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    HTLS Conductor Comparison

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    Jamil Salman Marcos
    The document discusses methods for increasing the capacity of existing overhead transmission lines. It describes low sag conductors as a method that maintains adequate electrical clearances while increasing capacity by allowing higher operating temperatures. Low sag conductors use special aluminum alloys that are resistant to heat and have low thermal expansion, preventing sag violations. Gap type conductors are highlighted as they have advantages over other conductor types for supporting higher loads without modifying existing infrastructure.

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    © All Rights Reserved
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    HTLS Conductor Comparison

    Uploaded by

    Jamil Salman Marcos
    260 views45 pages
    The document discusses methods for increasing the capacity of existing overhead transmission lines. It describes low sag conductors as a method that maintains adequate electrical clearances while increasing capacity by allowing higher operating temperatures. Low sag conductors use special aluminum alloys that are resistant to heat and have low thermal expansion, preventing sag violations. Gap type conductors are highlighted as they have advantages over other conductor types for supporting higher loads without modifying existing infrastructure.

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    HTLS Conductor comparison

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    HTLS Conductor comparison

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    The document discusses methods for increasing the capacity of existing overhead transmission lines. It describes low sag conductors as a method that maintains adequate electrical clearances while increasing capacity by allowing higher operating temperatures. Low sag conductors use special aluminum alloys that are resistant to heat and have low thermal expansion, preventing sag violations. Gap type conductors are highlighted as they have advantages over other conductor types for supporting higher loads without modifying existing infrastructure.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    260 views45 pages

    HTLS Conductor Comparison

    Uploaded by

    Jamil Salman Marcos
    The document discusses methods for increasing the capacity of existing overhead transmission lines. It describes low sag conductors as a method that maintains adequate electrical clearances while increasing capacity by allowing higher operating temperatures. Low sag conductors use special aluminum alloys that are resistant to heat and have low thermal expansion, preventing sag violations. Gap type conductors are highlighted as they have advantages over other conductor types for supporting higher loads without modifying existing infrastructure.

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    LOW SAG CONDUCTORS

    Introduction

    - There is a growing need to increase the power handling


    capacity of existing power transmission assets.

    - At the same time there is fierce opposition to the


    construction of new lines and the ability of obtaining right of
    ways is became more and more difficult.

    As a result of these conflicting pressures, increasing the


    thermal rating of existing overhead transmission lines is seen
    as a valid alternative to the construction of new lines.
    Methods of increasing lines capacity

    - Increment of the line voltage: very expensive solution due to


    necessity of new project, adaptation of installations to new voltage,..
    - Increment conductor tension: that solution might cause problems in
    towers – tower reinforce needed, new foundations, aeolian vibration, ..
    - Increment of conductor section: that solution might cause problems
    in towers – tower reinforce needed, new foundations. New project and
    permissions,..
    - Installation of bundle conductor - High cost. That solution cause
    problems in towers - necessity of reinforce tower, foundations,
    permissions, higher right of ways,..
    Methods of increasing lines capacity

    - Real-time monitoring system: it is used to determine the position of a


    conductor in space thereby determining the rating of the line in real
    time, to avoid design sags violation.

    - Electrical clearances (sags) re-asses with the possibility that the rated
    temperature of the line can be increased. Such physical modification
    might be done: moving suspension clamps, re-tensioning, raising
    conductor attachment heights, adding new structures in long spans.

    -Replacement of the existing conductor with a new conductor that


    has either lower electrical resistance and/or is capable of operation at
    high temperature within the existing line limits on sag and tension -
    LOW SAG CONDUCTORS.
    Ta rgets of low sa g conductor reconductoring

    • Increment of line ca pa city (a mpa city)

    - supporting the sea sona l or occa siona l dema nd pea ks a s


    well a s emergency overloa ds required by the grid
    opera tion during line life.

    - continuous opera tion a t higher tempera tures tha t existing


    conductor increa sing the electrica l loa d.

    • Do not modify the structures (towers a nd founda tions)

    • Ma inta in a dequa te electrica l clea ra nces (ma ximum sa gs)


    LOW SAG CONDUCTORS

    TECHNOLOGY:

    Increa se theca pa city (a mpa city) of the line with respect


    to its equiva lent conductor, ba sed on the increment of
    the working tempera ture, ma inta ining the electrica l
    clea ra nces due to low therma l expa nsion.
    Conventiona l Aluminium Ba sed Conductors
    Overhea ting = Loss of mecha nica l properties

    - ACSR c o nd uc to rs: ma d e of steel c ore + Al 1350 w ires


    - If working tem p era ture > 90ºC w ill lose sig nific a nt tensile
    streng th (“ a nnea l” ) over tim e
    - Ac c umula tive effec t
    - As the c o nd uc to r tem p era ture inc rea ses, the ra te o f
    a nnea ling inc rea ses ra p id ly
    - Ga lva nized steel c ore is a ffec ted a t 170 ºC
    - Alum inium Cla d steel c ore it is not a ffec ted b elow 300ºC
    Conventiona l Conductors
    Typica l a nnea ling curves for a luminium wires
    Low Sa g Conductors
    Therma l-Resista nt Aluminium Alloys

