Multan Electric Power Company

(MEPCO)

TECHNO – COMMERCIAL PROPOSAL

FOR

CAPACITY ENHANCEMENT OF
EXISTING 132KV OVERHEAD
TRANSMISSION LINE FROM KOT ADDU
POWER TO KOT ADDU CITY (KAP – 9 TO
KAD – 1 AND KAP – 8 TO KAD – 2)
USING HTLS – ACCC® CONDUCTOR.

August 2020

PAKISTAN CABLES LIMITED

CAPACITY ENHANCEMENT OF EXISTING 132KV TRANSMISSION LINE KAPCO TO KOT ADDU
CITY GRID STATION

Table of Contents

Commercial Offer .......................................................................................... 1

Technical Proposal ....................................................................................... 1

1. INRODUCTION TO ACCC CONDUCTOR ..................................................... 1

2. Comparison of ACSR Rail & ACCC Drake Conductor: ............................... 2

3. Sag Comparison – ACSR Rail Vs ACCC Drake Conductor: ......................... 2

4. ACCC Conductor Successful Projects in Pakistan ..................................... 3

4.1. 220kV Gatti – Nishatabad Transmission Line in NTDC Network .............. 3

4.2. 132kV Transmission Line in MEPCO Network .......................................... 3

5. Estimated Timelines:................................................................................ 4

i
CAPACITY ENHANCEMENT OF EXISTING 132KV TRANSMISSION LINE KAPCO TO KOT ADDU
CITY GRID STATION

LIST OF ABBREVIATIONS

ACCC Aluminum Conductor Composite Core

AC Alternating Current

ACSR Aluminum Conductor Steel Reinforced

CCT Circuit

D/C Double Circuit

DC Direct Current

EHV Extra High Voltage

km kilometer

kV kilovolt

m Meter

MW Mega Watt

MVA Mega Volt Ampere

S/C Single Circuit

S/S Substation
HTLS High Temperature Low Sag

ii
CAPACITY ENHANCEMENT OF EXISTING 132KV TRANSMISSION LINE KAPCO TO KOT ADDU
CITY GRID STATION

1. INRODUCTION TO ACCC CONDUCTOR

CTC Global has come up with a High Performance Aluminium Conductor Composite Core
(ACCC) Conductor for a Modern Grid.
ACCC Conductor uses a hybrid carbon fiber core which has below distinct properties;

• It is 70% lighter and 50% stronger than steel.

• It has a coefficient-of-thermal-expansion about 10 times less than steel.

Higher Current Carrying Capacity

• DOUBLE the Ampacity of corresponding ACSR.

• Continuous Operation at elevated temperatures around 180°C.

Energy Efficiency & Reliability

• 20 to 40% Reduction in Line Losses.

• 1350-O Fully Annealed Aluminium offers better conductivity.
• Proven Reliability Worldwide.
• Lighter weight and greater Ultimate Tensile Strength (UTS).
• Lower Sag provided by the ACCC Conductors

ACCC Conductor Projects:

• Around 75,000 km of ACCC conductor of different sizes are installed in about 675
project around the world.

Installation of ACCC Conductor

• The installation is not much different from the conventional conductor.

Page 1 of 4
CAPACITY ENHANCEMENT OF EXISTING 132KV TRANSMISSION LINE KAPCO TO KOT ADDU
CITY GRID STATION

2. Comparison of ACSR Rail & ACCC Drake Conductor:

The comparison of the ACSR Rail and ACCC Drake, conductor selected for this project
concludes that ACCC Drake have greater Aluminum content, greater Tensile Strength as
compared to the ACSR Rail Conductor. The DC Resistance of ACCC Drake conductor at 20
oC is quite less than the ACSR Rail. Technical Data Sheet of ACCC® Drake in enclosed as

Annexure – 1.
Comparison of Electrical & Physical Parameters:

From the above, ACCC DRAKE provide below significant improvement in the capacity of
transmission line

- Operate at maximum temperature of 180oC providing 1,678 Amperes. Providing

extra capacity for future load conditions.
- The Weight of this conductor is 1,565 kg/km, which is 2 – 3 % less as compared
Weight of ACSR Rail Conductor i.e. 1599.5 kg/km
- Loss reduction of around 15% due to the more Aluminum area in ACCC Drake against
the ACSR Rail.

