JPower Systems Corp Low sag uprating conductor Gap

J-Power Systems Corp Low sag up-rating conductor Gap type condcutor 240 SQMM J-Power Systems Corp Japan Copyright ©　2008 J-Power Systems All rights reserved. 1

J-Power Systems Corp INDEX 1. What is up-rating conductor? 2. Design concept & Key technology of up-rating conductor 3. Gap type conductor 4. Invar core conductor 5. Low sag performance 6. Comparison between Gap and Invar 7. Accessories 8. Supply Record 9. Conclusion Copyright ©　2008 J-Power Systems All rights reserved. 2

1 What is up-rating conductor? J-Power Systems Corp What is Low Sag Up-rating Conductor? Recent situation in OHTL • Antiquated and overworked • Objection from inhabitants to construct New T/L (EMF etc) • Lack of coordination with IPPs on the grid efficiency • Growth in electricity consumption due to economy expansion (commercial, industrial & residential) [Counter measure] Increasing transmission capacity of existing T/L by re-conductoring Low sag Up-rating conductor Copyright ©　2008 J-Power Systems All rights reserved. 3

1 What is up-rating conductor? J-Power Systems Corp Advantages &　Suitable occasion Advantages • • • Double the current capacity with the same size conductor No modifications or reinforcement on existing towers Need Re-conductoring only (Low cost and short period. ) Suitable Occasion • • Land Limitation. Social Restriction for New O/H Line construction. Short Period Up-rating is required. Big difference between Peak and Off-Peak Current. Copyright ©　2008 J-Power Systems All rights reserved. 4

1 What is up-rating conductor? J-Power Systems Corp Up rating method of Transmission Line <Ordinary> Up-rate existing line <High temperature conductor> Use Thermal resistant materials 1. Larger size conductor 2. Increase number of conductor/phase = Same size as existing conductor (No modification on towers) Ground clearance is enough? Re-build or Reinforcement of the existing towers is necessary Not enough Enough Low Sag Up-rating conductor Thermalt resistant Al alloy conductor TACSR Unique construction Gap type conductor Copyright ©　2008 J-Power Systems All rights reserved. Unique material Invar core conductor 5

1 What is up-rating conductor? J-Power Systems Corp Up-rating conductor Gap type conductor (Unique construction) Gap G TACSR/GZTACSR Thermal Resistant Al-alloy Gap construction Super thermal Resistant Al-alloy Invar core conductor (Unique material) ZTA C I R Invar Alloy Super Thermal Resistant Al-Alloy Copyright ©　2008 J-Power Systems All rights reserved. 6

2 Design concept & Key technology J-Power Systems Corp Low sag design concept <Design Concept> Gap: Sift the Knee pint temperature (ie. KPT) to lower side Invar: Control thermal expansion above KPT Al St Under KPT Over KPT: KPT is a temperature, at which Al layers do not bare any tension due to its thermal expansion in ACSR conductor. Tension (steel core only) Tension Low sag effect Sag (m) ACSR Invar Shift Gap KPT Conductor temperature (℃) Copyright ©　2008 J-Power Systems All rights reserved. 7

2 Design concept & Key technology J-Power Systems Corp History of key technology development Year 1961 Event ・TAL(58%IACS): installed on practical T/L (Japan) 1970 ・TAL(60%IACS): installed on practical T/L (Japan) 1971 ・Gap Type: installed on practical T/L (Japan) 1981 ・Invar core (XTACIR): installed on practical T/L (Japan) 1982 ・ZTAL: installed on practical T/L (Japan) 1984 ・ZTACIR: installed on practical T/L (Japan) 2008 Gap Type: supplied more than 11, 000 km incl. 400 k. V 620 mm 2, no voltage limit Invar Type: supplied more than 6, 000 km incl. 500 k. V 610 mm 2, no voltage limit All relevant technology has been developed by J-Power Systems Copyright ©　2008 J-Power Systems All rights reserved. 8

