21, rue d'Artois, F-75008 Paris http://www.cigre.

org

B2-209

Session 2004
CIGR

A Method for Expanding the Current Capacity of Overhead Transmission Lines K. Adachi* T. Kumeda Tokyo Electric Power Co., Inc. Fujikura Ltd. (Japan) K. Nagano J-Power Systems Corp.

Summary To expand the service capacity of existing transmission lines, we reviewed the conventional method of determining the current-carrying capacity of transmission lines, and established a technique to assess the line-specific reduction in strength of power cables during their service life. We then applied the technique to two lines and achieved a 20 to 30% increase in capacity. Since the soundness of power cables must be assessed before applying the technique, we developed a detection device to measure the state of corrosion of aluminum and steel in power cables, even while the cables are strung overhead. Moreover, since continuous observation of power cable temperature allows accurate assessment of the residual strength of power cables, we also developed an IC tag that can measure power cable temperature in real-time with excellent accuracy, and verified its effectiveness as a temperature monitoring tool. 1. Introduction With the liberalization of the electric power market in recent years, the electric power companies stance on capital investment is changing: they have upgraded overhead transmission lines in anticipation of increased demand. However, it is now more important to expand the service capacity of existing facilities when planning capital investment. The maximum current that can be carried by transmission lines is, in principle, determined by the reduction in tensile strength of power cables when they are heated by electric conduction, namely, how much the power cables soften. Taking the example of ACSR conductors, which are primarily used in transmission lines, the maximum current has been defined as that which reduces the tensile strength of aluminum wires in ACSR conductors by 10% over 30 years and this maximum current has uniformly been applied during the operation of transmission lines. This paper reviews the conventional method of determining the current-carrying capacity of transmission lines, and describes a technique to assess the residual strength of power cables (in terms of loss of strength due to thermal deterioration), as well as a related technique to assess the state of deterioration of power cables. By expanding the service capacity of existing facilities, the problem of heavily loaded lines will be solved and facility operations will be improved.

Email: ADACHI.KOUICHIS@tepco.co.jp

2. Review of the Technique to Determine the Current-carrying Capacity of Transmission Lines 2.1 Equations for Estimating Power Cable Temperature A considerable increase in power cable temperature occurs under breezy conditions rather than under high-temperature conditions, so it is important to accurately calculate the temperature under breezy conditions. We measured the power cable temperature in a breeze with a velocity of 1 m/s or less, using a wind tunnel, and verified the accuracy of the theoretically introduced method to estimate power cable temperature proposed by CIGRE[1].

Theoretical Value ( )

Measured Value ( )

Fig. 1: Comparison of Theoretical Values and Measured Values of Power Cable Temperature[2]

2.2 Technique to Assess the Thermal Hysteresis of Each Power Cable[3] To assess the limit of the flowing current, it is important to accurately estimate the thermal hysteresis of power cables. The temperature of a power cable changes due to meteorological conditions such as wind velocity, wind direction, air temperature and solar radiation as well as on the electric current flowing. Accordingly, we calculated the hourly temperature of the power cable that was continuously energized on constant load, taking into account meteorological data for the past 30 years obtained from meteorological observatories, and created the cumulative time (hour)temperature diagram in order to determine the reduction in strength. The new technique uses the strength reduction factor obtained from this diagram to assess the thermal hysteresis of power cables. Since there are meteorological observation points through the country that have collected data for the last 30 years or more, data are readily available.
12000 10000

Cumulative Time (hour)

8000 6000 4000 2000 93 0 0 10 20 30 40 50 60 70 80 90 100

Temperature (C)