    TENSILE Ma x. Tem p era ture Op era tion


    CONDUCTIVITY
    ALLOY STRENGTH
    (% IACS) Continuous Em erg enc y
    Min (Kg / m m 2)

    HAl 16,2 61,0 90 120

    58TAl 16,2 50,0 150 180

    60TAl 16,2 60,0 150 180

    KTAl 22,9 55,0 150 180

    UTAl 16,2 57,0 200 230

    ZTAl 16,2 60,0 210 240

    XTAl 16,2 58,0 230 310


    “Knee Point Tempera ture”

    Definition
    - The conductor temperature above which the aluminium strands of a
    composite conductor have no tension or go into compression caused by
    different material elongation when heated.
    - Knee point temperature is not a fixed value and depends of many factors like
    span length and mechanical tension.
    - Low sag conductors have different physical behaviour when working below or
    above the knee point temperature.
    - The conductor’s core thermal expansion coefficient is a key factor in the
    conductor performance, when it is working above Knee Point temperature.
    - There are some technologies that reduces the knee point temperatures
    improving conductor performance.
    Knee Point Temperature
    Conductor Cores performance comparison
    Low Sag Conductor Types
    HiTLS Conductor Types

    1.- GAP type Conductor (G(Z)TACSR). Fig 1


    Co nstituted b y a hig h m ec ha nic a l resista nc e steel c o re a nd
    severa l therma l resista nt a lum inium la yers tha t, b ec a use o f the
    g a p b etween the steel c o re a nd the inner a lum inium la yer, it’ s
    Fig 1
    free to m ove.

    2.- TACSR Conducto Fig 2. Ma d e of a ny kind of steel c o re a nd


    severa l therma l resista nt a lum inium la yers . No t a low sa g
    c o nd uc to r.

    3.- ZTACIR Conductor Fig 2. Ma d e o f a inva r a lum inium


    Fig 2
    c la d d ed c o re o r g a lva nized a nd severa l therma l resista nt
    a lum inium la yers

    4.- ACSS Conductor Fig 2. Ma d e of a ny kind o f steel c o re


    (severa l typ es) a nd severa l a nnea led a lum inium la yers

    5.- ACCR (Fig. 2) a nd ACCC Conductors (Fig. 3). Ma d e of


    c om p osite c o res a nd therma l resista nt a lum inium o r a nnea led
    a lum inium la yers . Fig 3
    Pros & Cons of HTLS conductors
    GAP TYPE CONDUCTORS
    G(Z)TACSR
    Why Gype Type Conductor?

    TREFINASA/SAPREM has selected Gap Type Conductor, by different reasons that make it
    the best choice for the replacement of existing conductors.

    Gap Type Conductor is produced with conventional materials (aluminium and steel),
    that have been used in the production of conductors for more than a century.
    Metallurgy and behaviour it is perfectly known. No material risk.

    Due to its unique installation methodology, conductor’s KNEE POINT is located at


    installation temperature without pre-tensioning. This is a very important fact because in
    other type of conductors knee point is located in the range of 100ºC, then conductor
    does not work like low sag conductor below this temperature. In the case of the Gap
    type conductors, because knee point is located at installation temperature, it works like
    low sag conductor from this temperature, providing a superior performance in the
    “intelligent” working temperature range (60ºC to 120ºC) where the losses are not too
    significant.

    Best ratio price /performance


    Why TREFINASA Ga p Conductor?

    - The Gap type conductor installation system has been improved by TREFINASA/SAPREM,
    in such a way that no longer installation is a handicap. By means of the use of a system
    patented by SAPREM, the installation costs have been reduced and the security of pay-off
    and sagging tasks have been enhanced appreciably.

    - TREFINASA uses Aluminium Clad Steel Wire for production of gap conductor steel core
    because of its demonstrated advantages against zinc and mischmetal coating based steel
    cores.
     Superior corrosion resistance
     Lighter weight
     Improves conductivity of steel core
     Long term stability in high temperature operation (ACS wire can withstand 300⁰C
    continuous operation without degradation)
     Even it is not recommended usage of zinc coating based steel core for
    temperatures higher than 170⁰C (there is literature confirming it), many
    manufacturers still supplies this kind of material.
     An internal TREFINASA study demonstrated that both galvanized and mischmetal
    steel wires suffered deterioration after heating samples at 300 ⁰C for 5 weeks,
    while ACS wire kept all initial characteristics.
    Gap Type Conductor

    Round or
    tra pezoid Hea t
    resista nt Al Wires
    Specia l
    Therma l
    Resista nce
    Grea se

    Tra pezoid Hea t


    resista nt Al Wires

    High Strength Aluminium Spa ce (Ga p)


