Practical Application High Temperature Low Sag Transmission Conductor

Leksono Hartanto PLP Indonesia

BACKGROUND :
Increase demand for electricity is a big issue of the day for many countries

HOWEVER :
Very high cost to install new power line Too difficult to acquire tower site & ROW Not enough time to built the new line Objections from inhibitants to build the new OH lines

SOLUTION :
Reconductoring existing line with

High Temperature Low Sag Conductor

Reconductoring with HTLS conductor -LIMITATIONS :

As power flow increase, the voltage at the receiving end of the line decrease, power flow is limited to that which yields a 5% drop The flow through particular circuit is limited in order to avoid overheating a power transformer or underground cable in series with OHL, reconductoring with HTLS will not help

Replacing existing power conductor while preserving the original structure, typically leaves electric & magnetic fields unchanged as the physical spacing & their geometric arrangement remainly unchanged.
Durability of connectors & hardware operating at conductor temperature as high as 250 deg.C

ECONOMIC EVALUATION :

COMPARISON :
ACSR conductor :
Steel core surrounded by nearly pure Aluminum Continuous operation Al. typically limited to 100 deg.C to avoid weakening the Al. strand over time. Al & St are subject to tension load that can reach high level as wind & ice increase Al. Thermal expansion limits line sag at high electrical loadings.

HTLS conductor :
High strength core (St, St Alloy or composite material) surrounded by multiple layers of Al. or Al.Alloys Continuous operation Al. typically as high as 200 to 250 deg. C Gap type of Japanese HTLS conductor only at St. core is subject to tension load. Since Al. expand much faster than the core as the conductor temperature rise & surely go to compression and resulting sag & birdcaging (opening strands). Particular conductor such as composite core must be strong enough to avoid failure under severe ice & wind load No conductor can be said commercially available unless connector & hardware available. Increase the current capacity 1.6-2.0 times of ACSR

CONDUCTOR TYPE :
Trapezoidal Strands and Gaps GTACSR

Trapezoidal Strands

ACSR/TW ACSS/TW

ACCC/TW

Round Strands

ACSR ACSS TACSR

ACSR/AS TACSR/AS

STACIR

ACCFR

ACCR

Reinforced Material

Steel

High Strength Steel

Al-Clad Steel

Invar

Carbon Fibre

Metal Matrix Composite

Glass & Carbon Fibre

Aluminum

Hard Aluminum 1350-H19 90C

Fully annealed Aluminum 200C

Aluminum Zirconium 150C

Aluminum Zirconium 210-240C

HTLS CONDUCTOR TYPE : 1. ACSS (Aluminum Conductor Steel Supported) :

Consisted of ordinary fully annealed Aluminum wire strand over a core of high strength or extra high strength steel. ASTM standard for this conductor has been existence for 15 years. The use of annealed Al. strands has been shown to greatly increase the mechanical self damping of ACSS. ACSS commonly available with trapezoidal (TW) Al. strand for the same OD offers lower resistance. Commercially available from multiple vendors in the US. Reconductoring, in most case allow an increase of at least 30% thermal rating. Relatively simple to tension string. Thoroughly tested both lab. & field. Small cost premium over regular ACSR when compared to others HTLS technologies.

2. (Z)TACSR :
Consisted of (Z)TAL wires (thermal-resistant Al.Alloy wire with zirconium added) strand over a core of galvanized steel wire. Same construction as conventional ACSR. Its not by design low sag conductor. The advantage : TAL --> AL. ALLOY NOT ANNEAL UP TO 150 Deg.C ZTAL --> AL. ALLOY NOT ANNEAL UP TO 210 Deg.C

3. (Z)TACIR :
Consisted of (Z)TAL wires (thermal-resistant Al.Alloy wire with zirconium added) strand over a core of Galvanized or Al.Clad Invar Alloy St wire . Same construction as conventional ACSR. INVAR is an iron-nickel alloy (Fe-36%Ni) with very small coeff. thermal expansion. ( one third of Galv. Or Al. Clad St wire). INVAR St. is not so strong as regular st, NOT RECOMMENDED in use at region where exposed by wind & ice load. Installation method & hardware accessories are virtually similasr as those used by conventional ACSR. Continuous temp. up to 200 deg.C Reconductoring, in most case allow an increase of at least 30% thermal rating. Premium cost is at least 300% of normal ACSR.

4. ACCR & ACCR/TW (Al. Conductor Composite Reinforcing) :

Consisted of (Z)TAL wires (thermal-resistant Al.Alloy wire with zirconium added) strand over a core of ceramic fiber embedded in an Aluminum matrix. Commercially available in limited qty from 3M company. Thoroughly tested both lab. & field. Coeff. thermal expansion of composite core is about half of Steel wire & less than a half of Steel weight. Strong enough for use in any loading environmental. Special hardware accessories (termination & suspension clamp). Continuous temp. up to 200 deg.C & emergency at 240 Reconductoring, in most case allow an increase of at least 30% thermal rating. Limited cost data indicate premium cost is at least 3000% relative to ACSR.

