Welcome to

HTLS Conductor
1. Capacity Upgrading 2. HTLS Conductor -. Conductor -. Fitti Fittings & Accessories A i -. Installation (String & Sagging) 3. Type Test Certificate 4. Experience 5. Economic Evaluation 6. Summary

* HTLS Conductor: High Temperature Low Sag Conductor

1. Capacity Upgrading
Increase in demand for electricity is a big issue of the day in many countries countries.
However,
Unexpected growth in electricity consumption due to economic expansion (commercial, industrial & residential) Too difficult to acquire tower sites and right-of-way Not enough time to built new lines Initial funds are limited Social objection to build new lines

Background

Solution

Uprating
of existing lines with g

High Temperature & Low Sag Conductor

2. HTLS Conductor

Optimized HTLSC

High current capacity

Long term reliability

Current Capacity
Low sag-tension property

Reliability

Sag

Optimized O ti i d HTLS Conductor

Installation
Conductor cost Economics Labor cost Low line loss

Easy and rapid installation Compatible to existing installation method

2. HTLS Conductor

Developmental Trend

The cutting edge technologies of capacity upgrading apply to various types of conductor. y
Key materials
Ampacity
5 6

Material Conductor Core GSW GSW GSW ESt ESt INVAR

x 2.0

GAP STACIR Conductor

1

Max. Max. operating current Conductor temp. (oC) Ratio Al TAl Hi-TAl TAl STAl STAl 90 150 150 150 210 210 x 1.0 x 1.55 x 1.5 x 1.55 x 2.0 x 2.0

Application

ACSR TACSR Hi-TACSR GTACSR GSTACSR STACIR

x 1.5

TACSR

GAP Conductor 3 Hi-

Uprating with increased sag Uprating for long span Uprating with equivalent Sag & Tension Properties

TACSR

3 4 5 6

x 1.0

Copper

ACSR

AAAC

1880 1910

1960

1980 1990 2000

Year

* A key to abbreviations: TAl: Thermal Resistant Aluminum-Alloy Wire Hi-TAl: High-tensile Strength Thermal Resistant Aluminum-Alloy Wire STAl: Super Thermal Resistant Aluminum-Alloy Wire GSW: Galvanized Steel Wire ESt: Extra High-tensile Strength Galvanized Steel Wire INVAR: a kind of Ni-Fe Alloy Wire Hi-TACSR is the same as KTACSR GSTACSR is the same as GZTACSR STACIR is the same as ZTACIR

2. HTLS Conductor

STACIR Conductor

A Ampacity U it Upgrading : x 2 ACSR di

High Strength AW
Aluminum-clad Invar
* Invar is a 36%Ni-Fe Alloy

No limitation for application area y ,g p g : Heavy wind & snow, galloping area Equivalent Sag-Tension Properties to conventional ACSR

STAL
Super Thermal Resistant Al-Alloy Conductor Al Alloy

No Modification & Reinforcement on Existing Tower Easy Installation with Same Method & Equipment as ACSRs Red ced Design Time and Cost Reduced High Reliability with Strong Track Record

2. HTLS Conductor

Thermal Resistant Al Alloy

Thermal resistant aluminum alloy wire containing Zr element has improved annealing resistance properties without loss of strength at p g p p g high operating temperature.
Annealing Properties
110

Physical Properties
Conductor Density (g/cm3) Al 2.7 61 16.2 ~ 17.9 90 120 x 1.0 ACSR TAl 2.7 60 16.2 ~ 17.9 150 180 x 1.55 Hi-TAl 2.7 55 22.9 ~ 25.7 150 180 x 1.5 STAl 2.7 60 (58) 16.2 ~ 17.9 210 240 x 2.0

100

Residual strength, %

Conductivity (%IACS)
90 80 70 60 50 0 100 200 300
o

Tensile Strength (kgf/mm2) Allowable Temp. (oC)

