ELECTRICAL OVERHEAD CONDUCTOR FOR HIGH VOLTAGE

LINES, SELF-PROTECTIVE AT FROST AND ICE DEPOSITION

A. IORGAa,b, R. SABANa, L. PALIIb, E. A. PATROI b

a
POLITEHNICA University,
Splaiul Independentei 313, District 6,
060042 Bucharest, Romania,
E-mail: iorga_alexandru@yahoo.com
b
National Institute for R&D in Electrical Engineering ICPE-CA,
Splaiul Unirii, Nr. 313, District 3,
030138, Bucharest Romania,
E-mail: palii-ls@icpe-ca.ro

Abstract

The aim of this work is realization of an electric overhead conductor for power
transmission network that is able to protect themselves from frost or ice deposits
caused by bad weather conditions. New quality of self-protection to the deposition of
frost/ice is conferred to the electrical conductor of electricity for overhead transport,
by the new functional materials based on Cr-Ni-Fe alloy.

I. Introduction

The present paper presents the studies and the research regarding the realization of an
electrical overhead conductor for high voltage transmission networks 220-400 kV, to
be able to protect themselves from frost or ice deposits caused by bad weather and
climate conditions, when extra weight added to the overhead conductor, lead to
accidental breakage and interruption of power supply on the vast territorial areas, with
major social and economic negative consequences [1, 2]. In literature there are
recorded multiple events of breaking of overhead conductors, particularly in areas
with cold climate [3, 4].

Innovative quality of this overhead conductor for electricity transport, lies in the fact
that function with self-protection, permanent, self-adjusting, without additional energy
consumption and is the same shape, type of construction and operating characteristics
as the standard currently conductors used for this purpose in the electric overhead
transmission networks [5].

New quality of self-protection on deposits of frost/ice is conferred to the overhead

electrical conductor, by the new multifunctional material Cr-Ni-Fe alloy. This alloy
shows magneto-electro-caloric characteristics suitable for this purpose and is sized for
the thermal effect to achieve the desired effect, namely the self protection to the
deposits of frost or ice on the conductor, even when the deposits are imminent [6, 7].

To solve these problems we manufactured and optimized alloy composition of Cr-Ni-

Fe and design the new conductor with self protection to frost/ice. We have been
developing a method that use the heat generated by the alternative magnetic field of a
magnetic material wire made from Cr-Ni-Fe alloy. The caloric value in the wire is due
to the hysteresis loss and eddy current loss [8].
II. Experiments
II.1. Basic approach

Based on literature studies regarding the alloys with low Curie temperature and the
experimental research, we prepare four alloys compositions of the ternary system Cr-
Ni-Fe (Table 1), designed to study the main physical and magneto-electric
characteristics, and to identify areas of composition that have a Curie temperature as
close to the point of frost/ice forming (-3oC) and at the same time to have a sufficient
contribution of heat to prevent the deposit of frost/ice on the overhead conductors.

Sample Chemical composition [wt. %]

P1 Cr11,5 Ni34 Fe54.5
P2 Cr10 Ni35 Fe55
P3 Cr11 Ni35 Fe54
P4 Cr12 Ni35 Fe53
Table 1: Chemical composition of alloys

Impurities in Cr-Ni-Fe alloys of any kind have a great influence especially on the
mechanical and chemical properties, essentially on the behavior of the alloy in
different technological processes [6]. Metals used had a purity of advanced
technology, namely: Cr and Ni (electrolytic grade) and Fe (type Armco). Melting was
done in controlled atmosphere (Ar) Heraeus furnace with induction heating at 10 kHz.
After casting, the alloys were annealed for stress relief and chemical homogeneity in
the composition; the thermal conditions were 3 hours at 700oC cooling with furnace.
Treatment was carried out in controlled atmosphere (Ar) at atmospheric pressure.

Constructive solution of choice for achieving self-protective electrical overhead

conductor to the deposition of frost/ice is the insertion of a certain number of Cr-Ni-
Fe alloy wires, replacing a number of wires in the outer layer of standard ACSR
conductor - Aluminium Conductor Steel Reinforced (diameter = 25mm) [5]; the wires
made from Cr-Ni-Fe alloy, have the same diameter as the threads in the standard wire
(diameter = 3.93 mm), so the conductor does not undergo any change in appearance
and mechanical properties, compared with standard conductor [9].