ACCRs Special hardware termination :

Compression Dead End (AFL) Helical Dead End (PLP)

Two layer construction of Thermolign Dead End has been succesfully in installation of ACCR conductor

2 steps compression procedure just like ACSR compression type, the difference is only the use of Aluminum insert inside the steel of end fitting to provide the strong bond bw core of ACCR and steel sleeve

ACCRs Special hardware splice :

Compression Splice (AFL)

Helical Dead End (PLP) Thermolign Full Tension Splice

ACCRs Special hardware Suspension Clamp :

Jumper Support Insulator :

Preformed type Suspension Assembly :

5. TACFR (Showa Electric) :

Consisted of (Z)TAL wires (thermal-resistant Al.Alloy wire with zirconium added) strand over a core of carbon fiber embedded in resin. Laboratory tested & limited field test in Japan. Hardware accessories are available. Claimed by manufacturer continuous temp. up to 150 deg.C Core thermal elongation is 10% of steel and modulus elasticity of carbon fiber reinforced resin is only about 2/3 of steel. Major question in regard long term corrosion between Aluminum & carbon resin as well as service life of resin. Doesnt offer significant advantage when applied to line caused the emergency rating of ACSR temperature limit is 140 deg.C

6. G(Z)TACSR (J-Power System) :

Consisted of (Z)TAL wires (thermal-resistant Al.Alloy wire with zirconium added) strand over a core of extra high strength galvanized steel. Laboratory & field tested (UK & Malaysia) . Special installation and suspension clamp. Max. continuous temperature TAL, 150 deg.C and ZTAL, 210 deg.C Reconductoring, in most case allow an increase of at least 30% thermal rating. Increase current capacity 1.6-2.0 times of regular ACSR conductor. Premium cost is at least 300% of normal ACSR.

Special feature of G(Z)TACSR:

1. Design Concept Shift the knee point to lower side 2. Knee point temperature is temperature at which Aluminum layers dont bare any tension due to its thermal expansion. 3. How do to shift the knee point to lower side ? Gap construction is allowing to be tensioning on steel core only so the sag due to tensioning prior to reach its knee point is more determined by modulus elasticity of Steel which is a half of Aluminum in contrast to regular ACSR conductor the sag due to tensioning prior to its knee point is determined by combining modulus elasticity of Aluminum & steel.

4. Special Installation

5. Hardware accesories Those are virtually same as regular ACSRs hardware accessories except dead end that are one size larger than those use in ACSR to allow for the increased current-carrying capacity. AGS is succesfully well proven suspension clamp accessories to install with HTLS conductor.

6. Hardware accesories cont In locations with large variations in span length or height, semi strain system for connection support is an option. In order to assure proper performance of the conductor, semi strain type suspension must be installed every three suspension spans.

7. ACCC (CTC) :
Consisted of Fully annealed Aluminum wires strand over of composite carbon/glass fiber core. Laboratory tested. Special hardware accessories and conductor handling due to its lowest modulus elasticity of core. Application at location which exposed by wind / ice load is questionable Max. continuous temperature 210-240 deg.C Reconductoring, in most case allow an increase of at least 30% thermal rating. Increase current capacity 2.0 times of regular ACSR conductor. Approximate premium cost is unknown.
Aluminum
Aluminum

28% more Aluminum

28% more Aluminum Steel Core Steel Core Traditional ACSR

Composite Core
Composite Core ACCC Conductor

Special feature of ACCC : 1. The core is unique among HTLS or conventional conductor because its much lower flexibility. Comparison of Reinforce wire / core
No Item Unit Steel Al Clad Steel 1275 1.5 10 6.59 16519 12.6 20.3 Invar/AI Composite

01
02 03 04 05 06 07 08

Tensile Strength
Elongation Weight of Zinc Coating Aluminum thickness * Density Modulus of elasticity Coefficient of linear expansion Conductivity

N/mm
% g/mm % g/cm3

1410
4 >260 7.78 21108 11.5 8

1080
1.5 10 7.1 15500

2161
1.9 11900 1.61 0

kg/mm
X 10-6/C %IACS

3.7
15

Special feature of ACCC : 2. For such reason special conductor handling is required due to its lowest modulus elasticity , special care & attention to not sharply bend.

3. Because the annealed aluminum is soft, additional emphasis should be not to give scuff on surface of Aluminum conductor.

Special feature of ACCC : 4. Sizing stringing sheave :

Dc

= outside diameter of the conductor = diameter of the bottom of the groove of the sheave where the conductor touches = not less than 20 x Dc

dg

Rg

Ds

Rg

= groove radius
= not less than 0.55 x Dc = not more than 1.1 x Dc for two layer ACCC Conductor = not more than 0.75 x Dc for three layer ACCC conductor = not more than 0.625 x Dc for four layer ACCC conductor

dg Commercial Size

= depth of the groove = not less than 1.25 x Dc

= overall diameter of sheave and depending on the sheave size can be

50 to 152 millimeters larger than the bottom of the groove diameter.

Special feature of ACCC : 5. Special hardware accesories :

Compression Dead End (FCI Burndy)

Deadend Body

Steel Eye

Collet

Inner Sleeve Collet Housing

Special feature of ACCC :

Compression Splice

Splice Body

Inner Sleeve

Collet Housing Splice Coupler

Collet

Special feature of ACCC :

Suspension Clamp AGS/Thermolign/CGS (PLP)

Thank You