Al
400

Continuous Emergency

STAl

500

Ampacity Applicable Conductor

Aging temperature, CX1hr

TACSR Hi-TACSR STACIR (River, Sea GAP GAP crossing)

* Al : Hard-drawn Aluminum wire * TAl : Thermal-resistant Aluminum-alloy wire Hi-TAl: High-tensile strength Thermal-resistant Aluminum-alloy Wire * STAl : Super Thermal-resistant Aluminum-alloy Wire

2. HTLS Conductor
Al-clad Invar has low thermal expansion coefficient value (1/3 to steel wire) at high operating temperature (210oC).
2,000

INVAR Core

Sag vs Temperature *

ACSR 795kCM Drake

40

Cable Sa - mm ag

Thermal Expansion
m

1,600

1,200

STACIR 795kCM Drake

800

m
Dim mension Ch hange,
30

400

Knee point temperature

20

50

100

150

200

250

300

Cable Temperature - deg C

x1/3
10
Cable Tension - kg g

4,000

Tension vs Temperature *

3,000

0 -100

2,000

100

200

Temperature, C

300

400

1,000

STACIR 795kCM Drake ACSR 795kCM Drake

0 50 100 150 200 250 300

Cable Temperature - deg C

Invar is a 36%Ni-Iron Alloy Low thermal expansion coefficient at high operating temperature

x2 Capacity Upgrading

Equivalent Sag and Lower Tension at High Operating Temperature

* Sag and Tension vs. Temperature Test was performed at Kinectrics International Inc., Canada.

2. HTLS Conductor
GTACSR / GSTACSR
Super Thermal Resistant Al-alloy (STAl) 210oC Al alloy Thermal Resistant Al-alloy (TAl) 150oC Gap structure

GAP Conductor

Ampacity Upgrading : - GTACSR : x 1.55 ACSR - GSTACSR : x 2 ACSR No limitation for application area : Heavy wind & snow, galloping area Equivalent Sag-Tension Properties to conventional ACSR No Modification & Reinforcement on Existing Tower S Special Installation Method & Tools required Reduced Design Time and Cost

(Super) Thermal Resistant Al-alloy Trapezoidal (Super) T id l (S ) Thermal Resistant Al-alloy Extra High-strength Ga a ed Stee Galvanized Steel Wire e Gap filled with special Heat-resistant Grease
Provide water proofing P t ti for galvanizing coating Protection f l i i ti on the steel core Lubrication between the steel core and aluminum layers

2. HTLS Conductor
The Effect of Gap structure
Tension High Temp. Temp
Sag is adjusted by the steel core only The tension of Aluminum is free Stress distribution is applied only to the steel core = 18~20x 10-6/oC (ACSR)

GAP Conductor

Tension

Steel Core < Outer Layer

Temp. at Installation

Knee point temp. = Sagging temp.

Sag (m)

= 11.5 x 10-6/oC (ESt)

Knee point temp. = Sagging temp. Temp (oC)

Sag characteristic of Gap conductor is the same as conventional ACSR

Low Temp.

Load is applied to both the steel core and the Aluminum layers

Tension

Tension

Steel Core = Outer Layer

2. HTLS Conductor

Fittings & Accessory

Appropriate design is needed to accommodate to reduce current heating and enhance heat radiation of clamp. g
Description Tension Clamp with Jumper terminal Mid Span Joint & Repair Sleeve p Suspension clamp Bundle spacer Vibration damper Insulator STACIR Conductor Larger Volume
(Compression, Wedge, Bolted)

GAP Conductor Larger Volume

(Compression type only)

Compression Type Dead-end Clamp

Larger Volume

Larger Volume
(Limited Usage)

standard standard standard standard

standard
(Armor grip type is not recommendable.)

standard standard

* Conductor dimension : 410mm2 Length (L) ACSR 590 675 STACIR GSTACSR

(Unit: mm)

Diameter (D) 48 52

standard

Temperature of Fittings and Accessories are equivalent to those of ACSR !