3. Sag Comparison – ACSR Rail Vs ACCC Drake Conductor:

Please note that there is significant improvement in sag in all loading conditions. The below
table shows the Conductor Core Co-efficient of Thermal Expansion values of both ACCC
and ACSR Conductors. Sag Comparison of both conductors is included in the Complete
Conductor Comparison Reports enclosed herewith as Annexure – 2.

Page 2 of 4
CAPACITY ENHANCEMENT OF EXISTING 132KV TRANSMISSION LINE KAPCO TO KOT ADDU
CITY GRID STATION

4. ACCC Conductor Successful Projects in Pakistan

4.1. 220kV Gatti – Nishatabad Transmission Line in NTDC Network

ACCC Conductor has been installed in the system of National Transmission & Despatch
Company, Pakistan since 22 May 2017. This project was completed on a 2.5 km, 220 kV double
circuit Transmission Line from Gatti Substation to Nishatabad Substation in the Faisalabad
District. Before installation of ACCC Drake conductor the line was energized with ACSR Rail
with rated capacity of 868 Amperes. After the installation of ACCC Drake the Line can operate
on 1640 Amperes on one circuit. Doubling the capacity of line by using the same Towers and
existing right of way in half the time of conventional conductor. Completion Certificate along
with Operational Acceptance Certificate are enclosed as Annexure – 3.

Stringing Works at 220 kV Gatti-Nishatabad Double Circuit T/Line – NTDC

4.2. 132kV Transmission Line in MEPCO Network

ACCC Conductor has been installed in MEPCO as a replacement of ACSR Coyote Conductor in
a 5 km, 132kV Single Circuit Transmission Line from NGPS to Industrial State, in order to
enhance the capacity of existing 132kV Transmission Line with same right of way and existing
structures. Transmission Line is in operation successfully for almost one and a half years now
and MEPCO has planned another project of capacity enhancement with HTLS Conductor,
tender of which is currently under evaluation. Completion Certificate along with Operational
Acceptance Certificate are enclosed as Annexure – 4.

Page 3 of 4
CAPACITY ENHANCEMENT OF EXISTING 132KV TRANSMISSION LINE KAPCO TO KOT ADDU
CITY GRID STATION

Stringing Works at 132kV NGPS – Industrial Estate Single Circuit T/Line – MEPCO

5. Estimated Timelines:
The Project Completion Period for Manufacturing, Supply and Re-conductoring is 4 – 5 Months.

Page 4 of 4
 Annexure – 1

Technical Data Sheet of

ACCC® Drake
DATA SHEET:
ACCC® DRAKE
ACCC® 520/71/281 (1026 kcmil)*
For questions, please contact CTC Application Engineering Department: applicationsupport@ctcglobal.com
Metric and US Units are considered separate PRELIMINARY
Aluminum Specification Metric US Units
2
Nominal Aluminum Cross-sectional Area*** 519.7 mm 1025.6 kcmil
Aluminum Conductivity/Type 63% % IACS 1350-O
Aluminum Nominal Weight** 1432.6 kg/km 962.8 lb/kft
Coefficient of Thermal Expansion 23.0 x10-6/°C 12.8 x10-6/°F
Aluminum Heat Capacity 1341.2 W-s/m-C 227.1 W-s/ft-F
ACCC® Core Specification (CTC Part Number 200-007) Metric US Units
2
Nominal Cross-sectional Area of Core 71.30 mm 0.1100 in2
Nominal Diameter of Composite Core 9.53 mm 0.375 in.
Core Nominal Weight 133.0 kg/km 89.2 lb/kft
Rated Strength of Core - 310 ksi (2137 MPa) 151.7 kN 34.1 kips
Coefficient of Thermal Expansion 1.61 x10-6/°C 0.894 x10-6/°F
Modulus of Elasticity 112.3 GPa 16.29 Msi
Core Heat Capacity 108.1 W-s/m-°C 18.3 W-s/ft-°F
ACCC® Conductor Specification Metric US Units
Overall Diameter of Conductor1 28.14 mm 1.108 in.
Nominal Cross-sectional Area of the Conductor 591.0 mm2 0.916 in2
Ultimate Tensile Strength of Conductor2 180.6 kN 40.6 kips
Conductor Nominal Weight** 1565.6 kg/km 1052.0 lb/kft
Coefficient of Linear Expansion Above Thermal Kneepoint 1.61 x10-6/°C 0.894 x10-6/°F
Coefficient of Linear Expansion Below Thermal Kneepoint 18.3 x10-6/°C 10.18 x10-6/°F
Final Modulus of Elasticity Above Thermal Kneepoint 112.3 GPa 16.29 Msi
Final Modulus of Elasticity Below Thermal Kneepoint 61.2 GPa 8.9 Msi
Maximum Allowable Operating Temperature at Surface3 180 o
C 356 o
F
Electrical Specification Metric US Units
Nominal DC Resistivity at 20ºC 0.0536 ohm/km 0.0863 ohm/mile
Temperature Coefficient of Resistance 0.00404 /°C 0.00209 /oF
Frequency 60 Hz 60 Hz
AC Nominal Resistance at 25ºC 0.0554 ohm/km 0.0892 ohm/mile
AC Nominal Resistance at 75ºC 0.0662 ohm/km 0.1065 ohm/mile
AC Nominal Resistance at 180ºC 0.0888 ohm/km 0.1428 ohm/mile
1786 @ 180C & 60 Hz
AC Current Rating at Given Temperatures4 @ 200C & 60 Hz
1884
GMR (estimated) 11.46 mm 0.0376 ft.
Inductive Reactance 0.247 ohm/km 0.3981 ohm/mile
Capacitive Reactance 0.147 Mohm-km 0.0912 Mohm-mile

