National Seminar

on
New Generation High Performance Conductors

4th Dec’14
 Compulsion for alternative – why?
Limitation of power flow
___________________________________
New line Existing line
 ROW Constraint (Overloaded/
 Increasing Uprate the
urbanization left capacity)
no inlet for critical
S/S.
 EHV Cable cost
still very high Replace/
Reconductoring
with efficient
conductor
Use efficient
conductor
from day
one
 What is efficient Conductor ?
ATTRIBUTES WHY

1) More current carrying capacity More power

2) High Conductivity Efficient power transfer
(Low Resistance)
3) Temperature rise with current More I2R loss

4) Ultimate Tensile Strength Sag Tension compliance

5) Co-efficient of linear expansion Sag for ground
limit clearance as per IE rules
6) Weight per meter Optimal loads for tower
design
7) Cost Conductor contributes
40% of line cost
 What GETCO is doing for new lines ?
Characteristics of various options:
Options of conductor Benefits / Short comings Category Cost factor

1) ACSR Zebra Presently used Moderate Temp. Comparatively

(220 kV) Low
2) ACSR Moose Presently used Moderate Temp. Comparatively
(400 kV) Low
3) AAAC Lower weight, Higher Sag, Moderately Higher Marginally High
Higher Resistance Temp. (90 ⁰C)
4) TACSR / ZTACSR Higher Sag, Higher Higher Temperature High
Resistance (150-210 ⁰C)
5) ACSS Higher Sag, Higher Higher Temperature High
Resistance (250 ⁰C)
6) AL59 Higher Sag, Lower Moderately Higher Marginally High
Resistance, Lower weight Temp. (95 ⁰C)
7) CCC Lower Sag, Lower HTLS (180 ⁰C) Very High
Resistance, Special T&P
8) Invar type Lower Sag, Higher HTLS (230 ⁰C) Very High
Resistance
9) GAP type Lower Sag, Higher HTLS (150-210 ⁰C) High
Resistance, Special T&P
 What GETCO is doing for new lines ?

• Adopted for 220 kV & 400 kV new lines.

• Options Available
1) Equal Diameter to ACSR
2) Equal Weight to ACSR
• Adopted - Equal Weight to ACSR Zebra
(220 kV)
- Equal Diameter to ACSR Moose
(400 kV)
 What GETCO is doing for new lines?
(220 kV)
Factors considered for decision making :
1) Current capacity required – 170 to 200%
of ACSR conductor
2) Project time – Use of existing tower
design, since new takes time.
3) Efficiency – I2R loss
4) Satisfy Sag-Tension requirement with
existing Tower Spotting Data
5) Dependency on supplier for hardware &
accessories suitable for high temperature
6) Competency and T&P to handle erection
of new conductor
7) Project cost (Deciding factor)
 What GETCO is doing for new lines?
(220 kV)
How AL59 suited for decision making:
Factors AL59 suitability
Current capacity requirement Doubled with moderate
Temperature rise (95 ⁰C)
Project time Suited to existing tower
design
Efficiency Low I2R losses even@ 95⁰C
Satisfy Sag-Tension with existing Satisfied with 3 meter
Tower Spotting Data extension and by limiting the
wind span
Dependency for Hardware & Adequate Indigenous
Accessories manufacturers
Competency of erection Does not require special
skill or T&P
Project cost Increases by 10% appx.
 What GETCO is doing for new lines ?
(220 kV)
Comparison of options:
PARAMETER AL59 (equal AL59 (equal
diameter to weight to ACSR
ACSR Zebra) Zebra)
1) Type 61/3.18 61/3.50
2) Diameter (mm.) 28.62 31.50
3) Weight (kgs./km.) 1336 1618
4) Cross section area 484 587
(sq. mm.)
5) Resistance (Rdc @ 20 0.06250 0.05070
0c) (ohms/km.)
6) UTS (KN) 121 141
7) Wind Span (meters) 385 350
8) Ampere Capacity 900 1030
 What GETCO is doing for new lines?
(220 kV)
Ultimate comparison with ACSR Zebra:
PARAMETER ACSR Zebra AL59 (equal
weight to ACSR
Zebra)
1) Resistance (Rdc @ 20 0.06869 0.05070
0c) (ohms/km.)

