Progress through power

Power Conductors & OPGW Cables

Business
Scope of Services
Sterlite provides power transmission & distribution companies with a holistic one-stop window for assessment, development &
implementation of solutions for their power transmission & distribution (T&D) networks.

ASSESS

DEVELOP

IMPLEMENT

T&D Network Assessments

- Assessment of existing &
potential power demand.
- Technical analysis.
- Assessment of suitable
solution options.

T&D Solution Development

T&D Solution Testing

T&D Solution Manufacture,

Inventory Management &
Supply
Technical Support & Service

Sterlite's power solutions comply with BIS, BS EN 50182, ASTM, CSA, IEC,
Gost, JIS and AS international standards.

Power Solution Suite

Sterlite offers a complete range of end-to-end power solutions for transmission and distribution in power networks.

11,12

11,12

1,2,3,4,6,7,8,9,10
Power Generation
Station

1200, 765, 500, 400, 220

132kV: HVAC
800, 500 kV HVAC

Power
Transmission
Line

Transformer

1. STER-AAAC Conductors
2. STER-ACSR Conductors
3. STER-AACSR Conductors

4. STER-ACAR Conductors
5. STER-AAC Conductors
6. STER-AL59 Conductors

Supported by a fully integrated manufacturing facility that converts ingots to bare overhead conductors, Sterlite's range of standard and
custom-designed power solutions deliver superior performance in transmission and performance reliability.

1, 2, 4, 5,6,7,8,9,10

1, 2, 3, 4, 5,6,7,8,9,10

Industrial
Building

220,132,66,33, 11kV

Substation

7. STER-ACSS Conductors
8. STER-TACSR Conductors
9. STER-STACIR Conductors
10. Special Alloy Conductors (1120, EHC, 6101, 6201)

Residential
Building

11. OPGW Cables

12. OPGW Accessories
13. STER-ACCC Conductors
14. STERLITE-ECO Conductors

Our other solutions:

Optical Fiber, Fiber Optic Cables, Structured Data Cables, Passive Solutions, ADSL2+ Modems,Telecom Integration & Managed Services (MPLS,
FTTH, DSL Broadband, NGN, WiMAX, CDN).

The Efficient Power Transmission Solution

The smart energy management solution

Diverse range of applications

Development of efficient power transmission is the need of the

NEW LINES

hour, aimed to alleviate the burgeoning demands from todays

RECONDUCTORING

GREEN SOLUTIONS

AL59 / 1120

STACIR

STERLITE ECOTM

TACSR

GAP

ACCC

If the challenge is to transmit more power over existing lines, high

ACSS

ACCC

ampacity conductors that are manufactured from a range of

STERLITE ECOTM

power utility system.

specialty materials, offer the most optimal means to increase line

ACCC

capacity at relatively low cost.

A range of speciality alloys offer superior thermal resistance that improves the efficiency in high current transmission.

Efficiency [A/mm2]
ACCC

Sterlite Eco

G(Z)TACSR
AAAC
UHC
ACSS

AAAC

TACSR

STACIR

ACSR
Current Rating [A]
+50%
+100%
Sterlites High Performance conductors combined efficiency and
increased current carrying capacity

Benefits in performance and costs

For re-conductoring:
Enhanced current carrying capacity.
No modification / reinforcement to existing towers.

For new lines:

Enhanced current carrying capacity.
Reduction in per unit transmission cost.
Higher corrosion resistance.
Shorter project duration.
Additional capacity of ~100% is reserved for future demand.

