Post on 04-Jul-2015
description
New generation of copper conductors for overhead lines NORDAC, September 2014 European Copper Institute – fernando.nuno@copperalliance.es
| Copper OHL - NORDAC 2014 2
COPPER ALLIANCE
Copper Alliance International Copper Association
> 50 years leading
organization in copper
promotion
43 global members:
copper producers and
fabricators
Sustainable Energy as one
of core initiatives
> 500 local members and
partners
3 | Copper OHL - NORDAC 2014
Sustainable Energy Promotion of mature technology
Renewables
Energy Efficiency
Home Electricity
Building Automation
Electrical Safety
Power Quality
Clean Energy Regulators Initiative
4 | Copper OHL - NORDAC 2014
Technology Development and Transfer Market introduction of new technology
Sustainable fish farming
Anti microbial surface
Air conditioning / heat exchangers
Electrical vehicles: motors and batteries
Gas water heaters with improved heat exchangers
Power and data over Ethernet cables
Earthquake protection
5 | Copper OHL - NORDAC 2014
| Copper OHL - NORDAC 2014 6
NEW GENERATION OF COPPER CONDUCTORS FOR OVERHEAD LINES
Advanced copper alloys largely exceed Cu ETP used in the past
| Copper OHL - NORDAC 2014 7
http://www.conductivity-app.org/alloy-sheet/33 http://www.lafarga.es/en/products-and-markets/overhead-lines-conductors/cables-mt-ht-et-tht
Cu ETP (past)
Cu Alloy (present)
Breaking load (MPa) 220 500
Conductivity (IACS) 100% 95%
Coefficient of thermal
expansion 10-6/K 17,7 16,8
> Twice strength
Preserved conductivity
Lower expansion
Additional features of advanced copper alloys - 1
| Copper OHL - NORDAC 2014 8
Operating temperature 150ºC – 200ºC
• High annealing temperature, creep free up to 200ºC or higher
• Offers extra 60% up to 100% spare capacity beyond 80ºC
EDS > 25%, even 30% • Fatigue – resistant, strength can be largely
exploited • Well featured against galloping
Corrosion-proof • Copper performance against corrosion • Additionally supported by coatings
Additional features of advanced copper alloys - 2
| Copper OHL - NORDAC 2014 9
Hydrophobic • Thanks to the high annealing
temperature of copper alloys, special coatings can be applied (which require high temperatures of deposition)
• Coating color is tailor made (anti-theft, mimetic with environment…)
Dielectric: no skin effect
Dielectric: reduced Corona losses & noise
COATINGS
| Copper OHL - NORDAC 2014 10
COPPER OFFER TO SYSTEM OPERATORS
Copper offer to System Operators - 1
| Copper OHL - NORDAC 2014 11
N-1 ENERGY EFFICIENCY
• 60% to 100% spare capacity when allowing conductor temperature increase
• Redistribution of power flows / Higher penetration of variable renewables
• Saves alternative investments in generation or T&D capacity
• 60% more conductivity than aluminium for equal section
• No skin effect (+ 10% conductivity)
• Article 15 of Energy Efficiency Directive
Copper offer to System Operators - 2
| Copper OHL - NORDAC 2014 12
DEMANDING WEATHER
CONDITIONS
Wind load Weight + ice load
Weight
Wind load
ACSR
COPPER
• Wind load: bigger conductor diameter + ice layer
• Wind load: smaller conductor diameter, reduced or no ice layer (hydrophobic coating)
Where copper alloys add value
| Copper OHL - NORDAC 2014 13
WINDY / ICY
CORROSIVE
RECONDUCTORING
IMPLEMENTING ENERGY EFFICIENCY
| Copper OHL - NORDAC 2014 14
PILOT PROJECTS
Ongoing pilot projects with copper alloys
| Copper OHL - NORDAC 2014 15
Codelco copper mines
Private line 20 km
• DSO Endesa, Pyrenees: 1,5 km -> Ice accretion
• DSO Endesa, Salt mine: 1,5 km -> corrosion
• DSO Estabanell: 20 km -> reconductoring an existing copper overhead line
| Copper OHL - NORDAC 2014 16
Summary
Summary
| Copper OHL - NORDAC 2014 17
