International Journal of New Innovations in Engineering and Technology
Single Core Cable Bonding Methodology in
Electrical (Petrochemical) Industries
T.Sathish Kumar, A.Rathinam, R.Satheeshkumar
PGStudent, Department of Electrical and Electronics Enineering, Paavai Engineering College Namakkal,
Tamilnadu.
Professor, Department of Electrical and Electronics Enineering, Paavai Engineering College Namakkal,
Tamilnadu.
Assistant Professor, Department of Electrical and Electronics Enineering, Paavai Engineering College,
Namakkal, Tamilnadu
Abstract-High voltage cables have metallic sheaths or screens surrounding the conductors over main insulation,
and/or armor and metallic wires over inner sheath surrounding the cables. During earth faults applied to directly
earthed systems, these metallic paths are expected to carry a substantial proportion of the total fault current,
which would otherwise flow through the general mass of earth& earthling grid, while returning to system
neutrals. These alternative return paths must be considered when determining the extent of the grid potential rise
at an electrical plant due to earth faults. For safety and reliable operation, the metallic sheath and screens of
power cables must be grounded.
I.INTRODUCTION
Single conductor medium and high-voltage power cables employ a coaxial design essentially consisting of a
metal conductor strands surrounded by insulation and an outer metallic sheath (outer conductor).
Semiconducting layers are provided at the interface between the conductor and the insulation, and between
the insulation and the metallic sheath in order to provide a smooth electrical interface for the insulation and
thus establish a uniform electrical stress pattern within the insulation. Cable core conductors are normally
comprised of aluminum or copper wires.
Fig 1. Cable cross section
II. LITRATURE SURVEY
Present day cable insulation materials generally consist of ethylene propylene rubber (EPR) or cross-linked
polyethylene (XLPE) or polyvinyl chloride (PVC). The cables are constructed with an outer metallic sheath,
which primarily comprises of one of the following:
Concentrically applied copper wires, aluminum wires, or helically applied copper tapes
Extruded lead or aluminum sheathes.
Longitudinally applied corrugated copper tapes sealed at the overlap.
Longitudinally applied thin copper or aluminum foil laminates sealed at the overlap.
Combination of wires with any of the above copper tapes
The magnetic field resulting from current flow through the core conductor couples the metallic sheath and
any other adjacent conductors. If the metallic sheath is also part of a continuous closed loop electric path,
transformer action induces a current flow in the coupled metallic sheath and other adjacent conductors.
Resistive losses due to the circulating currents in the metallic sheath then contribute to the temperature rise of
the cable, limiting the amount of current that can be carried by the cable and reducing cable efficiency.
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International Journal of New Innovations in Engineering and Technology
Conversely, if the electric path is interrupted through use of special bonding techniques, the metallic sheath
circulating currents will be reduced or eliminated resulting in greater loading capability for the cable but at
the disadvantage of developing a rise in metallic sheath voltage. Consequently, special bonding and
grounding arrangements have been developed to limit the magnitude of metallic sheath voltages and to
minimize the flow of circulating currents.
III. CABLE CONSTRUCTION
As part of the earlier cable designs, metallic sheath was exposed and in direct contact with the earth, water,
mud, and conduit. This resulted in corrosion problems caused by ac electrolysis, leading to metallic sheath
damage. Early efforts to limit such damage placed restriction on the maximum magnitude of sheath voltage,
limiting these voltages to the range from about 12 V to 17 V. Present cable designs generally include an outer
jacket that is insulating, and the likelihood of corrosion is thus effectively eliminated if the jacket remains
intact. Since application of special bonding results in the build-up of significant voltage levels on the metallic
sheath during faults and other abnormal operating conditions, designs take advantage of the state-of-the-art
electrical insulating properties of the jacket to meet needed voltage withstand requirements.
Fig 2. Induced voltage in a cable with a non-magnetic metallic sheath / armor
A graphite coating or an outer semi conductive layer is usually applied over the jacket at the factory to allow
for testing of the jacket’s electrical integrity.
With heavier loads on single conductor cable circuits, metallic sheath circulating current losses resulting from
multipoint solidly bonded and grounded systems can be excessive for the intended application. To mitigate
these losses, alternative metallic sheath grounding methods are available, and these are collectively referred
to as special bonding techniques. Because long circuits and high currents tend to be more common on
transmission class circuits, special bonding techniques tend to be more applicable on these types of circuits.
However, special bonding techniques can be applied on distribution circuits when operating conditions
dictate a reduction in circuit losses.
Metallic sheath losses also increase with the spacing between cables, particularly when multiple points
grounded; single-conductor cables are installed with wide spacing, such as when cables are placed in separate
ducts or when they are direct buried in spaced configurations. When cables are spaced apart, significantly
higher currents flow on the metallic sheath of solidly grounded systems, resulting in higher induced sheath
circulating current losses. Increased spacing decreases the effects of mutual heating but increases the effect of
magnetic coupling and therefore, increases metallic sheath circulating current losses resulting in lower cable
current ratings.
