SPE-Reconductoring Case Studies

RE-CONDUCTORING CASE STUDIES
FOR VARIOUS UTILITIES AND PRIVATE

COMPANIES
PRESENTED BY:
Er. S. M. TAKALKAR (MD)
TAKALKAR POWER ENGINEERS & CONSULTANTS PVT. LTD.
(TPECPL)
FOR, THE SOCEITY OF POWER ENGINEERS (INDIA), VADODARA CHAPTER
NATIONAL ANNUAL GENERAL MEETING
Case Studies of HPCs Employed By Utilities & Private

Companies
RE-CONDUCTORING CASE STUDIES FOR VARIOUS

UTILITIES AND PRIVATE COMPANIES
1. RAJ ASTHAN RAJYA VIJ PRASARAN NIGAM LIMITED
Rajasthan Rajya Vij Prasaran Nigam Ltd. (RRVPNL) has its transmission line network of
132 kV in Jaipur City. Some of the lines which were laid between 1960 to 1980 are now
covered by the expanded city. There is a great deal of encroachment along, across and
below the lines, which were once in open field. There are number of interconnected
transmission line network connecting their 132 kV Grid Sub Stations (GSS). Due to increase in
population & industrialization, demand of electricity has also increased and this is a biggest
issue Rajasthan Rajya Vij Prasaran Nigam Limited (RRVPNL) is facing now a days.
Installation of new power lines is very costly and there is not enough time to build new lines. It
is very difficult to acquire tower sites and right-of-way for construction of high voltage
overhead lines in urban and suburban areas. The best solution of increasing the capacity of
the line is Up-rating or Up- gradation of the existing lines. Up-rating of existing lines can
be achieved by increasing the thermal rating of the line. This can be done by changing the
existing conductor with a new High Performance Conductor (HPC) having higher operating
temperature, same mechanical properties and low sag values as compared to that of existing
conductor. Up-gradation can be achieved by increasing the voltage level of the lines and
thus augmenting the power supply. The most important aspect is Right of Way (ROW)
RRVPNL had identified some of the critical lines from the point of Up-rating. The lines are as
follows:
1)
2)
3)
4)
5)
6)
7)
132kV Chomu to 132kV Govindgarh (Combination of H pole and Tower)

132kV Chambal to 132kV Mansarovar
132kV Mansarovar to 132kV Sawai Mansingh stadium
132kV Puranaghat to 132kV Kunda Ki Dhani (KKD) ( Combination of H pole and
Tower)
132kV VKIA to 220kV VKIA
132kV VKIA - 132kV Vaishali- 132kV Hirapura
132kV Hirapura Rampura Dabadi Chomu (Combination of H pole and Tower)
Most of transmission lines stated above, connecting important 132 kV Grid Sub Station
(GSS) are already strung with ACSR Panther and ACSR Wolf Conductors. These
0
conductors are operating at their maximum operating temperature of 85 c thus providing

current of 464 Amp. Due to load growth, RRVPNL wants to increase their transmission line
capacity to twice as that
of their conventional ACSR Conductors.
Takalkar Power Engineers and Consultants Pvt.

Ltd. (TPEC)
Page
1

Companies
Technical Comparison for ACSR Panther & its equivalent HPC
Conductors
Properties
ACSR
ACCC
Panther
Casablanca
Cross Sectional Area (mm2)
262.00
303.9
0
Conductor Diameter (mm)
21.0
20.5
0
Modulus Of Elasticity (kg/cm2)
816000.00
Co-efficient of Linear Expansion

(/C)
17.8*10-6
Weight (kg/km)
974.00
UTS (kgf)
8826.00
DC Resistance @ 20 C Temp
(ohms/km)
Maximum Operating Temperature
0.13900
(C)
Voltage Level (kV)
85
0
1182466.87
above Thermal
Knee point and
636085.6 below
Thermal knee
1.61*10-6
above Thermal
Knee point (65
0c) & 18.9*10-6
below Thermal
knee Point
790.0
0
10408.77
0.10250
17
5
13
Nos. of conductor per phase
13
2
1
Nos. of Circuits
Line length (km)
2
1
Span in Mtrs.
32
32
5
5
Calculations are for Single Conductor Configuration & Single Circuit
Arrangement
Case 1 : Maintaining same Current as that of ACSR Panther at its
maximum operating temperature in all proposed
conductors
The following calculations are
85
77.4
carried out at temp stated
9
besides:
Current to be maintained:
46
46
4
4
AC Resistance (ohms/km)
0.1756
0.126
Line losses in kW/ckt
7
82
Power Factor
11
3
0.8
Power Transferred in MW/ckt
5
87
0.8
5
87
Sag at above mentioned temp &

0% wind
Tension to be maintained at 32 0C
& 100%
wind
7.8
1
6.2
4
2855.15
2854.99
Electrical design parameters for transmission line length of 10 kM

for Single
ckt. in MW
Sending
end power
87.0
87.0
0
0
Ltd. (TPEC)
Page
2

Companies
Receiving end power in MW
Total Induction of Line in H/Phase
Total Capacitance of Line in
F/Phase
Voltage regulation (%)
Efficiency (%)
85.9
3
5.53E-03
2.11E-01
1.4
3
98.6
9
86.2
3
5.55E-03
2.10E-01
1.1
8
99.0
5
Case-2 : Current in Amp at maximum continuous operating

temperature in all proposed
HPC
85
175
besides:
46
98
4
1
0.166
0.1756
6
11
48
3
1
Power Factor
0.8
0.8
5
5
87
18
5
6.6
7.8
0% wind
4
1
& 100%
2855.15
2854.99
wind
Saving per single circuit as in case-1 for duration of one
year:
Cost of power
loss in INR 4/- per
3959520
2873280
kW
Cost of Power transferred without
losses in
INR
4/- per
kW
Revenue
generated
in INR 4/Additional Revenue
generated as compared to
ACSR in INR
Additional Revenue
ACSR in INR (Crore)
3048480000
3048480000
3044520480
3045606720
-----------------
1086240
-----------------
0.1
1
Technical Comparison for ACSR Wolf & its equivalent HPC

Conductors
Properties
ACSR Wolf
ACCC
Copenhagen
195.00
251.0
0
18.1
18.2
3
815494.39

Ltd. (TPEC)
9
1208970.438
above Thermal
Knee point and
648318.04 below
Thermal knee
Page
3

Companies

(/C)
17.8*10-6
Weight (kg/km)
726.00
UTS (kgf)
6864.00
(ohms/km)
0.18710
(C)
Voltage Level (kV)
85
1.61*10-6
above Thermal
Knee point (65
0c) & 18.6*10-6
below Thermal
knee Point
669.7
0
7431.19
0.12790
17
5
13
13
2
1
Nos. of Circuits
Line length (km)
2
1
Span in Mtrs.
32
32
5
5
Calculations are for Single Conductor Configuration & Single Circuit
Arrangement
Case 1 : Maintaining same Current as that of ACSR Wolf at its
maximum operating temperature in all proposed
conductors
85
75.4
1
besides:
38
38
7
7
0.2361
0.156
8
70
Power Factor
10
6
0.8
5
73
0.8
5
73

0% wind
& 100%
win
7.5
7
6.7
0
2313.23
2312.91
Electrical design parameters for transmission line length of 10 kM

for Single ckt.
Sending end power in MW
73.0
73.0
0
0
Receiving end power in MW
71.9
72.3
9
3
Voltage regulation (%)
1.4
1.1
7
3
Efficiency (%)
98.5
99.0
4
3
Case-2 : Current in Amp at maximum continuous operating
temperature in all proposed
HPC

Ltd. (TPEC)
Page
4

Companies
besides:
85
38
7
0.2361
Power Factor
10
6
0.8
5
73
175
84
8
0.207
6
44
8
0.8
5
16
0

7.1
7.5
0% wind
0
7
& 100%
2313.23
2312.91
wind
Saving per single circuit as in case-1 for duration of one
year:
Cost of power
loss in INR 4/- per
3714240
2452800
kW
Cost of Power transferred without
losses in
INR
4/- per
kW
Revenue
generated
in INR 4/Additional Revenue
ACSR in INR
Additional Revenue
ACSR in INR (Crore)
2557920000
2554205760
2557920000
2555467200
-----------------
1261440
-----------------
0.1
3
The following points can be inferred from above attached Technical Comparison
Table:
1. Weight of ACCC Copenhagen conductor (kg/km) is 8% less as compared to ACSR.
0
2. DC Resistance at 20 c of ACCC Copenhagen conductor is 32% lower as compared to
ACSR thus boosting up ampacity and simultaneously decreasing losses.
3. Power Transferred (MW) of ACCC conductor at its maximum operating temperature is
120% higher as compared to that of ACSR.
0
4. Maintaining tension of ACSR at 32 c & full wind as starting condition in ACCC
conductor as in the case of Re-conductoring, we obtain reduction of 6% in the values of
sag at maximum operating temperature as compared to conventional ACSR conductor.
2. ODISHA POWER TRANSMISSI ON CORPORATION LIMITED

Odisha Power Transmission Corporation Limited (OPTCL) is having 132 kV lines running from
Chandaka to Mancheswar (circuit-2) of 5.88 km, Chandaka to Ranasingpur of 24.25 km,
Chandaka to Nimapura of 57.25 km and Tarkera to Chhend of (2X6.16 km) length and are
strung with ACSR Panther Conductor. ACSR Panther Conductor is having maximum current
rating of
327 Amp at maximum continuous operating temperature (75 0c).

