OVERHEAD POWER

TRANSMISSION SOLUTIONS
High Performance Conductors and Optical Ground Wire

EMPOWERING

HUMANITY
by addressing the toughest
challenges of energy delivery

Sterlite Power Transmission Limited

F-1, Mira Corporate Suits, 1 & 2, Mathura Road, Ishwar Nagar,
New Delhi - 110065, India | www.sterlitepower.com
/ sterlitepower / sterlitepower / sterlitepower / sterlitepower
Lasting Legacy
Sterlite Power Transmission Limited is at the forefront of the power transmission industry and shares Sterlite has four Business Units (BUs):
its lineage with the $13 billion natural resources giant, Vedanta Group. Driven by its core purpose of • SOLUTIONS
Empowering Humanity by Addressing the Toughest Challenges of Energy Delivery, it is committed to • INFRASTRUCTURE
revolutionising the power transmission sector by harnessing cutting-edge technology for efficient, • INVIT
reliable and smart energy delivery. • CONVERGENCE

01 © SPTL 02 © SPTL
Global Presence
Sterlite Power has a growing international footprint. It is a leading developer of intra and inter-state power Projects in India & Brazil
transmission in India and Brazil and a major manufacturer of power cables, power conductors and OPGW,
catering to 200+ customers across EPCs, Government & Private utilities in over 35 countries.
Customers across 35 countries

Australia
Benin (Africa)
Canada
Chile
Colombia
Costa Rica
Egypt
Finland
France
Gabon
Ghana
Guinea
India
Indonesia
Ivory Coast
Kenya
Malaysia
Mali
Nigeria
Namibia
Paraguay
Peru
Poland
Portugal
Saudi Arabia
Serbia
South Africa
South Korea
Spain
Sweden
Tanzania
Uganda
Uruguay
Venezuela
Zimbabwe

03 © SPTL 04 © SPTL
Power Solutions Partner
Sterlite Power has oriented all its offerings to addresses the three core customer challenges - shortage Sterlite works closely with customers to deliver custom solutions for assessment, development
of Space, Time and Money. To meet diverse customer needs, Sterlite offers comprehensive overhead & implementation requirements.
power transmission products including:
T&D NETWORK ASSESSMENTS DEVELOPMENT IMPLEMENTATION
• HIGH PERFORMANCE CONDUCTORS
• TYPICAL T&D ALUMINIUM CONDUCTORS
• Assessment of existing & • T&D solution development • T&D solution manufacture
• OPGW CABLES
potential power demand • T&D solution testing • Inventory management
• Technical analysis & supply
• Assessment of suitable • Technical support & service
solution options

OPGW

Genco
HPC

Power cable
Transo
Overhead T&D Conductors
including HPC OPGW

HPC
Power cable
Substation

25% of India's national grid

runs on Sterlite's conductors.
Enterprise

05 © SPTL 06 © SPTL
Efficiency combined with Pioneering High Performance
high current carrying capacity Conductor Solutions in India
Applications of HPC Solutions:

STER-ACCC© STER-STACIRTM GAP STER-ACSSTM

HIGH TEMPERATURE LOW SAG CONDUCTORS

OTHER HIGH PERFORMANCE CONDUCTORS

STER-TACSRTM STER-AL59TM /1120 STER-ECOTM DULL

1st ACCC deployment for India 1st STACIR deployment for Indian
STU 132 kV line, MSETCL Stu 132 kV line, APTRANCO

Deployment of TACSR & AL 59 on 1200 kV 1st ACCC deployment on distribution line 22 kV line.
UHVAC PGCIL. Test Station, Bina, MP TATA Power-Mumbai

ACSS supplied to RE Segment and Power Plants

07 © SPTL 08 © SPTL
 Enabling "Smart" Power Distribution
High Performance Conductors with our High Performance Conductors
Development of efficient power transmission

Efficiency [A/mm2]
is the need of the hour to alleviate the burgeoning
demands of today’s power utilities system.
Sterlite Eco ACCC

If the challenge is to transmit more power over

an existing line, high ampacity conductors that
ACSS
are manufactured from a range of speciality
AAAC
materials, offer the most optimal means to UHC
increase line capacity at a relatively low cost.
AAAC STACIR
A range of speciality alloys offer superior
thermal resistance that improves the efficiency in
high current transmission. TACSR G(Z)TACSR

As these new generation conductors enhance ACSR

the current carrying capacity, they are favourable
for use in reconductoring as well as new lines. +50% +100%
This provides the user high corridor intensity Current Rating [A]
and reduces congestion in existing lines.
Sterlite's High Performance Conductors combine
effciency and increased current carrying capacity

Benefits in Performance and Costs

RE-CONDUCTORING GREEN SOLUTION NEW LINES

• Enhanced current carrying • Low losses leading to lower • Enhanced current carrying
capacity for the same carbon emissions capacity
diameter/weight • Run at lower temperature • Reduction in per unit
• Minimum or no for the same current transmission cost
modification/reinforcement • Higher corrosion resistance
to existing towers • Shorter project duration
• Additional capacity of
100% is reserved for
future demand

1,2,3,4,6,7,8,9,10 11,12,13 11,12,13

1,2,3,4,5,6,7,8,9,10,13,14 1,2,3,4,5,6,7,8,9,10,13,14

220,132,66,33,11kV

1200,765,500,
400,220
132kV:HVAC
+ 800, 500kV
HVAC

Power Generation Station Transformer Power Transmission Line Substation Residential Building Industrial Building
Power cables Power cables

