key projects executed by the indian conductor...

IEEMA CONDUCTOR Division DECEMBER 2014 1

National Seminar on

NEW GENERATION HIGH PERFROMANCE CONDUCTORS

Key Projects executed by the Indian Conductor Industry


Outline 1. Overview of HPC Conductor History (India)

2. Technology & Policy Drivers: Power Transmission Sector of India

3. Past Supplies done by Indian Conductor manufacturers

3.1 High Temperature Conductors (AL-59, TACSR, ACSS/TW etc.)

3.2 High Temperature Low Sag Conductors (STACIR, GAP, ACCR, Composite Carbon

Core types etc.)

4. Case studies – Presence of Indian Conductor Industry

4.1 Reliance T/L 400 kV Quad D/C Samalkot P/S to Vemagiri – (TACSR type)

4.2 APTRANSCO 400 kV T/L of HNPCL Power Plant – (Al-59 Moose equv.)

4.3 BALCO 400 kV Transmission Line – (ACSS/TW Moose equv.)

4.4 Torrent Power, 220 kV Nicol-1 to Nicol-2 T/L – (CCC Zebra equv.)

4.5 IMFA, 132 KV S/C ICCL Grid - CHOUDWAR Grid & 132 kV S/C Chandaka –

Ransingpur T/L – (CCC Panther equv.)

4.6 APTRANSCO 132 kV T/L of Mehboobnagar – (Invar type conductor)

4.7 GETCO, S/C Gondal HadMata 66 kV T/L (TACSR type)

4.8 Tata Power, 22 KV line Saki-IIT, Maharashtra (CCC type)

4.9 International Perspective: AEP 345 kV Transmission Line in USA (CCC type)

5. Type Testing on HPC/HTLS Conductors


2008 • PGCIL called meeting for all Conductor Manufacturers

• There were two major challenges one of them was capacity building to meet current & expected challenges

• Second was readiness of Indian conductor industry for New Technology Conductor

2009 • Conductor Industry successfully developed Al-59 & Thermal Alloy

2010

• Conductor Industry successfully developed Super -Thermal Alloy & Annealed Aluminum

2012 • Composite Core Technology made available to Indian Power Utility

Overview of HPC Conductor History (India)


Technology & Policy Drivers:

Power Transmission Sector of India

Push for Technology – Key to Efficiency & Faster Growth

‘Make In India’ – Promotion of Domestic Manufacturing & Exports


Higher Efficiency in

Transmission & Distribution

Promote newer technologies instead of micro-specifications to the Grid Architecture & Design – Thrust on end result of Power, timelines and future proofing of New corridors being built.

Incentivization of Tx Losses

Usher in Transmission equipment into schemes and incentive plans for utilities towards reducing losses – e.g. R APDRP scheme today consider only transformer losses under its ambit while depriving the utilities to benefit from similar reduction possibilities from conductors.

Maximize Corridor Intensity

Link Carbon Footprint to Transmission utilities in terms of MW transferred per unit land – Incentivize usage of High Capacity Conductors / Multi circuit towers to serve n-1 / n-2 criteria.

Guidelines to Reckon:

New Technological advancements on Tx systems have been embodied in the recent revisions of the

National Transmission Planning Manual of CEA for planners;

Application based Electro Mechanical parameters have been well incorporated in CBIP’s ‘New

Transmission Manual’ revised in July 2014 for designers.

“ T&D Losses in 2011-12 cost the Indian Economy approx. 1% of its GDP” as per World Bank

Policy Drivers: Technology Solutions to Today’s Issues in Indian T&D Sector


What Stands in Way of ‘Make-in-India’ Vision?

Domestic manufacturing sector has stagnated ~ stubbornly sluggish economy hampered by high inflation and interest rates

A steep decline in investment in the last two years ~ share of manufacturing in country’s GDP around18% against the government’s target of 25%

Image of India as a preferred investment destination has taken a beating ~ India ranks a lowly 134 out of 189 countries in the World Bank’s ease of doing business index in 2014.

Indian Electrical Equipment industry is not able to compete effectively in global electrical equipment arena ~ Policy support mechanism is inadequate

India accounts for less than 1 % of global exports of electrical equipment.


