DESIGN OF CONDUCTOR, INSULATOR,

HARDWARE AND ACESORIES FOR

CONDUCTOR & EARTHWIRE

Rajesh Kumar
Deputy General Manager (Engineering-TL)

Powergrid Corporation of India limited

New Delhi

DESIGN AND OPTIMISATION OF POWER

TRANSMISSION LINES
Review of existing system and practices
Selection of clearances
Insulator and insulator string design
Bundle conductor studies
Tower configuration analysis
Tower weight estimation
Foundation volumes estimation
Line cost analysis & span optimization
Economic evaluation of line

SELECTION OF CLEARANCES
Tower Clearance (Strike Distance) for different swing
angles
Phase to Phase Spacing (Vertical, Horizontal)
Ground Clearance
Mid Span Clearance and Shielding Angle

MAXM.
SAG=12.87 M

GROUND
CLEARANCE =
8.84 M

MID SPAN CLEARANCE = 9.0 M (MIN)

TYPICAL 400KV S/C TOWER: CLEARANCES

B
PHASE TO PHASE
CLEARANCE =
8.0M (MIN)

A= CLEARNCE AT 0 DEG
SWING (FOR
SWITCHING / LIGHTNIG
OVERVOLTAGE)
B= CLEARNCE AT MAX
SWING (FOR POWER
FREQ.OVERVOLTAGE)

SELECTION OF CLEARANCES: TYPES OF

OVER VOLTAGES
Power Frequency Over voltage
Switching Over voltages
Lightning Over voltages

SELECTION OF CLEARANCES: TYPES OF

OVER VOLTAGES
Power Frequency Over voltage
Line to Ground Fault
A line to ground fault leads to an overvoltage on unfaulted
phases until situation is corrected. (1.4-1.7 p.u)
Ferranti effect
The steady voltage at the open end of uncompensated
transmission line, is higher because of capacitive charging
current and its magnitude shall depend on line length and
phase constant.

SELECTION OF CLEARANCES: TYPES OF

OVER VOLTAGES
Switching Over voltages
An overvoltage due to switching operation (1.2 to 3.5 p.u)
Line Energizing or Reclosing
Fault occurrence and clearing etc.
Lightning Over voltages

Direct Stroke Flashover

Back Flashover

INSULATION CO-ORDINATION
The maximum over voltage occurs very rarely and like wise
insulation strength very rarely decreases to its lowest value.
The likelihood of both events occurring simultaneously is
very limited.
Therefore considerable economy may be achieved by
recognizing the probabilistic nature of both voltage stress
and insulation strength and by accepting a certain risk of
failure.
This leads to substantial decrease in line insulation, spark
distances, tower dimensions, weight, ROW resulting in
decreased cost of line.
The decrease in line cost must be weighed against the
increased risk of failure and the cost of such failures.

SELECTION OF CLEARANCES
(CONTD.)
Phase to Phase Clearances: Dictated by live metal
clearances for standard tower configurations adopted
in India
Ground Clearances: Min clearance Based on I.E rules
and interference criteria (Electric field, surface
gradient, AN, RIV)
Mid Span Clearance: Between earthwire and
conductor: Based on I.E rules

INSULATORS

INSULATORS
Function
Provide Electrical insulation between live conductor
and earthed structure under operating and
overvoltage conditions
To act as a reliable mechanical link between the
structure and the conductor and keep the mechanical
integrity under normal operating and overload
conditions.

INSULATOR STRINGA string of insulators discs/units

INSULATING MATERIALS
Ceramic or porcelain
Glass

Annealed Glass: Mechanical stresses relieved by thermal

treatment
Toughened Glass: Controlled mechanical stresses induced by
thermal treatment

Polymer

EPDM
Silicone rubber
Silicone-EPDM Alloy

CAP & PIN DISC INSULATOR

DISC INSULATOR

Types Of Insulators Normally Used

AC lines: Standard disc or standard long rod
DC lines : Antifog disc type
Areas of High Pollution : Disc with high creepage or
Porcelain longrod or Polymer longrod insulators

INSULATOR AND INSULATOR STRING DESIGN

Electrical design considerations
Insulation design depends on
- Pollution withstand Capability
Min. nominal creepage dist. = Min nominal specific
creepage dist X highest system voltage phase to phase
of the system

Creepage Distance of insulator string required for different pollution

levels
Pollution
Level

Equiv. Salt Deposit Density

(mg/cm2)

Minm nominal specific

creepage dist (mm/Kv)

Light

0.03 to 0.06

16

Medium

0.10 to 0.20

20

Heavy

0.20 to 0.60

25

Very Heavy

>0.60

31

- Switching/ Lightning Over voltage

INSULATOR AND INSULATOR STRING DESIGN

Mechanical design considerations
a) Everyday Loading Condition
Everyday load 20 to 25% of insulator rated strength.
b) Ultimate Loading Condition
Ultimate load on insulator to not exceed 70% of its
rating. This limit corresponds roughly to pseudo-elastic
limit.

c) In addition, capacity of tension insulator strings at least

10 % more than rated tensile strength of the line
conductors.

