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TNB Initiatives Towards Energy Efficient Transmission Lines

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TNB Initiatives Towards Energy Efficient Transmission Lines TNB Initiatives Towards Energy Efficient Transmission Lines By : Ir. Zulkifli Mohd Yusof Transmission Division TENAGA NASIONAL BERHAD Malaysia 16 June 2015 1 TNB Initiatives Towards Energy Efficient Transmission Lines Keywords : * Energy Efficient T/Line * Challenges * HTLS * Transmission Line Construction 1. New rentice or Additional rentice. 2. Dismantling of existing overhead lines and New Rentice replacing with new. The Challenges 1. Landowners critical objections; land acquisitions and project delays can stretch over many years. 2. Cutting of trees (forest, oil palms, orchards) and disability of future land use when new rentice is acquired. 3. Significant costs in procuring rentice and access, New parallel and construction costs of new towers and rentice foundations. 2 ZulY 20 May 2015 Conventional Overhead Line Conductors – The ACSR PERLIS LANGKAWI Chuping Kangar Kuah TTPC Kota Bharu Kota Setar Alor Setar KEDAH Gurun Tanah Merah Bedong Sg. Petani PERGAU GELUGOR PRAI Georgetown Butterworth TEMENGOR PULAU PINANG Bukit Tengah Kuala Terengganu Kulim BERSIA Junjung Bukit Tambun KENERING KELANTAN 1. Typically ACSR is used : rounded SG PIAH UPPER SG PIAH LOWER Kuala Berang CHENDEROH KENYIR Gua Musang Kuala Kangsar TERENGGANU Taiping PERAK PAKA Ipoh Papan YTL 21,469 cct-km Batu Gajah aluminium strands with steel core and SEGARI Kampar JOR Ayer Tawar Telok Kalong Seri Iskandar Kuala Lipis Dungun Lumut WOH JANAMANJUNG ODAK Jerantut Teluk Intan greased (between Al and steel). PAHANG Kuantan Kuala Kubu Baru Mentakab Bukit Tarek SELANGOR Kg Awah Kuala Selangor Bentong Temerloh KL (N) KLWILAYAH (E) KAPAR Shah Alam PERSEKUTUAN KL (S) SERDANG CONNAUGHT BRIDGE Hicom G Muadzam Shah NEGERI SEMBILAN Banting GENTING SANYEN Salak Tinggi Kuala Pilah Seremban Gemas PD POWER Segamat TJPS Mersing POWERTEK MELAKA 2. Transmission losses when Melaka PAHLAWAN Melaka JOHOR MELAKA Yong Peng (N) Kluang Muar Batu Pahat Skudai YTL conventional ACSR is used for major Johor Bahru Pontian Kechil Pasir Gudang Gelang Patah TNB Grid PASIR GUDANG grid and trunk lines. Typical ACSR 3. Tall and robust tower structures are required to achieve ground clearances when crossing wide rivers and flat grounds (by virtue of the sagging properties of ACSR). Lightning arrestors may be necessary for tall towers. 3 ZulY 20 May 2015 TNB Road Map : Overhead Line Conductors ACSR has been the traditional choice for overhead line conductor due to its simple stranding and strength of its steel core. With the advancement of technology in material and stranding technique, new conductors with low transmission losses, higher temperature (capacity) and low sag can be deployed for future OHL as well as uprating the existing OHL. …FY2013 …FY2015 …FY2020 Low Loss ACSR Low Sag Low Loss High Capacity (round-shaped, High Capacity High Capacity Low Sag greased) (ACIR) (TACSR/TW) (ACCC/TW, . Enhancing ACCR/TW etc) local production capability. The traditional choice Uprating OHL without Reduction of losses, Reduction of losses of Conductor for dismantling of option for higher with option for higher installation. towers. High losses. capacity, low sag. Monitoring of capacity. transmission losses. Adoption for OHL across flat terrain . Continue assessment for Selected OHL Major (trunk) and wide river projects in Central 275kV and 500kV crossing. the optimised Extensively used. Area, and uprating new OHL linking choice of Local conductor 132kV for double power generating Feasible use for Conductor. manufacturers of existing plants and major uprating existing ability to produce. capacity. substations. overhead lines. 