2 Design concept & Key technology J-Power Systems Corp Thermal resistant aluminum alloy Conductivity(%) With a small quantity of Zr (zirconium) added, Thermal-resistant Al-alloy (ie. TAl / ZTAl) has improved annealing characteristics. Current capacity ratio Residual Strength (%) ZTAl 60 60 50 6201 TAl 52. 5 60 200% Op era 61 200 tin g HAl 160% Tem 150 per atu 100% re ( 0 C ) 90 100 th 200 treng S ile s n Te Annealing temperature (℃x 1 hr) Copyright ©　2008 J-Power Systems All rights reserved. 9 300 a) (MP

3 Gap type conductor J-Power Systems Corp Gap type conductor/ Cable construction Steel core as Tension Member Tension Aluminum layer as Conductor Thermal resistant Al-alloy/ Super Thermal resistant Al-alloy move separately and smoothly Extra high strength Galvanized steel (ESt) Gap (filled with heat-resistant filler) Important role of filler -Prevent water penetration -Make the St core smooth behavior -Prevent abrasion of innermost layer by Aeolian Vibration Copyright ©　2008 J-Power Systems All rights reserved. 10

3 Gap type conductor J-Power Systems Corp Gap type conductor/ Principal behind Low sag Over KPT Under KPT Outer layer = Steel core T Outer layer > Steel core Co-efficient of thermal linear expansion Gap T T ACSR: 19 ～ 20 x 10 -6 (1/℃) Al: 23 x 10 -6 (1/℃) -6 Steel: 11. 5 x 10 (1/℃) Pull St core only Gap ACSR Sag (m) AL layers G(Z)TACSR Shift Knee Point Temp. (around 120℃) Shift KPT by unique construction & Installation procedure Temp (℃) Sagging Temp. (= Knee Point Temp. ) Copyright ©　2008 J-Power Systems All rights reserved. 11

3 Gap type conductor J-Power Systems Corp Gap type condcutor/ Special Tensioning Method De-stranding & Expose steel INSULATOR ASSY Steel gripping clamp Aluminum gripping clamp Woven back AL-CLAMP De-stranded AL-Layers Copyright ©　2008 J-Power Systems All rights reserved. G(Z)TACSR 12

3 Gap type conductor J-Power Systems Corp Gap type conductor/ Maintenance Repair Sleeve : same as ACSR 　　　　　　in case of damage less than 10% of AL wires Mid Span joint : same as ACSR in case of damage more than 11% of AL wires ØTension load at repaired portion shall have more than 95% tension load of 　　Original conductor No need for special arrangement for GAP filler Heat Resistant Filler After 15 years usage stable characteristic Copyright ©　2008 J-Power Systems All rights reserved. 13

4 Invar Core Conductor J-Power Systems Corp Invar core conductor/ Cable construction Super thermal resistant aluminum alloy Aluminum clad invar alloy Invar alloy • Fe-36%Ni alloy • Very small coefficient of thermal expansion • “Invar” is an abbreviation of invariable ad cl AL Copyright ©　2008 J-Power Systems All rights reserved. [Coefficient of thermal linear expansion] Invar alloy : 3. 6 x 10 -6 (1/℃) Steel : 11. 5 x 10 -6 (1/℃) 14

4 Invar Core Conductor J-Power Systems Corp Invar core conductor/ Outer layer = Invar core T Principal behind Low sag Outer layer > Invar core Co-efficient of thermal linear expansion ACSR: 19 ～ 20 x 10 -6 (1/℃) Steel: 11. 5 x 10 -6 (1/℃) Invar： 3. 6 x 10 -6 (1/℃) Gap T T Sag (m) ACSR ZTACIR Control sag increase after KPT Knee Point Temp. (around 100℃) Sagging temp. Copyright ©　2008 J-Power Systems All rights reserved. Temp (℃) 15

5 Low sag performance J-Power Systems Corp Low sag performance/ Sag test Before current load (approx. 10℃) ACSR 1272 kcmil GZTACSR 520 SQMM Test line in JPS factory Span length 105 m Copyright ©　2008 J-Power Systems All rights reserved. 16

