41.

CIGRE International Symposium (Ljubljana 1st – 4th June 2021)

Reshaping the Electric Power System Infrastructure
[1178] paper number

DESIGN CONSIDERATIONS FOR UPRATING OF EHV LINES

- UTILITY PERSPECTIVE
PS1

Ashish Kr. Singh1 Chandra kant1 Rajeev Kr.1 Subhash C. Taneja1

1
– POWER GRID CORPORATION OF INDIA LIMITED, NEW DELHI

chandra.kant@powergridindia.com

Abstract – As the requirement of constructing new transmission lines is growing, public opposition to
this construction activity is also increasing. As such the transmission utilities have been trying to
maximize power transfer through the existing or new corridors. Conventionally, this has been achieved
via EHV & UHV transmission systems, multi-circuit transmission lines, etc. Lately utilities have also
harnessed the benefits of compact tower designs, pole structures, narrow base towers, etc. With the
advent of new conductor technologies, utilities have started constructing new transmission lines as well
as uprating the existing transmission lines with high-capacity conductors such as high temperature low
sag (HTLS) conductors for more effective utilization of transmission corridors.

Unlike new transmission lines, uprating of existing transmission lines is severely constrained by the
design and spotting of existing towers which have been designed considering conventional conductor.
Thus, selection of appropriate HTLS conductor is limited by the diameter, weight, maximum design
tension and sag of existing conventional conductor. Further, keeping in view the mid span clearance
requirements with shield wire, it is also necessary to limit the minimum sag values of the proposed
HTLS conductor to that of the existing conventional conductor. Moreover, it may not be sufficient to
limit the sag and tension values of HTLS conductor to that of the existing conventional conductor at
only the ruling span. As because of the varying sag profiles of these conductors, sag & tension may also
exceed that of the existing conductor at some other spans.

Power Grid Corporation of India Ltd. (POWERGRID), the Central Transmission utility of the country
owns & operates approx. 1,68,000 circuit kms of transmission lines & 252 substations and a large
network is under construction. POWERGRID has executed numerous transmission line uprating
projects using various types of HTLS conductors viz. INVAR, GAP & composite core conductors. Each
project involves myriad innovative measures to carry out reconductoring effectively and efficiently.
With the experience gained, important design criteria have been formulated, not only for ensuring the
safety of HTLS conductor at everyday conditions as well as at elevated temperature but also for ensuring
sag & tension compatibility with the existing towers

The paper describes some of these innovative measures as well as the novel design & selection criteria
evolved for Transmission Line Uprating projects through example cases.

Keywords: Uprating, mid span clearance, ampacity, knee-point, elevated temperature, radial
temperature difference, Core Magnetization Effect, Skin Effect, Experimental Plastic Elongation

1
 41. CIGRE International Symposium (Ljubljana 1st – 4th June 2021)
Reshaping the Electric Power System Infrastructure
[1178] paper number

1 INTRODUCTION
With the installed capacity addition of more than 200GW in India in past one decade, power
transmission sector has also grown by leaps and bounds. Already more than 434,000 circuit kms of
transmission lines have been constructed in the country. India is well on track to implementing the
targeted 175GW of renewable energy by 2022 and 450GW of renewable energy by 2030. Such
voluminous capacity addition would also necessitate commensurate strengthening of existing
transmission infrastructure and construction of new transmission lines. Enhancing the power
transmission capacity to such levels cannot be accomplished without intelligible planning of
transmission assets and minimal utilization of available land.

Uprating of transmission lines using High temperature Low Sag conductor provides a unique
advantage of utilizing the already available corridor for enhanced power flow of upto three to four
times of the existing capacity. This not only helps meet the power flow requirements with reduced
cost and time, but also without having any adverse impact on the environment as a whole due to no
new transmission corridor. At present, a number of HTLS conductor technologies are in prevalence
for example, INVAR, GAP, ACSS, composite core conductors, etc. Merits & Demerits of various
conductor technologies need to be carefully evaluated, before using them for reconductoring purpose.

2 HIGH TEMPERATURE LOW SAG (HTLS) CONDUCTORS

HTLS conductor are such stranded conductor which are capable of sustained operation at
temperatures above 100°C without change in initial mechanical and electrical properties and with
reduced thermal elongation to limit sag. Such conductors are typically characterized by a certain
‘knee-point temperature’ within their operating range, at which the entire mechanical stress is
transferred to the core and sag is essentially dictated by only core.

