“‘Reconductoring Using (January, 2006)Table of Contents ts Cable Vi. Vil. Vill. Vill. Capacity Upgrading Characteristics of STACIR Testing Accessories Installation Supply Record Case Study Economic Comparison SummaryBEB RBBB ER RRPRPRPRPRERPRRP EPP eee I. Capacity Upgrading LS cable Ml Background Increase in demand for electricity is a big issue of the day in many countries. However, Solution == Too difficult to acquire tower site Leela clits} existing line and right-of-way vin = Not enough time to construct new lines = Popular enmity to high voltage UTM UdI. Capacity Upgrading Ii Capacity Upgrading Metho ds q it Higher Voltage (154kV, 345kV, 765kV) Bundle Conductor (2B, 4B, 6B) LS eavic Increasing the tower volume & rebuilding the new line High Temperature & Low Sag ConductorsIl. Characteristics of STACIR IB Requirement for High Temperature Low Sag Conductors for Upgrading @ High Current Capacity Hi Long term reliability @ Sufficient sag-tension property Optimized HTLS Conductor Easy and rapid installation Compatible to exiting installation @ Conductor Cost method i Labor Cost 1 Low Line Lossll. Characteristics of STACIR i Characteristics of STAICR N Bs reared LEA LS cavic @ Ampacity Upgrading : x 2 ACSR x 1.7 AAAC @ No limitation for application area : Heavy wind & snow, galloping area | Equivalent Sag-Tension Properties to conventional ACSR ification & Reinforcement ‘ing Tower Easy Installation with Same Method & Equipments as ACSR’s j@ Reduced Design Time and Costs fj High Reliability with Many Experiences more than 10,000kms of STACIR Characteris i Characteristics of Super Thermal Al-Alloy Conductor (STAL) @ Tensile Property i Comparison with other conductors STAL (c=60%) Density (gicm*) Conductivity (%IACS) Tensile Strength |16.2~17.9| 16.2~17.9| 22.9-26.7| 16.2-17.9 (kgtimm2) poten 90 150 150 210 (a teh (X 1.6HAL)(X 1.6HAL)} (x 2.3HAL) Applicable Conductor a i 5 27 61 60 TAL (c=60%) (TAL HAL t =61%) TACSR |Hi-TACSR| STAICR sHAL —: Hard-drawn Aluminum sTAL Thermal Resistant Aluminum-Alloy +Hi-TAL : High Tensile Strength TAL *STAL : Super Thermal Resistant Aluminum-Alloyll. Characteristics of STACIR LS cavic Central High Strength Members for STAICR High tensile strength Al-clad Invar has very low thermal expansion coefficient and high tensile strength @ Thermal expansion @ Comparison with other steel 30 Density a) eres forte) Bee cr ay Cera 20 Bruny rn) erty (kgfimm?) Thermal Expansion [x10“] eo Resistance a aay Applicable Temperature [°C] aie aslll. Testing fel Compression Test for Al-clad Invar @ Test Objective To examine the bonding properties between Invar and Aluminum coating for aluminum clad invar wire @ Test Standard KEPCO ES 121-370~373 @ Test Condition -. Test specimen length : 10mm -. Compression load : 3,600 kgf @ Acceptance Criteria Observation for separation of aluminum and Invar wire at the end of the test specimen @ Test result Longitudinal Plane Vertical Plane Invar and aluminum wire were not separated. Noting extraordinary in the test specimen was found apparently. Testing Ls Cable HB Bending Test for Al-clad Invar @ Test Objective @ Test result To examine the bend properties of Aluminum clad Fractography after bending test invar wire @ Test Standard KEPCO ES 121-370~373 @ Test Condition -. Test specimen length : 30cm -. Bending Angle : + 90°(Left and Right) @ Acceptance Criteria Observation for separation of aluminum and invar wire at the end of the test specimen No exfoliation between aluminum layer and invar layerIll. Testing EB Long Term Aging Test for 10,000 Hours @ Test result @ Test Objective To examine tensile strength of Al-clad invar wire and STAL wire after aging of heat resistance test @ Test Standard KS C 3002 IEC 1232 IEC 60889 @ Test Condition -. Test specimen length : 350mm. -. Temperature : 200, 300, 400°C -. Duration : 10,000hours -. Increasing rate of load : 10mm/min @ Aluminum clad invar wire E 19 = 2007 + 300° = 400 Tensile strength, kgf/th eA 0 2009 4000 6000 8000 10000, Aging time, hrs MI STAL wire —.. 