

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 Accessories for Covered Conductors

•Insulators
I l t
•Connectors
•Automatic
Automatic tension joints
•Arc protection devices & Current Limiting Devices
•Live line and Earthing connectors
•Surge arresters
•Cross-arms
•Tension
T i & Suspension
S i fittings
fitti
•Dis-connectors

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 Accessories for Covered Conductors ….Continued 

An insulator support the “line” mechanically & maintains an Air Gap.

ƒFunction:
F ti
ƒSeparates Line from Ground
ƒlength of air gap depends primarily on system voltage, modified by desired
safety margin, contamination, etc.
ƒResists
Resists Mechanical Stresses
ƒ“everyday” loads, extreme loads
ƒResists Electrical Stresses
ƒsystem voltage/fields, overvoltages
ƒResists Environmental Stresses
ƒheat, cold, UV, contamination, etc.
ƒProducts:
•Pin insulators (Composite / Porcelain)
•Line post insulators ((Composite / Porcelain))
•Stay insulators (Composite / Porcelain)
•Dead end insulators – (Composite / Porcelain, Glass)
•Spool insulators – (Composite/ Porcelain)
•Strain insulators – (Composite / Porcelain)
•Use of composite insulators are always recommended
with covered conductor due to similarity in range of
Di-electric constant of Silicone Composite & PE/XLPE.

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 Accessories for Covered Conductors ….Continued 

Connectors
•Connectors should be corrosion resistant and inert to bimetallic electrochemical reactions
• It endure varying mechanical tensions and other forces detrimental to the connection.

Product:
•Arc protection devices
•Insulation piercing connectors

Fig. 4. Different components of new generation insulation piercing connector assembly 13
Accessories for Covered Conductors ….Continued 

Arc protection devices: The atmospheric overvoltages caused by

lighting and, in some cases, network overloads may cause conductor
breaks, particularly in the case of covered conductors.

Product:
•Power arc devices
•Spark gap horns
•Arc protection devices
•Arc protection horn

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Accessories for Covered Conductors ….Continued 

Earthing connectors: These connectors needed for temporary earthing

of the live-line.

Product:
•Live line connectors
•Stirrups
p
•Temporary earthing connectors
•Earthing horns
•Arc protection horns
•Sleeves

Heat Shrinkable Cover Al.

Al Sleeve
Midspan Joint for Covered Conductor
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Accessories for Covered Conductors ….Continued 

Tension & Suspension fittings: This section includes tension clamps,

helical ties, spiral vibration dampers and suspension clamps.

Products:
•Suspension
S i clamps
l
•Bird protector sets
•Tension clamps
•Waterproof
Waterproof tension clamps
•Bird protector sets
•Helical tie sets
•Spiral vibration dampers

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Accessories for Covered Conductors ….Continued 

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Accessories for LV Aerial Bunched Conductor

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Accessories for HV Aerial Bunched Conductor

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 Arc Protection

At the time of lightning strike on a line, the line is induced

with a over voltage of magnitude of several hundred kV
between phase and earth, which is very high in
comparison to the normal operating voltage. Over
Voltage travel along the line to the nearest pole where it
di h
discharges b igniting
by i iti an arc between
b t cross arm and d
conductor. After the over voltage has discharged a power
frequency short-circuit
short circuit current – the magnitude of which
depends on the short-circuit power of the network and
distance to the substation
substation- starts to flow through ionized
air resulting a power arc between phases. Power arc
magnitude
g is normally y several kilo amperes
p .
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 Arc Protection 
Along an ordinary bare conductor the power arc
can move freely but in case of covered conductor
the foot point of the localized arc does not move as
the covering forms an obstacle
obstacle. When arc is ignited
it burns and keeps burning till the conductor is
damaged or burned through
through.

Circuit breakers are not designed to respond quick

enough and in order to prevent damage to the
conductor Arc Protection Devices to be installed
installed.
These APD s are responsible for protection of
conductors and other network equipments
equipments.
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 Burndowns

Burndowns are mainly due to lightning-caused faults, but it is the

f lt currentt arc, nott the
fault th lightning,
li ht i th t burns
that b mostt off the
th conductor.
d t
•A covered conductor is susceptible to burndowns because when a
fault current arc develops, the covering prevents the arc from moving.
The heat from the arc is what causes the damage. Although ionized
air is a fairly good conductor, it is not as good as the conductor itself,
so the arc g gets very
y hot.
•On bare conductors, the arc is free to move, and the magnetic forces
from the fault cause the arc to move (in the direction away from the
substation; this is called motoring).
motoring) The covering constricts the arc to
one location, so the heating and melting is concentrated on one part
of the conductor. If the covering is stripped at the insulators and a fault
arcs across an insulator,
insulator the arc motors until it reaches the covering,
covering
stops, and burns the conductor apart at the junction.