6101

60
100

162

160

152
150
170

200
250
4

Tensile strength

Sterlites high performance conductor solutions

Sterlite Al59 Conductors
These are homogenous alloy conductors belonging to Aluminum + Magnesium + Silica Alloy type. These conductors have a conductivity of
59%, and hence have lesser DC resistance & higher current capacity.
Sterlite TACSR Conductors
New aluminum alloys having high thermal resistance can carry 50% to 60% more current as that of ACSR of the same size; while maximum sag
& maximum working tension remains almost same as that of ACSR.
Sterlite ACSS Conductors
These high temperature EC conductors consist of a stranded steel central core with one or more layers of 1350-0 aluminum wires. Steel core wires
are coated with Zinc 5% aluminum misch metal for corrosion resistance and the coating can withstand for continuous operation at 250 oC.
Sterlite STACIR Conductors
New aluminum alloys having high thermal resistance can carry twice as much current as that of ACSR of the same size while maximum sag &
maximum working tension remains the same as that of ACSR.
Sterlite ACCC Conductors
These are high ampacity, low loss hybrid conductors. The composition comprises carbon, glass fiber and trapezoidal shaped aluminum, that
are resistant to environmental degradation. These conductors can reduce line losses up to 30- 40% compared to conventional conductors of
the same diameter and weight. These have 28% more aluminum which greatly increases capacity, reduces losses, & hence cooler operating
temperatures. These are 25% stronger & 60% lighter vs. traditional steel core conductors. These have lower coefficient of thermal expansion
which leads to less sag at higher temperatures. The technology is patented by CTC Cable Corporation, USA and is licensed to Sterlite
Technologies.
Sterlite ECO Conductors
2
These can reduce I R loss of distribution lines by almost 33% as compared to ACSR. These can be used on existing tower structures along with
low loss solution for distribution lines of utilities & wind power companies.
Sterlite DULL Conductors
The current carrying capability of non-specular conductor i.e. Dull conductor is slightly increased because the emissivity of the conductor is
slightly increased . An increase in current capacity in the range of 5% can be achieved, for the same temperature rise, due to this increase in
surface emissivity.
International Standard
Ss4240814, SS4240813, ASTM B856, IEC, ASTM.

Conductivity
70
63
61
60 60
59

HAL

Annealed
Wire
TAL

50

10

50

85 95

STAL
120

150

210

250

Temperature

10
50

Sterlites OPGW Solution*

OPGW the smart energy management solution.
Development of smart energy management systems is the need of the hour, aimed to alleviate the burgeoning demands from todays power
infrastructures.
Optical Fiber Composite Ground Wire (OPGW) is a revolutionary solution that enables synergies between efficient power distribution grids and
high speed optical fiber based SCADA networks, giving power utility companies the unique capabilities of a telecom carrier or service provider.
OPGW replaces a conventional ground wire (or earth wire) to protect the transmission system from lightning strikes and serves as a conductive
medium for carrying fault currents to ground.
OPGW acts as a medium for real-time monitoring and security of the transmission system over which it is installed doubling up for SCADA
controls and network.
OPGW provides telecommunications capability utilizing the fibers.

Sterlite integrates its core expertise in fiber optic cables and bare overhead power conductors.
Since the past two decades, Sterlite has developed technical expertise in fiber optic cables and proven its capabilities in manufacture of energy
efficient bare overhead power conductors.
Sterlite has integrated these core strengths in its comprehensive OPGW solution that includes Optical Fiber Composite Ground Wire and related
hardware.
* Sterlites OPGW Solution includes design, manufacture, supply & installation.

(b) Mechanical performance

Sag and tension.
Vibration.
Galloping and Sheave.
(c) Environmental performance
Range of temperatures and wind zones.
Corrosion levels at the installation sites including
the pollution level (1-4).
Salinity levels.

Sterlite OPGW cables

Sterlite OPGW cables are made up of optical fibers contained in one
or more protective fiber optic units combined with concentric lay
stranded metallic wires in single or multiple layers.
Advanced technology is applied to produce stainless steel tubes
which are then filled with a special hydrogen absorbent,
thixotropic filling compound and made resistant to H 2
permeability due to the seam laser welded, hermetically sealed
construction.
The cable is of compact structure reducing both the ice load and
wind load and ensures quick dissipation of heat generated by short
circuit.