2.3% 2.5%

1.6% 1.5%

2.5% 2.7%

2.9%

3.2%

2006-07 2008-09 2010-11 2011-12

Share in Total Exports Share in Total Imports

Indian Electrical Equipment Exports & Imports

Increasing Trade Deficit in Electrical Equipment

Indian Electrical Equipment Exports & Imports

Year India’s electrical

equipment exports (US$ Bn)

Share in Total Exports

India’s electrical equipment Imports

(US$ Bn)

Share in Total Imports

2006-07 2.9 2.3% 4.7 2.5%

2008-09 4.6 2.5% 8.3 2.7%

2010-11 4.1 1.6% 10.9 2.9%

2011-12 4.6 1.5% 15.7 3.2%

Source: DGCIS

While Exports of Electrical equipment have been range bound, Imports have

grown at the compound growth rate of 27.2%

IMPACT ON EXCHEQUER


Supply by Indian Conductor Industry

HTC

AL 59 : > 12000 kms

TACSR : > 1500

kms

ACSS/TW : 250 kms


Supply + Existing Pipeline orders of Indian Conductor Industry

HTLS

Gap : > 10 kms

Invar : > 1000 kms

Carbon Composite

conductors : > 1200 kms


Case Studies


Reliance T/L 400 kV Quad D/C Samalkot P/S to Vemagiri – (TACSR type)

Customer – M/s Reliance Power, Mumbai

Length of the Line: 14 kms

Existing Conductor: ACSR Moose

New Conductor: TACSR equivalent Moose Conductor

Benefits Accrued:

Power transfer more than +50% from 500 MW to 800 MW.

Amalgamation of existing Right of Way

(ROW).


APTRANSCO 400 kV T/L of HNPCL Power Plant (AL-59 type) Customer – M/s APTRANSCO, Hyderabad


Suggested Conductor: ACSR Moose

New Conductor: AL-59 type ACSR Moose equivalent conductor

Benefits Accrued:

Power transfer more than +50% from 450 MW to 750 MW.

Ground Clearance was achieved through

safe installation with existing hutment area

below the Transmission Line


400 kV Korba, Chhatisgarh LILO line – (ACSS/TW type)

Customer – M/s BALCO, New Delhi


Suggested Conductor: ACSR Moose

New Conductor: ACSS/TW Curlew Conductor

Benefits Accrued:

Reduction in Line Losses due to annealed Al. having 63% conductivity.

Taking care of future: Load on this line will

get increased by atleast 40-50% in future and

this solution will suffice the purpose.


Case Study – 220 KV Kathwada to Vastral T/L (CCC) Customer – M/s Torrent Power, Ahmedabad

Length of the Line: 4.935 kms

Existing Conductor: ACSR Zebra

New Conductor: CCC equivalent Zebra Conductor

Benefits Accrued:

Power transfer more than Doubled from 125 MW to 300 MW.

Amalgamation of existing Right of Way

(ROW).


Case Study – 132 KV S/C ICCL Grid - Choudwar Grid (CCC)

Customer: IPP M/s IMFA, Bhubaneswar

Length of the Line: 3kms

Existing Conductor: ACSR Panther

New Conductor: CCC equivalent Panther

Conductor

Benefits accrued :

Power transfer Doubled from 75 MW to 150

MW.

Ground Clearance was achieved through safe

installation with existing hutment area below the

Transmission Line.


Case Study – 132 KV S/C Chandaka – Mancheshwar Line (CCC)

Customer – M/s OPTCL, Bhubaneswar

Length of the Line: 25kms

Existing Conductor: ACSR Panther

New Conductor: CCC equivalent Panther

Conductor

Benefits Accrued:

De-bottlenecking the existing congested

line by > 80%

Severe Right of Way(ROW) problem

effectively resolved.

http://www.google.co.in/url?url=http://edugeeks.in/optcl-govt-jobs-2013-235-posts-in-management-trainee-2/&rct=j&frm=1&q=&esrc=s&sa=U&ei=0FBkVLemIM3nuQTuq4DIDQ&ved=0CBsQ9QEwAw&usg=AFQjCNEY5cGMM4VowcfOz0ySCU0Wwi43wg


APTRANSCO 132 kV T/L nearby Hyderabad (Invar type) Customer – M/s APTRANSCO, Hyderabad


Suggested Conductor: ACSR Wolf & ACSR Panther

New Conductor: Invar type Wolf & Panther equivalent conductor

Benefits Accrued:

Power transfer almost doubled.