4 RTE WOT a 21% ee Meee t eet ete 2 rest pn B 2 = Nhe Dak 5 ee Aging time, hrsIll. Testing Wi Current Capacity Test @ STAICR 410mm? @ Test Standard IEC 61597 @ Test Condition -. Test specimen length : 20m -. Duration : 24hours -. Current : 1000, 1580, 1700, 2000A @ Conductor Temperature vs. Ampacity Current Capacity KEPCO Standard Test Results Temperature, °C @ Conductor temperature in accordance with current capacity 360. 300. 250. 200. Between Alclad invar layer and STAL layer Between STAI ayers 4s Surface layer J f re es * 500 1000 1500 2000 Current, AIll. Testing i Corona & Radio Interference Voltage Testlll. Testing Hl Corona & Radio Interference Voltage Test © Corona Test @ Requirement Corona extinction Voltage > 320kV (r.m.s.) i Test Results i Requirement © Radio Interference Voltage Test RIV $1,000UV at 305kV(r.m.s.) @ Test Results Corona inception Voltage (kV r.m.s) Step 360 362 367 Corona extinction Voltage (kV r.ms) 347 351 353 Test voltage (kV rm.) 125 155 185 215 245 275 305 335 Results (uV r.m.s) 0.68 0.68 0.85 1.15 1.50 2.34 2.54 3.89lll. Testing CS cable Hi High Temperature Stress Strain Test of aluminum clad invar wire @ Test set-up for HTSS Test @ Stress-strain curve in 210°C (Al.-clad Invar 7x 3.53mm) Dipacmet Meare ‘SD 6000 85%UTS eating Part Heating Source 0 0.0 01 02 03 04 05 06 07 08 Elongation, % Data Collector Drivine Pare= Ill. Testing cs Cable HB Dynamic Fatigue of aged aluminum clad invar wire @ Test Set-up @ Stress-fracture cycle curve of Al-clad invar with aging at 200°C -. Test specimen length : 800mm -. Test frequency : SHz(until it break) a 200°C Alclad invar - Initial stress : 60% of tensile strength " See eee tee tne (reduce until the specimen was finally 36. not broken) -. Fatigue cycle : 10’ cycles Stress, kgfimm2 re 3 10 16 18 10 Fracture Cycle, NIll. Testing Ls Field 1 STAICR 410mm? was installed in Gochang field test lab. By KEPRIIll. Testing Knee Point Test Conductor Temperature (°C) Nee Point of STAICR 410mm2 > Predicted value : 94.7 °C > Measured results : 80~100°C ¢ 7 ienaal] ; | | ate : Ki een nee Point’ a 1600 700 1800) 0 2000 2100 Tensile Load (kgf) Conductor Temperature (°C) t. Ave Knee Point? ate Tensile Load (kgf) = svtlll. Testing Hi Conductor Temperature vs Wind Speed » Conductor under Current Load: 100% Conductor Temperature [°C] Wind Speed (m/s) Winter Season Conductor Temperature [°C] . 4 Wind Speed (m/s) Summer Season|. Testing Hi Current Load vs. Average Temperature and Tension Temperature [°C] Tension [kgf] oe 3 @ 20 rs Applied Current (% of Full load) Winter Season «pen Tension avg SM1 avg SM2 avg.SM3 2200 se = 3S = Tension Sol 7 iH © avgsMt sae & avgSW2 Oo * v avg.SM3 2 a0 . 5 T & . a si => 2 & 5 2 é 2 Applied Current (% of Full load) Summer Season. Testing ll Field Test by Hydro One 2000 1800 1600 z & s 1200 1000 Cable Sag - mm Be 2) 88s 8 ° ACIR(STAICR) & ACSR Sag vs Temperature (795 kcmil Drake) 20 40 60 80 100 120 140 160 180 Cable Temperature - deg C 200 220 240 260 @ Span: 68.6m & 65.5m Mi Initial Load: 25%UTS —~ ACIR ACSR —— LG ModelIll. Testing Wi Field Test by Hydro One Cable Tension - kg 3 ACIR(STAICR) & ACSR Tension vs Temperature(795 kcmil Drake) 20 40 60 80 100 120 140 160 140 Cable Temperature - deg C @ Span: 68.6m & 65.5m B Initial Load: 25%UTS ~~ ACIR ACSR — LG ModelIll. Testing Il Field Test by Hydro One Creep Test of STAICR Drake y= 9:590E-05(nours) = 0.001 ee . Cable Strain -mmimm 0.0001 .00001 1 10 100 +000 10000 100000 Time - hours : Span: 