1. STER-AAACTM Conductors 5. STER-AACTM Conductors 9. STER-STACIRTM Conductors 12. OPGW Accessories

2. STER-ACSR TM
Conductors 6. STER-AL59 TM
Conductors 10. Special Alloy Conductors 13. STER-ACCCTM Conductors
3. STER-AACSR TM
Conductors 7. STER-ACSS TM
Conductors (1120, EHC, 6101, 6201) 14. STERLITE-ECOTM Conductors
4. STER-ACARTM Conductors 8. STER-TACSRTM Conductors 11. OPGW Cables

09© SPTL 10 © SPTL

STER-AL59TM STER-TACSRTM
These are homogenous alloy conductors of Aluminium + Magnesium + Silica Alloy type. These conductors have Sterlite® Thermal-resistant Aluminium-alloy Conductor, Steel Reinforced (TACSR) conductors are high ampacity
a conductivity of 59% and hence have lesser DC resistance and higher current carrying capacity. conductors, wherein the inner core is composed of galvanized steel and the outer layers are composed of
thermal-resistant aluminium–alloy.

Al59 Wire APPLICATION Thermal Aluminum APPLICATION

Alloy wire
Al59 alloy conductors are used in power TACSR conductors are recommended for new
transmission and distribution lines for a wide lines for high power transfer requirements.
voltage range (low to ultra-high voltage).
These conductors have higher current carrying
capacity and lower losses due to DC resistance.
AI59 conductors have high corrosion resistance,
Al59 Wire making them most suited for deployment Wire-Galvanized
in coastal regions. steel

BENEFITS
BENEFITS
• 26%-31% more current carrying capacity than ACSR of the same size, while maximum sag remains
the same and working tension is lesser than that of ACSR. New aluminium alloys having high thermal resistance can carry 50%-60% more current than ACSR of the same
• Resistivity is substantially lesser than that of ACSR/AAAC conductors, resulting in lower I2R losses. size, while maximum sag and maximum working tension remains almost the same as that of ACSR.
• Higher corrosion resistance than 6201 alloy series (AAAC). • Can carry 50%-60% more current than ACSR of the same size.
• Higher capacity new lines can be built to deal with future demands.

TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS

PROPERTIES AL59 (ACSR MOOSE AL59 (ACSR ZEBRA AL59 (ACSR PANTHER PROPERTIES TACSR (ACSR MOOSE TACSR (ACSR ZEBRA TACSR (ACSR PANTHER
EQUIVALENT) EQUIVALENT EQUIVALENT) EQUIVALENT EQUIVALENT) EQUIVALENT)

Typical factors 3.50 mm 0.1378 in 3.18 mm 0.1252 in 3.00 mm 0.1181 in Typical factors 3.53 mm 0.1378 in 3.18 mm 0.1252 in 3.00 mm 0.1181 in

Reference specifications SS 4240814 SS 4240814 SS 4240814 Reference specifications IEC 62004 IEC 62004 IEC 62004

Total cross section area 587.00 mm2 0.9099 in2 484.25 mm2 0.7506 in2 261.50 mm2 0.4053 in2 Total cross section area 596.99 mm2 0.9253 in2 484.25 mm2 0.7506 in2 261.50 mm2 0.4054 in2

Conductive wire Al59 Al59 Al59 Conductive wire Al Zr AT1 Al Zr AT1 Al Zr AT1

Core wire Al59 Al59 Al59 Core wire Galvanized Steel Galvanized Steel Galvanized Steel

Conductor diameter 31.50 mm 1.2402 in 28.62 mm 1.1268 in 21.00 mm 0.8268 in Conductor diameter 31.77 mm 1.2508 in 28.62 mm 1.1268 in 21.00 mm 0.8268 in

1618 1087.2 1336 897.8 720 483.8 2004 1346.6 1621 1089.3 972 653.2
Weight Weight
kg/gm lbs/mile kg/km lbs/mile kg/km lbs/mile kg/gm lbs/mile kg/km lbs/mile kg/km lbs/mile
14350 31636.3 12340 27205.01 6661 14684.97 16438 36239.54 14407 31761.96 10119 22308.55
Ultimate tensile strength Ultimate tensile strength
kg lbs kg lbs kgf lbs kg lbs kg lbs kg lbs
DC resistance at 0.05 0.08 0.06 0.10 0.11 0.18 DC resistance at 0.06 0.09 0.07 0.11 0.14 0.22
20°C temperature Ω/km Ω/mile Ω/km Ω/mile Ω/km Ω/mile 20°C temperature Ω/km Ω/mile Ω/km Ω/mile Ω/km Ω/mile
Maximum operating Maximum operating
95°C 203°F 95°C 203°F 95°C 203°F 150°C 302°F 150°C 302°F 150°C 302°F
temperature temperature
Current carrying capacity Current carrying capacity
at maximum operating 1094 Amp 958 Amp 654 Amp at maximum operating 1509 Amp 1302 Amp 831 Amp
temperature temperature

Assumptions: Ampacity is calculated based on, 450C (1130F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of Assumptions: Ampacity is calculated based on, 450C (1130F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of
solar absorption, 0.6 as coefficient of emmisivity and 1200 wt/sqm coefficient for solar radiation, at sea level. solar absorption, 0.6 as coefficient of emmisivity and 1200 wt/sqm coefficient for solar radiation, at sea level.

11 © SPTL 12 © SPTL
STER-STACIRTM STER-ACSSTM
Sterlite® Super Thermal Alloy Conductor Invar Reinforced (STACIR) conductor has outer layers composed of Sterlite® Aluminium Conductor Steel Supported (ACSS) conductor is a composite concentric lay–stranded
Super Thermal Aluminium (STAL) alloy wires that can operate up to 2100C (4100F). The inner core is composed conductor consisting of a stranded steel central core with one or more layers of 1350-0 (High Temperature)
of aluminium clad INVAR wires. INVAR is a metal alloy with 36% Ni in steel. aluminium wires.