CIGRE TB 763 [1] classifies HTLS conductor into following four categories:-

Type 1 Conductors consisting of a strength member made of steel, coated steel, or steel alloy, and
an envelope for which the high temperature effects are mitigated by means of thermal-resistant
aluminium alloys. For example, INVAR & GAP type HTLS conductor.

INVAR type HTLS Conductor consists of core of alloy of iron and nickel which has an extremely
low co-efficient of thermal expansion of about 1/3rd that of conventional steel wire. Since, these
conductors have thermal-resistant aluminium alloy in their outer layers, INVAR conductors can be
operated upto 210°C. Handling & stringing of this HTLS conductor is similar to conventional ACSR.

GAP type HTLS Conductor have a small gap maintained between inner steel core & outer thermal-
resistant aluminium alloy layers. The conductor is strung by tensioning the steel core only, using
special erection techniques. As a result, the stringing temperature becomes the knee point
temperature in such conductors. Therefore, the increase in sag of the conductor is governed only by
the coefficient of expansion of the steel core at all temperatures above the stringing temperature.
Thus, such conductors exhibit low sags at high operating temperatures. These conductors can also
be operated at temperatures of upto 210°C.

Type 2 Conductors consisting of a strength member made of steel, coated steel, or steel alloy, and
an envelope for which the high temperature effects are mitigated by means of annealed aluminium.
For example, Aluminium Conductor Steel Supported (ACSS) conductor.

2
 41. CIGRE International Symposium (Ljubljana 1st – 4th June 2021)
Reshaping the Electric Power System Infrastructure
[1178] paper number
ACSS conductor has a construction similar to that of standard ACSR conductor except that the
Aluminium strands are fully annealed. The 0-tempered annealed aluminium (1350-O) has higher
conductivity vis-à-vis hard drawn aluminium wires. Under typical operating conditions, ACSS
allows the entire mechanical load to be carried by the steel core. Since the Aluminium strands do not
take any mechanical load, the conductor may be operated at temperatures of the order of 200-250°C
without loss of strength.

Type 3 Conductors consisting of a metal-matrix composite (MMC) strength member, and an

envelope for which the high temperature effects are mitigated by means of thermal-resistant
aluminium alloys or annealed aluminium.

Metal matrix composite core conductors generally consist of thermal-resistant aluminium alloy
strands in the outer layers and a metal matrix composite core. Since, the permissible operating
temperature of metal-matrix composites is usually higher, these conductors can be operated upto
temperatures of the order of 210°C, based on the maximum permissible temperature of the thermal-
resistant aluminium alloy.

Type 4 Conductors consisting of a polymer-matrix composite (PMC) strength member, and an

envelope for which the high temperature effects are mitigated by means of annealed aluminium or
thermal- resistant aluminium alloys for HTLS applications.

PMC Conductors such as Carbon fibre composite core conductors may consist of 0-tempered
annealed aluminium wires or thermal-resistant aluminium alloy wires in their outer layers and a
single solid or stranded carbon fibre composite core. The maximum operating temperature of PMC
conductor is generally limited based on the maximum permissible temperature of the composite core.

3 SALIENT CONSIDERATIONS FOR UPRATING OF LINES

Unlike new transmission lines, uprating of existing transmission lines is severely constrained by the
design and spotting of existing towers which have been designed considering conventional
conductor. Thus, selection of appropriate HTLS conductor is limited by the diameter, weight,
maximum design tension and sag of existing conventional conductor.

Further, it may be mentioned that Uprating, usually, do not involve replacement of the entire insulator
strings and only the existing conductor clamps are replaced with suitable ones for the new HTLS
conductor. This is because, clamps for HTLS conductor are so designed that they are able to dissipate
large quantum of heat across their large surface area and thus, tend to remain at relatively low
temperatures, which are well within the limits of the rest of the hardware fittings as well as insulators.

Salient considerations for selection of HTLS conductor for Reconductoring of transmission lines are
elaborated below:

3.1. AMPACITY REQUIREMENTS:

HTLS conductor must be capable of handling the maximum power flow, under normal as well as in
contingency situations, without any deterioration of its electrical, mechanical & metallurgical
properties. Ampacity of HTLS conductor is, therefore, dependent on the constituent materials of
outer layers as well as of the core.