2. HTLS Conductor
ACSR & STACIR
String String Special String Work Pre-sagging by conductor come-along de-strand Al-strands Sagging Final sagging by steel gripping clamp

Installation

Gap Conductor

Recommendable String Plan

One Tension Section: up to about 2,200m (one mid-span joint allowable: up to about 4,400m) Continuous suspension spans: apply semi-strain assemblies String diameter

Steel clamp compression re-strand Al-strands

Clamp Compression

Al clamp compression

Conductor Size Tensioner Capstan String Block

300 mm2 ~ 600 mm2 1 500 mm 1,500 600 mm

Attach suspension clamp & damper

Attach suspension clamp & damper

2. HTLS Conductor

Installation for STACIR Conductor

The Installation Methods for STACIR are exactly the same as those used for ACSR (Stringing, Sagging & Clamping) .

2. HTLS Conductor

Installation for GAP Conductor

Special tools and accessories shall be considered for GAP conductor.

Semi-strain assembly for suspension tower Compression Type String Clamp
To avoid the steel core go inside aluminum layers

Steel Gripping Clamp

for final sag adjustment g j

Put additional tensioning function onto suspension tower every 5~6 suspension spans to keep the low sag properties

Conductor Come-along
for pre-sagging (same as conventional)

2. HTLS Conductor

Installation for GAP Conductor

St Core St Come-Along

GSTACSR

STAL

3. Type Test Certificates

Type tests for HTLS Conductor were successfully completed based on the International Standards by 3rd Party Laboratories.

4. Experience
Supply of High Temp. Conductor more than 16,900 km. Ready to Deliver High Qualified Products and Technology to the Customer.

Spain
ENDESA 18km 2002

Kuwait K it
MEW 4,008km (Under progress) 2010

Japan J
13km 2000

Korea
KEPCO 6,545km 1984~ POSCO 154km 1996~

China
1,036km 63km 2005~ 2006~ 340km 2007~ 11km 2008 16km 2008 7km 2009

Canada
HYDRO-ONE 2km 2004

Italy
ENEL 58km 2002

Iran
MREC 23km 2010

Venezuela
PDVSA 180km 2006

India
PGCIL 400km 2004 HVPNL 66km 2008

Egypt
EETC 576km 2008~

Malaysia
TNB 573km 2004~

Philippines
PEDC 136km 2010

Taiwan
TPC 227km 2008

4. Experience

KEPCO / Korea

KEPCO / Korea
Korea Electric Power Corporation

: Sinnamwon T/L (June 2000) (345kV, 2cct, 17km) ( )

Customer Concerns

Existing
ACSR 480mm2x2B Ampacity [A/cond.] Sag [m] Tension[kgf] 918 10.21 4,140

LS Proposal STACIR 410mm2x2B

1,707 9.79 4,140

KEPCO Experience
Unit: i it km U it circuit k

Increasing demand for electricity due to rapid growth of industry and factory automation Demand for peak load rate by 9% every year Very high cost to acquire new t tower site and right-of-way it d i ht f Not enough time to construct new power line Increasing concerns about environmental preservation and popular enmity to overhead power lines

Voltage grade 345kV 154kV Total

High Capacity Conductor 383 1,360 1,743

*based on from 1995 to 2006

Clients Certificate

* Condition : Zone , Span 300m Operating Temp.:ACSR 90oC, STACIR 210oC p g p ,

4. Experience
The longest Cross-sea transmission line (345kV) Cross Total Length : 78km

KEPCO / Korea

Steel Pipe Tower / Double circuit 2 Routes Conductor - HTACSR ,TACSR 480 , D Domestic D i and C ti Design d Construction t ti

YH T/P ~ Sin Si Heung S/S (38 2km) (38.2km)

4. Experience
The Longest Cross-Sea Transmission Line

KEPCO / Korea

4. Experience
TNB / Malaysia
Tenaga Nasional Berhad

TNB / Malaysia

: Port Klang P/S~Kapar S/S etc. (275kV, 2cct, 4km) TNB Experience

Frequent Black-out in Kuala Lumpur has been recurring High cost and difficulty to acquire right-of-way & erection / installation Could be completed within short period of time (2month) on full turnkey built