Super-Thermal Resistant APPLICATION Al 1350-0 wire APPLICATION

Aluminum Alloy wire (STAL)
STACIR/AW conductors are suited for re–conductoring ACSS conductors can be used as a low loss
applications. The capacity of existing transmission solution, as part of efficient transmission
line can be enhanced by simply replacing the networks. These conductors are suitable for
existing conductor without any modification to lines that transmit very high or fluctuating loads.
the tower.
BENEFITS
Aluminum-clad INVAR Wire Wire-Galvanized steel • Improved self–damping characteristics and high
degree of resistance to vibration fatigue.
• Can operate continuously at high temperatures up
to 250oC (482oF) with appropriate steel core
BENEFITS coating v/s 1000C (212oF) for standard ACSR, hence
can carry twice as much current as ACSR conductor.
• Can carry 100% more current than that of ACSR of the same size, while maximum sag and maximum
working tension remain the same as that of ACSR. • No creep.
• No modification or reinforcement is required to existing towers for uprating transmission and distribution lines. • Less susceptible to Aeolian vibration fatigue due to very low mechanical load on the annealed aluminium wire.
• Requires conventional installation techniques.
TECHNICAL SPECIFICATIONS • Allows for lower overall transmission cost.

PROPERTIES STACIR (ACSR STACIR (ACSR STACIR (ACSR TECHNICAL SPECIFICATIONS

MOOSE EQUIVALENT) ZEBRA EQUIVALENT) PANTHER EQUIVALENT
PROPERTIES ACSS CURLEW ACSS DRAKE ACSS HAWK
Typical factors 3.53 mm 0.1390 in 3.18 mm 0.1252 in 3.00 mm 0.1181 in
Typical factors 3.51 mm 0.1383 in 4.44 mm/ 0.1749 in/ 3.51mm/ 0.1383 in/
Reference specifications IEC 62004 IEC 62004 IEC 62004
3.45 mm 0.136 in 2.67 mm 0.1051 in

Total cross section area 597.00 mm2 0.9254 in2 484.50 mm2 0.751 in2 261.50 mm2 0.4054 in2
Reference specifications ASTM B856 ASTM B856 ASTM B856
Conductive wire Al Zr AT3 Al Zr AT3 Al Zr AT1
Total cross section area 591.00 mm2 0.9161 in2 468.50 mm2 0.7262 in2 281.50 mm2 0.4356 in2
Core wire Aluminium clad Invar Aluminium clad Invar Aluminium clad Invar Al1350-0 (Fully Annealed Al1350-0 (Fully Annealed Al1350-0 (Fully Annealed
Conductive wire
Al wires) Al wires) Al wires)
Conductor diameter 31.77 mm 1.2508 in 28.62 mm 1.1268 in 21.00 mm 0.8268 in Mischmetal Alloy Mischmetal Alloy Mischmetal Alloy
Core wire
Coated Steel Coated Steel Coated Steel
1993 1339.2 1582 1063.1 939 631.0
Weight
kg/gm lbs/mile kg/km lbs/mile kg/km lbs/mile Conductor diameter 31.62mm 1.2449 in 28.13 mm 1.1075 in 21.77 mm 0.8571 in
14641 32277.84 11968 26384.89 8436 18598.17
Ultimate tensile strength 1981 1331.2 1629 1094.6 976 655.8
kg lbs kg lbs kg lbs Weight
kg/km lbs/mile kg/km lbs/mile kg/km lbs/mile
DC resistance at 0.06 0.09 0.07 0.11 0.13 0.21
20°C temperature Ω/km Ω/mile Ω/km Ω/mile Ω/km Ω/mile 13807 30439.19 12742 28091.27 7779 17149.74
Ultimate tensile strength
kg lbs kg lbs kg lbs
Maximum operating
210°C 410°F 210°C 410°F 210°C 410°F DC resistance at 0.05 0.09 0.07 0.11 0.12 0.19
temperature
20°C temperature Ω/km Ω/mile Ω/km Ω/mile Ω/km Ω/mile
Current carrying capacity
Maximum operating
at maximum operating 1871 Amp 1626 Amp 1040 Amp 210°C 410°F 210°C 410°F 210°C 410°F
temperature
temperature
Current carrying capacity
at maximum operating 1854 Amp 1564 Amp 1120 Amp
Assumptions: Ampacity is calculated based on, 450C (1130F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of temperature
solar absorption, 0.6 as coefficient of emmisivity and 1200 wt/sqm coefficient for solar radiation, at sea level.
Assumptions: Ampacity is calculated based on, 450C (1130F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of
solar absorption, 0.6 as coefficient of emmisivity and 1200 wt/sqm coefficient for solar radiation, at sea level.

13 © SPTL 14 © SPTL
STER-ACCCTM
Sterlite Aluminium Conductor Composite Core (ACCC) conductor consists of a hybrid carbon and glass fiber core which TECHNICAL SPECIFICATIONS
is wrapped with trapezoidal shaped aluminium strands. The high strength structural core carries most of the
conductor’s mechanical load, while the fully annealed aluminium strands carry all of the conductor’s electrical PROPERTIES ACCC HELSINKI ACCC LISBON
current. ACCC conductor’s composite core is much lighter and stronger than conventional or high-strength steel core.
Typical factors 5.97 mm 0.2355 in 7.11 mm 0.2799 in
Trapezoidal Wire APPLICATION
Reference specifications ASTM B857, ASTM B609 ASTM B857, ASTM B609
Ideal for Reconductoring
• Increase capacity while improving line clearance Total cross section area 176.11 mm2 0.2730 in2 358.40 mm2 0.5555 in2
and losses.
Conductive wire 1350 0 temper AI 1350 0 temper AI
• Reduce strain on structures increasing life.