COMPARISON OF VARIOUS INSULATOR TYPES

POSITIVE ATTRIBUTES

NEGATIVE
ATTRIBUTES

Standard Porcelain
Disc Insulators

Long history of use

Performance
can
be
evaluated before use.
Indigenous manufacturers
available
Single unit can be replaced
on punctured detection
Life around 35 to 40 years

Hidden defects.
Usually for light pollution
areas only.
Susceptible to pollution
accumulation
Washing
difficult
as
pollution on under- ribs.

Standard
Glass
Disc Insulators

Long history of use

Performance
can
be
evaluated before use.
Single unit can be replaced
on punctured detection.
Puncture detection easy as
can be done visually.

Usually for light pollution

areas only.
Susceptible to pollution
accumulation
Washing
difficult
as
pollution on under- ribs.
No indigenous
manufacturers available.

Porcelain
/Glass
Insulators

COMPARISON OF VARIOUS INSULATOR TYPES

POSITIVE ATTRIBUTES

Porcelain/G
lass
Anti
Fog Disc
Insulators
Porcelain
Glass
insulators

NEGATIVE ATTRIBUTES

Standard

Long history of use

Usually used in medium pollution levels.
Performance can be evaluated before
use.
Indigenous manufacturers available
Single unit can be replaced on
punctured detection

Hidden defects
Susceptible
to
pollution
accumulation
Washing difficult as pollution on
under- ribs.

High
Creepage

Usually used in high pollution areas

Performance can be evaluated before
use.
Indigenous manufacturers available
Single unit can be replaced on
punctured detection.

Hidden defects
Susceptible
to
pollution
accumulation
Washing difficult as pollution on
under- ribs.

Special
Profile

Usually used for medium to high

polluted areas
Performance can be evaluated before
use.
Can be indigenously manufactured
Not easily susceptible to pollution
Washing is easy due to side ribs instead
of under ribs.
Single unit can be replaced on
punctured detection

Hidden defects

COMPARISON OF VARIOUS INSULATOR TYPES

POSITIVE ATTRIBUTES

NEGATIVE ATTRIBUTES

Porcelain
insulators

Porcelain
Insulators

Long

Rod

Long history of use in Europe,

performing satisfactorily in Indian
environment.
Performance can be evaluated before
use.
Can be indigenously manufactured
Relatively puncture proof
Low corona and RIV

To be specially designed for

polluted areas.
Few
Only
one
indigenous
manufacturers available.
Whole insulator string to be
replaced if found defective.

Polymer
Insulators

Composite
Insulators

Long

Rod

Hydrophobic & hence good pollution

withstand characteristic
Low weight & hence ease of
installation.
High impact strength.

glaze

Withstand contamination.

Coatings

Semi conducting
insulators

Life estimated as 15 to 20 years

compared to 35 to 40 years for
porcelain/glass disc insulator.
Few
Only
one
indigenous
manufacturers available.
Pollution performance on complete
string cannot be evaluated
No electrical routing tests on
complete string available.
Have to be handled carefully during
transportation and installation.
No IEC Standards available for
pollution design.
Increase power losses
No standards available.

Coated

Withstand contamination.

RTV
Silicon
Insulators

Reversal possible, if not applied

properly.

Failure Of Insulators
Categories Of Failures

Electrical Breakage of porcelain or puncture

Mechanical breakage of porcelain
Mechanical breakage of metal
Mechanical separation of cap/pin and shell

Probable Causes Of Failures

Surface crack / Internal micro crack in porcelain head

Cement Growth
Aeging
Lightning Over voltages
Pollution

Consequences Of Insulator Failures

Repeated Flashovers may cause grid disturbances.
Mechanical failure/ line drops result in prolonged
outage of the line.
Affect line availability & Power system operation
Safety Hazards
Revenue Loss Of Higher Order

INSULATOR FAILURES

CONDUCTOR

CONDUCTOR SELECTION SCENARIOS

Scenario I
Selection of conductor for a transmission line of identified voltage
level and specified minimum power flow but power flow capacity
becomes ruling factor in selection of conductor size (low voltage
lines).
Scenario II
Selection of conductor for a transmission line with identified
voltage level and a specified minimum power flow but voltage
level becomes ruling factor in selection of conductor/conductor
bundle size (EHV/UHV lines).

