Conference-1

Latest Technologies in T & D, Smart Grid, Renewable

Integration and Communication

UPGRADATION OF EXISITING 66 KV TRANSMISSION LINE WITH SUITABLE

HTLS CONDUCTOR TECHNOLOGY IN NEPAL

KARTHIKA PURNIMA.N
Sleepwalkers
India

SYNOPSIS

Utilities in almost all parts of the world face a common obstacle in the construction of new
overhead transmission line - obtaining land for their clearway (ROW). Moreover, due to the
ever increasing power demand and pressing needs of integrating renewable energy sources
into the grid, increasing the power transfer capacity of existing transmission line, seems to
be the one of the viable solution. The present condition of the existing transmission corridor
may be completely different from the one designed years ago. Hence, the selection of
suitable HTLS conductor technology considering ruling span and existing tower loadings
may not meet the ground clearance requirements. So, evaluating with respect to present
conditions like actual ground clearance of the complete transmission corridor, current tower
loadings, spotting and weather conditions is more important and would bring cost effective
and reliable solution. This paper elaborates the advantages of selecting technology,
considering the present conditions of the transmission corridor over the ruling span
methodology, in one such case in Nepal. The surveyed data of the existing line has been
used in PLS CADD for the selection of suitable HTLS conductor technology to double the
power evacuation capacity considering optimum cost and reliability.

KEYWORDS
Reconductoring, Uprating, transmission line, High Temperature Low Sag (HTLS) Conductor,
ground clearance.
1. INTRODUCTION

In many countries of the world, new power lines have not been built from many years as
obtaining right of way is difficult. Nevertheless, over the same period of the time, the world
experienced an increase in power consumption. But most of the transmission lines are
strung with conventional conductors like ACSR, AAC, AAAC, ACAR etc., and by using the
same lines it is difficult to draw more power. It has thus become necessary to uprate the
thermal power transfer capacity. Uprating of overhead line is possible by increasing current
carrying capacity of transmission line, but that may lead to increase in sag value by
considering ruling span with same towers/poles, which may not meet the ground clearance
of existing line. So, evacuating more power with present conditions such as existing ground
clearance and towers/poles, there is an optimal technique for Uprating the transmission line
with high temperature low sag conductors (HTLS).

HTLS has been used across the world to uprate the existing transmission line. The
investigation of different techniques to improve the transmission system capacity in power
network shows that HTLS conductor was useful in uprating by increasing current rating.
More than double increase in power capacity was obtained by replacing conventional
conductor with HTLS Conductor, which was evaluated to be the best solution from both
technical and economic aspects. This paper elaborates the advantages of selecting suitable
HTLS technology, with respect to the existing tower, weather and ground clearance
conditions of the transmission corridor over the ruling span methodology, in one such case in
Nepal to enhance the power transfer capacity.

2. HIGH TEMPERATURE LOW SAG CONDUCTORS

“High Temperature Conductor” is defined as a conductor that is designed for applications
where continuous operating temperature is higher than the traditional conductors which is
about 750C to 850C.

“Low Sag” is defined on the basis of at that particular operating temperature sag should
matches with ‘traditional conductors’ sag value.

HTLS Conductors are made by thermal-resistance aluminium/super thermal-resistance

aluminium/annealed aluminium layers stranded around a core of material with low coefficient
of thermal expansion.

Note: The maximum permissible duration of emergency operating temperature of HTLS

Conductor shouldn’t be more than 400 hours for total life of the conductor.

2.1. Conductive Layer – Aluminium

Generally, the conventional aluminium and its alloy has limitation of operating temperature
from 750C to 1000C throughout its life span. The conventional aluminium and aluminium
alloy (1350,1370,6201,6101, Al59,1120, etc) will lose its strength at higher temperature
because of annealing.
 The challenge of increasing the operating temperature of the aluminium and its alloy without
loss of its electrical conductivity was addressed with the following high temperature electrical
conductivity aluminium and its alloy:
a) High temperature EC grade – 1350 – Annealed Aluminium
b) Thermal resistant aluminium alloy – Al-Zr alloy (Aluminium-Zirconium)

TABLE:1 Comparison of different aluminium alloys

TABLE: 1
Properties ACSR (Hard Annealed TAL (Thermal STAL (Super
drawn 1350 Aluminium – Alloy Al Zr) Thermal Alloy
Al) 1350 Al Zr)
Tensile Strength in
MPa 160 60 160 160
Conductivity 61 63 60 60
%IACS
Continuous
Operating 85 250 150 210
Temperature

2.2. Core – Strength Member

Aluminium has good electrical conductivity and lesser density but the challenge is tensile
strength and endurance limit. So ACSR uses steel core as strength member for
reinforcement. Steel has higher strength, lower linear expansion than aluminium but the
constraint is lower electrical conductivity and higher density.