Metallic sheath losses in single-conductor cables depend on several factors, one of which is the sheath
bonding arrangement. Therefore, cable metallic sheath bonding and grounding are necessary to perform the
following functions:
• Limit sheath voltages as required by sheath sectionalizing joints.
• Reduce sheath losses to a minimum.
• Maintain a continuous sheath circuit for fault current return and adequate lightning and switching surge
protection
Some special bonding options include the following:
Single-point bonding
Multiple single-point bonding
Solid bonding / both end bonding
Cross bonding
o Continuous cross bonding
o Cross bonding with Transposition
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IV. SINGLE CABLE BONDING
A system is single point bonded if the arrangements are such that the cable metallic sheaths provide no path
for the flow of circulating currents or external fault currents. This is the simplest form of special bonding.
The metallic sheaths of the three cable sections are connected and grounded at one point only along their
length. At all other points there will be a voltage between metallic sheath and ground and between screens of
adjacent phases of the cable circuit that will be at its maximum at the farthest point from the grounded bond.
This induced voltage is proportional to the cable length and current. Single-point bonding can only be used
for limited route lengths, but in general the accepted metallic sheath voltage potential limits the length. The
maximum cable section length is governed by the permissible sheath standing voltage allowed at the isolated
end. For typically permitted sheath voltage rise levels (i.e., no higher than about 200 V), this method is
generally employed online lengths of up to about 2 km. Since there is no closed sheath circuit, except through
the sheath voltage limiter, current does not normally flow longitudinally along the sheaths and no sheath
circulation current loss occurs.
Fig 3. Single-point bonded system
Usually in single point bonded systems, the load side is earthed and is installed at the unearthed end to
protect the cable insulation during fault conditions.
During a ground fault on the power system, the zero-sequence current carried by the cable conductors could
return by whatever external paths are available.
Fig 4. Single-point bonding diagram for a circuit comprised of three cable lengths
Fig 5. Induce voltage distribution for Single point bonding.
A ground fault in the immediate vicinity of the cable can cause a large difference in ground potential rise
between the two ends of the cable system, posing hazards to personnel and equipment. For this reason,
single-point bonded cable installations need a parallel ground conductor, grounded at both ends of the cable
route and installed very close to the cable conductors, to carry the fault current during ground faults and to
limit the voltage rise of the sheath during ground faults to an acceptable level. The parallel ground continuity
conductor is usually insulated to avoid corrosion and transposed, if the cables are not transposed, to avoid
circulating currents and losses during normal operating conditions.
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For a single core armored cable, carrying an act. Load current, a voltage will be induced in the amour.
Similarly, a voltage will be induced in a metallic screen and/or metallic sheath of a single-core cable. The
magnitude of the induced voltage depends on factors which include the load current, the length of the cable,
the arm our diameter and the cable spacing. The amour is effectively the secondary of a transformer and the
conductor is the primary.
Single point bonding can only be used for limited route length but in general the accepted screen voltage
potential limits the length.
Advantage
No circulating current
No heating in the cable sheath/screen
Economical
Disadvantage
Standing voltage at the unearthed end
High voltage appears at unearthed end and can cause arching and damage to outer sheath.
Requires SVL if standing voltage during fault is excessive.
Requires additional earth continuity conductor for fault current if earth returned current is
undesirable. Higher magnetic fields around the cable compared to solidly bonded system.
Annex C of IEEE 575 gives different values as followed in different Countries for the allowable limit of
Standing end voltages.
V. SHEATH VOLTAGE LIMITER (SVL)
Cl.5.3.1 of Shell DEP 33.64.10.10-Electrical Engineering Design states “For single point bonded
installations, the earth bond shall be at the field end of the circuit, i.e. the generator, motor or transformer
terminations. Insulated cable glands shall be provided at the Switchboard termination”.
VI. MULTIPLE SINGLE POINT BONDED SYSYEM
It is also known as double length single point bonding System.
Cable metallic sheath continuity is interrupted at the midpoint and SVLs need to be fitted at each side of the
isolation joint.
Other requirements are identical to single–point–bonding system like SVL, Earth continuity Conductor,
Transposition of earth continuity conductor.
Effectively it consists two sections of single–point–bonding. There are no circulating currents, and Zero volt
is observed at the earthed ends, standing voltage at the two cable ends.