Fig. 2: Example of Calculating the Thermal Hysteresis of Power Cables

2.3 Equation to Assess Residual Strength of Power Cables To assess residual strength of power cables, since steel wires are not softened by heat at 200 which is upper level of using temperature in ACSR conductors[4], it is necessary to Email: ADACHI.KOUICHIS@tepco.co.jp 2

formulate the softening characteristics of aluminum wires. We investigated the tensile strength of aluminum wires that had been subjected to various thermal conditions (in terms of heating temperature and heating time) and performed phenomena-based metallographic analysis. Metallographic observations confirmed that the softening of aluminum wires occurred due to the realignment of dislocated molecules and the coarsening of subgrain networks. Assuming that softening occurs as a result of low temperature creep accompanied by a recovery phenomenon, the softening characteristics of aluminum wires were formulated as: f = 1 + t/1000(A ln(h+h0) + B/t + C) (1) where f is the softening rate of power cables; t, h and h0 are temperature (K), hour and a temperature-dependent constant determined by the initial creep speed, respectively; and A, B and C are parameters obtained using data from a heating test of aluminum wires. Figure 3 shows the relationship between the measured tensile strength obtained from the heating test of new unstranded ACSR 330 mm2 wires and the values calculated from eq. (1). Equation (1) also enables the softening of aluminum wires at high temperature to be accurately assessed.

Measured Value (kg/mm2)

Calculated Value (kg/mm2)

Fig. 3: Measured and Calculated Values of Tensile Strength

Once the model has been formulated, the softening that occurs at various temperature points can be corrected on a time basis, and so the reduction in strength of power cables can be calculated. The reduction in tensile strength of stranded wires can be calculated by multiplying the softening-induced reduction in strength of aluminum wires by the strength contribution of aluminum wires in power cables. The calculated values are considered to be on the safe side compared with the softening-induced reduction in strength of stranded wires. 2.4. Review of Acceptable Limit of Power Cable Deterioration The acceptable limit has conventionally been regarded as the state where the tensile strength of aluminum wires in power cables has fallen by 10%. However, this is equivalent to a reduction in tensile strength of stranded wires of about 5%. Since this means is a significant load margin for power cables, we reviewed the tensile strength limit.. 2.5 Assessment of Soundness of Power Cables Before examining whether or not to increase the current-carrying capacity, the soundness of power cables must be assessed. Power cables that are 30 years old or older often suffer from corrosion primarily due to sea salt. We therefore developed a means of quantitatively determining the extent of corrosion of overhead transmission lines even while they are strung overhead. Figure 4 shows an external view of the recently developed device. This device, which uses the eddy current flow inspection method, can separately determine the extent of corrosion of Email: ADACHI.KOUICHIS@tepco.co.jp 3

aluminum and steel. Using the fact that the eddy currents induced by the low frequency alternating magnetic field occur almost only in the steel, the low frequency alternating magnetic field is used to determine the extent of corrosion of the steel core. Meanwhile, the high frequency alternating magnetic field is used to determine the extent of corrosion of the whole ACSR conductor. Then, vector subtraction of the low frequency output from the high frequency output is performed to determine the extent of corrosion of aluminum. Finally, the tensile strength of stranded wires is obtained from calculations using the aluminum and steel wire data. To assess this technique, we compared, as shown in Fig. 5, measurements obtained by this technique with the results of an actual tensile test, regarding the tensile strength of corroded power cable samples (47 samples) and actually removed power cable samples (11 samples). The estimated error of the tensile strength was a maximum of 7%.

Fig. 4: External View of the Power Cable Corrosion Detection Device

Measured Value (New wires: 1)

Actual tensile test

Error for 95% residual tensile load: 4-5% Error for 90% residual tensile load: 6-7%

Calculated Value (New wires: 1)

The power Cable Corrosion Detection Device

Fig. 5: Relationship between Calculated and Measured Values of Tensile Strength of Stranded Wires

2.6 Revised Examination Procedures The revised procedures for applying the technique to determine the current-carrying capacity are summarized below. (1) Investigate corrosion of the power cables while they are strung using the corrosion detection device to check that they are not severely deteriorated. (2) Sample jumper wires to investigate the residual tensile strength of power cables. (3) Select a meteorological observatory from among those located along the target transmission line.