The core material for HTLS conductors should have:

• High strength
• Less density
• Less linear expansion
• Good modulus of elasticity

In the past, development in core materials were made to increase the strength of steel or to
reduce the linear expansion with alloy steel etc. But in the year 2002, composite materials
were introduced. The composite materials have higher tensile strength, less density, less
linear expansion but the challenges are compressive strength, modulus of elasticity.

Commercially available core materials are listed below

• Ultra High Strength Steel (UHS)

Steel • Extra High Strength Steel (EHS)
• High Strength Steel (HS)
 • High strength Invar
Alloy Steel • Invar

• Carbon fibre + Thermosetting

Carbon polymer (Epoxy) + Galvanic
fibre protection layer
Composite • Carbon fibre + Thermoplastic
polymer + Galvanic protection
layer
•

Metal
Matrix • Al 2O3 fibre in Aluminium Matrix
Composite

TABLE: 2 The list of commercially available HTLS technologies are as follows:

TABLE: 2
ACSS Aluminium Conductor Steel
Supported

TACSR Thermal Resistant Aluminium

Alloy Conductor Steel
Reinforced
GTACSR / Gap Type Ultra Thermal
GZTACSR Resistant Aluminium Alloy
Conductor Steel Reinforced
STACIR Super Thermal Aluminium
Alloy Conductor Invar
Reinforced
ACCC Aluminium Conductor
Composite Core

ACFR Aluminium Conductor Faber

Reinforced

ACCR Aluminium Conductor

Composite Reinforced
3. NEPAL 66 KV LINE TECHNICAL CONSEQUENCES

3.1 Scope of the Project:

The overhead transmission lines, having voltage level of 66 kv are mostly equipped with
ACSR 150 mm2 & ACSR 120 mm2 conductors.
To enhance the power transfer capacity, the first solution considered, was to install new
overhead line. For the new transmission lines increasing power transfer capacity is easy, as
it can be performed by increasing portion of aluminium or by increasing the number of
conductors in bundle.
However, this solution has several inconveniencies. First, land saturation that generates
difficulty to get right of way to install a new overhead line. Also, the period of time when the
need of a new line is identified, until the line is finally installed can be a decade or longer.
Another problem is that a new overhead line produces an increment of visual and
environmental impact. These factors make a sector of the society refuse the installation of
new overhead lines.
Taking into account the difficulties to install new line, second solution is to improve the
current rating of existing line by replacing traditional conductor with HTLS Conductor.
Reconductoring the line with HTLS conductors without any tower reinforcements with short
time execution and a reasonable cost. With two times the current carrying capacity, HTLS
Conductors maintaining the existing ground clearances.

3.2 Existing Tower Loadings:

Tower loading is the most vital input for designing any transmission line. The existing towers
in the 66 KV transmission line has been designed with various types of loads. In the load
calculation, wind plays a major role.

In this case the existing component of tower like insulator string, ground wire will rem ain the
same but the existing conductor will be replaced with new HTLS conductor. So, the only
change in component is overhead conductor.

The existing tower was designed with ruling span and wind conditions depending on the
weather condition of the corridors. So, the proposed HTLS conductor should have equal or
lesser loading conditions of the existing ACSR conductor under the designed conditions of
tower. So, the data of existing tower design plays a vital role in designing a suitable HTLS
conductor.

The conductor loading condition:

1) Transverse Load
Wind load on conductor
Mechanical tension of conductor
2) Vertical load
Loads due to weight of conductor
3) Longitudinal Load
Unbalanced horizontal
load due to mechanical
tension of conductor
 4. OUR APPROACH FOR RECONDUCTORING OF EXISTING LINE WITH
SUITABLE HTLS TECHNOLOGY

Survey the existing line

with respect to tower Create tower profile
Feed the survey similar to the
spotting, every 50
data into PLS existing tower
meters ground elevation
CADD heights
of existing corridor and
existing sag/ground
clearance

String the existing Tower spotting with

Creating existing respect to the
conductor with respect
conductor wir file existing tower
to the existing ground
clearance locations

Finalize the suitable Conclude the

Design different HTLS
HTLS technology or technology with
conductor technology to
any other technology respect to terrain
match the existing
solutions to meet the conditions and need
ground clearance
need of the customer of the customer
5. TECH

6. TECHNICAL ANALYSIS

To maintain the line’s safety in operation, for example to conserve the towers and the
insulating strings when using HTLS conductors, the following restrictions have to be fulfilled:
TABLE: 3

The HTLS conductor shall meet the following minimum requirements:

Description Unit Value

Overall diameter of complete mm Not exceeding 15.74
Conductor
Approx. mass of complete Kg/km Less than or equal to 528
conductor
Direction of lay of outer layer - Right Hand
 For maintaining the ground clearance of existing line, the HTLS Conductor should meet the
following sag tension requirements as specified in table: 4

TABLE: 4
Sag -Tension Requirements
Description Value
Tension at everyday condition (28 deg C, no wind) Not exceeding 25% of UTS of
proposed conductor
Tension at 20 deg C, full wind (53 kg/m2) not exceeding 50% of UTS of
proposed conductor
Tension at minimum temperature -5 deg C, 37.7 not exceeding 50% of UTS of
% of full wind (20 kg/ m2) proposed conductor
Maximum working stress allowed for conductor 1323 Kg

Table: 5 shows the comparison of technical characteristics that will have an impact on the
existing tower while replacing with different HTLS technologies.