Ltd. (TPEC)
Page
5

Companies
ACSR Panther Conductor is capable of catering maximum of 65 MW Power through its Single
Circuit Arrangement. OPTCL wants to cater additional power (160 MW per Single Circuit)
through its 132 kV Transmission Line Corridor. Lines are going to be overloaded so change
in the conductor by higher size is necessary. This will require strengthening of tower and
foundation. OPTCL may transfer its additional power by dismantling its existing towers and
upgrading the existing voltage level to some higher voltage level but it would ask for a larger
shutdown period. Construction of new transmission line would require right of way and
approvals from the various authorities and the procedure may ask for a larger project completion
time period.
Considering above facts, it is advisable to cater the additional power requirement through same
ROW and using same Towers by Re-conductoring of existing lines with new generation High
Performance Conductor (HPC) conductors.
An proven method of increasing transmission line thermal rating (up rating) involves
replacing the original (typically) steel-reinforced aluminum conductor (ACSR) with a HPC
conductor with approximately same diameter as that of the original conductor. Therefore,
OPTCL has approached M/s. Sterlite Technologies, to give appropriate solution related to
the conductor design for augmenting the capacity with minimum changes and thus
affording very little shutdown.
These conductors can carry higher amperes without much variation in the mechanical
properties of the conductor compared to one which is presently in service. This aspect makes it
possible to string high ampacity conductor on the existing structures with little change or no
change in the support structures and foundations.
For this particular application it is proposed to deploy ACCC Casablanca conductor instead of
existing ACSR Panther Conductor. Since the mechanical properties of ACCC Casablanca and
ACSR Panther conductor are nearly same, it will be possible to string them on the existing
transmission line structures without any modification and their foundations also need not
be changed. The maximum span is considered as 320M.
The High Performance Conductor (HPC), ACCC Casablanca conductor can carry 970 Amp at its
0
maximum continuous operating temperature (175 C). Mechanical sag of this conductor is
also less than that of the sag of existing ACSR Panther conductor
Technical Comparison of ACSR Panther & ACCC Casablanca
conductor
Properties
ACSR
ACCC
Panther
Casablanca
2
262.00
316.50
Cross Sectional Area (mm )
Conductor Diameter
(mm)
Weight (kg/km)
21.0
0
974.00
20.5
0
840.00
UTS (kg)
8826.00
10306.00
DC Resistance @ 20 C Temp (ohms/km)
0.13900
0.10330

Ltd. (TPEC)
Page
6

Companies
Maximum Operating Temperature (C)
75
175
Voltage Level (kV)
13
2
1
132
Nos. of Circuits
Line length (km)
Ruling Span (M)
32
320
0
Maintaining Ampacity of 800 Amp in proposed ACCC
conductor
The following calculations are carried
75
131.10
out at temp stated besides:
32
7
0.1701
800
0.1498
Power Factor
0.9
0.9
Power Transferred in MW/circuit
65
160
FOS at 32C Temperature, 0% wind
4.0
0
2.9
5.1
4
4.15
FOS at 05C Temperature, 2/3
rd
wind

Sag at maximum operating temp & 0%
0
wind
in M
Tension
at 32 c & 100% wind in kg
7
3.1
0
7.2
3.62
5.78
5
2843.12
2843.66
Ampacity at maximum operating temperature in proposed
conductors
The following calculations are carried
75
175.00
out at temp stated besides:
32
7
0.1701
970
0.1679
65
194
4.0
0
2.9
5.1
4
4.15
rd
FOS at 05C Temperature, 2/3 wind

Sag at maximum operating temp & 0%
wind
in M
Tension
at 32 0c & 100% wind in kg
7
3.1
0
7.2
5
2843.12
3.62
5.96
2843.66
Assumptions: Coefficient of Emissivity=0.45, Wind Velocity=0.6 m/s, Solar

absorption Coefficient=0.8, Constant of mass temperature coefficient of
2
resistance of conductor per C = 0.004, Solar Radiation=1045 W/mm , Ambient
0
Temperature=50 c.

Ltd. (TPEC)
Page
7

Companies
Requirement as per OPTCL Tender documents:
1. Overall diameter of complete conductor should not exceed 21 mm and 5% variation(+ &
-), Approximate mass of complete conductor should be less than or equal to 974 kg/km.
Ampacity shall be calculated as per IEEE 738 standard.
2. Minimum required Factor ofSafety (FOS) at 32C& 0% wind for the proposed HPC
conductor is 4.57, while the obtained FOS from ACCC Casablanca conductor comes out
to be 5.14.
3. Minimum required Factor of Safety (FOS) at 32C&100% wind for the proposed HPC
to be 3.62.
to be 4.15.
5. Minimum values of Sag at maximum operating temperature and 0% wind should be
strictly limited to 6.14 M, while ACCC Casablanca conductor gives maximum sag of just
5.96 M.
0
6. Design Tension of 132 kV towers should be strictly limited below 2918 kg at 32 c &
100% wind during Re-conductoring, while restringing ACCC Casablanca conductor over
0
the existing towers offers a tension of 2843.66 kg at 32 c & 100% wind.
The following points can be inferred from above attached Technical Comparison Table:
5. Weight of ACCC Casablanca conductor (kg/km) is 14% less as compared to ACSR.
0
6. DC Resistance at 20 c of ACCC Casablanca conductor is 26% lower as compared to
7. Maintaining Ampacity of 800 Amp in ACCC Casablanca which is 144% higher as
compared to maximum operating temperature of ACSR conductor, the power transferred
(MW) in case of ACCC Conductor boosts up by 145%.
8. Power Transferred (MW) of ACCC conductor at its maximum operating temperature is
196% higher as compared to that of ACSR.
0
conductor as in the case of Re-conductoring, we obtain reduction of 18% in the values of
sag at maximum operating temperature as compared to conventional ACSR conductor.
Technical Comparison of ACSR Panther & its equivalent HPC

conductors
Properties
ACSR
Panther
262.00

21.0
0
2
Modulus Of Elasticity (kg/cm )
816000.00

Ltd. (TPEC)
STACIR/TW
304.
2
20.4
1
614000 below
Thermal knee
0
point (40 c) and
1549439.348 above
Thermal knee point
Page
8

Companies
-6
Co-efficient of Linear Expansion (/C)
17.8*10
-6
Weight (kg/km)
974.00
UTS (kgf)
8826.00
(ohms/km)
0.13900
18*10 below
Thermal knee
0
point (40 c) and
-6
3.6*10 above
Thermal
974
9281.9
9
0.104
75
0
210
132
132
Nos. of Ckts
Line length (km)
320
320
(C)
Voltage Level (kV)
Span in Mtrs.
Maintaining current of 800 Amp in all proposed conductors

carried out at temp stated besides:
75
327
0.1701
Ohmic losses in kW/ckt

(considering loss factor = 0.53)
Cost of Ohmic Loss in Rs. (Considering
Rs.
165110/kW)
Power Factor
rd
FOS at 05C Temperature, 2/3 wind

Sag at maximum operating temp &
0% wind in M
0
Tension at 32 c & 100% wind in kg
29
4788190
0.1459
9
149
24601390
0.9
0.9
65
160
2.9
7
4.0
0
3.1
0
7.2
5
3.11
4.09
3.26
6.40
2843.12
2890.0
0
2206.98
2317.4
6
3050.5
Tension at 32 c & 0% wind in kg(For

Stringing purpose)
119.6
0
800
Tension at 5 c & 66% wind in kg

2972.23
5
Current at maximum operating temperature in all proposed
conductors
75
210.0
0

Ltd. (TPEC)
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9

Companies
Ohmic losses in kW/ckt
(considering loss factor = 0.53)
Cost of Ohmic Loss in Rs. (Considering
Rs.
165110/kW)
Power Factor
327
0.1701
29
4788190
114
1
0.183
4
380
62741800
0.9
0.9
65
228
Assumptions: Coefficient of Emissivity=0.45, Wind Velocity=0.6 m/s, Solar

absorption Coefficient=0.8, Constant of mass temperature coefficient of resistance of
2
0
conductor per C = 0.004, Solar Radiation=1045 W/mm , Ambient Temperature=50 c.
Requirement as per OPTCL Tender documents:

1. Overall diameter of complete conductor should not exceed 21 mm and 5% variation (+ &
Ampacity shall be calculated as per IEEE 738 standard.
conductor is 2.00, while the obtained FOS of STACIR conductor comes out to be 3.26.
conductor is 2.00, while the obtained FOS of STACIR conductor comes out to be 3.11.
strictly limited to 6.4 M, while STACIR conductor gives sag of 6.40 Mcatering 800
0
Amp at a temperature of 119.60 c.
0
5. Design Tension of 132 kV towers should be strictly limited below 2918 kg at 32 c &
100% wind during Re-conductoring, while restringing ACCC Casablanca conductor over
0
the existing towers offers a tension of 2890 kg at 32 c & 100% wind.
1. Weight of STACIR conductor (kg/km) is same as that to ACSR.
2. DC Resistance at 20 0c of STACIR conductor is 25.17% lower as compared to ACSR
thus boosting up ampacity and simultaneously decreasing losses.
3. Maintaining Ampacity of 800 Amp in STACIR which is 144.64% higher as compared to
maximum operating temperature of ACSR conductor, the power transferred (MW)
in case of STACIR boosts up by 146.15%.
4. Power Transferred (MW) of STACIR at its maximum operating temperature is 250.76%
higher as compared to that of ACSR.
0
5. Maintaining tension of ACSR at 32 c & full wind as starting condition in STACIR as in
the case of Re-conductoring, we obtain same values of sag at aoperating temperature
of
0
119.60 c as compared to conventional ACSR conductor.

Ltd. (TPEC)
Page
10

Companies
3. DAMODAR VALLEY CORPORATION, DVC
Damodar Valley Corporation has its 110 kV lines strung with ACSR Lark and AAAC
conductors on their 110 kV towers. ACSR Lark & AAAC Conductor are having maximum
0
current rating of 512 Amp & 616 Amp at maximum continuous operating temperature (75 c) for
0
ACSR Lark and 90 c for AAAC. ACSR Lark & AAAC Conductors are capable of catering
maximum of 85 MW & 102 MW Power through its Single Circuit Arrangements. DVC wants to
cater additional power (153 MW per Single Circuit) through its 110 kV Transmission Line
Corridor. This will require strengthening of tower and foundation. DVC may transfer its
additional power by dismantling its existing towers and upgrading the existing voltage level to
some higher voltage level but it would ask for a larger shutdown period. Construction of new
transmission line would require right of way and approvals from the various authorities and the
procedure may ask for a larger project completion time period.
For this particular application it is proposed to deploy ACCC Reykjavik conductor instead of
existing ACSR Lark Conductor. Since the mechanical properties of ACCC Reykjavik and ACSR
Lark conductor are nearly same, it will be possible to string them on the existing
transmission line structures without any modification and their foundations also need not be
changed. The maximum span is considered as 325M.
The High Performance Conductor (HPC),ACCC Reykjavik conductor can carry 959 Amp
at
0
175 C. Here the sag of this conductor is also less than that of the sag of existing ACSR Lark
conductor. Hence, existing tower and foundation need not be changed.
Technical Comparisons for ACSR Lark & ACCC Reykjavik
Conductor
Properties
ACSR Lark
ACCC
Reykjavik
2
248.40
266.00
Conductor Diameter
(mm)
Total Weight (kg/km) of the

conductor
UTS (kg)
(ohms/km)

Ltd. (TPEC)
20.4
4
923.30
18.8
2
702.40
9060.00
10040.77
0.14350
0.12630
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11

Companies
Maximum Operating
Temperature (C)
Voltage Level (kV)
75
175
11
0
1
110
Nos. of Circuit
Line length in km
Span in M
32
325
5
Ampacity to maintain power of 153 MW in ACCC
conductor
75.0
160.24
0
besides:
Current obtained at above
51
917
mentioned temp:
2
Ac Resistance in ohm/km
0.175553
0.197566
Line losses in kW/circuit
138.06
Power Factor
0.9
0
85
498.39
0.9
0
153
Tension maintained at 32deg C

5051.04
5050.83
& 100%
wind
Sag in M at temp stated above &
7.0
5.87
0%
0
wind
Ampacity at maximum operating temperature in all proposed
conductors
besides:
mentioned
temp:
Ac
Resistance in ohm/km
75.0
0
175.00
51
2
0.175553
0.205022
138.06
565.66

Power Factor
& 100%
wind
Sag in M at temp stated above &
0%
wind

Ltd. (TPEC)
0.9
0
85
5051.04
7.0
0
959
0.9
0
160
5050.83
5.94
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12