Advantage
No circulating current in the metallic sheath
No heating effect in the cable metallic sheath
Suitable for longer cable section compared to single–point–bonding system and solidly bonded
single-core system
Disadvantage
Suitable for 300~1000 m long cable sections, double the length of single–point–bonding system
VII. SOILD BONDING/ BOTH END BONDING
One way to eliminate the induced voltages is to bond the sheath at both ends of the cable circuit. This
eliminates the need for the parallel continuity conductor used in single-point bonding systems. It also
eliminates the need to provide SVL, such as that used at the free end of single-point bonding cable circuits.
The disadvantage of this bonding method is that the considerable heat caused by the circulating currents in
the cable sheaths reduces the current carrying capacity of the cable circuit.
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Fig 6. Solid bonded system
Fig 7. Induced voltage distribution for both end bonding
Advantages
Minimum material required
Most economical if heating is not a main issue
Provides path for fault current, minimizing earth return current and EGVR (Earth Grid Voltage
Rise)at cable destination
Does not require screen voltage limiter (SVL)
Less electromagnetic radiation
Disadvantages
Provides path for circulating current
Heating effects in cable screen, greater losses. Cable therefore might need to be de–rated or larger
cable is required
Transfers voltages between sites when there is an EGVR (Earth Grid Voltage Rise) at one site
Normally applies to short cable section of tens of meters long. Circulating current is proportional to the
length of the cable and the magnitude of the load current.
VII. CROSS BONDING:
A system is cross-bonded if the arrangements are such that the circuit provides electrically continuous sheath
runs from earthed termination to earthed termination but with the sheaths so sectionalized and cross-
connected to reduce the sheath circulating currents. In this type, voltage will be induced between metallic
sheath and earth, but no significant current will flow. The maximum induced voltage will appear at the link
boxes for cross-bonding. This method permits a cable current-carrying capacity as high as with single-point
bonding but longer route lengths than the latter. It requires screen separation and additional link boxes.
The most basic form of cross bonding consists of the cable length being divided into three approximately
equal sections called minor sections. Three minor sections form one major section. Each of the three
alternating magnetic fields induces a voltage with a phase shift of 120° in the cable sheaths. The cross
bonding of sheaths takes place in the link boxes. Ideally, the Victoria addition of the induced voltages results
in U (Rise) = 0. In practice, the cable length and the laying conditions will vary, resulting in a small residual
voltage and a negligible current in one major section. Since there is no or negligible current flow, there are
practically no losses in the screen. The total of the three voltages is zero, thus the ends of the three sections
can be grounded. The sheaths are bonded and grounded at the beginning and end of each major section.
Longer cable circuits may consist of several major sections in series. When the number of minor sections is
divisible by three, the cable circuit can be arranged to consist of more than one major section. In such a case,
the cable circuit could consist of either sectionalized cross bonding or continuous cross bonding.
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In the case of sectionalized cross bonding, the cables are transposed at each minor section, and the sheaths
are bonded together and grounded at the junction of two major sections and at the beginning and end of the
cable circuit.
In the case of continuous cross bonding, the cables are preferably transposed at each minor section and the
sheaths are cross bonded at the end of each minor section throughout the whole cable route. The three cable
sheaths are bonded and grounded at the two ends of the route only.
There are many variations of cross bonding for longer cable circuits.
Fig 8. Sectionalized cross-bonded cable with three major sections
Distance x
Induced voltage at
distance x
Fig 9. Induced voltage distribution for cross bonding
It breaks the electric continuity of each sheath. Three minor sections make up a major section, where the
sheaths are interconnected between them and also are bonded to earth. The length of each minor section must
be a third part of the total length of the distance between two earth-connections of the cable.
When dealing with triangular formation power cables, cross bonding eliminates the sheath currents. When
dealing with flat formation power cables, the cross-bonding system doesn’t eliminate totally the sheath
currents due to the lack of symmetry of the three cables, but cross bonding substantially reduces the sheath
currents.
Advantage
Not required any earth continuity conductor
Virtually zero circulating current in the screen
Standing voltage in the screen is controlled.
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Technically superior to other methods
Suitable for long distance cable network
Disadvantage
Technically complicated
More expensive
VII. CROSS BONDING WITH TRANSPOSITION
If the cross-bonding scheme does not allow to reduce totally the sheath currents, the cross bonding with
transposition allows to reduce the sheath currents further. It consists of transposing cyclically the three main
conductors in each minor section. This is the more suitable disposition to reduce the sheath currents.
Fig 10. Cross-bonding with transposition
Fig 11. Cable Installation for cross-bonding
General Guideline for the application of the bonding method
Bonding Method Length of Cable
(mtr)
Double point bonding If contractually acceptable. Also, generally applicable for MV cables
33kV and below. Cable derating & capacity to be ensured.
Single point bonding <500
Midpoint bonding Upto 1km
Cross bonding Long distance
Above table is not a substitute for calculation.
