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Power Conductors & OPGW CablesProgress through power

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  Business

Scope of Services

®Sterlite provides power transmission & distribution companies with a holistic one-stop window for assessment, development &implementation of solutions for their power transmission & distribution (T&D) networks.

T&D Solution Manufacture,Inventory Management &Supply

Technical Support & Service

T&D Network Assessments- Assessment of existing &

potential power demand.- Technical analysis.- Assessment of suitable

solution options.

T&D Solution Development

T&D Solution Testing

IMPLEMENT

ASSESS

 DEVELOP

Sterlite's power solutions comply with BIS, BS EN 50182, ASTM, CSA, IEC,

Gost, JIS and AS international standards.

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1,2,3,4,6,7,8,9,10

1200, 765, 500, 400, 220

132kV: HVAC

± 800, 500 kV HVACPowerTransmissionLine

Power GenerationStation

Transformer

11,12 11,12

®Sterlite offers a complete range of end-to-end power solutions for transmission and distribution in power networks.

4. STER-ACAR™ Conductors5. STER-AAC™ Conductors6. STER-AL59™ Conductors

Supported by a fully integrated manufacturing facility that converts ingots to bare overhead conductors, Sterlite's range of standard andcustom-designed power solutions deliver superior performance in transmission and performance reliability.

1. STER-AAAC™ Conductors2. STER-ACSR™ Conductors3. STER-AACSR™ Conductors

Power Solution Suite

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220, 66,33, 11kV132,

Substation

ResidentialBuilding

IndustrialBuilding1, 2, 3, 4, 5,6,7,8,9,101, 2, 4, 5,6,7,8,9,10

11. OPGW Cables

12. OPGW Accessories®

13. STER-ACCC Conductors14. STERLITE-ECO™ Conductors

Our other solutions:Optical Fiber, Fiber Optic Cables, Structured Data Cables, Passive Solutions, ADSL2+ Modems,Telecom Integration & Managed Services (MPLS,

FTTH, DSL Broadband, NGN, WiMAX, CDN).

7. STER-ACSS™ Conductors

8. STER-TACSR™ Conductors

9. STER-STACIR™ Conductors

10. Special Alloy Conductors (1120, EHC, 6101, 6201)

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100

200

250

160

60

Tensile strength

162 152

6101

150

170

The Efficient Power Transmission Solution

The smart energy management solution

Development of efficient power transmission is the need of the

hour, aimed to alleviate the burgeoning demands from today’s

power utility system.

If the challenge is to transmit more power over existing lines, high

ampacity conductors that are manufactured from a range of

specialty materials, offer the most optimal means to increase line

capacity at relatively low cost.

A range of speciality alloys offer superior thermal resistance that improves the efficiency in high current transmission.

Diverse range of applications

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  NEW LINES RECONDUCTORING GREEN SOLUTIONS

 

STACIR

GAP

ACCC®

 

TM

STERLITE ECO

ACCC®

AL59 / 1120

ACSS

TACSR

TMSTERLITE ECO

ACCC®

Efficiency [A/mm ]2

Current Rating [A]

AAAC

AAACUHC

ACCC®

+50% +100%

ACSS

G(Z)TACSR

ACSR

Sterlite’s High Performance conductors combined efficiency andincreased current carrying capacity

STACIR

For new lines:

Enhanced current carrying capacity.

Reduction in per unit transmission cost.

Higher corrosion resistance.

Shorter project duration.  Additional capacity of ~100% is reserved for future demand.

Benefits in performance and costsFor re-conductoring:

Enhanced current carrying capacity.

No modification / reinforcement to existing towers.

Sterlite Eco

TACSR

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10 50 120

10

50

50

210AL TAL STAL

Conductivity

AnnealedWire

6361

70

59

6060

85 150 25095

Temperature

Sterlite’s high performance conductor solutions

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®Sterlite Al59 Conductors

These are homogenous alloy conductors belonging to Aluminum + Magnesium + Silica Alloy type. These conductors have a conductivity of59%, and hence have lesser DC resistance & higher current capacity.