• Advanced copper alloys offer a competitive conductor for a number of niche applications: • Severe climate conditions • Corrosion • Upgrade of existing lines
• Technical feasibility has been assessed by DNV KEMA
• Economic benefits proven: • New lines: higher energy efficiency, lower life cycle cost, short payback time • Existing lines: in range with HTLS, but lower losses and simpler to install
Thank you
| Copper OHL - NORDAC 2014 18
For more information please contact
European Copper Institute - Fernando Nuño fernando.nuno@copperalliance.es
La Farga - Gustau Castellana gustau.castellana@lafarga.es
| Copper OHL - NORDAC 2014 19
DNV KEMA analysis Part 1 : new line
Conductors compared
ACSR – Hawk LA 280
20 | Copper OHL - NORDAC 2014
ACSR Eagle LA 350
Copper conductor
CAC 185
Additional considered conductors (under the same current conditions)
700 A @ 80ºC Higher investment
Lower losses
700 A @ 80ºC / 1115 A @ 150ºC Higher investment
Lower losses
630 A @ 80ºC
Conductor specification
| Copper OHL - NORDAC 2014 21
ACSR Hawk ACSR Eagle CAC 185
Cross section (mm2) 280 350 185
Current capacity at 80°C (A) 630 700 700
Current capacity at 150°C (A) - - 1115
Weight (kg/km) 982.3 1301.8 1652
Electrical resistance (Ohm/km) 0.1195 0.103 0.09
Tensile strength (kN) 85 123.6 93
Elasticity (kN/mm2) 77 81 50
Thermal expansion (1/°C) 0.0000189 0.0000178 0.000017
Max operational temp (°C) 80°C 80°C 150°C
Simulated route
70 km – 220 kV Double circuit
Simulated but realistic route
22 | Copper OHL - NORDAC 2014
• PLS-CADD • Based on standard EN 50341-1:2001 • Overhead line route is optimized for each
conductor type, based on the specified conductor properties.
• Tension vs suspension towers: 1:5
DNV KEMA study
Scenarii
23 | Copper OHL - NORDAC 2014
Load profile Cost of losses Time horizon
• 5 c€/kWh • 7 c€/kWh
0%
50%
100%
0% 50% 100%
Load Profile 1
0%
50%
100%
0% 50% 100%
Load Profile 2
• 15 years • 20 years
DNV KEMA study
Assumptions
24 | Copper OHL - NORDAC 2014
Projections Cost of conductors
• ACSR Hawk: 4 €/m • ACSR Eagle: 5 €/m • Copper 185 mm2: 15,5 €/m
• Inflation: +2% / year • Electricity:
• + 2,00% from year 1 to 10 • + 0,77% from year 11 to year 20
DNV KEMA study
Conditions
25 | Copper OHL - NORDAC 2014
80°C bundle current (A) per wire (A) Perc. of HAWK Case 1 HAWK 4 1880 470 100% Case1b EAGLE 4 1880 470 100% Case 2b Cu T1b 4x185mm2 4 1880 470 100%
Load cases as per EN 50341-1:2001
• LC 1a – Extreme wind at design temperature • LC 1b – Wind at minimum temperature • LC 2c – Unbalanced ice loads, different ice loads per
span LC 3 – Combined wind and ice loads
Same current in all
cases
Copper vs ACSR Payback time: 5 - 7 years Life Cycle Cost: lower by 10% - 20%
26 | Copper OHL - NORDAC 2014
ACSR Hawk LA 280
ACSR Eagle LA 350 Copper CAC 185
Cost of losses 183,5 174,9 138,0 Conductor cost 6,8 8,4 21,7 Stringing conductor 6,8 6,8 6,8 Towers & Foundations 32,3 33,9 29,2 Maintenance NPV 20 years 5,7 5,7 5,7
0
50
100
150
200
250 M
€ Breakdown of Life Cycle Costs for new lines (M€)
Cost of losses
Conductor cost
Stringing conductor
Towers & Foundations
Maintenance NPV 20 years
| Copper OHL - NORDAC 2014 27
DNV KEMA analysis Part 2 : refurbishing an existing line
Copper vs ACSR Same capacity upgrade as ACSS Lower losses, lower life cycle costs
| Copper OHL - NORDAC 2014 28
ACSR Hawk
@80ºC
ACSS Hawk
@150ºC
Copper CAC
4x165 mm2
@150ºC
Copper CAC
3x240 mm2
@150ºC Cost of losses 183,4 518,2 458,2 419,8 Conductor cost 6,8 8,4 19,4 21,2 Stringing conductor 6,8 6,8 6,8 6,8 Towers & Foundations 32,4 0,0 0,0 0,0 Maintenance NPV 20 years 5,7 5,7 5,7 5,7
0
100
200
300
400
500
600 M
€
Breakdown of Life Cycle Costs for upgrade of existing lines (M€)
Cost of losses
Conductor cost
Stringing conductor
Towers & Foundations
Maintenance NPV 20 years