Email: ADACHI.KOUICHIS@tepco.co.jp

(4) Select several patterns of current-carrying capacity and service life for the target transmission line and calculate a distribution of power cable temperature using the data from the selected meteorological observatory. (5) Solve the softening model equation using the calculated distribution of power cable temperature to estimate the reduction in strength of power cables. (6) Determine the pattern of current-carrying capacity and service life with which the reduction in strength of power cables falls within the acceptable limit (within the safety factor of 2.5 in Japan). 2.7 Example of Examination of Increasing the Current-carrying Capacity We used the technique to increase the current-carrying capacity of two 154 kV overhead transmission lines and achieved a 20 to 30% increase in capacity. This could reduce costs, for example, by eliminating the need to install replacement lines. 3. Real-time Power Cable Temperature Monitoring System 3.1 Development of IC Tag Since continuous observation of power cable temperature along actual transmission lines allows the residual strength of power cables to be evaluated with greater accuracy, we developed an IC tag that can measure power cable temperature in real-time with excellent accuracy. The IC tag, comprised of a CPU, a sensor and peripheral circuits mounted on a small substrate, radio-transmits the data measured by the sensor, which is picked up in real-time by land-based mobile equipment. The substrate size varies depending on the radio transmission distance. The recently developed IC tag can transmit the data up to approximately 50 m. It can measure up to 140C, using a silicon semiconductor temperature sensor with temperature drift. A thermistor can be used as a temperature sensor to measure up to 200C. Figure 6 shows an external view of the IC tag, and Fig. 7 compares the power cable temperature measured by a thermocouple with the values measured by the IC tag, revealing that the measuring precision of the IC tag is about 2C.

Fig. 6: External View of IC Tag

Temperature Measured by IC Tag (C) Temperature Measured by Thermocouple (C)

Fig. 7: Comparison with Measurements by Thermocouple

3.2 Verification Test of Tag Performance Email: ADACHI.KOUICHIS@tepco.co.jp 5

We measured the temperature of power cables and compression joint sleeves for two overhead transmission lines whose current-carrying capacity has been increased. The specifications of the IC tag used for the transmission lines are shown in Table 1.
Table 1: Specifications of IC Tag for Temperature Measurement
Size Power Transmission Frequency Power Transmission Distance Temperature Range L 105 mm W 15 mm H 18 mm 315 Hz 50 m -30C 125C

As shown in Fig. 8, the power cable temperature measured by the IC tag closely matches that calculated using the estimation equation[1] proposed by CIGRE based on on-site meteorological data. Thus, the IC tag is an effective temperature measuring tool.
Calculated Temperature (C) Temperature Measured by IC Tag (C)

Fig. 8: Comparison between Calculated Power Cable Temperature and Values Measured by IC Tag

Since it may be possible to collect various data by changing the sensor in the IC tag, the IC tag may be useful for many applications other than overhead transmission lines. 4. Conclusions We established a new technique to assess the current-carrying capacity based on design conditions for each transmission line (overhead line conditions, meteorological conditions in areas along transmission lines and other conditions), and confirmed that the transmission capacity can be increased by 20 to 30%. The increased accuracy of the equations used to calculate the current capacity enables a more accurate assessment to be performed. We developed a power cable corrosion detection device that uses the eddy current flow inspection approach. This device enables the soundness of power cables to be assessed, which is a prerequisite before considering whether or not to increase the transmission capacity. We also developed an IC tag that can perform real-time continuous monitoring of power cable temperature, and facilitates accurate assessment of the residual strength of power cables. References [1] CIGRE: The Thermal Behavior of Overhead Conductors, CIGRE WG22-12, Electra, No. 144, 1992 [2] Isozaki, et al.: Verification of the Wind Tunnel Effect on Thermal Radiation from Power Cables in Breezy Areas, T.IEE Japan, Vol. 121-B, No. 6, 2001 [3] Inoue and Kitamura: Assessment of the Thermal Hysteresis of Transmission Lines based on Data from Meteorological Observatories, T.IEE Japan Vol. 121-B, No. 5, 2001 [4] Electric Technology Reseach Association: High Capacity Conductor, Vol.32, No.1, 1976

Email: ADACHI.KOUICHIS@tepco.co.jp