®Sterlite TACSR ConductorsNew aluminum alloys having high thermal resistance can carry 50% to 60% more current as that of ACSR of the same size; while maximum sag& maximum working tension remains almost same as that of ACSR.

®Sterlite ACSS ConductorsThese high temperature EC conductors consist of a stranded steel central core with one or more layers of 1350-0 aluminum wires. Steel core wires

oare coated with Zinc 5% aluminum misch metal for corrosion resistance and the coating can withstand for continuous operation at 250 C.

®Sterlite STACIR ConductorsNew aluminum alloys having high thermal resistance can carry twice as much current as that of ACSR of the same size while maximum sag &maximum working tension remains the same as that of ACSR.

®Sterlite ACCC Conductors

®Sterlite ECO ConductorsThese can reduce I R loss of distribution lines by almost 33% as compared to ACSR. These can be used on existing tower structures along withlow loss solution for distribution lines of utilities & wind power companies.

®Sterlite DULL Conductors

The current carrying capability of non-specular conductor i.e. Dull conductor is slightly increased because the emissivity of the conductor isslightly increased . An increase in current capacity in the range of 5% can be achieved, for the same temperature rise, due to this increase insurface emissivity.

International StandardSs4240814, SS4240813, ASTM B856, IEC, ASTM.

These are high ampacity, low loss hybrid conductors. The composition comprises carbon, glass fiber and trapezoidal shaped aluminum, thatare resistant to environmental degradation. These conductors can reduce line losses up to 30- 40% compared to conventional conductors ofthe same diameter and weight. These have 28% more aluminum which greatly increases capacity, reduces losses, & hence cooler operatingtemperatures. These are 25% stronger & 60% lighter vs. traditional steel core conductors. These have lower coefficient of thermal expansionwhich leads to less sag at higher temperatures. The technology is patented by CTC Cable Corporation, USA and is licensed to SterliteTechnologies.

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Sterlite’s OPGW Solution*

OPGW – the smart energy management solution.

Development of smart energy management systems is the need of the hour, aimed to alleviate the burgeoning demands from today’s power

infrastructures.

Optical Fiber Composite Ground Wire (OPGW) is a revolutionary solution that enables synergies between efficient power distribution grids andhigh speed optical fiber based SCADA networks, giving power utility companies the unique capabilities of a telecom carrier or service provider.

OPGW replaces a conventional ground wire (or earth wire) to protect the transmission system from lightning strikes and serves as a conductivemedium for carrying fault currents to ground.

OPGW acts as a medium for real-time monitoring and security of the transmission system over which it is installed – doubling up for SCADAcontrols and network.

OPGW provides telecommunications capability utilizing the fibers.

®Sterlite integrates its core expertise in fiber optic cables and bare overhead power conductors.

Since the past two decades, Sterlite has developed technical expertise in fiber optic cables and proven its capabilities in manufacture of energyefficient bare overhead power conductors.

Sterlite has integrated these core strengths in its comprehensive OPGW solution that includes Optical Fiber Composite Ground Wire and relatedhardware.

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* Sterlite’s OPGW Solution includes design, manufacture, supply & installation.

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OPGW cables are required to withstand the effects fromi n s t a l l a t i o n a n d l o n g - t e r m i n - s e r v i c e e x p o s u r e t omechanical, electrical and environmental loads withoutallowing any significant degradation in its performance.

OPGW cables would need to fulfil l basic performancecriteria, to enable selection of an appropriate design.

(a) Electrical performance

Fault current performance to overcome the line-to-tower short circuits or system unbalances.

Lightning performance so that lightning arcs do notimpair the long term functionality of the cable.

(c) Environmental performance

Range of temperatures and wind zones.

Corrosion levels at the installation sites includingthe pollution level (1-4).

Salinity levels.

(d) Packing

The end-user needs to determine the length per reeldepending on:

The terrain of the installation site.

The type of installation to be carried out (‘Live Line’ or‘On Outage’).

Capacity of unreeling facility with installer.