Companies
Technical Comparisons for AAAC & its ACCC
equivalents
Properties
AAAC(37/2.88 ACCC
)
Reykjavik
2
241.00
266.00
Conductor Diameter
(mm)
20.2
0
693407.00
18.8
2
1208970.44
Co-eficient of Linear Expansion

(/C)
Total Weight (kg/km) of the
conductor
23*10^-6
1.61*10^-6
664.00
702.40
UTS (kg)
6761.80
10040.77
(ohms/km)
0.13921
0.12630
Maximum Operating
Temperature
(C)
Voltage Level (kV)
95
175
110
11
0
1
Nos. of Circuit
Line length in KM
Span in M
32
325
5
Ampacity to maintain power of 153 MW in ACCC
conductor
90.0
160.24
0
besides:
61
917
mentioned
6
temp:
Ac Resistance in ohm/km
0.178658
0.197566
203.38
Power Factor
0.9
0
10
498.39
0.9
0
153
2
&
100% wind
Sag in M at temp stated above
& 0%
wind
4585.89

Ltd. (TPEC)
8.0
9
4585.68
7.17
Page
13

Companies
Ampacity at maximum operating temperature in ACCC
conductor
90.0
175.00
0
besides:
61
959
mentioned
6
temp:
Ac
Resistance in ohm/km
0.178658
0.205022
203.38
Power Factor
0.9
0
10
565.66
0.9
0
160
2
&
100% wind
Sag in M at temp stated above
& 0%
wind
4585.89
8.0
9
4585.68
7.23
Assumptions: Coefficient of Emissivity=0.6, Wind Velocity=0.6 m/s,

Solar absorption Coefficient=0.5, Constant of mass
temperature coefficient of resistance of conductor
per
C
=
0.004, Solar
2
0
Radiation=1200 W/mm , Ambient Temperature=36 c.
Requirements as per DVC specification:
1. Power to be catered by HPC conductor should be 1.5 times the maximum power
transferred by ACSR Lark or AAAC Panther conductor.
2. Maximum vertical sag of the new proposed HPC conductor at its maximum operating
temperature should be less than existing ACSR Lark and AAAC Panther conductor
at their individual maximum continuous operating temperature.
The following point can be inferred from the above Technical comparison sheet:
1. Weight of ACCC conductor is 24% less as compared to ACSR Lark and 5% higher as
compared to AAAC Panther conductor.
2. DC Resistance of ACCC is 12% and 9% less as compared to ACSR Lark and AAAC
Panther conductors respectively.
3. As per DVC specification, power to be transferred through the proposed HPC conductor
should be 1.5 times to that existing ACSR Lark and AAAC Panther conductor
whichever is maximum. Transferring 153 MW at 917 Amp through the ACCC
conductor which is
79% and 48% higher as compared to existing ACSR Lark and AAAC Panther conductors
respectively.
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Companies
4. Power Transferred of ACCC conductor at its maximum operating temperature is 88% and
56% higher as compared to ACSR Lark and AAAC Panther conductors respectively.
5. Maintaining Tension of ACSR Lark and AAAC Panther conductors at 32 0c & 100%
wind in ACCC Conductor as in the case of Re-conductoring, vertical sag in case
of ACCC conductor decreases by 15% and 11% as compared to ACSR Lark and AAAC
Panther conductors respectively.
4. MAHARASHTRA ST ATE TRANSMI SSI ON CORPORATION LTD.

(MSTCL)
CASE STUDY NO: 4.1
The existing Parli-II (Girwali) 220/132/33 kV substation of MSTCL is having 220 kV Main Bus
of Twin 0.4 ACSR Zebra and 220 kV Auxiliary Bus of Single 0.4 ACSR Zebra. The Main Bus
gantry structures and column foundations are designed to take the mechanical load of twin
conductor only. This Main bus bar can be loaded for about 1300 Amps. With additional
demand, the bus bar current will go to 2800 Amps. For catering this load, it is necessary
to augment the bus bar capacity either by changing twin Zebra configuration to quad Moose or
by replacing existing ACSR Zebra with a HPC (High Temperature Low Sag) conductor of Twin
per Bundle configuration. Opting for quad Moose configuration will need change in the Bus
gantry structures and column foundations. This is extremely difficult from the outage point of
view. Therefore, MSTCL has approached M/s. Sterlite Technologies, Pune to give suitable
solution related with the conductor design for augmenting the capacity of the bus bar with
minimum changes and thus affording very little shutdown.
The HPC (High Temperature Low Sag) conductors can carry higher amperes without much
variation in the mechanical properties of the conductor compared to one which is presently in
service. This aspect makes it possible to string high ampacity conductor on the existing
structures with little change or no change. For this particular application it is proposed to
use Twin ACCC Kolkata conductor instead of existing Twin ACSR Zebra Conductor. Since the
mechanical properties of ACCC Kolkata and ACSR Zebra conductor are nearly same, it will be
possible to string them on the existing gantry structures without any modification and
their foundations also need no change. The maximum span of the bus between two gantries is
36M.
Sag tension calculation with existing span of 36M for ACSR Zebra conductor & ACCC Kolkata
conductor is enclosed herewith. The comparison of the mechanical properties and current
carrying capacities of ACSR Zebra & ACCC Kolkata conductor is given here under.

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Companies
Technical Comparison of ACSR Zebra & ACCC Kolkata conductor
Properties
ACSR Zebra
Cross Sectional Area (Sq mm)

Conductor Diameter
(mm)
484.5
0
28.6
ACCC Kolkata
603.28
2
703400.00
28.6
2
1144750.25
Co-eficient of Linear Expansion (/0C)
19.30*10-6
1.61*10-6
Weight (kg/km)
1621.00
1606.00
UTS (kg)
13284.40
17614.68
(ohms/km)
Emergency temperature (C)
0.06868
0.05390
10
5
75
200
220
22
0
2
Nos. of Circuit
Bus length (km)
36
36
134
6
3254
89
5
2165

(C)
Voltage Level (kV)
Span in M
Maximum Current to be transferred
in Amp for Twin per Bundle
Configuration
Maximum Power to be transferred in
MW for
Twin per Bundle Configuration
175
2
Maintaining same Ampacity of ACSR Zebra in ACCC Kolkata conductor

carried out at temp stated besides
in 0c
Current in Amp:
75
70.39
67
3
0.084
673
0.0660

Power Factor
8
23
0
0.9
179
0.9
44
8
448
Sag in M at above mentioned temp &

0.2
0.09
0%
windin kg worked out at 32 0C &
7
Tension
100%
3347.65
3347.60
wind
Tension in kg worked out at 0 0C &
5403.14
3654.61
66% wind
Maintaining Ampacity of 2800 Amp in the proposed ACCC Kolkata
Conductor for Twin Per
Bundle configuration

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Companies
Current of 1400 Amp to be transferred
--------2800
for
Twin per Bundle Configuration
Power to be transferred in MW for
--------1863
Twin per
Bundle Configuration
Ampacity equivalent to 1400 Amp to be transferred in proposed ACCC
Kolkata
Conductor
The following
calculations are
75
137.59
in 0c
Current in Amp:
67
140
3
0
0.084
0.0803
8
23
944
0
Power Factor
0.9
0.9
44
8
931

0.2
0.12
0% windin kg worked out at 32 0C &
7
Tension
100%
3347.65
3347.60
wind
Tension
in kg worked out at 0 0C &
5403.14
3654.61
66% wind
Ampacity at maximum continuous operating temperature in both ACSR
Zebra and ACCC Kolkata conductors
in 0c
Current in Amp:
Power Factor
0%
windin kg worked out at 32 0C &
Tension
100%
wind
Tension in kg worked out at 0 0C &
66% wind
75
175
67
3
0.084
1627
8
23
0
0.9
44
8
0.2
7
3347.65
5403.14
0.0883
1402
0.9
1082
0.14
3347.60
3654.61
Assumptions : Coeficient of Emissivity=0.6, Wind velocity=0.6m/s, Solar

Absorption
Coefficient=0.5, Constant of mass temperature coeficient of resistance
of conductor per
C = 0.004 for all conductors, Solar Radiation = 1200 Wt / sq m, Average
ambient temp= 45 deg C, Wind Pressure=45 kg/ sq m.

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Companies
The following can be observed from above table:
1. The ACCC Kolkata conductor is able to deliver 3254 Amps at its maximum operating
temperature of 1750C with Twin per Bundle configuration. At this temp the sag
of ACCC Kolkata conductor is 0.14M which is less as compared to existing ACSR Zebra
conductor at 750 C temperatures.
2. The tension of ACCC Kolkata conductor at 320C and 100% wind is equivalent to that of
ACSR Zebra conductor with same parameters.
3. The weight of ACCC Kolkata conductor is less than that of ACSR Zebra conductor.
Similarly, UTS of ACCC Kolkata conductor is almost 32 % higher than that of ACSR
Zebra conductor.
ACSR Zebra
Temperature
0
Change ( c)
70.39
75
85
95
105
115
125
135
145
155
165
175
ACCC Kolkata
Ampacity
AC
Resistance
Line
Losses
673
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0.0848
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
230
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Ampacity
673
757
908
1031
1135
1227
1308
1382
1450
1513
1572
1627
AC
Resistance
0.06604
0.06702
0.06912
0.07124
0.07336
0.07548
0.07763
0.07976
0.08188
0.08399
0.08614
0.08825
Line
Losses
179
230
342
454
567
682
797
914
1033
1154
1277
1402

1. Maintaining Ampacity of ACSR Zebra in ACCC Kolkata conductor, AC Resistance and
Line losses in case of ACCC Conductor reduces by 22%.
2. Line losses depends upon Ampacity & AC Resistance of conductor at varying
temperature, as the ampacity increases with increase in temperature line losses also
increases simultaneously.
MSTCL may operate ACCC Kolkata conductor at its maximum operating temperature for
a short duration during maximum peak hours and moreover line length is small so practically
line losses shall not be taken in account.
CASE STUDY NO: 4.2
The existing 100kV Padgha - Bhivandi Ckt-1 & Ckt-2 D/C transmission line of MSTCL is
strung with ACSR Goat conductor. ACSR Goat conductor is capable to cater 82 MW power per
circuit at its continuous maximum operating temperature. MSTCL wants to cater additional

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Companies
power through existing 100 kV D/C transmission line corridor. To cater the additional power
Installation using new line is very costly and time consuming. It is also difficult to acquire
right- of-way& approvals from the various authorities for construction of new transmission line.
MSTCL has approached M/s. Sterlite Technologies, to give appropriate solution related to
change in the support structures and foundatioins. For this particular application it is
proposed to deploy ACCC Brussels conductor instead of existing ACSR Goat Conductor.
Since the mechanical properties of ACCC Brussels and ACSR Goat conductor are nearly same,
it will be possible to string them on the existing transmission line structures without any
modification and their foundations also need not be changed. The maximum span is considered
as 325M.
Sag tension calculation with ruling span of 325M for ACSR conductor &ACCC Brussels
conductor is enclosed herewith. The comparison of the mechanical properties and current
carrying capacities of ACSR Goat & ACCC Brussels conductor is given here under.
Technical Comparison of ACSR Goat & equivalent ACCC Conductor
Properties
ACSR Goat