5 Low sag performance J-Power Systems Corp Low sag performance/ Sag test Under current load (approx. 210℃ ) GZTACSR 520 SQMM ACSR 1272 kcmil Test line in JPS factory Span length 105 m Copyright ©　2008 J-Power Systems All rights reserved. 17

6 Comparison between Gap and Invar J-Power Systems Corp Gap & Invar/ Construction & Material Items Gap Type conductor Invar core conductor Construction • Gap: between St Core and • Same as AL Layer. (filled by Filler) • Inner most layer: Trapezoidal shaped. Material conventional ACSR. ・Aluminum ; TAL or ZTAL [ (Super) Thermal Resistant AL Alloy ] • Core; ESt <Extra High Strength Steel> High Carbon Content Copyright ©　2008 J-Power Systems All rights reserved. • Core; Aluminum-clad Invar Content adjustment and Special heat treatment 18

6 Comparison between Gap and Invar J-Power Systems Corp Comparison Gap & Invar/ Properties Items Gap Type Conductor Tensile strength • Core: 1765 MPa Knee Point Temperature (KPT) • Sagging Temperature Sag control performance • From Sagging temp=KPT (133% of normal steel) Ambient temperature at sagging work. (From EDS condition) ※　by special sagging work. Copyright ©　2008 J-Power Systems All rights reserved. Invar core Conductor • Core: 1080 MPa (81. 6% of normal steel) • Approx. 100 deg. C depend on span length and tension • Over KPT (Approx. 100 deg. C) at High temperature region only. 　 19

6 Comparison between Gap and Invar J-Power Systems Corp Comparison Gap & Invar/ Advantage & Disadvantage Gap Type Conductor Advantage Invar core conductor • Low price • Conventional installation • Low KPT (exactly the same as normal ACSR) Disadvantage • Special installation (Construction period increase approx. 20%) • High price (Nickel & rare metal price) • High KPT (If the design temp. of existing T/L is relatively low, invar conductor don’t work. ) Copyright ©　2008 J-Power Systems All rights reserved. 20

7 Accessories J-Power Systems Corp Accessories /Application G(Z)TACSR ZTACIR Compression type (Standard, Large) Suspension clamp Bolt type (Standard) Damper Normal (Standard) Deadend clamp/ Mid span joint Copyright ©　2008 J-Power Systems All rights reserved. 21

7 Accessories J-Power Systems Corp Accessories/ Heat cycle test 1 Deadend clamp temperature Tension: 15%RTS (24. 9 k. N) D. C. Resistance (μΩ/m) Diameter (mm) Conductor 43. 8 34. 2 Deadend clamp 13. 1 68 Why deadend clamp temperature suppressed? Low　D. C. resistance →Reduce current heating Large diameter → Enhance radiative cooling Copyright ©　2008 J-Power Systems All rights reserved. 22

7 Accessories J-Power Systems Corp Accessories/ Heat cycle test 2 ⑤ Insulator ⑥Ambient ① ② ④Socket link ③Shackle ② Sus. clamp ③ ④ ⑤ ⑥ ①Conductor Copyright ©　2008 J-Power Systems All rights reserved. 23

8. Supply record J-Power Systems Corp Supply Record/ Gap type conductor(GZTACR, GZTACSR) Area Supply Qty (km) Middle East & Africa 6, 946 Asia 2, 422 Europe 1, 307 Others 9 Japan 781 Total 11, 465 Copyright ©　2008 J-Power Systems All rights reserved. 24

8. Supply record J-Power Systems Corp Supply Record/ Invar core conductor (ZTACIR) Area Supply Qty (km) Middle East & Africa 173 Asia 2199 Europe 77 Japan 4, 115 Total 6, 564 Copyright ©　2008 J-Power Systems All rights reserved. 25

9. Conclusion J-Power Systems Corp Conclusion • J-Power Systems Corp. ’s Low-sag up-rating conductors (Gap type/Invar core) increase the transmission capacity of existing T/L 1. 6/2. 0 times by only re-conductoring. • Low-sag up-rating conductor will serve big advantages to solve the problems of T/L. Copyright ©　2008 J-Power Systems All rights reserved. 26