(d) Packing
The end-user needs to determine the length per reel
depending on:
The terrain of the installation site.
The type of installation to be carried out (Live Line or
On Outage).
Capacity of unreeling facility with installer.
Additionally, considerations should be noted for excessive contact
pressure under hardware, the current transfer capability of the
connection of hardware with the OPGW cable and contact between
dissimilar materials that may cause excessive corrosion in some
environments.

The cable is designed to match the existing ground wires in more

or less equal outer diameter and pulling force-to-weight ratio.
Hence, the cable can replace the existing ground wire with no need
to change the route or towers.
Sterlites OPGW cable is produced strictly according to IEEE1138
and relevant international standards pertaining to its
constituents.

Sterlite OPGW hardware

The portfolio includes customized Suspension Sets, Tension Set
Assemblies, Vibration Dampers, Joint Boxes and Bonding Clamps.

Design considerations for OPGW cables

OPGW cables are required to withstand the effects from
installation and long-term in-service exposure to
mechanical, electrical and environmental loads without
allowing any significant degradation in its performance.
OPGW cables would need to fulfill basic performance
criteria, to enable selection of an appropriate design.
(a) Electrical performance
Fault current performance to overcome the line-totower short circuits or system unbalances.
Lightning performance so that lightning arcs do not
impair the long term functionality of the cable.

Sterlites Global Footprint

Power transmission & distribution solutions proven in global networks
Sterlite has been instrumental for the supply of technologically advanced power solutions to leading incumbents over 35 countries.

Sterlite has been a key partner in milestone projects across the globe:
- 'Svenska Kraftnat 500 kV DC Transmission Line Project',
interconnecting Sweden & Finland.
- 'India's first 765 kV EHV Transmission Line Project'.
- 'Accelerated Electricity Access Expansion Project', Ethiopia.
- 'National Integrated Power Pool', Nigeria.
- 'TIEAS 400 kV Networking Project', Turkey.
And many more

The Sterlite Advantage

Since the past decade, Sterlite has developed its technical expertise in manufacture of bare overhead power conductors and proven its
capabilities in developing solutions that have been tested and certified by leading independent laboratories across the globe.

The Sterlite Advantage

Among the largest integrated manufacturing facilities globally.
Strong focus on research and product development.
In-house domain expertise to provide customized solutions.
State-of-the-art in-house laboratories for testing of transmission and performance reliability parameters.
Solutions tested and certified by leading independent laboratories across the globe.

Fully Equipped Plants with International Standards

Sterlite has three fully equipped plants to manufacture Transmission & Distribution Line Conductors.
In-house Properzi Aluminium Rod rolling mills feed the manufacturing line for Transmission & Distribution Conductors. The mills manufacture
electrical grade Aluminium and Alloy Rods.
The plants have complete facilities for rod rolling, wire drawing, heat treatment and stranding to ensure precise tolerances to all international
standards and stringent specification.
A technology upgrade review is periodically undertaken to keep abreast with the latest manufacturing technology.
The cumulative annual installed capacity for Transmission & Distribution Line Conductors and Rods is 200, 000 MT.
Our facilities have state-of-the art NABL approved in-house laboratories.
Packaging is done in the non returnable chemically treated seaworthy wooden/steel drums with good practice design in line with International
standards.

Certifications

10

Testimonials

Notes

Notes

Notes

Sterlite is a registered trademark of Sterlite Technologies Limited.

sterlitetechnologies.com
China
Denmark
India
Netherlands
Russia
South Africa
Taiwan
Turkey
United Arab Emirates
United Kingdom
United States of America

About Sterlite
Sterlite Technologies Limited is a leading
global provider of connectivity solutions for
the power & telecom industries.

email: communications@sterlite.com

RECYCLABLE

October 2011

Equipped with a suite that includes power

conductors, power cables, OPGW Cables,
optical fibers, fiber cables, data cables and a
comprehensive telecom solutions portfolio,
Sterlite's vision is to 'Connect every home on
the planet'. Sterlite is also executing multimillion dollar power transmission system
projects, pan-India.