Ground Clearance was achieved through safe

installation with existing hutment area below the

Transmission Line


Case Study – 66 kV D/C Line Gondal Hadmatala (TACSR type)

Customer – M/s GETCO, Vadodara


Existing Conductor: ACSR Dog

New Conductor: Thermal Conductor equivalent to ACSR Dog Conductor

Benefits accrued :

Power transfer increased from 22 MW to 38 MW.

Excellent Cost benefit compared to building new 66 kV line with ACSR Panther conductor or voltage upgradation.


Case Study – 22 kV S/C Line Sakinaka to IIT, Mumbai (CCC)

Customer: M/s. Tata Power

Length of Line: 5.1 Km

Existing Conductor : ACSR Dog

New Conductor: CCC equivalent Dog

Conductor

Benefits accrued :

Power transfer Doubled from 30MW Vs

70MW

Ground Clearance was achieved therough

safe installation with existing hutment area

below the Transmission Line.


AEP has commissioned the largest energized reconductor project ever – for any conductor type

The project is 386 circuit Km (240 circuit miles) in length double bundled 345kV – total conductor length over 2600 Km

The transmission line is a critical link to South Texas and is so heavily loaded it cannot be taken out of service to replace the conductor in a conventional manner

Energized reconductoring with CCC conductor provides an immediate increase in capacity to relieve congestion without new construction

No tower replacements, minimal cross arm replacements due to corrosion – line is 30 years old

World’s Largest Energized Reconductoring Project – by AEP in USA


Type Testing Requirements – 1/3

1 UTS test on Complete conductor

(GAP & CCC Conductors with special

dead ends) BS EN/ IEC Standards/ JCS

2 AC Resistance test PGCIL Standards

3 Thermal resistance test for 1 Hour IEC 62004

4 Thermal resistance test for 400 Hour IEC 62004

5 Creep at ambient Temp. IEE 1138, SS 424 08 14, IEC 61395 & Powergrid specification

6 Creep at Elevated Temp Powergrid specification

7 SAG at Elevated temp -

8 Stress Strain at elevated temp IEC 61089 & Powergrid specn

9 Fatigue and Endurance test Powergrid/ IEEE Draft standard

Sr. No. Tests Description Ref. Standard



Sr. No.

Tests Description Ref. Standard

10 Aeolian Vibration test IEEE Draft/ IEC 60794

11 Shieve Test IEC 60794, OPTCL , WBSETCL & Powergrid Specifications

12 Axial Impact test IEC 60794, OPTCL, WBSETCL & Powergrid Specifications

13 Compression test Powergrid , OPTCL & WBSETCL Specifications

14 Crush Strength test IEC 60794, OPTCL , Powergrid & WBSETCL Specification

15 Salt Fog Test ASTM B 117

16 AC Resistance at various temperatures OPTCL , WBSETCL Specification

17 Self Dampening IEEE 563

18 Stiffness IEC 60794


19 High temperature endurance & creep test on

stranded conductor WBSETCL, OPTCL & Powergrid specification

20 Tensional Ductility Test IEC 60794, WBSETCL, OPTCL & Powergrid specification

21 Coefficient of linear expansion on core/ core

strands WBSETCL, OPTCL & Powergrid specification

22 Heat Resistant test on Zinc-5% aluminium

coated steel core wires IEC 62774 draft spec.

23 Temperature cycle test WBSETCL, OPTCL & Powergrid specification, ANSI C 119.4 100X 5 cycles

Sr. No. Tests Description Ref. Standard


Indian Conductor Industry seek support from CPRI to have these testing facilities in India so we san same lots of time & have indigenization of HTLS technology effectively.

Support from MOP/CEA for creation of above facilities in India to

have “Make in India” concept.


Thank You

key projects executed by the indian conductor...

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