68.6m & 65.5m Wi Initial Load: 25%UTS @ 10 year’s creep: 0.078%LS-: 1€ IV. Accessories Hi Compatibility of Accessories STAICR can use the same accessories as same diameter of ACSR’s Existing insulators also can be used for STACIR Suspension clamp with Armor Rod 8 Vibration Damper @ Armor Rod @ Twin Bundle SpacerIV. Accessories i Current Carrying Accessories Dead-end clamp has bigger dimension than ACSR’s to satisfy increased current ™ Compression Type Dead-end Clamp @ Compression Type Joint Sleeve i Repair Sleeve {Dimension 410mm] Ze = So x= oe To - fooIV. Accessories Hi Temperatures of dead-end clamps after hear cycles test ee | tech ew Seroe 9 | Saree 0 | Sorweii | Sorwwie @ Test Conditions: . - * # - Conductor: STAICR 240mm? L- a =e = . Surface temperature of conductor reel [era | eee 5 e 2 240°C +10/-5°C 5 penne 2 . Test load: 13,480N (15%RTS) a serene aaa ~ T = . Test duration: 100 cycles 6 Here % & * 1cycle: ambient temp. 0 a ee = 240°C+10/-5°C for 30min. oie —> ambient temp. a ants | ra e a ml Test Result: a fen [een ice = . Maximum temperature of clamps: 66 °C |_— f _|—| == ® a | x = T =» s see 2 aes eaeIV. Accessories @ Temperatures of dead-end clamps after heat run test @ Temperatures of joint sleeves after heat run test essed] Sutie tre. inert at ro es ae at eee =e Hi Pa tettl | TRICIT [raceal Tamacer ese ESR KE Seow | seve | Sree? | Seon 5 = a igs er icea (aes @ @ 2 *|.s |= | ad a z abi | PRESTR HP ane a a Ce ee =” rm @ a eee S Cee 2 a” * © 1 2 a 2 & R 5 o | a ar 2 a 91 0 13 a ze 2 oe | z | » a we a * @ o 13 0 Ea 7m & ® 7 “6 mo | 2m 2 si 2 6 # 0 2 2 es | a 2 # 0 2 | 7 a ve a a 2 fe a » | 2 oo 22 2 % aw a 18 fk [eam |r [sc a ca ao oe [ee Test Conditions: . Conductor temperature 240°C +10/-5°C . Test duration: 400 hours Test Result: . Maximum temperature of clamps: 91°C Test Conditions: . Conductor temperature 240 °C+10/-5°C . Test duration: 400 hours @ Test Result: . Maximum temperature of clamps: 116°CLS eavic IV. Accessories i Connection Points between STAICR and Convention Conductor @ T-Clamp T-Clamp for single conductor Jointing 4— ACSRIV. Accessories Hi Connections to Convention Conductors using T-Clamp Need to consider current carrying capacityIV. Accessories ts _ Connections to Bus Bars STACIR or Existing conductor (Considering current capacity) a Bus BarV. Installation Ls Cable STAICR has the same installation method as conventional ACSR (Stringing, Sagging and Clamping)V. Installation Ls Cable STAICR can reduce outage time in semi Live-line installation because of high efficiency on installation work Malaysia TNB Case |_FrsticutReplacement) _Seoond Cut Replacement Enough time for shut down Not enough time for outage => Needed Rapid installation Work 1, Determine shut-off period not considering electric load 1, Determine outage period (© One HTLS circuit has double ampacity) considering electric load (ex. straight holidays) 2. One HTLS circuit : Increasing capacity 2. One circuit : Shut down Other circuit : Shut down Other circuit : Increasing capacity (Over loaded) 3. Start replacement work 3. Installation Work should be finished quickly Installed STAICR inished Installation work for 4km in 5 days , in one monthVI. Supply Record = ES cable Complete Size Value Of ¥ Ordered Date of No.] Customer ProjectName | Ores "bNon | voltage | (xy a Be) |Get Material Stranding | (Mil US) 240n STACIR & 1 Wee : ‘Acc’y aeay 2874 pol 39.3 1995~2005 IKorea 345kV 10a HSTACIR 480u0 | frome Kwang-yang TIL | STACIR 164kV 75 330mr 0.78 1996. Oct. ay SNES Field Trial test | STACIRE | sony 18 240me 0.17 2002. Sep. 1Spain Acc’y ENEL STACIR & 4 Ay es heey : 58 240m 0.63 2003. Apr. KERJA-KERJA 47 0.62 2004. Jan. 6 ee TTSB STACINS “|| 276k, 154 410m 4.0 2006. Feb. meet ME 2 53 08 2006. Jun. High Capacity East- PcIL STACIR & 8 | Minaia [North Interconnector] STACY 400kV 369 530m 52 2005. Oct. NCIP a 7 STACIR & 7 IChina Beixin-Bei'an PUT Acc’y 110kV 15.6 180n0° 0.2 2005. Jan WuBei-Xing@iao | STACIR& 8 | Changzhou pc| Wilelunaciac eee vow | 273 | 3600! 