Reduced Line Losses in New Lines Core wire Composite Core Composite Core
• Under equal load conditions reduces line losses by
Composite Core 30%-40% compared to conductors of the same Conductor diameter 15.65 mm 0.6161 in 21.78 mm 0.8575 in
diameter and weight. 455 305.7 957 642.8
Weight
• 100% more capacity building towards future demands. kg/km lbs/mile kg/km lbs/mile
7036 15511.71 10574 23311.65
Ultimate tensile strength
kg lbs kg lbs
BENEFITS 0.19 0.30 0.09 0.14
DC resistance at 20°C temperature
Ω/km Ω/mile Ω/km Ω/mile
• With 28% more annealed aluminium in a trapzoidal configuration the ACCC conductor of the same diameter
as ACSR, can double the current (ampacity) rating; Higher operating effciency reduces line losses and Maximum operating temperature 175°C 347°F 175°C 347°F
associated emissions by more the 35%, resulting in more power delivered and lower power generation costs.
Current carrying capacity
• ACCC conductors use a patented carbon/glass/thermoset resin core that provides height strength and at maximum operating 710 Amp 1079 Amp
reduces height temperature sag. temperature
• Can re–conductor existing pathway without structural modification and reduce capital expenses on
new lines.
PROPERTIES ACCC COPENHAGEN ACCC DRAKE
• Uses conventional installation methods, tools and mostly conventional hardware. Requires no special tools
and limited special training.
Typical factors 5.97 mm 0.2350 in 9.53 mm 0.3752 in
• Resists enviromental degradation–will not rust, corrode or cause electrolysis with aluminium conductors
and components. Reference specifications ASTM B857, ASTM B609 ASTM B857, ASTM B609

Total cross section area 246.57 mm2 0.3822 in2 588.30 mm2 0.9119 in2

Conductive wire 1350 0 temper AI 1350 0 temper AI

Core wire Composite Core Composite Core

Conductor diameter 18.30 mm 0.7205 in 28.14 mm 1.1079 in

657 441.5 1558 1046.9

Weight
kg/km lbs/mile kg/km lbs/mile
7443.9 16410.97 18691 41206.55
Ultimate tensile strength
kg lbs kg lbs
0.13 0.21 0.06 0.09
DC resistance at 20°C temperature
Ω/km Ω/mile Ω/km Ω/mile

Maximum operating temperature 175°C 347°F 175°C 347°F

Current carrying capacity

at maximum operating 858 Amp 1484 Amp
temperature

Assumptions: Ampacity is calculated based on, 450C (1130F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of
solar absorption, 0.6 as coefficient of emmisivity and 1200 wt/sqm coefficient for solar radiation, at sea level.

15 © SPTL 16 © SPTL
STER-ECOTM Overhead T&D Aluminium Conductors
Eco Series conductors consists of trapezoidal shaped special aluminium alloy containing magnesium, silicon
and copper stranded with round core. The trapezoidal shape provides upto 96% compactness.

STER-ACSRTM & STER-ACSR-AW

Trapazoidal APPLICATION
Aluminium Wire
Eco Series conductors are innovative, efficient, low
loss & most importantly an economical solution
for re–conductoring power lines and constructing 6/1 7/1 12/7 36/1 24/7 26/7
new lines. The higher efficiency of Eco Series
conductors enables significant saving when
substituted in grid systems for normal ACSR or
Aluminium Core AAAC conductors. Also, for delivery of same
power to the customers, Eco Series conductors
enable power generators to reduce the amount
of power they must generate and hence lower
emissions.
BENEFITS 30/7 30/19 54/7 54/19 84/19
• Upto 30% less I2R losses for same sized conductor.
• For same output runs cooler by 5-100C (41-500F), hence lower carbon emissions.
STER-AACTM & STER-AAACTM
• Contributes to lowering emission of greenhouse gases.
• Can be deployed with existing structural designs.

TECHNICAL SPECIFICATIONS

PROPERTIES ECO PANTHER

Typical factors 2.37 mm 0.0933 in

7 19 37 61 91
Reference specifications SS42408013, 14

Total cross section area 314.11mm2 0.9161 in2 STER-ACARTM

Conductive wire Al59 wire

Core wire Al59 wire

Conductor diameter 20.50 mm 0.8071 in

866 581.9
Weight
kg/km lbs/mile
7430 16379.55 4/3 15/4 12/7 18/19 24/13 30/7
Ultimate tensile strength
kg lbs
0.10 0.15
DC resistance at 20°C temperature
Ω/km Ω/mile

Maximum operating temperature 95°C 203°F

Current carrying capacity

at maximum operating 750 Amp
temperature

33/4 33/28 42/19 48/13 54/7

Assumptions: Ampacity is calculated based on, 450C (1130F) ambient temperature, 0.6 m/s wind velocity, 0.5 as coefficient of
solar absorption, 0.6 as coefficient of emmisivity and 1200 wt/sqm coefficient for solar radiation, at sea level.

17 © SPTL 18 © SPTL
STER-ACSRTM
Aluminium Conductors Steel Reinforced (ACSR), also known as Bare aluminium conductors, are one of the most
CONDUCTOR MODULUS OF ELASTICITY* LINEAR COEFFICIENT*
widely used conductors for transmission. The conductor consists of one or more layers of aluminium wires stranded SR. NO.
CONSTRUCTION MPA KSI /0C /0F
over a high strength steel core that can be single or multiple strands depending on the requirement. There can be
various stranding combinations of Al and steel wires lending flexibility to obtain suitable current carrying
11 45AI/7Steel 61000 8847 20.9 X 10-6 11.6 X 10-6
capacity and mechanical strength for the application.
12 48AI/7Steel 62000 8992 20.5 X 10-6 11.4 X 10-6
APPLICATION
13 54AI/7Steel 70000 10153 19.3 X 10-6 10.7 X 10-6
Overhead T&D lines-MV, HV & EHV (11 kV to 800 kV Lines).

