CIGRÉ 2001 TUTORIAL On Types and Uses of High Temperature Conductors

Study Committee B2
Technical Advisory Group B2-AG-06

Cigr AG06 Seminar Bangkok
Types and Uses of High

Temperature Conductors
Brian Wareing
Brian Wareing.Tech
g Ltd
Chester, UK
Convenor Cigr AG06 WG48 Experience with the Mechanical
Performance of New Conductor types
types
Secretary Cigr AG07 WG28 Weather effects on Overhead Lines
Scope
Look at the range of new bare conductor types
available
Appreciate new conductor characteristics and
suitability in comparison with standard conductor
types
Make you aware of the requirements when
choosing conductors
Covers construction, design
g and operation
p
See how network up-grading problems can be
solved cost-effectively by conductor choice
Types and uses of High

Temperature
3 Cigre AG06 Bangkok Conductors
Basic Types
Cigr has categorised new conductors in
four basic types
Type
yp 1. Conductors composed
p of a steel core and
an envelope for which the high temperature
effects are controlled by means of thermal-
resistant aluminium alloys (e.g.
(e g GAP,
GAP TAL HACIN)
Type 2. Conductors composed of a steel core and
an envelope for which the high temperature
effects are controlled by means of annealed
aluminium or aluminium alloy (e.g. ACSS)

Temperature
Basic Types
New conductor types
Type 3. Conductors composed of a non-metallic core,
andd an envelope
l ffor which
hi h th
the hi
high
h ttemperature
t
effects are controlled by means of thermal resistant
aluminium alloys
y ((e.g.
g ACCR))
Type 4. Conductors composed of a non-metallic core,
and an envelope for which the high temperature
effects are controlled by means of annealed
aluminium or aluminium alloys (e.g. ACCC)

Temperature
Basic Structure of traditional
bare wire conductors
AAAC, AAC,
ACAR, Copper
ACSR
Compacted ACSR

Temperature
Aluminium
Standard Aluminium and Aluminium Alloys can only operate
continuously at temperatures up to 93C without causing
metallurgical decay resulting in lifetime reduction
TAL and ZTAL aluminium have essentially the same conductivity
and tensile strength as ordinary electrical conductor grade
aluminium but can operate continuously at temperatures up to
150C
150 C and 210C,
210 C, respectively, without any loss of tensile strength
over time.
Fully annealed aluminium is chemically identical to ordinary hard
drawn aluminium and can operate indefinitely at temperatures at
250C (and higher) without any change in mechanical or electrical
properties but has a much reduced tensile strength.

Temperature
Temperature
Core Material
Galvanised steel is the normal core material for standard
ACSR conductors. This is subject to corrosion and
potential failure when the galvanising has disappeared
High Tensile steel is used when stronger conductors with
less sagg are required
q
Invar steel is used for low sag because of its very low
thermal expansion coefficient
Hi h strength,
High t th llow conductivity
d ti it aluminium
l i i alloy
ll can b be
used as a core material to give improved strength to
AAAC conductors.
Temperature
Steel aluminium or composite cores
Steel,
A conductive core will take part of the AC

current and heat up
Steel can sag more due to heating
Ceramic fibre reinforced aluminium can be
stressed under thermal cycling due to mismis-match
match
in expansion coefficients
Pure composite
p core will not take significant
g
current

Temperature
4.5

Temperature
High temperature conductor types

Temperature
High Temperature Conductors
High
High Temperature Conductor
Conductor is defined as a conductor
that is designed for applications where continuous
operation is above 100C or the conductor is designed to
operate in emergency conditions above 150C
150 C.
In fact some can be run at over 200C continuously and
over 220C for short times.
This gives us spare capacity or redundancy in the
network for future expansion
To take advantage of the high temperatures (and so
Ampacities) low sag is also required and this uses the
technique of the Knee point

Temperature
Knee Point
Occurs for all ACSR type conductors when the
tensile load is transferred from the (high expansion
coefficient) aluminium to the (low expansion
coefficient)) core
This produces a change of angle in a
sag/temperature graph
The point at which this occurs is known as the Knee
point

Temperature
15
Original 400 mm 2 Zebra ACSR

14 560 mm 2 ZTACIR
26.5 kN @10 0C
38 kN @ 10 0C
Sag of 366 m Standarrd L2 Span, m
13
Original design
maximum sag,
1950s
12
620 mm 2 Matthew GZTACSR

38 kN @ 10 0C
11
10
Knee points
2
570 mm Sorbus AAAC
9 36.9 kN @ 10 0C
8
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
0
C d t T
Conductor Temperature,
t C

Temperature
New
Conductor 3M
Types ACCR
Lumpi HACIN
ACSS
CTC ACCC
J-Power
G
Gap Types and uses of High
Temperature
16 Cigre AG06 Bangkok Conductors16
Type 1- J-Power Gap
1. High Temperature aluminium alloy