ACSR 400 mm2 (Zebra) 719Amp/cond. 719Amp/cond

STACIR 410mm2 1,584Amp/cond. 1 584Amp/cond

Voltage

275kV

* Operating Temp.: ACSR 75oC STACIR 183oC

132kV Total

Conductor . Length (km) 47 294 53 124 108 55 681

Year 2004 2006 2006 2009 1010 2008

Clients Certificate

4. Experience
ENEL / Italy
Enel Distribuzione SpA

ENEL / Italy ENDESA / Spain

: Model section (April 2003)

( (Cable Length, 51km) g , )

Customer Concerns
STACIR

Rapid increase overloaded line Need to exchange existing line for Upgrading conductor

240mm2 1,207Amp/cond.
* Condition : wind pressure 88kg/m2 safety factor 2.0 Operating Temp.: ACSR 90oC STACIR 210oC

Technical & Commercial Proposal : December 2002 ece be 00 Delivery : April 2003 Installation Start : September 2003

ENDESA / Spain S Spa

Empresa Nacional de Electricidad S.A,

: Field Trial Test (Nov. 2001) (110kV, 2cct, 3km) Existing

ACSR/AW 477MCM(Hawk) 606Amp/cond.

Customer Concerns Rapid increase in the demand for electric power

LSs Proposal
STACIR 240mm2 1,207Amp/cond.

Technical & Commercial Proposal : November 2001 Delivery : September 2002 Installation : December 2002 Under Field Test : January 2003

4. Experience
Power Grid / India

Power Grid / India

LILO of one circuit of 400kV DC, Dadri-Ballabhgarh New T/L of 30km Invar Moose Conductor Package associated with high capacity East- North Interconnector-II (Award No.C-41408-L175/NOA-I/1403)

Customer Concerns

Existing
ACSR Moose x 4B Ampacity [A/phase]

LS Proposal STACIR/AW Moose x 2B Contract: September 2004 Qty of conductor: 396km Type Test: August 2005 D li Delivered: September 2005 d S t b

Increasing demand for electricity due to rapid y p growth of industry and factory automation Demand for peak load rate High cost to acquire new tower site and right-of-way Not enough time to construct new power line

2,456

3,400

* Condition : Span 400m Operating Temp.:ACSR 75oC, STACIR/AW 210oC

4. Experience
China
Increasing demand and investment of electricity for Beijing Olympics Hi h cost and difficulty to acquire High t d diffi lt t i right-of-way & erection / installation Could be completed within short period of time

NCIP, CPC, GZPSC, KSPSC, BEPC & KEPC / China

04: 1st BukSin-Bukan T/L (110kV, 2cct, 4.3km) 05: 2nd WuBei-Wu T/L (220kV, 2cct, 4.5km) 06: 3rd Babao-Shangchun T/L (220kV, 2cct, 55km) 07: 8 Packages for GZPSC KSPSC KEPC BEPC & NCIP 07: GZPSC, KSPSC, KEPC, 08: 8 Packages, GZPSC, BEPC & LYSC Capacity upgrading by replacement of the existing ACSR with HTLSC conductor

2008 Beijing Olympics

Clients Certificate

4. Experience

PGCB / Bangladesh

PGCB / Bangladesh (SIEMENS)

Power Grid Company of Bangladesh

: 230/132kV sub-station at Tongi & Hasnabad and 132/33kV sub station at Kalyanpur sub-station

Layout Plan & Sectional Elevation

Users Certificate

ACSR 400mm2 Zebra 737A

STACIR 400mm2 Zebra

1,645A

4. Experience
: Capacity Upgrading 220kV O.H.T.L

EETC / Egypt

EETC / Egypt
Egyptian Electricity Transmission Co.