ADVANTAGES 14 54AI/19Steel 68000 9863 19.4 X 10-6 10.8 X 10-6

Its low weight combined with high tensile strength allows larger span runs. Electrical losses by corona effect 15 84AI/7Steel 65000 9427 20.1 X 10-6 11.1 X 10-6
are greatly reduced, due to the larger diameter size. Economical transmission and distribution of electrical
energy can be achieved by ACSR, at very high voltages and distances. 16 84AI/19Steel 64000 9282 20.0 X 10-6 11.1 X 10-6

MANUFACTURING CAPABILITY
SR. NO. DESCRIPTION RANGE

SR. NO. DESCRIPTION RANGE

01 Permissible Temp in continuous operation 850C 1850F

01 Conductor Area 10.6 mm2 to 1393 mm2 0.0164 in2 to 2.1592 in2
02 Temp in a short circuit (duration up to 5 s) 2000C 3920F

02 Conductor construction 6A/ 1 Steel to 84AI/19 Steel

STANDARDS
03 Conductivity of Aluminium 61% IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant national and international standards.

PHYSICAL PROPERTIES

At a temperature of 200C (680F), the density of hard–drawn aluminium has been taken as 2.703 g/cm3 (168.74
lb/cf) and for steel wire 7.78 g/cm3 (485.69 lb/cf).

CONDUCTOR MODULUS OF ELASTICITY* LINEAR COEFFICIENT*

SR. NO.
CONSTRUCTION MPA KSI /0C /0F

01 6AI/1Steel 81000 11748 19.2 X 10-6 10.7 X 10-6

02 6AI/7Steel 75000 10878 19.8 X 10-6 11.0 X 10-6

03 12AI/7Steel 107000 15519 15.3 X 10-6 8.5 X 10-6

04 18AI/1Steel 66000 9572 21.2 X 10-6 11.8 X 10-6

05 24AI/7Steel 74000 10733 19.4 X 10-6 10.8 X 10-6

06 26AI/7Steel 77000 11168 18.9 X 10-6 10.5 X 10-6

07 30AI/7Steel 82000 11893 17.8 X 10-6 9.9 X 10-6

08 26AI/19Steel 76000 11023 19.0 X 10-6 10.5 X 10-6

09 30AI/19Steel 81000 11748 17.9 X 10-6 9.9 X 10-6

10 42AI/1Steel 60000 8702 21.2 X 10-6 11.8 X 10-6

19 © SPTL 20 © SPTL
STER-ACSRTM/ AS or STER-ACSRTM / AW STER-AACTM
Aluminium Conductors, Aluminium Clad Steel Reinforced (ACSR/AS or ACSR/AW) are concentrically stranded AAC conductor is also known as aluminium stranded conductor. These conductors consist of several layers of
conductors with one more layers of hard drawn 1350-H19 aluminium wires on Aluminium Clad steel wire core. aluminium wires stranded concentrically. AAC are manufactured from electrolytically refined aluminium with a
The core can be single wire or stranded depending on the size. minimum purity of 99.7%

APPLICATION APPLICATION

High voltage overhead transmission & distribution lines and coastal regions.
ADVANTAGES
A higher UTS can be achieved by increasing core and higher current carrying capacity by increasing
AI content. The mechanical properties of ACSR/AS conductors are similar to ACSR conductors but
they offer improved ampacity and resistance to corrosion beacause of the presence of aluminium
clad steel wires in the core. These conductors are better replacement for ACSR conductors where
corrosive conditions exist.
MANUFACTURING CAPABILITY
All Aluminium Conductor (AAC) have high ratio of electrical conductivity to weight, high flexibility
and low UTS. Also the aluminium has low levels of brittleness.
ADVANTAGES
All Aluminium Conductors (AAC) are used in low voltage overhead lines in urban areas and in high
voltage substation conductoring. They are also used in very cold areas due to low brittleness of
aluminium in the MV lines.
MANUFACTURING CAPABILITY

SR. NO. DESCRIPTION RANGE

SR. NO. DESCRIPTION RANGE
01 Conductor Area 10.6 mm2 to 1095 mm2 0.0164 in2 to 1.6973 in2
01 Conductor Area 10.6 mm to 1393 mm
2 2
0.0164 in to 2.1592 in
2 2

02 Conductor construction 7AI to 91 AI

02 Conductor construction 6AI/1ACS to 84AI/19ACS
03 Conductivity 61%
03 Conductivity of Aluminium 61%

PHYSICAL PROPERTIES
04 Conductivity of ACS Wire 20.3%
At a temperature of 200C (680F), the density of hard–drawn aluminium has been taken as 2.703 g/cm3 (168.74 lb/cf).
PHYSICAL PROPERTIES
CONDUCTOR MODULUS OF ELASTICITY* LINEAR COEFFICIENT*
At a temperature of 200C (680F), the density of hard–drawn aluminium has been taken as 2.703 g/cm3 (168.74 SR. NO.
CONSTRUCTION MPA KSI /0C /0F
lb/cf) and aluminium clad steel wires 6.59 g/cm3 (411.40 Ib/cf)
01 7 Strands 60000 8702 23.0 X 10-6 12.8 X 10-6
CONDUCTOR MODULUS OF ELASTICITY* LINEAR COEFFICIENT*
SR. NO. 02 19 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6
CONSTRUCTION MPA KSI /0C /0F