    Cla d Steel Core
    Gap Type Conductor (Fundamentals)

    - In it’s initia l sa gging condition, the


    mechanica l stress is only a pplied to the steel
    core. The a luminium la yers a re inert (no
    tension) - KNEE POINT IS AT SAGGING
    TEMPERATURE
    - The spa ce (ga p) between the steel core a nd
    the first a luminium la yer contributes to steel
    core movement; grea se a lso contributes.
    - Therefore, conductor’s therma l expa nsion
    coefficient is only a luminium cla d steel core’s
    (11,9 x 10-6)
    - In the ca se of an ACSR conductor,
    coefficient’s va lue is a lmost double (20 x 10-
    6), beca use the a luminium wires contribution.
    SAG AND TENSION CALCULATION for GTACSR

    Remember!
    •In initia l sa gging condition, mecha nica l stress is only a pplied to the steel core.
    •The a luminium la yers a re inert (no tension)
    •Knee Point Tempera ture is a t sa gging tempera ture

    BELOW KNEE-POINT ABOVE KNEE-POINT


     Conductor Situation: Conductor Situation:
    Low Temp. and Overload Conditions High Temperatures
    - Mechanical Condition: -Mechanical Condition:
    Tensile Load > Tensile load at KPT Tensile Load ≤ Tensile load at KPT
    - Aluminium with tensile load (no inert) -Aluminium without tensile load (inert)
    - Conductor behaves like an ACSR -Conductor behaves like an Low Sag Cond

    Conductor parameters for calculation Conductor parameters for calculation

     E (Modulus of elasticity): composite E (Modulus of elasticity): steel core


     α (Coef. of thermal expansion): composite α (Coef. of thermal expansion): steel core
     S (Conductor area); Aluminium + Steel S (Conductor area); only steel core
    SAG AND TENSION CALCULATION for GTACSR

    INSTALLATION ACSR

    Knee-Point
    GTACSR

    GTACSR

    LOW SAG CONDUCTOR


    AS CONVENTIONAL
    CONDUCTOR
    WHAT COMPETITORS SAID ABOUT GAP?
    GAP CONDUCTOR SAGGING
    To adjust the conductor to the final sag just
    pull it from the steel core
    SAPREM®METHOD
    for GAP TYPE CONDUCTOR SAGGING
    G(Z)TACSR FITTINGS
    GTACSR FITTINGS

    COMPRESSION CLAMP SUSPENSION CLAMP


    TESTS
    Principal Standards for gap testing

    •IEC 6240 Ed1.0 - Concentric lay stranded overhead electrical


    conductors cointaining one or more gap(s)

    •EN 50182 - Conductors for overhead lines - Round wire concentric lay
    stranded conductors

    •EN 61395 - Creep Test procedures for stranded conductors

    •IEC 62004 - Thermal-resistant aluminium alloy wire for overhead line


    conductor

    •EN 61232-96 - Aluminium clad steel wires for electrical purposes

    •EN 61284 - Overhead lines. Requirements and tests for fittings


    CONDUCTOR TEST

    •Surface condition; Diameter; Inertness; Lay ratio


    •Mass per unit length
    •Cross sectional area
    •Gap Measurement
    •Resistance
    CONDUCTOR TEST

    Strain-Stress and Creep Test


    CONDUCTOR TEST

    SLIP & BREAKING LOAD TEST


    CONDUCTOR TEST

    GAP

    Sag/Tension
    ACSR vs. Temperature
    TEST
    CONDUCTOR TEST

    CONDUCTOR SELF-DAMPING AND AEOLIAN VIBRATION TESTS


    THERMAL-RESISTANT ALUMINIUM
    ALLOY WIRE TEST

    •Diameter •Tensile Strenght


    •Electrical Resistivity •Elongation
    •Thermal-Resistant Property
    ALUMINIUM-CLAD STEEL WIRE TEST

    •Diameter
    •Torsional Test
    •Thickness of Aluminium Test
    •Tensile Stress Test
    •Stress at 1% Elongation Test
    •Elongation Test
    GREASE TEST

    •Mass per unit Length


    •Drop Point
    FITTINGS TEST
    Suspension Clamp Slipping and Breaking Test

    Compression Clamp Tensile Stress Test


    FITTINGS TEST

    THERMAL BEHAVIOUR OF INSULATOR AND FITTINGS


    ALL IN ONE SOLUTION

    TREFINASA/SAPREM offers whole support to finalise


    the Project, from the design to the installation stage:
    •Conductor design according to Customer needs
    •Technical uprating study
    •Special fittings proposal
    •Technical support for calculation and installation
    •Installation tools can be provided
    •Installation training to Contractors
    •Supervision on site for installation
    ALL IN ONE SOLUTION

    ORGANISATIONAL CHART

    HIGH TEMPERATURE LOW SAG CONDUCTORS

    Conductor Conductor Engineering Fittings


    design manufacturing
    Technical Installation
    support method
    THANKS FOR YOUR ATTENTION

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