Under specified ambient conditions, ampacity can be determined on the basis of Heat Balance
Equation described in various standards. For reconductoring projects in POWERGRID, Ampacity
calculations are being carried out on the basis of IEEE-738. The latest IEEE-738: 2012 [2] also
specifies methodology for calculating radial temperature difference between the core and outer layers
of the conductor. This is especially significant in cases where ampacity of conductor is limited by

3
 41. CIGRE International Symposium (Ljubljana 1st – 4th June 2021)
Reshaping the Electric Power System Infrastructure
[1178] paper number
the temperature withstand capability of the core such as in case of some of the composite core
technologies and cores with galvanized coatings. For obtaining the AC current carrying capacity of
conductor, due considerations are given to uneven current distribution due to Core Magnetization
Effect as well as Skin Effect.

3.2. PHYSICAL REQUIREMENTS:

In order to prevent the loads due to the new conductor from exceeding the design limits of the existing
tower, the size & weight of the HTLS conductor should not exceed that of the existing conductor.

Further, for selection of appropriate conductor size, due considerations must also be given to corona
performance. Drastic reduction in conductor sizes, which may result in the conductor surface gradient
exceeding corona onset gradient of the conductor, should not be permissible.

3.3. SAG & TENSION CHARACTERISTICS:

Usually, selection of HTLS conductor for reconductoring projects is based on the limits of maximum
design tension as well as maximum sag of the existing tower. However, it is also imperative to limit
the minimum conductor sag so as to avoid any possibility of infringement of mid span clearance with
the shield wires.

Standards/ Regulations in India limit the maximum permissible tension in conductor in everyday
condition and in ultimate loading condition to 25% and 70% of the Ultimate Tensile Strength (UTS)
of the conductor respectively. Since, Breaking strength of conductor reduces at elevated
temperatures, it is ensured that the conductor tension at such elevated temperatures are well within
the above mentioned limits. Further, such reduction in breaking strength at elevated temperature is
not unrestrained and is duly checked through an Ultimate Tensile Strength test at elevated
temperature.

Since, in such conductors, knee point condition results into the core bearing the entire mechanical
stress, it is also necessary to limit the tension under knee-point condition to certain percentage of the
core UTS. In POWERGRID, this tension is limited to 40% of the core UTS.

Experimental Plastic Elongation (EPE) method is the mostly used methodology for sag tension
calculations of HTLS conductors. This method assumes a non-linear elongation for stranded
conductor, due to strand deformation and settlement, when loaded for the first time. However, once
loaded, the conductor behaves linearly at tensions below the initial tension.

For ensuring linear sag tension behavior even at high conductor tensions, Pre-tensioning of
conductor, prior to final sagging, is adopted in some countries. However, in view of safety
considerations, Pre-tensioning is generally avoided for Uprating of old transmission lines and instead
Over-tensioning is adopted.

3.4. STRINGING & INSTALLATION:

In addition to the numerous design considerations, reconductoring projects are characterized by

myriad challenges during execution. Since, most of these lines are old and form an important power
transmission link, it is generally not possible to get long shutdowns and stringing/ destringing is
required to be carried out under live line conditions. For such transmission lines, reconductoring is

4
 41. CIGRE International Symposium (Ljubljana 1st – 4th June 2021)
Reshaping the Electric Power System Infrastructure
[1178] paper number
generally carried out in section-wise manner so that immediately on completion of sagging of the
section, jumpers can be reconnected and power flow can be continued.

Installation of HTLS conductors involves usage of special tool and tackles such as self-gripping
come along clamps, tandem sheaves, neoprene lined sheaves, roller arrays, banana fairleads for
tensioners, etc. During reconductoring, HTLS conductor payout is carried out using the existing
conductor as pilot wire. The compression of dead ends is carried out at crossarm level using working
platforms. Some of the HTLS conductor technologies require additional care to avoid sharp bending
angles that may be detrimental to the core of the conductor.

At times, special hardware such as semi-strain assembly are required to be used for some of the
HTLS conductor technologies so as to address the lower section length limits of these technologies.
Such requirements may be averted in case of new lines where design and spotting of towers can be
carried out as per the chosen HTLS conductor technology.

3.5. ECONOMIC ANALYSIS:

Selection of HTLS conductor generally involves holistic comparison of capital cost i.e. the cost of
conductor, associated fittings & accessories, cost of stringing & installation, etc. as well as the cost
of losses during normal operating conditions. In order to obtain the estimated cost of losses,
generally, average losses are calculated by multiplying a suitable loss load factor.

Sometimes, when comparative evaluation of ohmic losses amongst different HTLS conductor
alternatives is difficult, in order to limit the losses, resistance of HTLS conductor can be restricted
to that of the equivalent ACSR conductor.