Additionally, considerations should be noted for excessive contactpressure under hardware, the current transfer capability of theconnection of hardware with the OPGW cable and contact betweendissimilar materials that may cause excessive corrosion in someenvironments.

(b) Mechanical performance

Sag and tension.

Vibration.

Galloping and Sheave.

Design considerations for OPGW cables

Sterlite OPGW cables

Sterlite OPGW cables are made up of optical fibers contained in one

or more protective fiber optic units combined with concentric laystranded metallic wires in single or multiple layers.

Advanced technology is applied to produce stainless steel tubeswhich are then filled with a special hydrogen absorbent,thixotropic filling compound and made resistant to H 2permeability due to the seam laser welded, hermetically sealedconstruction.

The cable is of compact structure reducing both the ice load andwind load and ensures quick dissipation of heat generated by shortcircuit.

The cable is designed to match the existing ground wires in more

or less equal outer diameter and pulling force-to-weight ratio.Hence, the cable can replace the existing ground wire with no needto change the route or towers.

Sterlite’s OPGW cable is produced strictly according to IEEE1138and relevant international standards pertaining to itsconstituents.

Sterlite OPGW hardware

The portfolio includes customized Suspension Sets, Tension SetAssemblies, Vibration Dampers, Joint Boxes and Bonding Clamps.

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Sterlite’s Global Footprint

Power transmission & distribution solutions proven in global networks

®Sterlite has been instrumental for the supply of technologically advanced power solutions to leading incumbents over 35 countries.

®Sterlite has been a key partner in milestone projects across the globe:

- 'Svenska Kraftnat 500 kV DC Transmission Line Project',interconnecting Sweden & Finland.

- 'India's first 765 kV EHV Transmission Line Project'.

- 'Accelerated Electricity Access Expansion Project', Ethiopia.

- 'National Integrated Power Pool', Nigeria.

- 'TIEAS 400 kV Networking Project', Turkey. And many more

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®The Sterlite Advantage

Since the past decade, Sterlite has developed its technical expertise in manufacture of bare overhead power conductors and proven itscapabilities in developing solutions that have been tested and certified by leading independent laboratories across the globe.

®The Sterlite Advantage

®Sterlite has three fully equipped plants to manufacture Transmission & Distribution Line Conductors.

In-house Properzi Aluminium Rod rolling mills feed the manufacturing line for Transmission & Distribution Conductors. The mills manufactureelectrical grade Aluminium and Alloy Rods.

The plants have complete facilities for rod rolling, wire drawing, heat treatment and stranding to ensure precise tolerances to all internationalstandards and stringent specification.

A technology upgrade review is periodically undertaken to keep abreast with the latest manufacturing technology.

The cumulative annual installed capacity for Transmission & Distribution Line Conductors and Rods is 200, 000 MT.

Our facilities have state-of-the art NABL approved in-house laboratories.

Packaging is done in the non returnable chemically treated seaworthy wooden/steel drums with good practice design in line with Internationalstandards.

Fully Equipped Plants with International Standards

Among the largest integrated manufacturing facilities globally.

Strong focus on research and product development.

In-house domain expertise to provide customized solutions.

State-of-the-art in-house laboratories for testing of transmission and performance reliability parameters.

Solutions tested and certified by leading independent laboratories across the globe.

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Certifications Testimonials

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Notes

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Notes

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Notes

®Sterlite is a registered trademark of Sterlite Technologies Limited.

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sterlitetechnologies.com

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Denmark

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Netherlands

Russia

South Africa

Taiwan

Turkey

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United States of America

email: communications@sterlite.com

Sterlite Technologies Limited is a leadingglobal provider of connectivity solutions forthe power & telecom industries.

Equipped with a suite that includes powerconductors, power cables, OPGW Cables,optical fibers, fiber cables, data cables and acomprehensive telecom solutions portfolio,Sterlite's vision is to 'Connect every home onthe planet'. Sterlite is also executing multi-

million dollar power transmission systemprojects, pan-India.

About Sterlite