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 (A) Arc Protection Device (APD)

APD s are designed

g to direct the ggenerated arc to a safer and sufficient
distance from conductor and insulator . An APD implemented with an arcing
horn is the best option for pin and line post insulators.

Arc protection devices for Branch Pole

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 (B) Power Arc Device (PAD)
With Small Short Circuit currents, an arc will move slowly and stress the
insulator for a longer period. To avoid damage to the insulator the Arc must be
created directly in the spark gap, so the short circuit occurs through the cross
arm and trips the circuit breaker. PAD are independent of direction of power and
so that can be installed both sides of Insulator. It can be used with Tension and
suspension
i Insulators.
I l t

Installation of Power Arc Device

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Power Arc Device with Tension Insulators
 (C) Current Limiting Devices (CLD)

In an attempt
p to pprotect the conductor, CLD can be used along g with a
Surge arrester, but in this case a smaller size of surge arrester to be
installed. This protection method also provides the consumers with an
uninterrupted power supply, because the arc protection does not cause
high speed auto-recloser operation.
Advantage of CLD is uninterrupted distribution to consumers.

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 Integrated Insulator – Arc Protection and 
Lightning Arrester (IIAPLA)
h ( )
(The self‐protected insulator)
Features:
• Integrated
Integrated Insulator
Insulator‐ Arc Protection Device ( IIAPLA) protects overhead transmission 
Arc Protection Device ( IIAPLA) protects overhead transmission
line up to 33 kV against direct lightening and back flashover.
• It performs the function of composite insulator and a lightening arrestor 
simultaneously.
i lt l
• Built in rapid quenching makes IIAPLA almost insensitive to 
short circuit current.
• It has comparatively longer life to conventional solutions.
y p g
• Its reliability and life span is high.

These products are under development in Supreme.

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 Rapid Quenching – Inbuilt Arc 
Protection Device (RQAPD)
( )
It is used for overhead power line for protection of operating voltage with bare
and covered conductors against lightening over voltages and their dangerous
consequences.

200C to 500C.
Designed for outdoor operation at ambient temperature ranging for ‐20 C

Main component of the arrester is the easy and rapid quench system consisting of
a silicon rubber body with certain number of steel electrodes and Fibre reinforcing
rod inside, terminal electrode and mounting unit for mounting at an insulator’s pin
or a cross arm.

Features:
Low maintenance.
Easy to install
y
Work in tough conditions.
High reliability and life span.
Th
These products
d t are under
d d development
l t iin S
Supreme.

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 INTERNATIONAL PRACTICES RELATING TO 
COVERED CONDUCTOR
COUNTRIES CONDUCTOR
UK • XLPE covered conductor
FINLAND • Fully compacted Al‐ alloy covered with a black XLPE sheath (up to 24 kV)
• Maximum EDS Tension of 30 N/mm2
SWEDEN • Uncompacted Al‐alloy for 12‐24 KV
• Diameter range of 62 to 241 mm
• XLPE sheath nominal thickness of 12 mm
• Carbon black must not be less than 2% (Note: Now Sweden uses 0‐0.5 % carbon black 
b bl k b l h ( d b bl k
in HDPE sheath)
NORWAY • Sheath should be 2.3mm thick black XLPE with 2‐3% carbon black content
SPAIN • Deals with AAAC and ACSR conductor sizes and sheath material and dimensions
Deals with AAAC and ACSR conductor sizes and sheath material and dimensions
• It does not cover installation.
FRANCE • It covers AAAC conductor material only
• The sheath is stated as black XLPE
The sheath is stated as black XLPE
USA • Extruded black semi conducting polymer
• The nominal thickness varies from 0.4 to 0.5mm depending on system voltage.
BRAZIL • XLPE covered conductor

Ref: EA Technology on Covered Conductor System for Distribution

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