Conductor Diameter
(mm)
399.
6
25.9
7
703400

(/C)
19.3*10^-6
Weight (kg/km)
1491.30
UTS (kg)
13765.00

Ltd. (TPEC)
ACCC Brussels
477
25.1
4
1121305 above
Thermal knee point
(90
0C) & 636085.6
below
-6
1.61*10 above
Thermal knee
point(90
-6
0C ) & 18.9*10
below
1275.0
0
13873.60
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Companies
(ohms/km)
75
0.0673
0
175
100
100
Nos. of Circuit
21
21
325
325
(C)
Voltage Level (kV)
0.08935
Line length (km)

Span in M
The following calculations are carried out at temp C as stated below

Case-1 :Maintaining same Current in ACCC Conductor
Temp C
Current in Amp:
75.0
0
577
69.8
3
577
0.109
8
230
0.081
7
171
3
0.8
5
82
Power Factor
4
0.8
5
82
Tension to be maintained at 32
0C &
5640.59
5644.5
8
100%
wind
0%
7.3
6.6
9
8
wind
Case-2 :Current at maximum operating temperature of ACCC conductor
Temp 0c
Current in Amp:
Power Factor
75.0
0
577
0.109
8
230
3
0.8
5
82
175.0
0
139
6
0.109
8
1348
1
0.8
5
199
0C &
5640.59
5396.8
3
100%
Sag
atwind
above mentioned temp &
0%
7.3
7.0
wind
9
1
Assumptions: Coeficient of Emissivity = 0.6, Wind velocity = 0.6 m/s,
Solar absorption coefficient = 0.5, Constant of mass temperature
coefficient of resistance of conductor per C
= 0.004 for other conductors, Solar Radiation = 1200 Wt / sq m,
Average ambient temp=
45 deg C, Wind Pressure=117.96 kg/m^2,
Wind zone=3.

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Companies
1. The ACCC Brussels conductor is able to deliver 1396 Amps at its maximum operating
0
temperature of 175 C with single configuration. At this temp the sag of ACCC Brussels
conductor is 7.01M which is 380mm less as compared to existing ACSR Goat conductor
at its maximum operating temperature 750C .
2. It can also seen from the calculation that ACCC Brussels is capable to transmit the
199MW power at its maximum continuous operating temperature of 1750C whereas
ACSR Goat is transmitting 84MW power at its maximum operating temperature of 750C.
3. The tension of ACCC Brussels conductor at 320C and 100% wind is equivalent to that of
ACSR Goat conductor with same parameters.
4. The weight of ACCC Brussels conductor is 15% less than that of ACSR Goat conductor.
ACSR Goat
Temperature
0
Change ( c)
69.83
Ampacity
-------
75
80
90
100
110
120
130
140
150
160
170
175
577
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
AC
Resistance
-------
0.1098
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
ACCC Brussels
Line
Losses
(kW/ckt)
-------
Ampacity
577
2303
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
658
726
841
936
1019
1092
1158
1218
1273
1324
1373
1396
AC
Resistance
0.0817
0.08312
0.08445
0.08710
0.08978
0.09247
0.09512
0.09777
0.10046
0.10310
0.10578
0.10844
0.10980
Line Losses
(kW/ckt)
1714
2267
2804
3881
4807
6049
7146
8260
9389
10526
11682
12879
13481

1. Maintaining Ampacity of ACSR Goat (at 750C) in ACCC Brussels conductor (at
69.830C), AC Resistance and Line losses in case of ACCC Conductor reduces by 25%.
2. Line losses depends upon Ampacity & AC Resistance of conductor at varying
temperature, as the ampacity increases with increase in temperature line losses also
increases simultaneously. However, considering the critical ROW issue & need to
transmit more power there is no alternative but to go for HPC. Besides, the losses are
worked out at continuous maximum current and temperature of 175C. This may not be
a reality. Therefore the losses may not be very high.
CASE STUDY NO: 4.3
The existing MSETCL (200/100kV) Receiving substation at Magthane, Borivali is having 220
kV Main Bus of Twin 0.4 ACSR Moose. The Main Bus gantry structures and column
foundations are designed to take the mechanical load of twin conductor only. This Main bus
bar

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Companies
can be loaded for about 1500 Amps. With additional demand, the bus bar current will go to
3100
Amps.
This has become necessary to allow the additional power evacuation from the existing bus to the
proposed GIS of R-Infra in the substation of MSETCL. The existing bus gantries of the
substations cannot withstand the load of Quad Moose and replacing them would need a very
long shut down. The metropolitan city of Mumbai cannot afford long shut down.
Therefore, MSETCL has approached M/s. Sterlite Technologies, Pune to give suitable solution
related with the conductor design for augmenting the capacity of the bus bar with minimum
changes and thus affording very little shutdown. For this particular application it is proposed
to use Twin ACSS Curlew conductor instead of existing Twin ACSR Moose Conductor. Since
the mechanical properties of ACSS Curlew and ACSR Moose conductor are nearly same, it will
be possible to string them on the existing gantry structures without any modification and
their foundations also need no change. The maximum span of the bus between two gantries is
39M.
The comparison of the mechanical properties and current carrying capacities of ACSR Moose&
ACSS Curlew conductor is given here under.
Technical Comparison of ACSR Moose & ACSS Curlew
conductor
Properties
ACSR Moose
ACSS Curlew
Typical Factors
ACSR 54/7/3.53mm
54/7/3.513 mm
Ref Spec.
IS 398 Part V
ASTM B586
AL/Steel Area
AL 528.21 / St 68.78 591
Conductive Wire
Al 1350 H19
Core Wire
Galvanized Steel

Modulus Of Elasticity
2
(Kg/cm )
Linear Co-efficient
Conductivity of Conductor
Weight (Kg/Km)
Emergency temperature
31.7
7
70400
0
-6
19.3*10
52
%
200
4
105
Maximum Operating
85
Temperature (C)
Current Carrying Capacity
880
(Amp)
at 85 CCarrying Capacity
Current
(Amp)
at 100 C
Ltd. (TPEC)
Al1350 O (Fully
Annealed
Al
wires)
Galfan
Coated STC 6
Steel
31.62
3
70400
0
11.5*10
6
53.24
%
198
3
310
210
1075
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Companies
Current Carrying Capacity
(Amp)
at 110 C
Current
Carrying Capacity
(Amp)
at 120 C
Current
Carrying Capacity
(Amp)
at 130 C
Current
Carrying Capacity
(Amp)
at 140 C
Current
Carrying Capacity
(Amp)
at 150 C
Current
Carrying Capacity
(Amp)
at 160 C Sag in Mtrs
Conductor
(Span =
40m) at 85Sag
C in Mtrs
Conductor
(Span =
40m) at 160
C
Conductor
Tension
in kg
(Span =
40m) at 85Tension
C
Conductor
in kg
(Span =
40m) at 160
C (Span =
Conductor
FOS
40m) at
85
C
Conductor
FOS (Span =
40m) at
160
C (Kgf)
Strength
DC Resistance
@ 20
C
DCTemp
Resistance
@ 75
C Temp
DC
Resistance
@ 85
C Temp
DC
Resistance
@
100
C Temp
DC Resistance
@
110
C Temp
DC
Resistance
@
120
C Temp
DC
Resistance
@
130
C Temp
DC Resistance
@
140
C Temp
DC
Resistance
@
150
C Temp
DC
Resistance
@
160 C Temp
(ohms/Km)
(ohms/Km)
(ohms/Km)
(ohms/Km)
(ohms/Km)
(ohms/Km)
(ohms/Km)
(ohms/Km)
(ohms/Km)
(ohms/Km)
1180
1275
1360
1438
1511
1582
1.1
6
-
335.3
0
46.9
2
16200.00
0.0559
6
0.0682
7
0.0705
0
-

Ltd. (TPEC)
1.26
312.6
4
45.6
5
1427
1
0.0547
7
0.0668
2
0.0690
1
0.0723
0
0.0744
9
0.0766
8
0.0788
7
0.0810
6
0.0832
5
0.0854
4
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Companies
1. The ACSS Curlew conductor is able to deliver 1703 Amps at its maximum operating
temperature of 2100C with single configuration. At this temp the sag of ACSS Curlew
conductor is 1.26M which is 100mm more as compared to existing ACSR Moose
conductor at its maximum operating temperature 850C .
2. It can also seen from the calculation that ACSS Curlew is capable to transmit the 536
MW power with single configuration at its maximum continuous operating temperature
of 2100C whereas ACSR Moose is transmitting 251 MW power at its maximum
operating temperature of 850C.
3. The tension of ACSS Curlew conductor at 320C and 100% wind is equivalent to that of
ACSR Moose conductor with same parameters.
4. The weight of ACSS Curlew conductor is 1.04% less than that of ACSR Moose
conductor.
5. TRANSMISSI ON CORPORATION OF ANDRA P RADESH LIMITED

(APTRANSCO)
Transmisssion Corporation of Andra Pradesh Limited (APTRANSCO) is having 132 KV line
running from Shapurnagar IDPL Chinthal DC feeder & Ghanapur-Bandlaguda. The line is
continuously loaded to its full capacity. The existing line is strung with ACSR Panther & ACSR
Wolf conductor strung mainly on PRS type Structures.
ACSR Panther Conductor is having maximum current rating of 254 Amp at maximum
0
continuous operating temperature (75 c).
ACSR Panther Conductor is capable of catering maximum of 48 MW Power through its Single
Circuit Arrangement. APTRANSCO wants to cater additional power (170 MW per Single
Circuit) through its 132 kV Transmission Line Corridor. Lines are going to be overloaded so
change in the conductor by higher size is necessary. This will require strengthening of tower
and foundation. APTRANSCO may transfer its additional power by dismantling its existing
towers and upgrading the existing voltage level to some higher voltage level but it would ask for
a larger shutdown period. Construction of new transmission line would require right of
way and approvals from the various authorities and the procedure may ask for a larger project
completion time period.
ROW and using same Towers by Re-conductoring existing lines with new generation High
APTRANSCO has approached M/s. Sterlite Technologies, to give appropriate solution
related to the conductor design for augmenting the capacity with minimum changes and
thus affording very little shutdown.