2) A.C. Resistance (@ 0.08487 0.06855

maximum operating Temp.) @670c @950c
3) Ampere Capacity (AT – 500 1030
40 0c)
4) Power Transfer capability 181 MW 373 MW
in MW @ p.f. 0.95 per ckt.
5) Net Power Transfer for 175 MW 350 MW
100 km. line
 What GETCO is doing for new lines ?
(220 kV)
Changes adopted to satisfy Tower Spotting Data:
• Options to counter higher sag at full
temperature (950c),
1) Reduction of Normal span
2) Use of extension permanently
• Practice adopted by GETCO
1) Use of extension permanently –
lesser cost & additional margin
available for ground clearance.
2) Reduction in Maximum wind span to
attend wind load increased due to
diameter increase.
 PROJECT COST (220 kV)

ACSR Zebra AL59 with AL59 with

conductor +3 meter reduced normal
extension span

Project Cost 100 110.2% 111.20%

 What GETCO is doing for new lines ?
(220 kV)

Conclusion:
• Double the Ampere Capacity & Net power
transfer capacity by addition of appx. 10%
to project cost and without operating line
at excessive higher temperature .
• Low resistance compared to ACSR Zebra
even at rated Temperature results in to
lower loss for same power transfer & do
not aggravate % Voltage Regulation.
• No special erection methodology, special
tools tackles, special design Hardwares &
Accessories required.
• Indigenous supply available for conductor
and hardwares.
 What GETCO is doing for new lines ?
(400 kV)

• Adopted AL59 for 400 kV New Lines.

• Options Available
1) Equal Diameter to ACSR Moose
2) Equal Weight to ACSR Moose
• Adopted - Equal Diameter to ACSR
Moose.
 What GETCO is doing for new lines ?
(400 kV)
Comparison among options:
PARAMETER AL59 (equal AL59 (equal
diameter to weight to ACSR
ACSR Moose) Moose)
1) Type 61/3.50 61/3.89
2) Diameter (mm.) 31.50 35.01
3) Weight (kgs./km.) 1618 2000
4) Cross section area(mm2) 587 725
5) Resistance (Rdc @ 0.05070 0.04095
200c) (ohms/km.)
6) UTS (KN) 141 174
7) Ruling Span(Sag-Tension) 370 363
8) Wind Span 400 363
 What GETCO is doing for new lines?
(400 kV)
Ultimate comparison with ACSR Moose:
PARAMETER ACSR Moose AL59 (equal
diameter)

1) Resistance (Rdc @ 20 0c) 0.05596 0.05070

(ohms/km.)

2) A.C. Resistance (@ maximum 0.0722 @800c 0.06855 @950c

operating Temp.)

3) Ampere Capacity (AT – 40 0c) 790 1030

(130% higher)

4) Thermal Power Transfer capability 936 MW 1220 MW

in MW per ckt. (130% higher)
(p.f. 0.95, factor 0.9)
6) Project Cost 100% 106 -108%
 What GETCO is doing for new lines?
(400 kV)
How AL59 suited for decision making:
Factors AL59 suitability
Current capacity requirement Increased 30% with moderate
Temperature rise (95 ⁰C)
Project time Suited to existing tower design
Efficiency Low I2R losses
Satisfy Sag-Tension with Satisfied with normal tower and
existing Tower Spotting Data by limiting the ruling span
matching with actual field
observation
Dependency for Hardware & Adequate Indigenous
Accessories manufacturers
Competency of erection Does not require special skill or
T&P
Project cost Increases by 6-8% appx.
 What GETCO is doing for new lines ?
(400 kV)

• Thermal capacity increased by 30% at

increase of project cost 6-8%
• As the Sag at maximum operating
temperature is increased, ruling span is
reduced by appx. 7%.
• By retaining wind and weight span
additional benefit of reduction in
vertical load & longitudinal load added
FOS for existing tower design .
 CONDUCTOR COST

Conductor Cost Comparison

(Lac Rs./km.)
ACSR Zebra 2.265 **

ACSR Moose 2.827 **

AL59 (61/3.50) 2.952 130% of Zebra

104.5% of Moose
 GETCO Expectations

• Indigenous manufacturers – conductor,

hardware
• Availability of erection agencies
• Indigenous testing agencies
• Innovative erection technology e.g. live
line
• Optimum cost
Thank You