- 2008: 1st Upgrading Project in Cairo zone pg g j - 2010: 2nd Upgrading Project in Cairo & Alexandria zone

Capacity Upgrading 220kV O.H.T.L. in Cairo Zone

-. Neither modification of the existing structures nor construction of new structures will be required -. C Current capacity shall b equal or more th 1 300 A t it h ll be l than 1,300 Amps.

Existing O.H.T.L.
Capacity 1. Conductor : ACSR 380/50mm2 ACSR 380/88mm2 2. Current Capacity : 675 Amps. Loading Condition 1. Ruling Span : 360 m 2. Maximum Allowable Tension (MAT); 1) Maximum horizontal tension : < 5,290 kgf ) g 2) Safety factor: > 2.5 (< 40% UTS) 3) Condition: 35m/s wind at 0oC (Wind pressure : 56.25kg/m2) 3. Everyday Stress (EDS) ; 1) Safety factor: > 4.0 (< 25% UTS) 2) Condition: No wind at 25oC
Capacity Upgrading using g Existing structures

Capacity Upgrading with STACIR 238/97

4. Experience

MEW / Kuwait

MEW / Kuwait
Ministry of Electricity & Water

: The Supply & Installation of 400kV O/H At Al-Zour North Station (Tender No. :MEW/25/2008~2009) : New Transmission (4,118 conductor.km)
Technical Parameters
STAL

Description

Unit

Project Milestone

Cross sectional view

ESt Grease

Tech. Proposal : Feb. 2009 Approval by MEW : Dec. 2009 Contract : Jan. 2010
Sulaibiya Z S/S Fintas Z S/S

Conductor designation Structure Overall diameter Crosssectional area Aluminum Core Conductor Core Aluminum Core Total T t l

GSTACSR 410mm2 15/4.6 STAL + 10/TW STAL

nos./mm mm mm mm2 mm2 mm2 kg/km kN ohm/km

oC

7/3.0 ESt 27.6 9.0 414.0 49.5 463.5 463 5 1,563 > 138.1 0.0711 < 210 1,557 @ 210oC 12.68

Delivery : 2010 ~ 2011 Construction : 2011

Nominal weight Ultimate tensile strength D.C resistance at 20oC Allowable temperature Current capacity Max. sag

A m

5. Economic Evaluation
Capacity Upgrading
Comparative Cost Analysis (Operation Period : 30 Years)
Build Period Based on 30 route.km

Build New Line with ACSR 24 Months (Long) Required High Cost Required

Replacement by GAP 9 Months (Medium) Not Required No Cost Not Required

Replacement by Invar 6 Months (Short) Not Required No Cost Not Required 53%

100%

Preliminary work Cost of right of way Tower Foundation Conductor & Ground wire 4.1 Conductor Furnishing 4.2 Stringing 4.3 Ground-wire Furnishing 4.4 Ground-wire Stringing Line Accessories Grounding Opportunity Cost Maintenance Cost due to Difference of Build Period -

47% Down

Construction Cost C

Required Required Required Required Required Required High Cost g -

Required Required Not Required Not Required Partially Required Not Required Low Cost o Complicated

Required Required Not Required Not Required Partially Required Not Required Low Cost o same as ACSR Replacement By HTLSC Construction of New Line

6. Summary
Double ampacity uprating with STACIR/GSTACSR Conductor on the existing towers
STACIR/GSTACSR have more than double ampacity of conventional ACSR. STACIR/GSTACSR have equivalent sag-tension properties to conventional ACSR. Conventional fittings and accessories for ACSR can be used for STACIR/GSTACSR Conductor except compression fittings fittings. Same installation method as conventional ACSR is applied for Invar Conductor. STACIR/GSTACSR have hi h long-term reliability with strong track record. h t li bilit ith t t k d high l

HTLSC Information Request

Power utilities do use STACIR/GSTACSR Conductor for their uprating project !

LS Cable are ready to provide our customers with best products and Solutions

Total Solution Provider, LS Always with Our Customers, LS Customers Leading Solution, LS

Thank You Th k Y