Ltd. (TPEC)
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Companies
For this particular application it is proposed to deploy INVAR Conductor size
30/7/3mm(Invariable to temperature) conductor equivalent to size of ACSR/AAAC Panther
conductor on existing towers without their re-modeling / strengthening. Since the mechanical
properties of STACIR and ACSR Panther conductor are nearly same, it will be possible to string
them on the existing transmission line structures without any modification and their foundations
also need not be changed. The maximum span is considered as 320M.
Technical Comparison for ACSR Panther & STACIR
Conductors
Properties
ACSR
STACIR
Panther
30/3m
m
Al+7/3mm
IS 398 Part II
Typical Features:
Ref Specification
2
261.50

261.64
21.0
0
2
30/3.00 +
7/3.00
IECmm
62004
815494.00

(/C)
17.8*10
-6
21.0
0
747706.42
above thermal
knee point (50
0
C) and
454536.18
below thermal
knee point
-6
3.7*10 for
temperature
above thermal
knee point (50
0
C) and
-6
15.43*10
below thermal
knee point
939.00
Weight (kg/km)
974.00
UTS (kgf)
9140.67
8766.56
(ohms/km)
Maximum Operating
0.13900
0.13120
75
210
132
132
Nos. of Circuits
Line length (km)
320
320
Temperature
(C)
Voltage Level (kV)
Span in Mtrs.
Case 1 : Maintaining same Current as that of ACSR Panther in

STACIR conductor

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Companies
besides:
75
254
0.1701
74.5
5
254
0.1604
33
31
Power Factor
0.8
5
48
0.8
5
48

0%
wind
7.0
6
4.5
1
C&
4847.09
4848.71
100% wind
0
C & 0%
2285.72
3007.68
wind
Case 2 : Current in Amp at maximum continuous operating
temperature in ACSR Panther & STACIR conductors
besides:
75
210
254
945
0.1701

Power Factor
0%
wind
0
C&
100% wind
0
C & 0%
wind
Saving in Case 1:
0.2313
33
0.8
5
48
620
0.8
5
178
7.0
6
5.4
9
4847.09
4848.71
2285.72
3007.68
Cost of power loss in INR 4/- per

kW for
1 year
Cost of Power transferred in INR
4/- per kW for 1 year
1156320
1086240
1681920000
1681920000
Revenue generated in INR 4/-
1680763680
1680833760
Additional Revenue
ACSR in INR for 1 year
-----------------

Ltd. (TPEC)
7008
0
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Companies
Additional Revenue
ACSR
(Crore)
SavingininINR
Case
2:
-----------------

kW for
1 year
Cost of Power transferred
without losses in INR 4/- per
kW
for 1 year
Revenue
generated in INR 4/Additional Revenue
Additional Revenue
ACSR
in INR (Crore)
Assumptions:
0.01
1156320
21724800
1681920000
1680763680
6237120000
6215395200
-----------------
4534631520
-----------------
453.46
(1) Coefficient of Emissivity

= 0.45 (2) Wind velocity =
0.6 m/s
(3) Solar absorption co-efficient = 0.8
(4) Constant of mass temperature coeficient of resistance of
conductor per C =
(5) Solar Radiation = 1045 Wt / sq m
0
(6) Average ambient temp= 55 C
2
(7) Wind Pressure=150 kg/m
Requirement as per APTRANSCO Tender documents:

1. Overall diameter of complete conductor should not exceed 21 mm and 5% variation (+ &
Ampacity shall be calculated as per IEC 1597 standard.
strictly limited to 6.5 M, while STACIR conductor gives sag of 5.49 M at maximum
operating temperature of 210 degC
3. Design Tension of 132 kV towers should be strictly limited below 4847.09 kg at 32 0c &
100% wind during Re-conductoring, while restringing STACIR conductor over
0
1. Weight of STACIR conductor (kg/km) is 3.59% as compared to ACSR.
0
2. DC Resistance at 20 c of STACIR conductor is 5.61% lower as compared to ACSR thus
boosting up ampacity and simultaneously decreasing losses.
3. Ampacity in STACIR at maximum operating temperature (210 0c) is 271.92% higher as
(MW) in case of STACIR boosts up by 270.83%.

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Companies
0

the case of Re-conductoring, we obtain a reduction of 22.15% sag at anoperating
0
temperature of 210 c as compared to conventional ACSR conductor.
ACSR Wolf Conductor is having maximum current rating of 218 Amp at maximum continuous
0
operating temperature (75 c).
ACSR Wolf Conductor is capable of catering maximum of 41 MW Power through its Single
Circuit Arrangement. APTRANSCO wants to cater additional power (146 MW per Single
Circuit) through its 132 kV Transmission Line Corridor. Lines are going to be overloaded so
change in the conductor by higher size is necessary. This will require strengthening of tower
and foundation. APTRANSCO may transfer its additional power by dismantling its existing
towers and upgrading the existing voltage level to some higher voltage level but it would ask for
a larger shutdown period. Construction of new transmission line would require right of
way and approvals from the various authorities and the procedure may ask for a larger project
completion time period.
ROW and using same Towers by Re-conductoring existing lines with new generation High
APTRANSCO has approached M/s. Sterlite Technologies, to give appropriate solution
related to the conductor design for augmenting the capacity with minimum changes and
thus affording very little shutdown.
For this particular application it is proposed to deploy INVAR Conductor size 30/7/2.59 mm
(Invariable to temperature) conductor equivalent to size of ACSR Wolf conductor on existing
towers without their re-modeling / strengthening. Since the mechanical properties of
STACIR and ACSR Wolf conductor are nearly same, it will be possible to string them on the
existing transmission line structures without any modification and their foundations also
need not be changed. The maximum span is considered as 320M.

Ltd. (TPEC)
Page
28

Companies
Technical Comparison for ACSR Wolf & STACIR
Conductors
Properties
ACSR Wolf
STACIR
Typical Features:
Ref Specification
2

------------------------
30/7/2.59 mm
IEC 61089
195.00
194.90
18.1
3
832863.40
18.1
3
838532.11
below thermal
knee point (50
0
C) and
1549031.6
above thermal
knee point
-6

(/C)
-6
19.3*10
3.7*10 for
temperature
above thermal
knee point (50
0
C) and
-6
14.9*10
below thermal
knee point
699.00
Weight (kg/km)
726.00
UTS (kgf)
6864.00
6612.64
(ohms/km)
Maximum Operating
0.18710
0.17670
75
210
132
132
Nos. of Circuits
Line length (km)
320
320
Temperature
(C)
Voltage Level (kV)
Span in Mtrs.
Case 1 : Maintaining same Current as that of ACSR Wolf in STACIR

conductor
75
74.5
1
besides:
218
218
0.2286
0.2156
33
31
Power Factor
0.8
5
41
0.8
5
41

0%
wind
5.5
8
4.6
5

Ltd. (TPEC)
Page
29

Companies
0
C&
3723.21
3723.39
100% wind
0
C & 0%
1715.67
1682.34
wind
Case 2 : Current in Amp at maximum continuous operating
temperature in ACSR Wolf & STACIR conductors
besides:
75
218
0.2286

Power Factor
0%
wind
0
C&
100% wind
0
C & 0%
wind
Saving in Case 1:
kW for
1 year
Cost of Power transferred in INR
4/- per kW for 1 year
Revenue generated in INR 4/Additional Revenue
Additional Revenue
ACSR
(Crore)
SavingininINR
Case
2:
kW for
1 year
Cost of Power transferred
without losses in INR 4/- per
kW
for 1 year
Revenue
generated in INR 4/Additional Revenue
210
776
0.3113
33
0.8
5
41
562
0.8
5
146
5.5
8
5.7
7
3723.21
3723.39
1715.67
1682.34
1156320
1086240
1436640000
1435483680
1436640000
1435553760
-----------------
7008
0
-----------------
0.01
1156320
19692480
1436640000
5115840000
1435483680
5096147520
-----------------
3660663840

Ltd. (TPEC)
Page
30

Companies
Additional Revenue
ACSR
in INR (Crore)
Assumptions:
-----------------
366.07
(1) Coefficient of Emissivity

= 0.45 (2) Wind velocity =
0.6 m/s
(4) Constant of mass temperature coeficient of resistance of
conductor per C =
(6) Average ambient
0
temp= 55 C (7) Wind
2
Pressure=150 kg/m
Requirement as per APTRANSCO Tender documents:

1. Overall diameter of complete conductor should not exceed 18.13 mm and 5% variation (+
& -), Approximate mass of complete conductor should be less than or equal to 974
kg/km. Ampacity shall be calculated as per IEC 1597 standard.
2. Design Tension of 132 kV towers should be strictly limited below 3723.21 kg at 32 0c &
100% wind during Re-conductoring, while restringing STACIR conductor over
0
1. Weight of STACIR conductor (kg/km) is 3.71% as compared to ACSR.
0
2. DC Resistance at 20 c of STACIR conductor is 5.55% lower as compared to ACSR thus
boosting up ampacity and simultaneously decreasing losses.
3. Ampacity in STACIR at maximum operating temperature (210 0c) is 255.96% higher as
(MW) in case of STACIR boosts up by 256.09%.
0
the case of Re-conductoring, we obtain a slight increase of 3.40% sag at an operating
0
temperature of 210 c as compared to conventional ACSR conductor.
6. GUJ ARAT ENERGY TRANSMISSSION CORPORATION LTD. (GETCO)

Due to rapid Industrial growth around Rajkot in Gujarat the following transmission lines
under the jurisdiction of transmission division Rajkot, are getting over loaded.
1. 66 kV Vikram Punitnagar H-Frame Line of length 5 km.
2. 66 kV Vikram Punitnagar D/C Line of length 5 km.
3. 66 kV Shapar Sidheshwar D/C Line of length 3.5 km.
4. 66 kV Vikram Shapar D/C Line of length 4 km.

Ltd. (TPEC)
Page
31

Companies
The above lines are strung with ACSR Dog Conductor which can carry about 300 Amp only.
It has therefore become necessary to augment the capacity of above line to extent of above
500
Amps. An attractive method of increasing transmission line thermal rating (up rating) involves
replacing the original (typically) steel-reinforced aluminum conductor (ACSR) with a High
Performance Conductor (HPC) conductor with approximately the same diameter as the original
ACSR but being capable of operation at temperatures as high as 150C with less
thermal elongation than ACSR.So the best solution is Re-conductoring of existing
lines with High Performance Conductor (HPC) Conductor. Ideally, these special
HPC conductors can be installed and operated without the need for extensive modification
of the existing structures and foundations.
The High Performance Conductor (HPC),TACIR Dog (Thermal Alloy Conductor steel
Reinforced) conductor is having almost the same mechanical properties of ACSR Dog
conductor. Here the sag of this conductor is also less than that of the sag of existing ACSR Dog
M/s Sterlite has made submission to M/s Gujarat Energy Transmission Corporation (GETCO),
which indicates that it is possible to change the existing ACSR DOG conductor by TACSR DOG
Conductor for raising the load ability of the existing 66kV S/C or D/C Lines. This can be done
without any change in the existing Tower Structures. GETCO has many lines in their Power
system, which are getting over loaded and it is not possible to change the Towers or add more
Towers to the Lines.
Technical Comparison of ACSR Dog & TACSR Dog

conductor
Properties
Cross sectional Area (mm)
Modulus Of Elasticity (Kg/cm )
ACSR Dog
118.
5
14.1
5
775000
-6
Linear Co-efficient
Weight (Kg/Km)
Strength (Kgf)
19.8x10
394
330
5
DC Resistance
C
DCTemp
Resistance
C
Temp
DC Resistance
112 C Temp
DC Resistance
150 C Temp
0.279200
0.331690
(ohms/Km) @ 20
(ohms/Km) @ 67
(ohms/Km) @
(ohms/Km) @