01 6AI/1ACS 74000 10733 19.3 X 10-6 10.7 X 10-6 03 37 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6

02 26AI/7ACS 71000 10298 19.1 X 10-6 10.6 X 10-6 04 91 Strands 55000 7977 23.0 X 10-6 12.8 X 10-6

03 30AI/7ACS 74000 10733 18.0 X 10-6 10.0 X 10-6

SR. NO. DESCRIPTION RANGE
04 54AI/7ACS 65000 9427 19.5 X 10-6 10.8 X 10-6
01 Permissible Temp in continuous operation 750C 1670F

SR. NO. DESCRIPTION RANGE 02 Temp in a short circuit (duration up to 5 s) 2000C 3920F

01 Permissible Temp in continuous operation 750C 1670F STANDARDS

IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant national and international standards.
02 Temp in a short circuit (duration up to 5 s) 2000C 3920F

STANDARDS
IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant national and international standards.

21 © SPTL 22 © SPTL
STER-AAACTM STER-ACARTM
AAAC (All Aluminium Alloy Conductors)-Several layers of aluminium alloy (generally AI-Mg-Si) stranded in Aluminium Conductor Alloy reinforced (ACAR) is formed by concentrically stranded wires of Aluminium 1350
concentic layers. Designed using a high strength aluminium alloy to achieve a high strength-to-weight ratio; and high strength Aluminium–Magnesium-Silicon (AIMgSi) alloy core. The number of wires of each depends on
affords better sag characteristics. the cable design. The typical design comprises a stranded core of AIMgSi alloy strands but in certain cable
constructions, the wires of AIMgSi alloy strands can be in layers throughout the Aluminium 1350 strands.
APPLICATION
APPLICATION
All Aluminium Alloy Conductors (AAAC) are extensively used for primary and secondary transmission
Aluminium Conductors Alloy Reinforced (ACAR) are extensively used for overhead distribution and
in bare overhead distribution and transmission lines (11 kV to 800 kV lines) and HV substations.
transmission lines.
Also, usable in highly polluted industrial areas and coastal regions due to corrosion resistance.
ADVANTAGES
ADVANTAGES
ACAR has better mechanical and electrical properties as compared to an equivalent ACSR, AAC or
AAAC has good corrosion resistance, however due to the absence of steel, its resistance is lower
AAAC. A very good balance between mechanical & electrical properties makes ACAR the best
than ACSR. AAAC can carry 15-20% extra current and has a higher life span (60 years) as compared
choice where ampacity, strength and low weight are main consideration for line design. ACAR
to ACSR of equal size (30 years). The surface hardness of AAAC is 80 BHN while ACSR has hardness
offers higher strength and ampacity than ACSR of same weight. A higher UTS and current carrying
35 BHN. This reduces damage to the surface during handling, thereby leading to lesser corona
capacity can be obtained by increasing aluminium alloy and aluminum content respectively.
losses and ratio interference at EHV. AAAC can be operated with stable temperature of 850C
against ACSR conductors which are stable upto 750C. Since AAAC has higher strength-to-weight MANUFACTURING CAPABILITY
ratio, span can be increased by 2-15% resulting in overall reduction of cost in tower supports and other
accessories in the transmission line system.
SR. NO. DESCRIPTION RANGE
MANUFACTURING CAPABILITY
01 Conductor Area 10.6 mm2 to 1520 mm2 0.0164 in2 to 2.356 in2

SR. NO. DESCRIPTION RANGE 02 Conductor construction 4AI/3AI Alloy to 72AI/19 AI Alloy

01 Conductor Area 10.6 mm2 to 1095 mm2 0.0164 in2 1.6973 in2 03 Conductivity of Aluminium 61%

02 Conductor construction 7AI Alloy to 91 AI Alloy 04 Conductivity of AI Alloy 52.5% to 53%

03 Conductivity of Aluminium 52.5% to 53%

PHYSICAL PROPERTIES

PHYSICAL PROPERTIES At a temperature of 200C (680F), the density of hard–drawn aluminium has been taken as 2.703 g/cm3 (168.74 lb/cf)
/0F
and aluminium alloy wires 2.70 g/cm3 (168.56 Ib/cf)
At a temperature of 200C (680F), the density of hard–drawn aluminium has been taken as 2.703 g/cm3 (168.74 lb/cf).

CONDUCTOR MODULUS OF ELASTICIITY* LINEAR COEFFICIENT*

CONDUCTOR MODULUS OF ELASTISITY* LINEAR COEFFCIENT* SR. NO.
SR. NO. CONSTRUCTION MPA KSI /0C /0F
CONSTRUCTION MPA KSI /0C /0F /0F
01 7 Strands 62000 8992 23.0 X 10-6 12.8 X 10-6
01 7 Strands 62000 8992 23.0 X 10-6 12.8 X 10-6
02 19 Strands 60000 8702 23.0 X 10-6 12.8 X 10-6
02 19 Strands 60000 8702 23.0 X 10-6 12.8 X 10-6
03 37 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6
03 37 Strands 57000 8267 23.0 X 10-6 12.8 X 10-6
04 61 Strands 55000 7977 23.0 X 10-6 12.8 X 10-6
04 61 Strands 55000 7977 23.0 X 10-6 12.8 X 10-6

SR. NO. DESCRIPTION RANGE

SR. NO. DESCRIPTION RANGE
01 Permissible Temp in continuous operation 850C 1850F
01 Permissible Temp in continuous operation 850C 1850F
02 Temp in a short circuit (duration up to 5 s) 2000C 3920F
02 Temp in a short circuit (duration up to 5 s) 2000C 3920F
STANDARDS
STANDARDS IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant national and international standards.
IEC, BS, ASTM, CAN-CSA, DIN, IS, AS and relevant national and international standards.

