Alloy Conductors in Transmission Lines

S.S. Raj - Technical Advisor

National Seminar on Transmission & Distribution of Energy, New Delhi March 10, 2005

Conductors in Transmission Lines

Brief history of Conductor usage Copper Conductors in transmission lines until late 1890s All Aluminium Conductors before turn of the Century. ACSR introduced in the USA in 1907 and continued almost exclusively throughout the world until about 1939 Alloy developed in France in 1923, first used in a 60kV line in 1928 in France, and from 1939 in USA / Canada.

National Seminar on Transmission & Distribution of Energy, New Delhi

March 10, 2005

Revolution of Alloy in the Transmission Line

France developed 6101 alloy in 1923 & the first French Specification for Alloy released and started stringing alloy conductors. Sweden & Norway introduced Alloy of their own kind with Conductivity- 57% & 59% in the late 1950s. USA switched-over to Alloy from 1930s. Aluminium Association, USA introduced various alloy grades including 6201. Australia has developed 1120 alloy & commissioned new lines replacing old ACSR. UK has developed HC & EHC 6201 alloy for reconductoring of ACSR. Middle East countries especially Dubai, Qatar, Yemen & Saudi Arabia started procuring Alloy conductors since late 1960s. Bangladesh recently switched over to 6201 ASTM Alloy for 132kV & 220kV TL projects(since 1999)
March 10, 2005

National Seminar on Transmission & Distribution of Energy, New Delhi

Typical comparison: ACSR Moose vs Alloy Moose

ACSR Moose 54/7/3.53mm 893 amps 161kN 165 Mpa Low 8.2 Alloy Moose 61/3.55mm 891 amps 160kN 280 Mpa High 9.77 Economical due to lesser weight & longer span

Characteristics

Reference Specification

Current Carrying Capacity Conductor UTS Al-Strand Strength Corrosion Resistance Strength to weight ratio Tower & Supporting structure

IEC 61089 BS 3242, BS 215 part2 BS 3242, BS 215 part2 Cigre Report by working group 22-14 Ratio of Breaking Load to mass of conductor in kgs Cigre Report by working group 22-14
March 10, 2005

Standard

National Seminar on Transmission & Distribution of Energy, New Delhi

Other advantages of Alloy

AAAC with lower electrical resistance lighter in weight- 13 to 16% but of same breaking strength of ACSR. About 15% Lesser transmission loss in comparison with ACSR Increased life span in comparison with ACSR Conductors. Easier handling during erection.

National Seminar on Transmission & Distribution of Energy, New Delhi

March 10, 2005

Global Demand* (Alloy vs ACSR)

(*except India)

33%

ACSR

Alloy
67%

National Seminar on Transmission & Distribution of Energy, New Delhi

March 10, 2005

Alloy Conductors used by International Utilities

Region Bangladesh Australia Middle East North & East Africa Scandinavian Countries UK & France USA & Canada Alloy Grade 6201 1120 6201 6201, 6101 Al57, Al59 EHC, 6101 6201 Specification IEC, ASTM AS BS, ASTM IEC, NFC, EN SS, EN NGC, NFC ASTM, CSA
March 10, 2005

National Seminar on Transmission & Distribution of Energy, New Delhi

T4 Inline processing: Consistency of metallurgical properties

Separate Melting & Tilting Furnace Alloying in Launders during transfer of molten metal to tilting furnace for better uniformity of alloying elements Nitrogen Stirring for uniform distribution of Magnesium Silicide Ceramic foam filters of 30ppi for effective filtration of impurities Inline solutionising for rod in the Rolling Mill Electrical heating furnace for Precipitation age hardening

National Seminar on Transmission & Distribution of Energy, New Delhi

March 10, 2005

T4 Alloy - CONTINUOUS CASTING & ROD ROLLING PROCESS IN STERLITE

M AL ELT LO IN YI G & NG

INGOT CHARGING IN MELTER

MELTING FURNACE
ALLOYING BOX

TILTING FURNACE 1

TILTING FURNACE 2

CASTING LAUNDERS

TIBOR ROD GRAIN REFINING

IDLER CASTER BELT MS CASTER

CERAMIC FILTER BOX FLOATING GUIDE

INDUCTION HEATER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Quenching

2 1
COILER

CASTING MACHINE

BAR STRAIGHTENER

ROLLING MILL ( 15 STAND 3 HIGH )

Casting

Thermo-Mechanical Processing

Technical Merits: T4 Alloy Vs conventional M-Temper Alloy

Uniform solutionising No intermediate quenching Smooth wire drawing Consistent metallurgical properties Faster production

National Seminar on Transmission & Distribution of Energy, New Delhi

March 10, 2005

Alloy conductors developed for our International Clients

Alloy Conductors Al59 (400kV)

Specification

Specification Reference SS 424 08 14

Conductivity

UTS

Country

Swedish

59.0% IACS

230 Mpa

Norway

1120 (132kV)

Australian

AS 1531

58.83% IACS

240 Mpa

Australia

6101(400kV)

French

NFC 34-125

53.0% IACS

342 Mpa

Algeria & Morocco

6201(220kV)

American

ASTM B399

52.5% IACS

280 Mpa

Bangladesh & Africa

Type testing for the above alloy conductors were performed at International Laboratories viz., EDF- France, JPOWER Systems- Japan etc.
National Seminar on Transmission & Distribution of Energy, New Delhi March 10, 2005

Exports of Alloy Conductors

Algeria Bangladesh Benin Malawi Morocco

Mozambique Norway South Africa Uganda

National Seminar on Transmission & Distribution of Energy, New Delhi

March 10, 2005

Sterlites Endeavour

STERLITE is committed to the cause of producing and supplying optimal conductors of alloy grade to Utilities for taking the best potential out of aluminium as the most user friendly metal in the power transmission as well as the one which offers the maximum value for money. Our earnest appeal to the Utilities, Consultants and construction Engineering companies is to make Techno-Economic evaluation of the power transmission from project to project and make the optimal conductor selection. We extend our wholehearted cooperation for joining in such efforts by making experimental studies, testing and developing the conductors.
March 10, 2005

National Seminar on Transmission & Distribution of Energy, New Delhi

Thank You

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