Ltd. (TPEC)
TACSR Dog
118.
5
14.1
5
775000
11.5x10
394
366
6
-6
0.27800
0.33026
NA
0.38030
NA
0.42256
75
150
Page
32

Companies
Current Carrying Capacity (Amp)
at
67 CCarrying Capacity (Amp)
Current
at
112 C
Current
Carrying Capacity (Amp)
at 150 C
Conductor Sag in Meters
(Span = 260m) at 67 C & no wind
(Span = 260m) at 112 C & no
wind
(Span = 260m) at 150 C & no
wind
Conductor Tension in Kg
(Span = 260m) at 0 C & 66%
wind
(Span = 260m) at 112 C & no
wind
(Span = 260m) at 150 C & no
wind
Conductor FOS
Conductor FOS
Conductor FOS
(Span = 260m) at 112 C & no
wind
Conductor FOS
(Span = 260m) at 150 C & no
wind
AC Resistance (ohm) @ 67C
Power Loss in kW/km @ 67C (3
phase
2
Double
Circuit)
=I *AC@Resistance
Power Loss
in kW/km
112C(3
phase
2
Double
Circuit)
=I *AC@Resistance
Power Loss
in kW/km
150C (3
phase
2
Double Circuit) =I *AC Resistance

Ltd. (TPEC)
268
NA
NA
269
480
577
5.3
2
4.37
NA
5.33
NA
6.11
1315.58
1291.05
626.26
761.61
NA
624.38
NA
545.03
4.0
0
4.00
5.2
8
4.81
NA
6.05
NA
6.73
0.331950
NA
NA
0.33052
0.38053
0.42277
143
144
NA
526
NA
845
Page
33

Companies
Here calculated value of sag is 5.32 m against the maximum allowable
sag is
8.23 m (27' - 0'')
0
1. Ampacity in TACIR at maximum operating temperature (150 c) is 115.29% higher

as compared to maximum operating temperature of ACSR conductor.
2. Maintaining tension of ACSR at 32 0c & full wind as starting condition in TACIR as in
the case of Re-conductoring, we obtain a increase of 68.23% sag at an
0
operating temperature of 150 c as compared to conventional ACSR conductor.
COMPARATIVE STATEMENT FOR ACSR DOG & TACSR DOG CONDUCTOR AS
PER IS:802,1978
BASIC INPUTS CONSIDERED
UNITS
ACSR
DOG
TACSR
DOG
Normal Span
185.00
185.00
Cross section area
1.19E-04
1.19E-04
U.T.S.
Kg
3305
3785
Weight
Kg/M
0.394
0.394
Modulus of Elasticity E
Kg/M
7.75E+09
7.75E+09
1.98E-05
1.15E-05
Kg/M
45.00
1.415E02
45.00
1.415E02
Wind pressure
Overall Diameter
LOADING
CONDITION
SAG-(M)
ACSR
TACSR
DOG
DOG
TENSION-(Kg)
ACSR
TACSR
DOG
DOG
F.O.S.
ACSR
TACSR
DOG
DOG
C No wind
1.36
1.36
1243.87
1243.38
2.66
3.04
C 66% wind
1.25
1.25
1350.41
1350.22
2.45
2.80
C Full wind
1.16
1.16
1458.25
1457.42
2.27
2.60
32
C No wind
2.04
1.71
826.75
984.07
4.00
3.85
32
C 66% wind
1.72
1.50
980.41
1120.29
3.37
3.38
32
C Full wind
1.51
1.35
1117.54
1246.44
2.96
3.04
67
C No wind
3.04
2.22
554.35
758.36
5.96
4.99
67
C 66% wind
2.33
1.83
722.53
919.07
4.57
4.12
67
C Full wind
1.94
1.59
867.58
1059.01
3.81
3.57
C No wind
4.32
3.00
390.55
562.46
8.46
6.73
113

Ltd. (TPEC)
Page
34

Companies
113
C 66% wind
3.12
2.30
540.31
731.44
6.12
5.17
113
C Full wind
2.50
1.92
673.49
875.85
4.91
4.32
Comparison of Sag and Tension between ACSR Dog & TACSR Dog Conductor as under:
1. It will be worthwhile to indicate that the tower design is governed basically by the two
important parameter related with the conductor. There are as under:
2. Sag of conductor at maximum temperature and no wind condition - This condition
determines the height of bottom cross arm above the ground level.
3. The tension of conductor at 0 deg. C with 66% wind or at 32 deg. C with 100% wind
whichever is higher This condition relates to the strength of the tower and also has a
direct effect on the weight of the tower/s as well as foundation quantities.
4. If 1 - a and b are satisfied by any alternate conductor, the intermediate values of sag and
tension are in significant.
5. It can be seen from the sag tension calculation that the sag of TACSR Dog Conductor at
113 deg. C. is comparable to that of ACSR Dog at 67 deg. C. In addition to this, the
tension of ACSR Dog & TACSR Dog are comparable at 0 deg. C & 66% wind.
6. The GETCO officials have an apprehension that the values of sag and tension at
intermediate loading (intermediate temperature between 67 deg. C & 113 deg. C), the
values of sag and tension of both the conductors will vary. This cannot be denied but so
far as the transmission line tower design practice in the country is concerned, whatever is
indicated 1 a & b above is valid. The intermediate values of sag and tension of proposed
TACSR Dog Conductor have no significance what so ever be, in the critical aspects of
the tower design.
It can be further stated that the replacement can be done easily without any change in hardware.
This is obvious from the point of view that the Ferrous and Aluminum components of hardware
and clamps/connectors deform at much higher temperature (250 deg. C and above).
7. TORRENT POWER LIMITED

Due to rapid Industrial growth in Ahmadabad in Gujarat the existing 132 kV D/C Torrent power
line from New Pirana to Vinzol under the jurisdiction of transmission division Ahmadabad, is
getting over loaded.
The line is strung with ACSR Panther Conductor which can carry about 440 Amps only. It has
therefore become necessary to augment the capacity of above line to extent of above 1058
Amps.

Ltd. (TPEC)
Page
35

Companies
An attractive method of increasing transmission line thermal rating (up rating) involves
replacing the original (typically) steel-reinforced aluminum conductor (ACSR) with a High
Performance Conductor (HPC) conductor with approximately the same diameter as the
original ACSR but
being capable of operation at temperatures as high as 2000c with less thermal elongation
than
ACSR. So the best solution is Re-conductoring of existing lines with High Performance
Conductor (HPC) Conductor. Ideally, these special HPC conductors can be installed and
operated without the need for extensive modification of the existing structures and foundations.
The High Performance Conductor (HPC), ACCC Lisbon (Aluminum Conductor Composite
Core) conductor is having almost the same mechanical properties of ACSR Panther conductor.
Here the sag of this conductor is also less than that of the sag of existing ACSR Panther
M/s Sterlite has made submission to M/s Torrent Power Limited, which indicates that it is
possible to change the existing ACSR Panther conductor by ACCC Lisbon Conductor for
raising the load ability of the existing 132 kV D/C Lines. This can be done without any change
in the existing Tower Structures.
Technical comparison of ACSR Panther & ACCC Lisbon
PropertiesConductors
ACSR
ACCC LISBON
2
PANTHER
262.00
358.
4
Conductor Diameter(mm)
21.0
21.7
0
8
1144750.25
above Thermal
2
Knee point and
767000.00
640163.10
below Thermal
knee point.
-6
1.61*10 above
Thermal Knee
-6
point and
Co-eficient of Linear Expansion (/C)
17.8*10
-6
18.76*10 below
Thermal knee
point 956.6
Weight (kg/km)
976.00
UTS (kgf)
(ohms/km)
Emergency temperature (C)
(C)
Voltage
Level (kV)
Normal Span, m
Nos. of Ckts
Ltd. (TPEC)
9128.00
0.13900
10
5
75
13
2
32
5
1
1
0
10570.84
0.09000
200
175
132
325
1
1
Page
36

Companies
Line length (km)
FOS @ 0 C, 36% wind
FOS @ 32 C, 0% wind
FOS @ 32 C, 100% wind
Conductor Tension, kg @ 32 C, 100%
wind
Following calculations are at temp,
(C)
(If
not mentioned)
Current
Carrying Capacity (Amps)
Sag , 0% wind (m)
Line losses in kW
Power Factor
MW Transferred (MW)
Cost of power per kW in Rs.
Cost of Powerloss for 1 year (Rs.)
Cost of Power for 1 year (Rs.)
Revenue Generated for 1 year (Rs.)
1
2.7
5
4.0
0
2.0
7
4404.67
1
4.3
7
6.0
7
2.4
0
4404.63
75.0
0
44
0
0.170070
7.2
3
98.7
8
0.9
110.5
0
850
0.122727
7.5
5
266.0
1
0.9
88
4
3461129
3083520000
3080058871
170
4
9321010
5956800000
5947478990
Additional Revenue Generated for 1

--2867420119
year (Rs.)
Table:
1. Weight of ACCC Lisbon conductor (kg/km) is 1.98% less as compared to ACSR Panther.
2. DC Resistance at 20 0c of ACCC Lisbon conductor is 35.25% lower as compared to
3. Ampacity in ACCC Lisbon conductor at maximum operating temperature (1750c) is
154.43% higher as compared to maximum operating temperature of ACSR conductor,
the power transferred (MW) in case of ACCC Lisbon conductor boosts up by 154.32%.
0
4. Maintaining tension of ACSR at 32 c & full wind as starting condition in ACCC Lisbon
as in the case of Re-conductoring, we obtain a slight increase of 4.426% sag at
an
operating temperature of 175 0c as compared to conventional ACSR conductor.
8. TATA POWER COMPANY LI MITED

CASE STUDY NO: 8.1
Existing 220 kV Double Circuit Transmission line from Kalwa to Salsette of M/s Tata Power
Company Limited is strung with Twin ACSR Panther & Single ACSR Moose conductor. The
Route length of the double circuit line is 8 kms. The double Circuit line is strung with twin
ACSR Panther for about 7.5 km and remaining 0.5 km with ACSR Moose conductor. Due to
increase in power demand the existing line is getting loaded.