23 © SPTL 24 © SPTL
Manufacturing Expertise Superior Packaging
Sterlite Power is among the largest fully integrated power product manufacturers globally. Sterlite uses packaging specifically designed to withstand transportation and handling and have standard
nomenclature for identification.
As a major player in the power industry with experience of over a decade, Sterlite has garnered technical
expertise in the manufacture of bare overhead conductors and has proven capabilities in developing Features and benefits
solutions that have been tested and certified by leading independent laboratories. • Outer protection of conductors with thick PE sheet and solid PP sheet in place of wooden lagging.
Inner surface of flange and barrel are protected with PPE Solid Sheet. The Drums are painted with one
Sterlite’s reputation for superior product delivery is due to:
prime coat and then with synthetic enamel.
• Three plants that manufacture Overhead T&D conductors and OPGW cables in India.
• Optimum mechanical protection without breaking/splintering like wooden batten.
• Fully equipped plants that have end-to-end facilities for rod rolling, wire drawing, heat treatment and
• Impact and puncture resistant (second layer of solid sheet).
stranding to ensure precise tolerances to all international standards and stringent specifications.
• Environmental resistance-long life, unaffected by climate change and UV exposure unlike wood, zero risk
• In house Properzi Aluminium Rod rolling mills that feed the manufacturing line for Transmission and
of deterioration and fungus.
Distribution conductors. The mills manufacture electrical grade Aluminium and Alloy Rod.
• Nail free-no risk of nail damage to conductor.
• Periodic technology upgrade review to keep abreast with the latest manufacturing technology.
• Reusable-can be dismantled and reused as and when required.
• Strong focus on research and development. In-house domain expertise is used to create customised
• Can be stored as long as possible.
solutions for clients.

Benchmarking Impeccable Quality

Our centralised quality control department comprises a team of experienced engineers. At our fully
equipped laboratories, we continuously monitor quality parameters at all stages from raw material inflow,
in process and final inspection.

In-house state of the art NABL accredited laboratories for Quality Control & Testing
Based on specific customer requirements, the Transmission & Distribution conductors are put through
stringent type tests before dispatch.

Sterlite offers conductors that confirm to several international standards such as:
European Norms (EN) | Swedish Standards (SS) | IEC | American Standards (ASTM) | Indian Standards
(IS) | Australian Standards (AS) | Canadian Standards (CSA)

Sterlite Power solutions have been tested & certified by various renowned laboratories across the globe
including ERDA (India), CPRI (India), Kinectrics (Canada), Veld VNL (Hungary), SAG FGH (Germany),
EDF (France), NETFA (South Africa), SABS (South Africa), CSERI (China), Tag Corporation (India) and
NABL (India).

25 © SPTL 26 © SPTL
 OPGW Offerings
India’s only fully integrated OPGW manufacturer & solution provider

Live line installation on BOOM Solution deployment in dense Live line installation 220 kV line,
basis 138 kV line MTCIL forest 110 kV line, TAN TRANSCO GETCO
(JV with MSETCL)

Building over 3200 Km of OPGW Over 8000 Km of OPGW cable & Approved by all major State
Network on BOOM basis in hardware supplied globally for Utilities in India
Maharashtra upto 765 kV lines

Customer Centric Innovation

Due to its steadfast focus on innovation and constant outlook towards the future, Sterlite Power has also
developed expertise in optic fiber and energy efficient bare overhead conductors. Sterlite Power has

OPGW Offerings
integrated its core capabilities to bring comprehensive OPGW solutions that include Optical Ground Wire
and related hardware. Sterlite Power possesses the planning, application & design engineering and
execution capabilities to meet the requirement of Power Systems/Utilities for communication, protection
and commercial purposes. Sterlite delivers end-to-end services for communication networks on overhead
systems used to transmit power.

ACS Wire Design A - Central Steel Tube Design

Steel Loose Tube Effective on lines below 400 kV
Filling Jelly
Optical Fiber
Low wind load areas

Alumminium Tube PBT-Central Core Aluminium Sheathed Tube Design

Thermal Barrier Effective for 400 kV and above
FRP Hog wind load areas
PBT Tube with Fibers Effective design for fiber management
ACS Wires

Al Alloy Wires Design B/D-High Strength Design

Steel Tube with Fibers
Extremely high spans like river crossing, high ice
and galloping conditions
ACS Wires
High fault current design in desert regions
ACS Wires