4 ZulY 20 May 2015 Conductors Used/On-Going Projects in TNB System Normal use ACSR i.e. Existing and New OHL TACSR[SA]/TW To Reduce Line Losses i.e. New OHL ACCC Special Application ACIR i.e : Line Uprating (MVA) LowSag (HTLS) for Existing OHL ACCC High Temperature ZulY 20 May 2015 The Low Sag, High Capacity Conductor – Aluminium Conductor Invar Reinforced (ACIR) 1. In 2001, the High Temperature Low 3. The first projects using this Sag (HTLS) conductor type conductor is the uprating of 275kV Aluminium Conductor INVAR Port Klang – Kapar P/Stn in 2001, Reinforced (ACIR) was proposed to the new 275kV at DUKE Highway in be used in TNB system as an 2005 and the uprating of 132kV alternative to ACSR conductor. Proton – Hicom in 2010. 2. ACIR conductor are used in projects where uprating of existing Typical ACIR OHL to double its capacity is required. This is especially so when acquisition of right-of-way for new OHL projects is getting more difficult. Typical TACSR/TW 6 ZulY 20 May 2015 The Low Loss, High Capacity Conductor (TACSR(SA)/TW) 1. In 2010, the Low Loss Conductors 3. The first project using this conductor (TACSR[SA]/TW) are introduced for is the new 275kV Ulu Jelai Hydro the new 500kV and 275kV P/Stn to Tapah in 2010. transmission lines installed in TNB system to reduce transmission 4. However, due to Sag limitations, the losses. TACSR[SA]/TW cannot be used to uprate the existing OHL to double its 2. The conductor provides approx. capacity. 20% reduction to transmission losses as compared to the conventional conductor (ACSR) of similar size. Typical TACSR/TW Typical TACSR/TW 7 ZulY 20 May 2015 The Low Loss, High Capacity and Low Sag Conductor - Aluminium Conductor Composite-Carbon Core (ACCC) 1. In the search to find an optimum 3. In 2014, a comprehensive study on alternative to the ACSR which has the ACCC/TW conductor was limited conductor capacity and its undertaken. It was found to be considerable transmission losses, suitable for uprating existing lines. It and the increased objections to is also suitable for new lines in acquire new OHL rentice, the High urban areas and flat terrain. Capacity Low Loss and Low Sag conductors are sought. 2. The conductor required capacity vis-à-vis the sag and losses properties need to be leveraged. A complete life-cycle cost which include construction and material Typical ACCC/TW costs and the transmission losses need to be considered. 8 ZulY 20 May 2015 The ACCC (Aluminium Conductor Composite-Carbon Core) 1. The ACCC/TW comprise of annealed aluminium strands of trapezoidal shaped at the outer layers and a fibreglass coated carbon core. It also provides approx.20% reduction to transmission losses as compared to the conventional conductor (ACSR) of similar size and at similar temperature. Manufacturing of ACCC/TW Dublin at Tenaga Cable Industry (TCI) in Malaysia (Carbon composite core from USA) 9 ZulY 20 May 2015 The ACCC for the 275kV Pengerang Overhead Line Project 2 km Johor River Crossing 1. The ACCC/TW has been adopted for the 275kV transmission line project linking the main grid to the Pengerang petrochemical development. 