4 POWERGRID EXPERIENCE
Some of the cases illustrating POWERGRID’s endeavor towards Uprating of existing lines are discussed
below:-

4.1. RECONDUCTORING OF 400 KV D/C SILIGURI-PURNEA TRANSMISSION LINE:

The 400 kV D/C Siliguri-Purnea transmission line, having line length of approx. 175 km, was
initially constructed using Twin ACSR Moose conductor. In order to avert overloading of the
transmission line during peak power flow scenario, the transmission line was uprated using HTLS
conductor having ampacity, twice of that of the ACSR Moose conductor. GAP type conductor with
maximum operating temperature at 150°C has been used for uprating of the transmission line.

Since, the line is passing through the narrow chicken neck area, having enormous space or Right-
of-the-Way constraints, uprating of this line has avoided the need of constructing additional 400kV
line thereby, making an efficient utilization of the precious corridor.

Salient details of the existing transmission line and the replacement conductor are as follows:-

S.No. Description Before After

Reconductoring Reconductoring
1. Conductor bundle configuration Twin Twin
2. Conductor Type ACSR Moose GTACSR 540 mm2
3. Current carrying capacity 614 Amperes 1228 Amperes

5
 41. CIGRE International Symposium (Ljubljana 1st – 4th June 2021)
Reshaping the Electric Power System Infrastructure
[1178] paper number
4. Conductor Diameter 31.77 mm 31.5 mm
5. Conductor weight 2004 kg/m 1943 kg/km

4.2. RECONDUCTORING OF 400 KV D/C FARAKKA-MALDA TRANSMISSION LINE:

400 kV D/C Farakka-Malda transmission line, having line length of approx. 43 km, was constructed
with Twin ACSR Moose conductor and was getting heavily loaded due to high power flow across
Eastern-Northern corridor during winter months and during scarce hydro availability from Bhutan
& Teesta power stations. INVAR type HTLS conductor was used for uprating of the existing
transmission line to double the power transmission capacity. Steady state conductor temperature
corresponding to the rated ampacity is approx. 146°C

Salient details of the existing transmission line and the replacement conductor are as follows:-

S.No. Description Before After

Reconductoring Reconductoring
1. Conductor bundle configuration Twin Twin
2. Conductor Type ACSR Moose STACIR 402 mm2
3. Current carrying capacity 614 Amperes 1228 Amperes
4. Conductor Diameter 31.77 mm 28.91 mm
5. Conductor weight 2004 kg/m 1780 kg/km

4.3. RECONDUCTORING OF 400KV D/C RANGPO-SILIGURI TRANSMISSION LINE:

400 kV D/C Rangpo-Siliguri transmission line, having line length of approx. 110 km, was
constructed with Twin ACSR Moose conductor. However, under outage of another transmission
line at Rangpo Substation i.e. 400kV (Quad) Rangpo-Kishanganj line, this line would have been
overloaded. Therefore, this line is being reconductored using GZTACSR conductor having
ampacity as twice that of ACSR Moose conductor. Steady state conductor temperature
corresponding to the rated ampacity is approx. 157°C

Salient details of the existing transmission line and the replacement conductor are as follows:-

S.No. Description Before After

Reconductoring Reconductoring
1. Conductor bundle configuration Twin Twin
2. Conductor Type ACSR Moose GZTACSR 578 mm2
3. Current carrying capacity 787 Amperes 1574 Amperes
4. Conductor Diameter 31.77 mm 31.77 mm
5. Conductor weight 2004 kg/m 2004 kg/km

5 CONCLUSION
Since, Uprating of existing lines with High Temperature Low Sag conductor results into
enhancement of power transfer capability of an existing corridor, it can be regarded as an
excellent solution for minimization of land use & environmental impact of transmission
networks. However, constraints in the design of HTLS conductor, due to use of existing towers,
should be duly analysed and evaluated prior to selection of the appropriate reconductoring
solution. Further, additional design criteria due to elevated temperature operations and
occurrence of knee-point below the maximum operating temperature, as discussed above,
should also be considered.

6
 41. CIGRE International Symposium (Ljubljana 1st – 4th June 2021)
Reshaping the Electric Power System Infrastructure
[1178] paper number
REFERENCES

[1] CIGRE Technical Brochure 763: Conductors for the uprating of existing overhead lines

[2] IEEE 738-2012: Standard for Calculating the Current-Temperature Relationship of Bare
Overhead Conductors