ACCC® is produced using 1350-O (fully annealed) aluminum.

1) Minimum hub diameter of the conductor reel must meet the requirements of CTC F-750-032.
2) Strength at ambient temperature. Based on 96% of the 1350-O minimum tensile strength (8500 psi/58.6 Mpa) and 100% of the composite core mininum
tensile strength (310 ksi/2137 Mpa).

3) Maximum operating temperature of ACCC® is 180°C and a maximum emergency temperature of 200°C (10,000 hours over the life of the conductor).

4) Conditions: 2 ft/s (0.6 m/s) wind, 0 ft (0 m) Elevation, 0.5 Emis. 0.5 absorp., 25°C Ambient temp., 96 W/sq. ft (1033 W/sq. m) sun radiation
*ASTM name designation: mm² nominal aluminum area/mm² nominal core area/mm nominal diameterx10 (nominal kcmil aluminum)
**ACCC® Conductors are required to exhibit lay lengths (ratios) that conform to ASTM B 857 or EN 50540.
***Different configurations among conductor manufacturers may result in slight variations within the parameters of indicated values for a given size in
accordance with the stated specification.
F-730-513-NC www.ctcglobal.com Date Produced: 7/1/2019
 Annexure – 2

Comprehensive Conductor
Comparison Report
 Main Comparison Report

Project Name: 132kV Kot Addu Power to Kot Addu City Transmission
2/14/2020 12:25:02 PM GMT (or UTC) Project Location: Multan, Pakistan
Comparison
Conductor Information Base Conductor Not Selected Not Selected
Conductor #1
Type ACSR ACCC®
483 mm² 520 mm²
Size ( Unit - Code Word)
RAIL DRAKE
Aluminum Area (mm²) 483.4 519.7
Diameter (mm) 29.591 28.143
Rated Strength (kN) 115.2 183.3
Weight (kg/km) 1,599.5 1,565.0
Electrical Characteristics
DC Resistance at 20°C (ohms/km) 0.0591 0.0536
AC Resistance at 25°C (ohms/km) 0.0618 0.0554
AC Resistance at 75°C (ohms/km) 0.0740 0.0662
Conductors per phase 1 1
Number of Circuits 1 1
Ampacity (A) at Temperature (°C) (60) - 400 (60) - 422
Ampacity (A) at Temperature 2 (°C) (75) - 722 (75) - 755
Ampacity (A) at Temperature 3 (°C) (100) - 1,036 (100) - 1,081
Ampacity (A) at Rated Operating Temp (°C) (75) - 722 (180) - 1,678
Ampacity (A) at Maximum Temp (°C) (100) - 1,036 (200) - 1,787
Solar Absorptivity 0.50 0.50
Emissivity 0.50 0.50
Economic Analysis
Line Losses (2.00 km, 1600 Peak Amps)
Steady-State Temperature (ºC) at Peak Ampacity 178 167
Resistance at Peak Operating Amps (ohm/km) 0.09933 0.08590
First Year Line Losses (MWh) 3,843 3,323
Difference in First Year Line Losses vs Base Conductor(MWh) -- -520
% Difference in First Year Line Losses vs Base Conductor (%) -- -14 (%)
First Year Line Loss Savings vs. Base Conductor Base Conductor
-- 25,984
(USD/Year)
Line Loss Savings per meter of Conductor vs Base Conductor
-- 4.33
(USD/m/Year)
30 year Line Loss Savings vs Base Conductor (USD) -- 779,519
Difference in First Year COЇGenerated vs Base Conductor (MT) -- -323
Difference in 30 year COЇGenerated vs Base Conductor (MT) -- -9,697
First Year Value of COЇ -- 8,075
First Year Equivalent Number of Cars -- 62
First Year Equivalent Number of Homes -- 29
Generation Savings
Generation Capacity Required to Supply Line Losses (MW) 0.44 0.38
Difference in Generation Capacity vs Base Conductor (MW) -- -0.06
Difference in Capital Cost of Capacity vs Base Conductor (USD) -- -59,000
Initial Sag/Tension at Above-Stringing Temperature (15 °C)
Ruling Span (m) 300.0 300.0
% RTS 20.0 14.5
Sag at Initial Sagging Temperature (m) 7.71 6.53
Total Initial Tension at Structure at Sagging Temperature (kN) 23.0 26.6
Total Conductor Weight/phase (kg/km) 1,599.5 1,565.0
 Main Comparison Report

