Case Study: Medium Voltage Covered Conductors (MVCC) | SPDCL

The Challenge

SPDCL’s overhead distribution network suffered from severe vulnerability to external environmental factors, resulting in snapped conductors and multi-hour power disruptions:

• Environmental & Wildlife Faults: Falling trees, heavy winds, rains, debris, birds, and animals frequently contacted open power lines, triggering immediate phase-to-phase or phase-to-ground short circuits.
• Tight Project Deadlines: The utility needed to secure a critical feeder network in time for the high-profile Pushkar Festival, where power interruptions could impact millions of attendees.
• Strict Operational Constraints: Replacing legacy bare conductors required working within limited daily shutdown windows while maintaining strict on-site safety protocols.
• Grid Losses & Security Issues: Uncovered distribution lines left the network exposed to power theft through direct line tapping and transformer overloading.

The Approach

To meet the non-negotiable deadline without compromising installation quality or safety, Raychem RPG executed an end-to-end operational strategy:

• Rapid Air-Freight Supply Chain: Air-lifted MVCC materials directly from Sweden to eliminate long ocean transit times and meet strict project schedules.
• Local Workforce Development: Trained and onboarded local service contractor teams to expand deployment capacity while maintaining safety standards.
• Continuous On-Site Field Support: Mobilised a dedicated Raychem RPG field team to manage daily shutdowns, track conductor tensioning, and ensure rapid installation.

The Solution

Raychem RPG replaced vulnerable bare wires with advanced Medium Voltage Covered Conductors (MVCC), a system designed with specialised insulating layers that protect against accidental contact:

• Temporary Contact Resilience: The protective insulation withstands phase-to-earth voltages, preventing line trips when tree branches, objects, or animals touch the line.
• Compact Right of Way (RoW): Reduced phase-to-phase and clearance requirements, allowing lines to pass safely near trees, structures, and narrow corridors.
• Anti-Theft & Infrastructure Defence: Inhibits direct line tapping, prevents unauthorised connections, and shields internal conductors from atmospheric corrosion.

Execution & Strategic Growth

Raychem RPG’s field operations team worked continuously for 88 days straight to assemble, install, and energise over 500 km of MVCC ahead of the Pushkar Festival.

Following the flawless, zero-outage execution during the event, SPDCL expanded the project, placing repeat orders for an additional 3,500 km of MVCC across its distribution network.

Key Results & Benefits

• Full Investment Payback (ROI in 2 Years): Reduced power downtime and increased billing efficiency delivered complete return on investment within 24 months.
• Zero Festival Outages: Guaranteed reliable power delivery throughout the high-demand Pushkar Festival period.
• Lower Operational & Maintenance Costs: Mitigated emergency repairs, line re-tensioning, and conductor splicing caused by storm damage or tree falls.
• Enhanced Environmental & Public Safety: Lowered the risk of forest fires, human electrocution, and accidental contact with live lines.
• Simplified Infrastructure Footprint: Reduced required line clearances, streamlining construction in densely populated or heavily forested areas.