Calculation of Power frequency sheath overvoltage
Following are the equations provided in IEEE-575 for the calculation of power frequency sheath voltage for
single point bonding method.
(A) Three Phase Fault
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International Journal of New Innovations in Engineering and Technology
For Trefoil formation single circuit where Sab = Sbc = Sca above equations reduce to following
For the other common formation of cables laid flat in which the axial spacing of adjacent cables = S, the
sheath voltage gradients are given by Equation
(B) Phase-to-phase Fault
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International Journal of New Innovations in Engineering and Technology
(C) Single Phase-to-Ground Fault
Accessories for High Voltage Cable Sheath Bonding:
High voltage cable systems must always be earthed. The earthling, sometimes referred to as grounding, very
much depends on cable parameters and on the application of cable systems.
(1) Link Box
Link box are used to realize the earthling at terminations or joints. Link boxes can be realized for three phase
or for single phase earthling. Link box can also be equipped with SVL.
Fig 12. Link Box
Link Box is electrically and mechanically one of the integral accessories of HV underground above ground
cable bonding system, associated with HV XLPE power cable systems.
Link boxes are used with cable joints and terminations to provide easy access to sheath breaks for test
purposes and to limit voltage build-up on the sheath.
In HV Cable, the bonding system is so designed that the cable sheaths are bonded and earthed or bonded with
earth via SVL in such way as to eliminate or reduce the circulating sheath currents.
(2) Sheath Voltage Limiters (SVL) (Surge Arrestors)
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International Journal of New Innovations in Engineering and Technology
SVL is protective device to limit induced voltages appearing on the bonded cable system due to short circuit.
It is necessary to fit SVL’s between the metallic sheath and ground inside the link box. The metallic sheath
separation of power cable joint (insulated joint) will be protected against possible damages as a result of
induced voltages caused by short circuit by break down of SVL.
Fig 13. Surge Voltage Limiter
For single point bonding, the voltage is induced linearly along the whole cable length and at the ‘open end’ a
standing voltage occurs. The open end should be protected with a Sheath Voltage Limiter (SVL) This
diminishes the chance of over voltages occurring inside the cable screen, protects the cable system and
ensures that relevant safety requirements are upheld.
Fig 14. Link box with SVL
(3) Insulated Cable Glands
Insulated cable glands are used to allow the cables to be earthed at one end only (Single point bonding/Mid-
point bonding) and insulated at the field end. This gland ensures that no contact is made between the earth
circuit carried through the amour and the electrical equipment enclosure through which the cable enters via
insulated cable gland.
VIII. CONCLUSION
If grounded at only one end, any possible fault current must traverse the length from the fault to the grounded
end, imposing high current on the usually metallic sheath of conductor. Such a current could readily damage
or destroy the sheath and require replacement of the entire cable rather than only the faulted section.
With both ends grounded, the fault current would divide and flow to both ends, reducing the duty on the
sheath, with consequently less chance of damage.
Multiple grounding, rather than just grounding at both ends, is simply the grounding of the cable sheath at all
access points, such as manholes or pull boxes. This also limits possible sheath damage to only the faulted
section.
Hence depending on various factors like the laying pattern, sheath voltage calculations and length the type of
bonding is to be chosen.
ATTACHMENTS
Att-1–IEEE Guide for Bonding Shields and Sheaths of Single-Conductor Power Cables Rated 5kVthrough
500 kV (IEEE SD 575™-2014)
Att-2-Power installation standard sheath voltage limiter for single core HV cables typical installation-
P16A/B/C
Att-3-“ELECTRA NO 28” issued by CIGRE study committee No 21, May 1973
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International Journal of New Innovations in Engineering and Technology
REFERENCES
[1] Voltages induced in the non-magnetic, metallic sheaths and/or amour of single-core cables by Mark Coates and John Ware
Technical implementation of cross bonding on underground high voltage lines projects by Antonio Sorel, Ângela Moura&Maria
Carvalho
[2] Natarajan C., Neelakrishnan G., Akila P., Fathima U., Sneha S. “Performance Analysis and Implementation of 89C51 Controller
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[3] C. Nagarajan, G.Neelakrishnan, R. Janani, S.Maithili, G. Ramya “Investigation on Fault Analysis for Power Transformers Using
Adaptive Differential Relay” Asian Journal of Electrical Science, Vol.11 No.1, pp: 1-8, 2022.
[4] G.Neelakrishnan, K.Anandhakumar, A.Prathap, S.Prakash “Performance Estimation of cascaded h-bridge MLI for HEV using
SVPWM” Suraj Punj Journal for Multidisciplinary Research, 2021, Volume 11, Issue 4, pp:750-756
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[6] C.Nagarajan and M.Madheswaran - ‘Performance Analysis of LCL-T Resonant Converter with Fuzzy/PID Using State Space
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