CASE STUDY

Sterlite completes first-ever ACCC stringing in India for Torrent Power

Reconductoring done on 132 kV transmission lines between Pirana and Vinzol, Gujarat, thereby doubling the capacity of the lines.

Background
Torrent Power Ltd, one of the leading electrical utilities in the Indian power sector and part of the Torrent Group, is one of the most experienced private sector players in Gujarat. Besides an all-round experience in generation, transmission and distribution of power, the company has a proven track record of implementing large power projects. The high points of Torrent's foray into power have been the acquisitions of two of India's oldest utilities The Surat Electricity Company Ltd and The Ahmedabad Electricity Company Ltd. Torrent turned them into first rate power utilities, in terms of operational efficiencies and reliability of power supply. Today, Torrent has a generation capacity of 1647.5 MW and distributes power to more than 3 million customers annually in Ahmedabad, Gandhinagar, Surat, Bhiwandi and Agra.

Reconductoring done on 132 kV transmission lines between Pirana and Vinzol, Gujarat, thereby doubling the capacity of the lines.

Project Aims
Torrent Power aimed to increase transmission capacity on its existing 132 kV transmission lines between Pirana and Vinzol, Gujarat while maintaining low losses. However, this was not possible using the existing ACSR Panther conductor due to the thermal limit of the conductor and excessive sag of the conductor. Torrent Power made a thorough assessment of various technologies available in the market such as GAP, ACSS and STACIR in addition to ACCC. This assessment included the assessment of conductor's peak load handling and normal load losses and as a result ACCC was found as the most suitable solution for the application as ACCC provides lowest of losses among all the HTLS conductors at the same time maintaining sag less than ACSR at close to double the power transfer.

The Solution
Sterlite Technologies Limited offered Aluminum Conductor Composite Core (ACCC) Lisbon conductor the first of its kind in India, as a solution to relieve line congestion. Sterlite executed this turnkey project for Torrent Power and the scope of work involved supply as well as installation of the conductor on 132 kV transmission line from Pirana to Vinzol in Gujarat. The ACCC conductor's hybrid carbon and glass fiber composite core offers many advantages compared to an all-aluminum or steel-reinforced conventional conductor. These are high ampacity, low loss hybrid conductors. The tensile strength of carbon core is five times more than that of conventional steel used in ACSR conductor. Besides, the sag of ACCC conductor is less than that of ACSR conductor. The composition comprises carbon, glass fiber and trapezoidal shaped aluminum, that are resistant to environmental degradation. These conductors can reduce line losses up to 30-40% compared to conventional conductors of the same diameter and weight. These have 28% more aluminium which greatly increases capacity, reduces losses, & hence cooler operating temperatures. Further, these are 25% stronger & 60% lighter when compared to traditional steel core conductors. The Conductor has lower coefficient of thermal expansion which leads to less sag at higher temperatures. The technology is patented by CTC Cable Corporation, USA and is licensed to Sterlite Technologies.

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CASE STUDY

Installation
The highlight of the project was that this line was installed having one circuit in live condition without disrupting the power supply. In most cases when you are installing a new ACCC Conductor, it can be done as maintenance rather than having to shut the entire line especially in a double circuit line. Further, the actual installation is shorter as compared to any other HTLS or conventional conductors with the use of ACCC conductor because the hardware is designed in such a way that when you dead-end or splice the wire, you only have to use one crimp to put ACCC conductor in place, versus what is typically two crimps with most other Hardware systems for conductors available. This means reducing the critical hardware installation time to close to half that of a conventional installation. The reason for the same is the core of ACCC is fastened using a patented innovative design of precision machined mechanical lock mechanism which reduces time considerably as compared to compression joints. While the stringing of ACCC is similar to that of ACSR, care should be taken that the bending angle is not be less than 30 degree, so as to protect the core from damages. It can be stringed with tension and pull method, and the bending Radius should not be less than 0.76m. "Completion of this installation is a vital step in moving forward with our utility customer engagements. It is important to illustrate our conductor's ease of installation to customers as we prepare for commercial projects over the coming months," says K S Rao, COO Telecom & Power Conductors, Sterlite Technologies Limited. "We are confident ACCC conductors will make a significant contribution to the capacity and reliability of the power grid in India. Also, in India, reconductoring is a technically and economically viable alternative, as transmission operators face increasing opposition while seeking new rights-of-way. Moreover, innovative HTLS products like ACCC conductors help minimise the environmental impact and remain compliant with national legislation and international design standards.

The Results

Qualified and experience talent pool Sterlite has a qualified talent pool, experienced in network design, project management, network implementation and network maintenance.

ACCC technology affords utilities the ability to use existing towers, therefore allowing them to avoid having to seek permits and invest in reinforcing tower structures, which can shorten the amount of time it can take for the line to be reconductored, and save losses due Credible partners to inability to cater to the consumers. Torrent Sterlite has partnered with reputed project Power is satisfied with the working of the management companies and Original ACCC Lisbon conductor, as it benefitted by Equipment Manufacturers (OEMs), to ensure saving construction costs of new towers that the delivery of the project i s While providing additional power transferred streamlined. capacity to cater to peak load demand, while reducing losses at normal loading scenarios. Solution development for newer applications Sterlite continues to enhance its portfolio taking into account the bandwidth needs The competence of Sterlite's HTLS conductor evolving from client applications. installation was evident from this project. This p ro j e c t p rove s t h e fe a s i b i l i t y of a Local Support reconductoring projects in the most congested lines where one line can be on live With offices in 10 countries, Sterlite always condition while replacing the other circuit has a relationship manager who is a mere with the high performance conductor which phone call away, to understand your growth will take over the maximum capability of both aspirations and to explore areas where it add value to your business. the circuits fitted with conventional conductor over the single circuit. The stringing of the ACCC conductors on the existing 132 kV transmission lines and About Sterlite Technologies working to a common set of goals has meant Sterlite Technologies is a leading global no delays in deployment, no loss of provider of transmission solutions for the performance and simple on-site integration. power and telecom industries. Equipped with a product portfolio that includes power conductors, optical fibers, telecommunication cables and a comprehensive telecom systems / solutions The Sterlite Advantage portfolio, Sterlite's vision is to 'Connect Global experience every home on the planet. Sterlite is also Sterlite has a significant experience in executing multi-million dollar power implementation of projects for Government transmission system projects, pan-India. incumbents, utilities and enterprises. End-to-end project implementation Sterlite ensures complete control over the value chain and delivers end-to-end project management services. Qualified and experience talent pool Sterlite has a qualified talent pool, experienced in network design, project management, network implementation and network maintenance.

Conclusion

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