2. The 45 km double-circuit overhead line traverses a generally flat terrain and crosses a wide river mouth (Johor River) in the south of Peninsular Refinery and Petrochemical Malaysia. Integrated Development (RAPID) Project at Pengerang 3. ACCC/TW Dublin which equals ACSR Zebra in size is adopted for the project, providing the efficiency in conductor weight hence optimising the poles / tower and its associated foundations. 4. The transmission losses will be significantly reduced over the project life cycle, a value-add to the efficiency of the grid. Typical Poles located in a River Crossing 10 ZulY 20 May 2015 TNB Initiatives Towards Energy Efficient Transmission Lines Case Study Choosing a Conductor to Uprate an Existing 275kV 2xACSR Zebra (683MVA) to a 1000MVA Capacity 11 ZulY 20 May 2015 Case Study : Proposed Uprating of an Existing 275kV 2xACSR Zebra (683MVA) Transmission Line Substation B BMRH 275kV T/LineT 148 JJNG-BMRH Proposed uprating of existing 275kV T/Line from T131 to Substation B, 5km of 2x400mm2-Zebra (683MVA) T 131 JJNG Proposed uprating of existing 275kV T/Line from Substation A to T75, 26km of 2x400mm2-Zebra (683MVA) T 1 T 75 T 75 Completed new 275kV T/Line T75-T131, Substation A Substation SGRI 100km of 3x400mm2-Zebra (1000MVA) Substation X 12 ZulY 20 May 2015 Choice of Conductors DESCRIPTION ACSR Zebra Hi-STACIR ACCC/TW Dublin ACCR Drake TACSR(SA)/TW CONDUCTOR CONDUCTOR BUNDLING 3 X ACSR Zebra 2 x Hi-STACIR 2 x ACCC/TW Dublin 2 x ACCR Drake 2 x TACSR(SA)/ TW DIAMETER (mm) 28.62 28.5 28.14 28.65 28.62 WEIGHT (kg/m) 1,621 1,625 1,583 1,383 1,814 Low Loss - Aluminium Aluminium Conductor Aluminium Conductor Aluminium Conductor Aluminium Conductor NAME Conductor Steel Steel Reinforced Invar Reinforced Composite Core Composite Reinforced Reinforced CORE WIRE Galvanised Steel Al-Clad Invar Carbon Fiber Aluminium Fiber Al-Clad Steel Super-thermal Al wires Annealed 1350 Al-Zirconioum Thermal Resistant OUTER WIRE 99.5% Aluminium (STAL) Aluminium Alloy (Z-tal) Aluminum Alloy OPERATING 75⁰C Continuous 210⁰C Continuous 180⁰C Continuous 210⁰C Continuous 150⁰C Continuous TEMPERATURE 100⁰C Emergency 240⁰C Emergency 200⁰C Emergency 240⁰C Emergency 180⁰C Emergency SAG AT PEAK 12.73m 10.84m 10.02m 8.77m 9.80m OPERATING AMPS at 97⁰C at 75 ⁰C at 106⁰C at 95 ⁰C at 105 ⁰C (to achieve 1000MVA) (hence, not feasible) 13 ZulY 20 May 2015 Comparison of Sags (at 365m Span) Ruling condition : Rated tensile strength (RTS) is 22.2% of ultimate. (i.e FOS = 4.5) at 32 degC everyday temperature. No wind. 10.84 10.02m at 106⁰C 10.84m at 75 ⁰C 8.77m at 95 ⁰C 9.8m at 105 ⁰C 14 ZulY 20 May 2015 Comparison of Construction Costs Land Conductor Line Rentice Fittings for Cost for new OHL/ Item acquisition prices Cost Total Cost length chain reconductoring Reconductoring cost (+ 5% sag) 38,812,000 Construct 5 km 2 * 25,800,000 1,512,000 0 11,500,000 New OHL 145,604,400 (3 x ACSR Zebra) 26 km 1 ** 39,130,000 7,862,400 0 59,800,000 106,792,400 5 km 2 0 5,378,562 1,345,485 350,000 7,074,047 Reconductoring 43,859,091 (2 x Hi-STACIR) 26 km 1 0 27,968,522 6,996,522 1,820,000 36,785,044 5 km 2 0 2,835,000 1,345,485 350,000 4,180,485 Reconductoring 28,089,007 (2 x ACCC Dublin) 26 km 1 0 14,742,000 6,996,522 1,820,000 21,738,522 5 km 2 0 24,570,000 1,345,485 350,000 25,915,485 Reconductoring 162,846,007 (2 x ACCR Drake) 26 km 1 0 127,764,000 6,996,522 1,820,000 134,760,522 Notes : * Additional 2 chains rentice required .
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