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Leksono Hartanto

PLP Indonesia

Practical Application High Temperature Low

Sag Transmission Conductor

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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

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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 highas 250 deg.C

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ECONOMIC EVALUATION :

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COMPARISON :

ACSR conductor : HTLS conductor :

Steel core surrounded by nearly pure Aluminum High strength core (St, St Alloy or composite material)

surrounded by multiple layers of Al. or Al.Alloys

Continuous operation Al. typically limited to 100 deg.C

to avoid weakening the Al. strand over time.

Continuous operation Al. typically as high as 200 to

250 deg. C

Al & St are subject to tension load that can reach high

level as wind & ice increase

Gap type of Japanese HTLS conductor only at St. core

is subject to tension load.

Al. Thermal expansion limits line sag at high electrical

loadings.

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

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CONDUCTOR TYPE :

Aluminum

Reinforced

Material

Round

Strands

Trapezoidal

Strands

Trapezoidal

Strands

and Gaps

Hard Aluminum

1350-H19

Fully annealed

Aluminum

Aluminum

Zirconium

Aluminum

Zirconium

SteelHigh Strength

Steel

Al-Clad

SteelInvar Carbon Fibre

Metal Matrix

Composite

Glass & Carbon

Fibre

90C 200C 150C 210-240C

ACSR ACSS TACSR ACSR/AS TACSR/AS STACIR ACCFR ACCR

ACSR/TW ACSS/TW ACCC/TW

GTACSR

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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.

HTLS CONDUCTOR TYPE :

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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

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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.

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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.

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ACCRs Special hardware termination :

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

2 steps compression procedure justlike 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

Two layer construction of Thermolign

Dead End has been succesfully in

installation of ACCR conductor

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ACCRs Special hardware splice :

Compression Splice (AFL)Helical Dead End (PLP)

Thermolign Full Tension Splice

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ACCRs Special hardware Suspension Clamp :

Preformed type Suspension Assembly :

Jumper Support Insulator :

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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

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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.

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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 bareany 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 ofAluminum & steel.

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4. Special Installation

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5. Hardware accesories

Those are virtually same as regularACSRs 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 HTLSconductor.

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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.

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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.

28% more

Aluminum

Composite CoreSteel Core

Aluminum

28% moreAluminum

Composite CoreACCC ConductorTraditional ACSR

Steel Core

Aluminum

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Special feature of ACCC :

1. The core is unique among HTLS or conventional conductor

because its much lower flexibility.

Comparison of Reinforce wire / core

11900155001651921108kg/mmModulus of elasticity06

3.7

01520.38%IACSConductivity08

1.6112.611.5X 10-6/CCoefficient of linearexpansion07

1.97.16.597.78g/cm3Density05

-1010%Aluminum thickness *04

--->260

-

g/mmWeight of Zinc Coating03

-1.51.54%Elongation02

2161108012751410N/mmTensile Strength01

CompositeInvar/AIAl Clad

SteelSteelUnitItemNo

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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 emphasisshould be not to give scuff on surface of Aluminum conductor.

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Special feature of ACCC :

4. Sizing stringing sheave :

Rgdg

Dc= outside diameter of the conductor

Ds= diameter of the bottom of the groove of the sheave where the

conductor touches

= not less than 20 x Dc

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= depth of the groove

= not less than 1.25 x Dc

Commercial

Size

= overall diameter of sheave and depending on the sheave size can be50 to 152 millimeters larger than the bottom of the groove diameter.

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Special feature of ACCC :

5. Special hardware accesories :

Compression Dead End (FCI Burndy)

Deadend Body

InnerSleeve

Collet

Housing

Steel Eye

Collet

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Special feature of ACCC :

Compression Splice

Inner Sleeve

Collet Housing

Collet

Splice Body

Splice Coupler

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Special feature of ACCC :

Suspension Clamp

AGS/Thermolign/CGS (PLP)

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Thank You