04 2008. Dec. > Total Length of Conductor : 3,690 kmVII. Case Study KEPCO / Korea Sinnamwon T/L (June 2000 Korea Electric Power Corporation (345kV, 2cct, 17km) Customer Problems Existing LGC Proposal © Alllines were installed © Increasing demand for electricity CSR STACIRIAW _ and run very well without any due to rapid growth of industry 4g0mix2B 410m'x2B problems and factory automation Ampacity © Demand for peak load rate [Acond.] by 9% every year Sag[m] 10.21 j 9.79 918 1,707 © Acquire certification of KEPCO 3 KEPCO Experience 4,140 Unit: eircult km © Not enough time High Tete rat " Pi es aoe ec ied + condition : Zone I), Span 300m aca 2a © Very high cost to acquire new tower site and right-of-way Tension[kgf] 4,140 (Operating Temp. ACSR 90, STACIR/AW 210°C 871 © Increasing concerns 1,112 about environmental preservation and popular enmity to overhead power linesVil. Case Study CHILECTRA / Chile AAAC Line (November 2004) (110kV, 2cet, 8.8km) LS cavic HI-STACIR upgrades ampacity of same structure of AAAC up to 70% Customer REquirements Existing transmission line to be upgraded _ LGC Proposal Existing LGC Proposal conductor Option 1 Option 2 by two option Type AAAC STACIR Hi-STACIR © Option 1 Replacement by HTLS conductors Dimension 500 (1.000 MCM) 406 810 with same structure as existing AAAC ane 29.05 29.05 38.4 © Option 2 ‘Nominal Weight kgkm 1379 1,624 Construction of new transmission lines using HTLS conductors ‘Maximum Operat Temperature 90 210 210 Maximum Current > Transmission capacity ra 1,076 1,853 2,769 (00%) 72%) (S27MVA) : 519 MVA per circuit Maximum final 5.19 5.05 10.79 @ 300m Span @ 229m Span__}|_@ 229m SpanLs Cable vi Economic Comparison HB Economic comparison to determine uprating method Construction Recordletorin Construction Description of New Line a: of New Line with ACSR with STAICR Preliminary work Required | Curtail Tower Foundation Required Z Curtail Tower Erection Required fr Curtail Conduetor & Ground wire f 4.1 Conductor Furnishing Low price High price High price Construction | 2 stinging Required Required Curtail Cost 4.3 Ground-wire Furnishing Required re Required 4.4 Ground-wire Stringing Required x Required Line Accessories Required || Required Required | Grounding Required | a Required Cost of right of way Required cil x Required See Line Loss ow High High Cost ecco tea Construction Period Long Shortest Short RevenueVill. Economic Comparison Existing Line : 275kV, 2cct, 22km - Conductor : ACSR 400m (Zebra) x 2 - Transmission Capacity: 685 MVA tS Cable Total cost (20 years) 1 2.6 33.2 MUSD fe Fprtunity venue ‘ost ) Upgrading () Option 1: Construct New Conductor : ACSR 400m"(Zebra) x 4 Transmission Capacity: 1,370MVA ae | © Option 2: Reconductoring Conductor : Hi-STACIRIAW 410m x 2 | Transmission Capacity: 1,367MVA | eh Construction New ACSR Line Reconductoring Hi-STACIR/AW * Opportunity Revenue = Power Capacity x Construction Period (t) x [Power Selling-Power Cost] x 20% * Construction Period ~ Construction of New Line : 2 years - Reconductoring with STACIR : 1 yearVII. Summary LS cavic Double ampacity uprating with STACIR on the existing steel towers STACIR has more than double ampacity of conventional ACSR STAICR has equivalent sag-tension properties to conventional ACSR Not current carrying accessories for conventional ACSR can be used for same size of STACIR Same installation method as conventional ACSR is applied for STACIR STACIR has high reliability with many experiences more than 10,000km