Project Name: 132kV Kot Addu Power to Kot Addu City Transmission
2/14/2020 12:25:02 PM GMT (or UTC) Project Location: Multan, Pakistan
Comparison
Conductor Information Base Conductor Not Selected Not Selected
Conductor #1
Type ACSR ACCC®
483 mm² 520 mm²
Size ( Unit - Code Word)
RAIL DRAKE

Sag/Tension at Stringing Temperature

Sag at Peak Operating Amps
Temp (ºC) 178 167
Sag (m) 12.84 8.45
Total Structure Tension (kN) 14.0 20.6
Sag at Rated Operating Temperature
Temp (ºC) 75 180
Sag (m) 9.83 8.48
Total Structure Tension (kN) 18.1 20.5
Sag at Maximum Temperature
Temp (ºC) 100 200
Sag (m) 10.62 8.52
Total Structure Tension (kN) 16.8 20.4
Max Allowable Temperature at Sag of 10 m
Max. Allowable Temp (ºC) 81 200
Sag (m) 10.01 8.52
Total Structure Tension (kN) 17.8 20.4
Ampacity (A) 812 1,787
Wind/Ice or Cold Temperature Sag/Tension
Temperature (°C) = -20
Wind Pressure (Pa): = 0
Radial Ice Thickness (mm) = 0
Total Sag (m) 6.39 5.98
Total Structure Tension (kN) 27.7 29.0
% RTS 24.1 15.8
Max. Allowable Tension (kN): 30.00 30.00
Max. Tension (% RTS) 60.00 60.00
Knee Point Temperature Sag/Tension
Knee Point Temperature (°C) 190 65
Sag (m) 13.14 8.25
Total Structure Tension (kN) 13.7 21.1

Assumptions and Inputs:

Line and Load: Line Length (km) = 2.00, Voltage (kV) = 132, Voltage Type = AC, Phases/Circuit = 3,
Peak Amps = 1600, Total Peak Power (MVA) = 366,Load Factor (%) = 50.
Environmental Inputs: Sun Radiation (W/m²) = 1032.1, Ambient Temp. (ºC) = 45.0, Elevation (m) = 0, Wind Angle (deg.) = 90,
Latitude (neg = South) = 30, Wind (m/sec) = 0.61.
Wind/Ice or Cold Temperature Sag/Tension: Temperature (°C) = , Windspeed(Loading) (km/hr) = 0.0, Safety Factor (N/m) = 0.00,
Radial Ice Thickness (mm) = , Ice Density (kg/m³) = 0.
Economic: Cost of Energy Generation (USD/MWh) = 50.00, Installed Generation Cost (USD/kW) = 1000.00, COЇ (kg/kWh) = 0.622.

Note 1:Conductor Ampacity and Temperature calculations based on IEEE 738-2006.

Note 2:Red Text: Maximum Conductor Temperature Exceeded
 Annexure – 3

Completion Certificate and

Operational Acceptance
Certificate of 220kV Gatti –
Nishatabad T/Line Project in
NTDC
 Annexure – 4

Completion Certificate and

Operational Acceptance
Certificate of 132kV NGPS –
Industrial Estate Transmission
Line Project in MEPCO