TABLE: 5
ACSR vs HTLS reconductoring Comparison Considering Ruling Span 298 meters

Description Unit ACSR ACSS STACIR ACCC ACFR

Conductor Diameter Mm 15.74 15.4 15.02 15.65 15.7
DC resistance at 20 deg C Ohm/km 0.2398 0.2465 0.2943 0.1859 0.1792
Min UTS of conductor KN 47.6 45.3 51 69 46
Weight Kg/km 528 525 522 470 457
Modulus of Elasticity Kg/mm2 7885 8134 8165 6779 6265
Co-efficient of linear expansion X 10 -6 /°C 18.33 17.86 14.4 17.36 18.76
Maximum allowable continuous operating
temperature DegC 75 250 210 180 180
Emergency operating temperature DegC 100 280 240 200 200
Ampacity at 75 Deg C A 290 283 256 325 335
AC resistance at 75 Deg C Ohm/km 0.2935 0.3018 0.3602 0.2277 0.2188
Sag at 75 Deg C Meters 9.15 8.28 8.52 7.22 8.16
Maximum ampacity that can pump per
conductor without exceeding the ACSR A N/A 483 580 707 724
Sag
Temperature at above ampacity Deg C N/A 125 195 180 180
Ruling span Meters 298 298 298 298 298
Tension 28 Deg C, no wind Kg & % 758 & 16 832 & 18 792 & 15 762 & 11 885 & 19
Tension at 20 Deg C, Full wind pressure
(53 kg/mm2) Kg & % 1323 & 27 1308 & 28 1323 & 25 1314 & 19 1265 & 27
Tension at -5 Deg C, wind pressure (20 Kg & % 1021 & 21 1021 & 22 1015 & 20 1021 & 15 1021 & 22
kg/mm2)
Losses at 290 A per CKM
(Loss load factor 0.53, circuit - single, Kw 39.2 40.4 48.2 30.4 29.3
Route Length - 1 Km)

The calculations of steady-state thermal rating, given a maximum allowable conductor

temperature, weather conditions, and conductor characteristics were performed by the
computer using PLS CADD based on the IEEE Std 738 - 2006. For steady – state thermal
rating, the following parameters were adopted:

- Wind speed: 0.56 m/s;

- The angle between wind and conductors: 900;
- Emissivity: 0.45;
 - solar absorptivity: 0.8;
- Air temperature: 400C
- Solar radiation:1045 watt/sq.m;
- Elevation above sea level:1300 meters;

Current carrying capacity comparison graph at 75 Deg C for Different Conductors

HTLS Conductors Sag comparison at ≥ double current carrying capacity

Graphical representation is based on below assumptions

Ruling span: 298 meters

Everyday temperature: 28 deg C
Operating temperature at double current capacity of each HTLS conductor

*The above graphical representation showing the results of sag value for different type of
HTLS technology at after creep condition.
Conclusion:

The replacement of existing conductor should improve the mechanical reliability of the line
conductor. To uprate the 66 KV line in Nepal by using high temperature conductors is
considered as a feasible desideratum from the technical point of view. All the selected
conductors can be strung to accomplish equal or smaller sag than the initial one, but at
higher temperature.

Finally, from techno – commercial point of view, the detailed analysis of the suitable
conductor technology can be considered on the basis of techno commercial evaluation of
different HTLS technology by the customer. From the detailed technical analysis considering
maximum power transfer capacity without violating the ground clearance of existing line, the
most attractive solutions are Invar & Composite core technologies. The utility can
reconductoring the line either with Invar or composite core conductors if cost will be
accepted.

REFERENCES

Working group of 22.12 CIGRE 207, Thermal Behaviour of Overhead Conductors, Tech.
Brochure 207, 2002

Working Group SC 22-12 Cigre (Chairman R. Stephen). “The thermal behaviour of overhead
conductors Section 1 and 2 Mathematical model for evaluation of conductor temperature in
the steady state and the application there of” (Electra number 144 October 1992 pages 107-
125).

LFE_CIGRE High Performance Conductors An International viewpoint

Standards:

IEEE Std. 738-2006 IEEE Standard for calculating the Current-Temperature relationship of
bare Overhead conductors.