2. Inner layer forms a tube containing
free moving high tensile steel core in grease
1. Very low vibration levels
2. Used world wide
Temperature
Pros and Cons - Gap
Low vibration levels Cannot be joined
Knee p
point at erection Special
p fittings
g
temperature* Grease can
Long history of use dissociate
Sag relies on steel
core
Can be noisy
* Erection temperature can be 5C in UK, 50C in Middle East, 30C in SE Asia
All this affects the final sag!
Temperature
Type 1 - Lumpi
Lumpi-Berndorf
Berndorf HACIN
High Temperature Zirconium Aluminium alloy

Aluminium coated Invar steel core no corrosion
U
Uses standard
t d d ACSR fittings
fitti
High ampacity Galvanised steel
Salt spray test
Used by NIE in UK ACS

Temperature
Pros and Cons ZTAL/HACIN
Uses standard fittings Higher knee point than

Can be joined Gapp ((~50C))
ACS has long history of High strength low sag
use in OPGW Invar Steel core can be
Can be treated as expensive
conventional ACSR
Aluminium coating avoids
corrosion
Invar use gives low sag
Temperature
Annealed Aluminium
Type 2 - ACSS
ACSS can be stranded using
either round or trapezoidal
shaped annealed aluminium
wires.
In either design, the conductor
depends primarily on the steel St l core
Steel
core wires for mechanical
strength.
This core may be aluminised,
galvanised, zinc-5%aluminium
Mischmetal coated or aluminium
clad steel Types and uses of High
Temperature
Pros and Cons - ACSS
Soft aluminium
al mini m
TW means smaller
requires care in
cross-section and so
handling
lower wind loads
Higher knee point
Can be joined
than Gap
Sag determined by
Pure Aluminium has
steel
lower strength
g than
High conductivity alloy
Used in USA Can suffer corrosion
Temperature
Type
yp 3 - 3M ACCR
Aluminium
Al i i matrix
t i core
Very strong
N steel
No t l
High temperature aluminium alloy
E
Expensivei Types and uses of High
Temperature
Pros and Cons - ACCR
No steel so no corrosion High knee point (~70C)

Core as strong as steel Can creep
High temperature Expensive
operation (>200C)
Core lower expansion
coefficient than steel
Low kg/m

Temperature
Type
yp 4 - CTC ACCC
Carbon
C b fibfibre core ((stronger
t and
d lilighter
ht ththan steel)t l)
High temperature, high conductivity aluminium
Can operate up to 250C
250 C
Low tension so less stress on structures
Veryy low sags
g
Installed in several countries Types and uses of High
Temperature
25
Pros and Cons - ACCC
Extremely strong
composite core (50% Special fittings
stronger than steel) Soft aluminium requires
Virtually no increase in care in
i h
handling
dli
sag above knee point Minimum bending radius
High conductivity alloy for core
Can be used up to very
high
g temperatures
p
Used world-wide
Very low kg/m
Temperature
Fittings
Most new conductor types require special fittings
An exception is the ZTAL/HACIN ACSR which can use
existing
i ti conventional
ti l fitti
fittings
These fittings may run hotter than normal and so may
incur some overheating unless specifically designed for
high temperature operation
But commonly many HT conductors are run at <100C in
normall operation
ti so fitti
fittings only
l hhave tto withstand
ith t d hi
high
h
temperatures for short periods

Temperature
Conductor range
The new conductor types are mainly aimed at
tower lines
Th reason for
The f this
thi is
i that
th t there
th iis a minimum
i i
size that trapezoidal stranded conductors can be
made
However, these conductors can be used on
wood pole lines and some (e.g. ACCC) are in
use on 33kV networks in USA and UK (HACIN is
due to be erected in Oman at 33kV).
Temperature
Economics
New conductors are expensive between 3
and 6 times more than conventional
conductors but it is generally towers that are
expensive and conductor costs <10% of
overall line costs.
So is doubling of power capacity worth a 20%
increase in line cost? Generally yes!
However many HT conductors are run at
However,
<100C in normal operation (N-1 basis) and
this reduces IR losses
Temperature
Economic re
re-conductoring
conductoring
In the UK, re-conductoring 132kV wood pole lines with

Poplar (200mm AAAC) and tower lines with Sycamore
(250mm AAAC) size equivalent HT conductors should
need no tower strengthening so reduce overall costs.
Typically,
yp y CTC ACCC Casablanca can g give an 80%
ampacity gain (when restricted to 150C) and Lumpi-
Berndorf s 194TAL/HACIN a 50% increase in ampacity
compared with Poplar at 75C
75 C

Temperature
New Build
For new lines the sag limitation imposed by Poplar will not be
present. So in terms of ampacity only, without taking into
account sags, the best performing conductors on a UK P27
summer rating
ti att 150C were
CTC ACCC Amsterdam with 110% increase
3M ACCR 575-T23, CTC ACCC Oslo and Lumpi-Berndorf