27 © SPTL 28 © SPTL
Design Considerations
OPGW cables are required to withstand the effects of installation and long-term in-service exposure to
mechanical, electrical and environmental loads without significant degradation in performance.
OPGW cable fulfils the following key performance indicators for selection in appropriate designs:
Electrical Performance
• Fault current performance
to overcome the
line-to-tower short circuits
or system imbalances
• Lightning performance to
ensure lightning arc does
not impair long-term
functionality of the cable
Packing
The end-user needs to
determine the length per reel
on the basis of:
• Terrain of the installation site
• 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
Mechanical Performance
• Sag and tension
• Vibration
• Galloping and Sheave
Supply Length
• Maximum length per reel
is 4 km.
• Length per reel available
as per customer request.
Quality and Reliability
Sterlite undertakes tests on all products to ensure quality and reliability. Below is an overview of the results:
Environmental Performance
• Range of temperatures
and wind zones
• Corrosion levels at
installation sites including
pollution level between 1-4
• Salinity levels
Continuous improvements may result in specification changes without prior notice. Any warranty relating to any products is
only contained in the form of a written agreement between SPTL and the direct purchasee of such product(s).
29 © SPTL
Test Parameters Reference Standards Sterlite Products’ Performance
Stress-Strain 1EEE-1138 No visual damage to the cable;
Ch.5.1.1.11 fiber showed no significant
IEC 61089, Annexure B strain or induced attenuation.
Tensile Strength IEEE-1138 Cable breaking strength ≥ 95%
Ch 4.2.2.3 RTS and no single wire was
IEC 60794-1-2, Method E1 broken.
Sheave IEEE-1138 No significant damage to any
Annexure D component of the cable; fiber
IEC 60794-1-2, Method E9 attenuation ≤ 0.1 dB/Km at
1550 nm.
Aeolian Vibration IEEE-1138 No significant damage to any
Annexure B component of the cable; fiber
IEC 60794-1-2, Method E19 attenuation ≤ 0.1 dB/Km at
1550 nm.
Galloping IEEE-1138 No significant damage to any
Annexure C component of the cable; fiber
attenuation ≤ 0.12 dB/Km at
1550 nm.
Creep EIA/TIA 455-25A-1989 and Fiber attenuation ≤ 0.02 dB/Km
EIA 455-41-1985 at 1550 nm. Cable elongation
IEC 61395 ratio: 0.02%.
Temperature Cycling EIA/TIA 455-3A-1989, using a Fiber attenuation ≤ 0.03 dB/Km
modified version of temperature at 1550 nm.
cycling Test Condition B, -40°C
to +85°C two cycles.
IEC 60794-1-2, Method F1
Seepage of Flooding FOTP EIA/TIA The compound did not flow or
Compound 455-81A-1991 drip
IEC 60794-1-2, Method E15
Short Circuit IEEE-1138 No significant damage to any
Annexure A component of the cable; fiber
IEC 60794-1-2, Method H1 attenuation = 0.05 dB/Km at
1550 nm.
Lightning Arc 1EEE-1138 Fiber attenuation < 0.05 dB/Km
Ch.6.4.3.4 at 1550 nm. Remaining RTS
IEC 60794-1-2, Method H2 >75% of Cable RTS
30 © SPTL
Sterlite’s OPGW Installation Projects Installation Hardware
World class cable products need high quality hardware support. Sterlite Power’s portfolio extends to include
the following hardware essentials:

• TENSION ASSEMBLY
• VIBRATION DAMPER
• SUSPENSION ASSEMBLY
• DOWNLEAD CLAMPS
• SPLICE ENCLOSURE

Tension
Assembly
COASTS - Coastal region of Tamil Nadu, India (230 kV) DESERTS - Desert region of Gujarat, India (220 kV)

Vibration Suspension
Damper Assembly

Tension
Assembly

FORESTS - Dense forest of Valparai, India (110 kV)

Downlead Clamps

Splice Enclosure

Approach Cable to
Fiber Mangement System
RESIDENTIAL AREAS - Residential area in Jaipur, MULTIPLE LINE CROSSING - Multiple line crossing in Orissa,
India (132 kV) India (132 kV)

31 © SPTL 32 © SPTL
Sterlite OPGW Accessories Client Endorsement
Tension Assembly Anchor Shackle
Tension assemblies are designed for use with OPGW Extension Link Reinforcing Rods
cable at termination, section and joint tower positions.
They can hold up to 95% of the OPGW RTS & maintain Clevis Thimble Dead End "STERLITE DELIVERS ON ITS COMMITMENT TO
optical integrity over the operating load range.
SUPERIOR PRODUCT QUALITY.
OPGW Cable
THEIR MANUFACTURING PLANTS FOR CONDUCTOR
Ground Clamp AND OPGW ARE STATE OF THE ART FACILITIES
Reinforcing Rods
Armor Rods
WITH THE LATEST TECHNOLOGY.
EPDIM Insert
Suspension Assembly THE QUALITY ASSURANCE LABORATORIES ARE
Bolt Suspension assemblies are designed for use with OPGW
cable at suspension tower positions. They reduce static ALSO OF HIGH STANDARDS."
compressive stresses at the support point and cushion - Lakshmi Narayana P, (Designation), Adani
the OPGW cable against the dynamic stress of
Fiber Cable
Aeolian vibration.
Optional Ground Point

Vibration Damper "WE ARE MORE THAN SATISFIED WITH

Vibration Dampers effectively reduce the level of Aeolian
vibrations on Optical Ground Wire (OPGW) cables. They THE PRODUCT THAT STERLITE HAS SUPPLIED."
respond to wind induced line vibrations that are - Gary Stewart, Lines Acquisition Specialist, Powerlink Queensland
characterized by high frequency, low amplitude motion.

Down Lead Clamps

Fixing clamps are used to guide OPGW cables from
the top of the structure to the splice box for grounding
"STERLITE SUPPLIED ACSR MOOSE CONDUCTOR
the cable. They provide proper spacing and holding
strength without damaging the cable.
ON AN IMMEDIATE BASIS FOR OUR 400KV
MADHUGIRI – BIDADI TRANSMISSION LINE. THEIR
SUPPORT HELPED US IN GETTING OUR
Splice Enclosure
Splice enclosure is used for the storage of spliced fiber
SUBJECT LINE SUCCESSFULLY INSPECTED BY CEA
& storing the same on the transmission tower. Hence,
it is specifically made with an armour of metal on the
AS PER SCHEDULE."
- P G Suresh Kumar, Director, Kudgi Transmission Limited (A wholly owned subsidiary of L&T IDPL)
outside to protect the enclosure from electrical fields.

33 © SPTL 34 © SPTL