Scenario III
Selection of conductor for high power capacity long distance
transmission lines where selection of voltage level and
conductor/conductor bundle size are to be done together to
obtain most optimum solution (HVDC Bipole).

BUNDLE CONDUCTOR SELECTION AND

OPTIMISATION
Size, Type and Configuration of Conductor influences
- Tower and its geometry
- Foundations
- Optimum spans
- Rating and configuration of Insulator string
- Insulator swings
- Ground clearance
- Line interferences like electric field at ground,
corona, radio & TV interference, audible noise etc

ELECTRIC FIELD INTENSITY UNDER TRANSMISSION LINES PRACTICES OF VARIOUS

UTILITIES/ COUNTRIES
ELECTRIC FIELD INTENSITY BELOW LINE (KV/M)

At ground
UTILITY/COUNTRY
HYDROQUBEC, CANADA

Level

At 1.0M
above
ground

At 1.8M
above
ground

At edge of
right of way

10

10

i. Maximum

15/10

5/5

ii. Mean transverse & longitudinal field

10/7

b. People agglomerating zones

USSR

a. Uninhabited areas

15

b. Inhabited areas

c. Road Crossings

10

a. Inhabited areas

b. Other areas

ESKOM, SOUTH AFRICA

FURNAS, BRAZIL
a. Rural Zones/zones near highways

TEPCO, JAPAN

ELECTRIC FIELD INTENSITY UNDER TRANSMISSION LINES PRACTICES OF VARIOUS

UTILITIES/ COUNTRIES
ELECTRIC FIELD INTENSITY BELOW LINE (KV/M)

At ground
UTILITY/COUNTRY
HYDROQUBEC, CANADA

Level

At 1.0M
above
ground

At 1.8M
above
ground

At edge of
right of way

10

10

i. Maximum

15/10

5/5

ii. Mean transverse & longitudinal field

10/7

b. People agglomerating zones

USSR

a. Uninhabited areas

15

b. Inhabited areas

c. Road Crossings

10

a. Inhabited areas

b. Other areas

ESKOM, SOUTH AFRICA

FURNAS, BRAZIL
a. Rural Zones/zones near highways

TEPCO, JAPAN

ELECTRIC FIELD ON HUMAN BEINGS: SUMMARY OF JOINT

RESEARCH BY CEGB, ENEL & EDF
Field Strength(KV/M)

10

15

20

25

15

25

30

20

35

55

60

20

40

60

80

95

1.5

1.5

A
B
Perception
C

E
F
F
E
C
T

A
Discomfort

S
A
M
P
L
E
%
A
G
E

A Arms beside the body

B- One arm stretched horizontal
C- One arm stretched upright.

RADIO INTERFERENCE VOLTAGE

One of the possible consequences of transmission line
corona discharges is radio interference noise.
The corona discharge process is pulsatory in nature,
producing pulses of current and voltage in transmission
line conductors. The frequency spectra of these pulses
can cover a considerable portion of radio frequency
band . Any unwanted disturbance due to corona within
the radio frequency band is called radio noise.

RI (db/1uV/M at 1MHz)

RADIO INTERFERENCE STUDY RESULTS

56
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
0

10

20

30

40

50

60

70

LATERAL DISTANCE (M)

400 kV , Grd Clearance= 9m

800kV, Grd. Clearance= 31.5m

800kv, Grd. Clearance= 23.5m

RI, TVI & AN LEVELS AT ELECTRIC FIELD RIGHT OF WAY (2.0 KV/M)
FOR DIFFERENT GROUND CLEARANCES
Distance from
center phase
Ground Clearance
(M)
RADIO
INTERFERENCE
Db/luV/M

FOR 800KV SYSTEM

FOR 400KV SYSTEM

42.0 M

26.0M

12.0

15.5

17.0

23.5

31.5

9.0

42.5

41.2

40.8

39.0

37.2

40.0

SNR

23.5

24.8

25.2

27.0

28.8

26.0

Remarks

(S-Satisfactory, G-Good)
TV
INTERFERENCE
Db/luV/M

11.5

9.4

8.6

6.0

4.0

7.5

SNR

35.5

37.6

38.4

41.0

43.0

39.5

Remarks

(S-Satisfactory, F Fair, G Good)

AUDIBLE
INTERFERENCE
Db

58.7

58.2

58.0

57.3

56.6

54.0

Remarks

(H-High, M Moderate)

CONDUCTOR - LOADABILITY OF EHV TRANS. LINES

Stability limit: Determined by system configuration.
Thermal limit: Determined by conductor size & its permissible
temp.
Indian practices for max. conductor temp for ACSR:
- 65deg C in 1970s .
- Increased to 75 degrees in 1980s.
- Increased to 85 degrees in 2003
Line Loadabilty generally restricted by stability limit. Thermal
limits are not fully exploited for longer lines.
FACTs, Series compensation etc.,improve stability limits &
enable loading close to thermal limits.