Ltd. (TPEC)
Page
37

Companies
ACSR Panther conductor can cater maximum current of 546 Amp at its maximum continuous
operating temperature and with twin per bundle configuration max of 1064 amp. With
increase in power demand, current to be catered is about 1800 Amp per bundle conductor
configuration.
In order to cater the increase in power demand, twin ACSR Panther shall be replaced with twin
Moose conductor or with High Performance Conductor (HPC) Panther equivalent conductor as
these new generation conductors are having same overall diameter and mechanical strength
as that of conventional ACSR conductors.
As the existing tower structure are designed with twin ACSR Panther conductor and
replacing them with twin ACSR Moose, tower foundations need to be re-designed to take the
load of twin ACSR Moose conductor and would also need a longer shut down.
The
metropolitan city of Mumbai cannot afford such long shut down.
Therefore, M/s Tata Power Company Limited has approached M/s. Sterlite Technologies,
Pune to give suitable solution related with the conductor design for augmenting the capacity of
the line with minimum changes and thus affording very little shutdown.
For this particular application it is proposed to use Twin ACCC Casablanca conductor instead of
existing Twin ACSR Panther Conductor. Since the mechanical properties of ACCC Casablanca
and ACSR Panther conductor are nearly same, it will be possible to string them on the existing
tower structures without any modification and their foundations also need no change.
The comparison of the mechanical properties and current carrying capacities of ACSR Panther&
ACCC Casablanca conductor is given here under.
Technical Comparison of ACSR Panther & equivalent

Conductors
Properties
ACSR Panther
Typical Factors:
30/7/2.99 mm
2
262

21.2
3
2
Weight (kg/km)
Ltd. (TPEC)
725500
-6
19.3*10
975.0
0
ACCC
Casablanca
---------316.5
0
20.5
0 above
1182466.87
Thermal knee
0
point (90 c) and
636085.6 below
Thermal knee
point -6
18.9*10 below
Thermal knee
0
point (90 c) and
-6
1.61*10 above
Thermal knee
point
790
Page
38

Companies
UTS (kg)
909
5
0.136
1040
9
0.1025
220
220
Nos. of Ckts
Line length (km)
350
350
(ohms/km)
(C)
Voltage Level (kV)
Span in Mtrs.
8
75
0
175
Case 1 : Maintaining Current of 900 Amp per Subconductor

for Twin
Bundle Configuration per Single Circuit
Current to be maintained in Amp:
Power Factor
Sag at above mentioned temp & 0%
wind
Tension to be maintained at 32 degC&
100%
wind
degC& 0%
wind(For Stringing)
85.6
4
550
0.173
2
251
136.8
4
900
0.151
0
587
5
0.8
5
346
0
0.8
5
566
8.7
4
4431.81
2273.32
8.4
4
4431.1
6
2113.8
4
Case 2 : Current at maximum operating temperature per

Subconductor for Twin Bundle Configuration per single
Circuit
Power Factor
wind
Tension
to be maintained at 32 deg
C& 100%
wind Capitalization for Case 1
Cost

Ltd. (TPEC)
85.0
0
546
0.172
9
247
4
0.8
5
343
8.7
7
4431.81
175
102
9
0.166
6
846
5
0.8
5
647
8.5
9
4431.1
6
Page
39

Companies
Cost of power loss at a tariff of INR 4/for

ACSR Panther and ACCC
88,125,600.0
0
205,684,800.00
Revenue without Power Loss (@

Rs 4/- per kWh) for ACSR Panther
& ACCC per year
12,123,840,000
.00
19,832,640,000.0
0
Revenue generation (INR) @ for ACSR

Panther
& for ACCC per year
12,035,714,400
.00
19,626,955,200.0
0
Additional Revenue Generation

compared to
ACSR for 1 year INR for ACCC per year
Additional
Revenue
Generation
compared to ACSR for 1 year INR for
ACSR Panther & ACCC in Crore
------------
------------
7,591,240,800.0
0
759.1
2
Assumptions:
(1) Coefficient of Emissivity = 0.45
(2) Wind velocity = 0.6 m/s
(4) Constant of mass temperature coefficient of resistance of conductor per C = 0.004
for all conductors.
(6) Average ambient temp= 40 deg C
2
(7)Wind Pressure=124.87 kg/m , Wind zone=3
Table:
1. Weight of ACCC Casablanca conductor (kg/km) is 18.97% less as compared to ACSR
Panther.
0
2. DC Resistance at 20 c of ACCC Casablanca conductor is 25.07% lower as compared to
0
3. Ampacity in ACCC Casablanca conductor at maximum operating temperature (175 c) is
88.46 % higher as compared to maximum operating temperature of ACSR conductor,
the power transferred (MW) in case of ACCC Casablanca conductor boosts up by 88.62
%.
0
Casablanca as in the case of Re-conductoring, we obtain a slight increase of 2.05 % sag
0
at an operating temperature of 175 c as compared to conventional ACSR conductor.

Ltd. (TPEC)
Page
40

Companies
Current Carrying Capacity per Subconductor as

per IEC-1597 (1995)
Temp in
0
c
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
200
ACSR Panther
Ampacity
AC Resistance
93
0.153764
234
0.156482
315
0.159207
377
0.161932
428
0.164676
472
0.167399
511
0.170122
546
0.172866
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
ACCC Casablanca
Ampacity
AC Resistance
113
0.115533
270
0.117568
362
0.119602
432
0.121636
490
0.123668
540
0.125729
584
0.127760
624
0.129797
660
0.131834
694
0.133870
724
0.135930
753
0.137965
780
0.139999
805
0.142058
829
0.144091
851
0.146123
872
0.148181
893
0.150212
912
0.152243
931
0.154300
949
0.156330
966
0.158366
982
0.160423
998
0.162459
1014
0.164516
1029
0.166551
1098
0.176787
CASE STUDY NO: 8.2

Existing 110 kV Double Circuit Transmission line from Arkay Switchyard 110 kV to Valuthur
110/220 kV Swithchyard of M/s Tata Power Company Limited is strung with single
ACSR
Panther conductor. The Route length of the double circuit line is 4.311kms. Due to increase in
power demand the existing line is getting loaded.
ACSR Panther conductor can cater maximum current of 476 Amp at its maximum continuous
operating temperature. With increase in power demand, current to be catered is about 900
Amp. In order to cater this increase in power demand, ACSR Panther shall be replaced with
Moose conductor or with High Performance Conductor (HPC) Panther equivalent conductor
as these new generation conductors are having almost same overall diameter and mechanical
strength as
Ltd. (TPEC)
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41

Companies
that of conventional ACSR conductors. As the existing tower structure are designed with ACSR
Panther conductor and replacing them with ACSR Moose, tower foundations need to be redesigned to take the load of ACSR Moose conductor and would also need a very long shut down.
the line with minimum changes and thus affording very little shutdown.For this particular
application it is proposed to use ACCC Casablanca conductor instead of existing ACSR Panther
Conductor. Since the mechanical properties of ACCC Casablanca and ACSR Panther conductor
are nearly same, it will be possible to string them on the existing tower structures without any
modification and their foundations also need no change. The comparison of the mechanical
properties and current carrying capacities of ACSR Panther& ACCC Casablanca conductor is
given here under.
Technical Comparison of ACSR Panther & ACCC

Conductor
Properties
ACSR Panther
Typical Factors:
Cross Sectional Area (Sqmm)
Conductor Dia
(mm)
-------------262
21.0
0
816000
ACCC Casablanca
10 TW/6 TW/1/7.11
mm
303.9
0
20.5
0
1182466.87 above
Thermal knee point
(70
0
c) and 636085.6
below
-6
Weight (kg/km)
UTS (kgf)
(ohms/km)
Maxiumum Operating Temperature
(C)
Voltage Level (kV)
-6
17.8*10
974.0
0
8826.
0
0.13900
Span in Mtrs.
10408.77
85
0.1025
0
175
110
110
4.31
1
325
4.31
1
325

Line length (km)
18.9*10 below
Thermal knee point
0
(70 c) and
-6
1.61*10 above
Thermal knee point
790
Case 1 : Maintaining Current of ACSR Panther in ACCC

Casablanca Conductor per Single Circuit
Ltd. (TPEC)
Page
42

Companies
Power Factor
wind
100%
wind
0%
wind(For Stringing)
85.0
0
476
0.17472
511
0.8
5
75
7.8
1
77.5
2
476
0.126
7
371
0.8
5
75
6.35
4742.72
4744.7
0
2206.77
2192.2
4
Case 2 : Current at maximum operating temperature in both

Conductors per
Single
Circuit
85.0
0
476
0.17472
175
995
511
0.166
6
213
Power Factor
0.8
5
75
3
0.8
5
156

wind
Tension
to be maintained at 32 degC&
100%
wind
7.8
1
4742.72
6.7
5
4744.7
0
Case 3 : Maintaining Current of ACSR Panther in ACCC

Casablanca Conductor per Double Circuit
Power Factor
wind
85.0
0
476
0.17472
102
4
0.8
5
150
7.8
1

Ltd. (TPEC)
77.5
2
476
0.126
7
743
0.8
5
150
6.35
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43

Companies
100%
wind
0%
wind(For Stringing)
4742.72
4744.7
0
2206.77
2192.2
4
Case 4 : Current at maximum operating temperature in both

Conductors per
Double
Circuit
Power Factor
wind
100%
wind
85.0
0
476
0.17472
102
3
0.8
5
149
7.8
1
4742.72
175
995
0.166
6
426
5
0.8
5
313
6.7
5
4744.7
0
Assumptions:
(4) Constant of mass temperature coefficient of resistance of conductor per C = 0.004 for
all conductors.
2
(7)Wind Pressure=146.71 kg/m Wind zone=6, Terrain Category=3,Relaibility Level=1.
Table:
1. Weight of ACCC Casablanca conductor (kg/km) is 18.97% less as compared to ACSR
Panther.
0
2. DC Resistance at 20 c of ACCC Casablanca conductor is 25.07% lower as compared to
0
88.46 % higher as compared to maximum operating temperature of ACSR conductor,
the power transferred (MW) in case of ACCC Casablanca conductor boosts up by 88.62
%.
0
Casablanca as in the case of Re-conductoring, we obtain a slight increase of 2.05 % sag
0
at an operating temperature of 175 c as compared to conventional ACSR conductor.
Ltd. (TPEC)
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44

Companies
Current Carrying Capacity as per IEC-1597 (1995)

Temp in
0
c
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
200
ACSR Panther
Ampacity
AC Resistance
159
0.161210
262
0.163908
332
0.166606
387
0.169325
435
0.172021
476
0.174717
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
ACCC Casablanca
Ampacity
AC Resistance
187
0.119602
304
0.121636
384
0.123668
448
0.125729
502
0.127760
549
0.129797
591
0.131834
629
0.133870
664
0.135930
696
0.137965
725
0.139999
753
0.142058
779
0.144091
804
0.146123
827
0.148181
849
0.150212
870
0.152243
890
0.154300
910
0.156330
928
0.158366
946
0.160423
963
0.162459
979
0.164516
995
0.166551
1069
0.176787
CASE STUDY NO: 8.3

Existing 22 kV Double Circuit Transmission line No. 5& 6 running from Saki Receiving Station
to IIT of M/s Tata Power Company Limited is strung with single ACSR Dogconductor. The
Route length of the double circuit line is 3.50kms. Due to increase in power demand the
existing line is getting loaded. ACSR Dog conductor can cater maximum current of 300 Amp at
its maximum continuous operating temperature.
With increase in power demand, current to be catered is about 670 Amp. In order to cater this
increase in power demand, ACSR Dog shall be replaced with Panther conductor or with High
Performance Conductor (HPC) Dog equivalent conductor as these new generation conductors are
having almost same overall diameter and mechanical strength as that of conventional ACSR
conductors. As the existing tower structure are designed with ACSR Dog conductor and
replacing them with ACSR Panther, tower foundations need to be re-designed to take the load of
ACSR Panther conductor and would also need a very long shut down.