294TAL with around a 90% increase

Temperature
Cigr AG06 Bangkok Conductors
Uses of new conductors
The optimum use of new conductors depends on the
problems
bl with
ith currentt networks
t k and
d th
the llocall
environment
Polluted areas
High ambient temperatures
Ice prone areas
Non-icing areas
Sag problems
Span lengths

Temperature
Network Requirements
Affordable rere-conductoring
conductoring or new
new-build
build
Efficient (low loss) conductor
High capacity
Low Sag
Running cold a conductor that delivers high ampacity
at a lower temperature has
Lower line losses
Longer fitting life
Less chance of breaking regulatory
clearances Types and uses of High
Temperature
Polluted areas
Need to choose a conductor which does not have an
unprotected steel core that is likely to corrode e.g.
Composite
C i cored d conductors
d
Aluminium coated steel cores
Gap has a steel core in a grease layer so will
not corrode if grease stays

Temperature
High ambient temperatures
Need to have a conductor that can operate at well above

ambient temperature to get high power capacity e.g.
HT conductors
d with
i h annealed
l d aluminium
l i i can
operate continuously at up to 250C
ZTAL can operatet up tot 200C

Temperature
Ice prone areas
Heavy ice loads can cause excessive sags
Some conductors can have customised cores
for heavy ice load areas
ACCC has the option of high pre-tension so
that nearly all the load falls on the extra strong
core

Temperature
Small sag at high ampacity
Main emphasis here is on electrical low sag performance

which requires high ampacity and low expansion
coefficient of the core e
e.g.
g
The carbon fibre composite core which has
lowest electrical sag of all HT conductors
Invar steel which has a much lower coefficient
of thermal expansion than other steels

Temperature
Span lengths
Long spans require very strong and low sag conductors
The strongest conductor by far is that with a
carbon fibre composite core which is more
than twice as strong as any steel or
al mini m matrix
aluminium matri core

Temperature
Specific Tensile Strength
Conductor strength and weight directly impact the amount
of sag (D) and tension (H) in an overhead conductor.
Specifically,
Specifically
D= w*S/(8*H)
where;
S=span length
w= weight per unit length
Thus (H/w)
Th (H/ ) is
i directly
di tl related
l t d to
t specific
ifi tensile
t il strength.
t th
Generally the higher the H/w, the less the conductor sags.

Temperature
Typical values of H/w for Sycamore
equivalent conductors
Sycamore equivalent HT conductors
Conductor UTS(kN) kg/m H/w(kN.m/kg)
Sycamore 85 0.835 101.8
ACCCOslo 148 0.992 149.2
Gap265 108 1.098 97.9
HACIN246 97 1.088 88.9
ACCR575T23 126 1.037 121.4

Temperature
Summary
Described the more commonlyy available Highg
temperature conductors
Briefly given advantages and disadvantages of the four
basic types
Explained why they can be of benefit even if not required
to be run at high
g temperatures
p
Explained the importance of the knee point
Provided some basic examples of use
GAP, ACCC and ZTAL/HACIN currently being field
tested in UK
Have a read of Cigr TBs 425 and 426
Temperature
Cigr AG06 Bangkok Conductors
Finally
SCB2 AG06 WG48 will ill look at Experience
E perience with
ith
the Mechanical Performance of New Conductor
types
types
SCB2 AG07 WG51 under Dale Douglass looks
at the electrical aspects

Temperature

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Study Committee B2

Technical Advisory Group B2-AG-06

Types and Uses of High

Types and uses of High

Types and uses of High

Types and uses of High

Types and uses of High

Types and uses of High

A conductive core will take part of the AC

Types and uses of High

Types and uses of High

Types and uses of High

Types and uses of High

Types and uses of High

Original 400 mm 2 Zebra ACSR

620 mm 2 Matthew GZTACSR

Types and uses of High

1. High Temperature aluminium alloy

High Temperature Zirconium Aluminium alloy

Types and uses of High

Uses standard fittings Higher knee point than

No steel so no corrosion High knee point (~70C)

Types and uses of High

Types and uses of High

In the UK, re-conductoring 132kV wood pole lines with

Types and uses of High

CTC ACCC Amsterdam with 110% increase

3M ACCR 575-T23, CTC ACCC Oslo and Lumpi-Berndorf

Types and uses of High

Types and uses of High

Types and uses of High

Need to have a conductor that can operate at well above

Types and uses of High

Types and uses of High

Main emphasis here is on electrical low sag performance

Types and uses of High

Types and uses of High

Types and uses of High

Sycamore equivalent HT conductors

Conductor UTS(kN) kg/m H/w(kN.m/kg)

Sycamore 85 0.835 101.8

ACCCOslo 148 0.992 149.2

Gap265 108 1.098 97.9

HACIN246 97 1.088 88.9

ACCR575T23 126 1.037 121.4

Types and uses of High

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