CONDUCTOR HEAT BALANCE

Heat Generated = Heat Dissipated
Heat Generated = I2R + Solar radiation (qs)
Heat Dissipated = Convection Cooling (qc)+ Radiation
Cooling (qr)
I2R = (qr) + (qs) - (qs)

The above equation solved for conductor temperature at

point of heat balance

Conductor Current Carrying Capacity : Variation w.r.t

Max. Permissible Temp
1400
Conductor- ACSR Moose
Ambient Temp: 45 degC
Solar Radiation: 1045 W/sqm
Wind Velocity :2km/hr
Absorption Coeff: 0.8
Emmisitivity Coeff: 0.45

Current Carrying Capacity

(degC)

1200
1000
800
600
400
200
0
65

75

85

95 115 125

Max Permissible Temp (deg C)

CONDUCTOR BUNDLE SELECTION:

METHODOLOGY
Preliminary set of conductor bundle/ sizes identified
to start optimization

Parameters like insulation requirements, limits for corona,

RIV,TVI,AN,EF,thermal ratings, line losses and statutory clearances
identified
Detailed analysis of various alternatives in respect of following to be
carried out to select the configuration
- Basic insulation design and insulator selection
- Tower configuration analysis.
- Tower weight and foundation cost analysis.
- Capital line cost analysis and span optimization.
- Line loss calculations.
- Economic evaluations (PWRR) of alternatives.
- Comparison of interference performance including field effects.)
- Cost sensitivity analysis.

CONDUCTOR OPTIMISATION PROCEDURE

Preliminary selection
- Thermal rating of the conductor / conductor
bundle
- Manufacturing facilities
- Experience of other utilities.
- System voltage alternatives.
- Construction convenience.
- Line Loss Considerations.
- Terrain conditions and ground profile.
- Span length requirements.
- Right of way limitations.

CONDUCTOR SELECTION DESIGN

CONSIDERATIONS
BASIC CONSIDERATIONS (NON VARIABLE)
1) Loading condition and reliability level for the
transmission line.
2) Insulator co-ordination.
3) Limit load conditions for structure, conductor, insulator
and hardware as well as limit conditions for swing of
conductor and insulator strings.
4) Allowable limits for:
i
Electric and magnetic fields.
ii. Radio and TV interference
iii. Space charge density.
5) Minimum Ground clearance
6) Parameters for economical evaluation.

CONDUCTOR SELECTION OTHER

CONSIDERATIONS (VARIABLE)
- Type of insulator; disc insulator, long rod or composite.
- Type of insulator strings i.e I, V or combination of both.
- Tower Geometry; horizontal, vertical, triangular or other.
-Tower family; suspension towers, angle tower suspension
mode, angle towers in tension mode etc.
- Phase to phase/ pole-to-pole spacing.
- Mid span clearance.
- Protection/shielding angle
- Protection against conductor/bundle conductor vibrations.
- Span considerations.
- Right of way considerations.

CONDUCTOR SELECTION FOR SPECIAL

TRANSMISSION SYSTEM
UPRATING OF LINES
- Sag of the selected conductor at maximum operating
temperature should not exceed the sag of the original conductor
- No extra loadings on the structure at various design conditions.
UPGRADING OF LINES
- Line interference in respect of RIV, TVI, AN, EF, MF etc. should
be within acceptable limits
- Conductor surface gradient within acceptable limits
- Asymmetric bundle
COMPACT LINES
- Lowest possible sag and swing for required quantum of power
- Considerations involved in uprating/ upgrading

CONDUCTOR BUNDLE SELECTION:

ESTIMATION OF TOWER WEIGHTS AND
FOUNDATION VOLUMES
For each alternative of conductor and insulator
configuration
Tower Weight Estimation
- Preliminary tower design studies conducted
- Estimation based on regression analysis and
empirical formulae
Foundation Volume Estimation
- Preliminary foundation design studies
conducted