To obtain wires, the alloys were processed by hot (forging) and cold (rolling and
drawing) forming processes. Wires made by drawing have 3.9 mm in final diameter,
the wire drawing speed being ~ 0.8 m / sec (Figure 1).

Fig. 1: Magnetic material wire made by Cr-Ni-Fe alloy

II.2. Preliminary calculation of self-protective conductor reinforced with wires from
Cr-Ni-Fe alloy

Frost deposited on the conductor when the temperature reaches -3oC; for practical
calculations we use a temperature of 0oC, making sure that additional heat input
brought by thermo-magneto-electric effects of the new conductor with wires from Cr-
Ni-Fe alloy, to maintain minimum temperature conductor 0oC. Cr-Ni-Fe alloys made
by us for this purpose, characterized by the Curie temperature preset value between
10oC - 65oC, shows a better metallurgical process for obtaining the necessary wires
and good physic and structural characteristics for features thermal processes.

To achieve a stable thermal process, we choose the material with Tc higher than 0oC
to have a relatively large amount of magnetic flux density at 0oC, but not more than
30oC – 50oC to avoid over heating of the cable when the ambient temperature is
positive.

Additional thermal contribution to the conductor brought by new multifunctional

wires, aims to capture part of the electromagnetic radiation at standard frequency of
50Hz when at the temperature of 0oC wires are in ferromagnetic state. The heat effect
of induced eddy currents in the wires and alternative changing of the magnetic field
value with opponent coercive magnetic field of the wires, are calculated with
formulas known in electrical engineering. The contribution of eddy currents through
the equation 1:

π d 2 ω 2 Bmax
2
d2
Pe = N ⋅ ⋅ (1)
4 16 ρ

where,
Pe - eddy current losses [W]
N – number of wires that will be replaced
B – magnetic flux density [T]
ω = 2πf – frequency [Hz]
ρ – resistivity [Ω·m]
d – diameter of the conductor [mm]

When the magnetic field through the core changes, the magnetization of the core
material changes by expansion and contraction of the tiny magnetic domains it is
composed of, due to movement of the domain walls. This is a lossy process, because
the domain walls get "snagged" on defects in the crystal structure and then "snap" past
them, dissipating energy as heat. This is called hysteresis loss. It can be seen in the
graph of the B field versus the H field for the material, which has the form of a closed
loop. The amount of energy lost in the material in one cycle of the applied field is
proportional to the area inside the hysteresis loop. Hysteresis loss increases with
higher frequencies as more cycles are undergone per unit time. If B is assumed
uniform at power frequencies, the average power per unit volume yields the result in
equation 2:

2
2 fSBmax
Ph = (2)
µ
where,
Ph - hysteresis losses [W]
B – magnetic flux density [T]
f – frequency [Hz]
S – shape factor [mm2]
µ – permeability

From the amount of heat lost by the system and the heat brought by one wire made
from the new multifunctional alloy replaced will result the number of necessary wires
that have to be replaced in the outer layer of the standard ACSR conductor. For
practical reasons and based on calculations made, we considered that the insertion
with N = 4 wires replaced is the most advantageous and meets the objective proposed.

II.3. Tests in climate chamber

Experimental Model – EM – of the conductor (Figure 2), on which we have done the
tests, was made by replacing 4 wires of Cr-Ni-Fe multifunctional alloy with the same
number of Al wires in a sample of standard conductor. The conductor on which we
have done the laboratory tests had a length of 1500mm.

Fig. 2: Overhead electrical conductor with self-protection to the deposition of frost/ice- experimental
model

Climatic chamber tests focused on determining the Curie temperature J = f (t) and
observing self-protective conductor in function in bad weather conditions. Curie point
measurements were made on toroidal samples (Ø30 x Ø25 x 5mm, cast and annealed)
in closed magnetic circuit, using a wattmeter and a climate chamber. Samples were
wound with an equal number of turns, so we used 70 turns to 30 turns for primary and
secondary. For functional testing of the experimental model we used a complex test
installation, shown schematically in Figure 3.
 Fig. 3: Scheme of the installation for verification of the behavior of EM in climate chamber with
severe weather conditions

Legend:
• 1: Climate chamber;
• 2: Conductor with insertion of Cr-Ni-Fe multifunctional alloy;
• 3: Standard conductor;
• 4: Supply connections;
• 5: Standard conductor out of function;
• 6: Connectors;
• 7: Shunt 1000A/0.25V;
• 8: Power supply 0-500A;
• 9: Control panel.