Ltd. (TPEC)
Page
45

Companies
the line with minimum changes and thus affording very little shutdown.For this particular
application it is proposed to use ACCC Helsinki conductor instead of existing ACSR Dog
Conductor.
Since the mechanical properties of ACCC Helsinki and ACSR Dog conductor are nearly same,
it will be possible to string them on the existing tower structures without any modification
and their foundations also need no change. The comparison of the mechanical properties and
current carrying capacities of ACSR Dog& ACCC Helsinki conductor is given here under.
Technical Details of ACSR Dog & ACCC Helsinki

Conductor
Properties
ACSR Dog
6/4.72 mm +
7/1.57
mm
120.
Typical Features:
2
0
14.1
5
ACCC Helsinki
------------181.7
0
15.6
5
1188989 above
Thermal knee
0
point (55 C) &
655453.61
below
Thermal knee
point.
74000
0
-6
-6
19.8*10
Weight (kg/km)
UTS (kgf)
39
4
3265.00
DC Resistance @ 20 C Temp (ohms/km)
0.27920
Emergency temperature
Maximum Operating Temperature (C)
which can
be withstand
Voltage Level (kV)
Normal Span, m
Nos. of Ckts

Ltd. (TPEC)
1.61*10
above
Thermal
knee
0
point(55 C )
&
-6
18.7*10 below
479.7
0
7034.00
0.18610
10
5
85
200
175
22
22
22
5
1
225
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46

Companies
Line length (km)
Conductor Tension @ 32 C, 100% wind
in
kg
Conductor
Tension @ 32 C, 0% wind in
kg
Sag at 0% wind ,85c for ACSR Dog and
at
0%wind,175c
forCapacity
ACCC Helsinki
Current Carrying
(Amps)
Temp at which 300 Amp for ACSR Dog &
670 Amp for ACCC Helsinki conductor is
carried through
AC Resistance (ohms/km) at 85c for
ACSR Zebra and at 175c for ACCC
Kolkata
Line losses (kW) per conductor
Power Factor
MW Transferred (MW) per circuit
1.00
0
1235.33
1.00
0
1235.09
816.5
4
4.7
9
30
0
85.0
0
761.9
2
5.05
0.352028
95.0
5
0.9
0
10
670
175.0
0
0.301770
406.3
9
0.8
5
21
Assumptions:
(4) Constant of mass temperature coefficient of resistance of conductor per C = 0.004
for all conductors.
2
(7)Wind Pressure=52 kg/m
Table:
0
1. DC Resistance at 20 c of ACCC Helsinki conductor is 33.34% lower as compared to

0
2. Ampacity in ACCC Helsinki conductor at maximum operating temperature (175 c) is
123.33% higher as compared to maximum operating temperature of ACSR conductor, the
power transferred (MW) in case of ACCC Helsinki conductor boosts up by 110 %.
0
3. Maintaining tension of ACSR at 32 c & full wind as starting condition in
ACCC Helsinki as in the case of Re-conductoring, we obtain a slight increase of 5.42
% sag at
an operating temperature of 175 0c as compared to conventional ACSR conductor.

Ltd. (TPEC)
Page
47

Companies
9. UP Power Transmiss ion Corporation Limited ( UPPTCL)
UP Power Transmission Corporation Limited (UPPTCL) is having 132 kV lines running from
Muradnagar to B.S. Road in the district of Ghaziabad and is strung with AAAC
Panther Conductor on the towers designed with ACSR Panther of 18 km length. ACSR
Panther Conductor is having maximum current rating of 408 Amp at maximum continuous
operating
temperature (750c).
ACSR Panther Conductor is capable of catering maximum of 81MW Power through its Single
Circuit Arrangement. UPPTCL wants to cater additional power (212 MW per Single Circuit)
through its 132 kV Transmission Line Corridor. Lines are going to be overloaded so change
in the conductor by higher size is necessary. This will require strengthening of tower and
foundation. UPPTCL may transfer its additional power by dismantling its existing towers and
upgrading the existing voltage level to some higher voltage level but it would ask for a larger
shutdown period. Construction of new transmission line would require right of way and
approvals from the various authorities and the procedure may ask for a larger project completion
time period.
UPPTCL has approached M/s. Sterlite Technologies, to give appropriate solution related to
For this particular application it is proposed to deploy ACCC Casablanca conductor instead of
existing ACSR Panther Conductor. Since the mechanical properties of ACCC Casablanca and
ACSR Panther conductor are nearly same, it will be possible to string them on the existing
transmission line structures without any modification and their foundations also need not
be changed. The maximum span is considered as 325M.
The High Performance Conductor (HPC), ACCC Casablanca conductor can carry 970 Amp at its
0
maximum continuous operating temperature (175 C). Mechanical sag of this conductor is
also less than that of the sag of existing ACSR Panther conductor

Ltd. (TPEC)
Page
48

Companies
Technical Comparison of ACSR Panther & ACCC
Casablanca Conductor
ACCC
Properties
ACSR
Casabla
Panther
nca
6/4.6 +
Typical Factors
30/7/3.00 mm
Ref Spec.
Cross sectional Area
(mm)
IS 398 Part II
Conductive Wire
Al 1350 H19
Core Wire
Conductor Diameter
(mm)
Modulus Of Elasticity
2
(Kg/cm )
Linear Co-efficient
Weight (Kg/Km)
Strength (Kgf)
No of circuit
No of Conductors
per phase
Voltage Level(kV)
DC Resistance
(ohms/Km)
@
20 C Temp
Emergency
temperature
Maximum Operating
Temperature
26
2
Galvanized
Steel
21
10/4.58
mm
(equivale
nt round
ASTM B
857
303.9
1350 OTemper
TW Al
Wire
Composit
e
Core
20.5
767000
-6
1182870
17.8x10
97
6
9128.00
1
1.61*10
790
10408
1
13
2
0.13
9
10
5
75
132
-6
0.1025
200
180
Current Carrying Capacity:

Current Carrying
Capacity
(Amp)
75 C
CurrentatCarrying
Capacity
(Amp)
180 C
CurrentatCarrying
Capacity
(Amp) at 210 C
40
8
472
NA
1062
NA
NA
Conductor sag in Mtrs:

Ltd. (TPEC)
Page
49

Companies
Conductor Sag in Mtrs
(Span = 325m) at 75
C
Conductor Sag in Mtrs
(Span = 325m) at
180
C
Conductor
Sag in Mtrs
(Span = 325m) at
210 C
AC Resistance
(ohms/Km)
@
C Temp
AC75
Resistance
(ohms/Km)
@
C Temp
AC180
Resistance
(ohms/Km)
@ 210 C Temp
8.8
3
6.58
NA
7.06
NA
NA
AC
Resistance
0.1701
NA
NA
0.1257
0.1686
NA
Line
Losses:
I R Losses (kW/Km)
84.9
84.03
@
3
2
75
C Temp
I R Losses (kW/Km)
NA
570.49
@
180
C Temp
2
I R Losses (kW/Km)
NA
NA
@
210 C Temp
MW
Transferred:
MW transferred (MW)
81
94
@
75
Temp
MW C
transferred
(MW)
NA
212
@
180
C Temp
MW transferred
(MW)
NA
NA
@
210 C Temp Losses per Power Transferred:
2
I R Losses / MW @
75 C Temp
0.105%
0.089%
I R Losses / MW @
180 C Temp
NA
0.269%
I R Losses / MW @
210 C Temp
NA
NA
NOTE-It is to be noted that Line losses and Power Transferred

are calculated for single circuit line. So values of line losses would
be kW/single circuit & that of Power Transferred would ne
MW/single circuit. The length of line is considered as 1 kM.

Ltd. (TPEC)
Page
50

Companies
Table:
1. Weight of ACCC Casablanca conductor is 19.05% less as compared to ACSR
Panther conductor.
2. DC Resistance at 20 0c of ACCC Casablanca conductor is 26.25% lower as compared to
0
160.29% higher as compared to maximum operating temperature of ACSR conductor, the
power transferred (MW) in case of ACCC Casablanca conductor boosts up by 161.73 %.
0
Casablanca as in the case of Re-conductoring, we obtain a slight increase of 20.04 %
sag
at an operating temperature of 175 0c as compared to conventional ACSR conductor.

Ltd. (TPEC)
Page
51

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RE-CONDUCTORING CASE STUDIES

FOR VARIOUS UTILITIES AND PRIVATE

Case Studies of HPCs Employed By Utilities & Private

RE-CONDUCTORING CASE STUDIES FOR VARIOUS

132kV Chomu to 132kV Govindgarh (Combination of H pole and Tower)

conductors are operating at their maximum operating temperature of 85 c thus providing

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Case Studies of HPCs Employed By Utilities & Private

Co-efficient of Linear Expansion

Nos. of conductor per phase

Line length (km)

Power Transferred in MW/ckt

Sag at above mentioned temp &

Electrical design parameters for transmission line length of 10 kM

Case Studies of HPCs Employed By Utilities & Private

Case-2 : Current in Amp at maximum continuous operating

Technical Comparison for ACSR Wolf & its equivalent HPC

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Case Studies of HPCs Employed By Utilities & Private

Co-efficient of Linear Expansion

Nos. of conductor per phase

Line length (km)

Power Transferred in MW/ckt

Sag at above mentioned temp &

Electrical design parameters for transmission line length of 10 kM

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Case Studies of HPCs Employed By Utilities & Private

Power Transferred in MW/ckt

Sag at above mentioned temp &

2. ODISHA POWER TRANSMISSI ON CORPORATION LIMITED

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Case Studies of HPCs Employed By Utilities & Private

DC Resistance @ 20 C Temp (ohms/km)

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Case Studies of HPCs Employed By Utilities & Private

Voltage Level (kV)

Line length (km)

Nos. of conductor per phase

Ruling Span (M)

Power Transferred in MW/circuit

FOS at 32C Temperature, 0% wind

FOS at 05C Temperature, 2/3

FOS at 32C Temperature, 100% wind

Power Transferred in MW/circuit

FOS at 32C Temperature, 0% wind

FOS at 05C Temperature, 2/3 wind

Assumptions: Coefficient of Emissivity=0.45, Wind Velocity=0.6 m/s, Solar

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Case Studies of HPCs Employed By Utilities & Private

Technical Comparison of ACSR Panther & its equivalent HPC

Cross Sectional Area (mm )

Modulus Of Elasticity (kg/cm )

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Case Studies of HPCs Employed By Utilities & Private

Co-efficient of Linear Expansion (/C)

Nos. of conductor per phase

Line length (km)

Maintaining current of 800 Amp in all proposed conductors

Ohmic losses in kW/ckt

FOS at 05C Temperature, 2/3 wind

Tension at 32 c & 100% wind in kg

Tension at 32 c & 0% wind in kg(For

Tension at 5 c & 66% wind in kg

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