CONDUCTOR BUNDLE OPTIMISATION

PRESENTATION AND ANALYSIS OF RESULTS
i. Capital cost of line

- Cost of each item, construction cost

ii. Cost of Line losses
- Annual Lost Cost = Annual Demand Cost +
Annual Energy Loss Cost
iii. Results of economic evaluation (PWRR or Annual
Cost basis)
iv. Cost Sensitivity

800KV S/C KISHENPUR-MOGA TRANSMISSION LINE

DESCRIPTION

ALTERNATIVES/PARAMETERS/ RESULTS

Conductor Bundle

(I) 8 nos. ACSR types with dia ranging from 30.56mm to 38.2mm. (2) 5 nos.
ACAR types with dia ranging from 30.40mm to 35.80mm. (3) 5 nos. AAAC
types with dia ranging from 31.50mm to 35.8mm.

Spans

300 m,350 m,400 m,450 m,500 m,550 m,600 m

Basic Design Considerations

(A) Wind Zone
(B) Reliability Level
(C) Power Flow
(D) System Voltage
Results
(A) Optimum Conductor Bundle
(B) Span
i. Ruling
ii. Maximum Wind Span
iii. Weight Spans
iv. Maximum ratio wind to weight span.
Line Parameters
(A) Clearances
i. Live Metal Clearance
ii. Minimum Ground Clearance
iii. Minimum Phase Clearance
(B) Insulator String
i. Suspension Towers
0 deg. (I-V-I)
5 deg.(I-V-I)
15 deg. (V-V-V)
(C) Interference Performance
i. Audible Noise
ii. Radio Interference

Wind Zone 4 as per IS:875(1987)

2 as per IS:802 (1995)
2500 MW
800kV
QUAD ACSR BERSIMIS
400 m
400 m
200 to 600 m for suspension towers, -200 to 750 m for tension towers
1.4

5.10 m for switching surge,1.3m for power frequency

15.0m
15.0 m

Double I Suspension with 2x 40 nos, 120 kN disc insulators and single

suspension V string with 35 nos, 210kN disc insulators in each arm.
Double I Suspension with 2x 40 nos, 120 kN disc insulators and double
suspension V string with 2x35 nos, 160/210kN disc insulators in each arm.
Double V Suspension with 2x35 nos, 210kN disc insulators in each arm
58dBA
50 dB/1V/m at 834 kHz

CONDUCTOR BUNDLE OPTIMISATION FOR 1500MW, 500Kv HVDC BIPOLE

DESCRIPTION

ALTERNATIVES/PARAMETERS/ RESULTS

Conductor Bundle

i. Triple ACSR Bersimis ii. Quad ACSR Bersimis

iii. Quad ACSR Moose iv. Quad ACSR Morkuklla
v. Quad ACSR Zebra vi. Pentagonal ACSR Zebra

Spans

350 m,400 m,450 m,500 m

Basic Design Considerations
(A) Wind Zone
(B) Power Flow
(C) System Voltagw

Medium Wind Zone asper IS:802 (1977)

1500 MW
500kV

Results
(A) Optimum Conductor Bundle
(B) optimum Span

QUAD ACSR BERSIMIS

400 m

Line Parameters
(A) Clearances
i. Live Metal Clearance
ii. Minimum Ground Clearance
iii. Minimum Pole Spacing

3.66 m
13.5 m
13.0 m

(B) Insulator String

i. Suspension Towers
ii. Tension Towers

Single V with 38 nos. 160kN disc insulators in each arm. Quad tension with
38 nos., 160kN disc Insulators in each arm.

(C) Interference Performance

i. Audible Noise
ii. Radio Interference
iii. TV interference

32 dBA
39 dB/1V/m at 834 kHz
2dB at 95 mhz

CONDUCTOR TYPES
ACSR
AAAC
ACAR
AAC
New Technology Conductors
- Trapezoidal/ Compact
- ACSS
- INVAR
- Self Damping
- Vibration Resistant

VIBRATION ANALYSIS
BASIC PRINCIPLE

ENERGY BALANCE BETWEEN WIND INDUCED

ENERGY AND DISSIPATED ENERGY BY CABLE SELF
DAMPING & VIBRATION DAMPERS

LIMITING FACTORS

VIBRATION AMPLITUDES
BENDING STRESS/STRAIN AT CLAMPS

SPACER-DAMPER DESIGNS
BASIC COMPONENTS

CENTRAL FRAME / BODY / MASS

CLAMPS (For attachment to the sub-conductors)
ARMS / ARTICULATION (connecting clamps to central
frame)
RESILIENT / DAMPING ELEMENTS