Test facility is composed primarily of a climate chamber with the possibility of

adjusting temperature range from -30oC to +50oC, 100% humidity and speed wind up
to 16m/s. Construction type camera is compact, tight connection and have the
possibility of crossing plate measuring circuits and power supply. Maximum current
supply voltage is 5 to 10V. In the climate chamber, beside the self-protection
conductor, we have been introduced also a control conductor (not connected to the
power supply) and one standard conductor connected in series with the conductor
with self-protection to deposition of frost/ice as you can see in Figure 3.

IV. Results and discussions

One of the key issues was the choice of the favorable Curie temperature Tc value of
the multifunctional alloy in relation with frost/ice temperature forming (-3oC) on the
conductor. We took into account that the Curie temperature multifunctional alloy
wire, to have a value close to the temperature of formation of frost/ice, thus avoiding
an additional thermal input of the system and any shortcomings of this state. In Table
3 are obtained values after Curie point measurement and Figure 4 shows one curve J =
f (t) used to determine the Curie temperature.

It should be noted that due to specific properties of new functional materials at

positive temperatures, it behaves like an ordinary electrical conductor. At zero
temperatures, the reverse transformation of its status, the functional material becomes
ferromagnetic, with a progressive increase of magnetic induction Bs, as the
temperature drops, producing heat in increased quantities.

Sample Chemical composition [wt %] TC value [oC]

P1 Cr11,5 Ni34 Fe54.5 + 24
P2 Cr10 Ni35 Fe55 + 60
P3 Cr11 Ni35 Fe54 + 65
P4 Cr12 Ni35 Fe53 + 45
Table 3: Measured values of Curie temperature Tc

Climate chamber measurements on the self-protection conductor to the deposition of

frost/ice reveals that, the experimental model with 25mm diameter and 4 Cr-Ni-Fe of
3.9 mm diameter wires, connected to power supply testing installation at 320A/50Hz
(~ 50% of nominal capacity) at stabilized climate chamber temperature of -15oC,
standard conductor has a temperature of -4.2oC, and for the new conductor made by
us with Cr-Ni-Fe wires insertion, temperature is +0.3°C (Figure 5) .

-10 0 10 20 30 40 50 60 70
0.24 0.24

0.22 0.22

0.20 Js(5) 0.20

0.18 0.18

0.16 0.16

0.14 P1 0.14
Js (T)

0.12 0.12

0.10 0.10

0.08 0.08

0.06 0.06

0.04 0.04

0.02 0.02

0.00 0.00
-10 0 10 20 30 40 50 60 70
o
T ( C)

Fig. 4: Graphic Js = f (t ° C) for P1 sample Fig. 5: Thermogram image after temperature

stabilization of the climate chamber

Conductor temperature difference between standard and self-protective conductor to

the deposition of frost/ice power was 4.5°C. The frost was observed on the non-
connected conductor as well and in a thicker layer.

V. Conclusions

The new conductor made by us ensures the self-protection at frost/ice deposits on the
electric overhead transport lines, without requiring additional energy consumption,
without human or automatic intervention of control and with no bad ecological
effects. The commutation yes/no to extra calories that ensure the un-deposition of
frost/ice on the overhead conductor is achieved by pre-stable and reverse modification
of thermo sensitive properties of the Cr-Ni-Fe multifunctional alloy wires.

Since the heating conductor with multifunctional Cr-Ni-Fe wires compared to the
standard conductor is 53% more and the Joule effect losses are less than 1.5%, result
that further heating of the new conductor at negative temperatures, is not due to Joule
losses effect.
The new conductor ensures high energetic security, eliminating the high voltage lines
transportation relays damage caused by the supplementary mechanical burden due to
deposition of frost/ice on these conductors. This work is patented.

Acknowledgement
The work has been funded by the Sectoral Operational Programme Human Resources
Development 2007-2013 of the Romanian Ministry of Labour, Family and Social
Protection through the Financial Agreement POSDRU/6/1.5/S/16 and with the
support of the project FP7 – REGPOT – 229906/2009.

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