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Compact uninsulated conductors for power transmission lines

Провода неизолированные КУСИЛ-А
Провода неизолированные КУСИЛ-А

Compact uninsulated conductors for power transmission lines

Compact uninsulated conductors for power transmission lines
  • Affordable prices, no markups or overpayments;
  • Stability of production and rhythm of deliveries;
  • We comply with GOSTs and all technological standards.

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Delivery is carried out as soon as possible after the order is placed.

Uninsulated wires KUSIL-A, -AS, -TAA according to TU 3511-032-76960731-2014

including high-temperature and compact ones, for overhead power lines.

  • Wires are the main component of overhead power lines—they conduct electric current. Due to its low weight and good electrical conductivity, aluminum has become the primary material for wire manufacturing.

    Typically, uninsulated aluminum and aluminum-steel wires made of round wire are used for overhead power lines with voltages starting from 35 kV.

    Aluminum wires determine the electrical characteristics of the conductor, while the steel core provides mechanical properties.

  • KUSIL-ApS-Z
    Compact KUSIL-ApS-Z wire with Z-shaped wire and a steel core

Main issues in the operation of power line wires

    • The larger the outer diameter of the wire, the higher the corona discharge losses. Therefore, for voltages exceeding 220 kV, it is necessary to choose wires with a larger cross-section compared to the optimal one, which negatively affects the economic performance of power lines.
    • Due to the large wire diameter, the sag increases, and wind load becomes higher, resulting in shorter distances between power line supports.
    • Another issue with power line wires is icing. In mountainous areas, ice accumulation on wires can reach a thickness of 150-200 mm. Icing leads to power line failures, causing wire breaks and support structure damage.

    In 2016, NPP “Gerda” mastered the production of compact uninsulated KUSIL-Ap wires based on trapezoidal and Z-shaped wires. The wire surface is smooth, with virtually no gaps between the upper wires. Profiled wire (trapezoidal and Z-shaped) is made from the following materials:

    • Aluminum alloy (KUSIL-Ap) – operation at temperatures up to 90°C;
    • Aluminum-zirconium alloy AT-1 (KUSIL-TAA-1) – operation at temperatures up to 150°C (180°C for up to 400 hours);
    • Aluminum-zirconium alloy AT-3 (KUSIL-TAA-3) – operation at temperatures up to 210°C (240°C for up to 400 hours).

    The core of wires with profiled wire can be made from the following materials:

    • Steel “S” (KUSIL-ApS);
    • Reinforced steel “Su” (KUSIL-ApSu);
    • Composite “K” based on carbon fiber (KUSIL-ApK).

    Wires based on trapezoidal wires (KUSIL-Ap) and Z-shaped wires (KUSIL-Ap-Z) have undeniable advantages over traditional wires with round wires.

Advantages

    • KUSIL-Ap and KUSIL-ApZ wires allow power transmission with a smaller diameter while matching the capacity of similar wires with round conductors of larger cross-section and weight.
    • Reduced wind load due to the smaller diameter and smooth surface.
    • Less icing and snow accumulation due to the smooth surface and absence of gaps between wires.
    • The overlapping Z-shaped wires in the outer layer (KUSIL-Ap-Z wires) form a barrier that provides additional waterproofing.
    • Lower likelihood of wire “galloping,” which typically occurs during ice formation.
    • Reduced corona losses.
    • Low acoustic noise levels during operation.
    • High-temperature aluminum-zirconium alloy wires ensure reliable operation under significant overload conditions.
    • Smaller sag allows for increased spacing between supports (longer spans).

Design of KUSIL-TAApS-1 240/39 wire (TU 3511-032-76960731-2014)

  • The nominal cross-section of the wires, the number and nominal diameter of round wires, or the equivalent diameter of trapezoidal or Z-shaped profiled wires, the number of wire layers, and the nominal outer diameter of the wires must comply with the values specified in Tables 1-4.

Table 1. KUSIL-(A, -AKP, -AA, -AAKP, -TAA-1, -TAAKP-1, -TAA-3, -TAAKP-3)

Nominal cross-section, mm²Number of wiresNominal wire diameter, mmNumber of layersNominal outer diameter of the wire, mmConstruction length, m, not less than
1671,715,14 500
2572,1316,394 000
3572,517,54 000
5073193 500
7073,55110,652 500
9574,1112,32 000
120192,82141 500
150193,15215,751 250
185193,5217,51 000
2401942201 000
300373,15322,051 000
350373,45324,151 000
400373,66325,621 000
450373,9327,31 000
500374,15329,051 000
550613,37430,331 000
600613,5431,5800
650613,66432,94800
700613,8434,2800
750613,95435,55800

Table 2. KUSIL-(AS, -ASKP, -AAS, -AASKP, -TAAS-1, -TAASKP-1, -TAAS-3, -TAASKP-3)

Nominal cross-section, mm²Aluminum or aluminum alloy part of the wireSteel coreNominal diameter, mmConstruction length, m, not less than
Number of wiresNominal wire diameter, mmNumber of layersNumber of wiresNominal wire diameter, mmNumber of layersWireCore
10/1,861,5111,5–4,51,53 000
16/2,761,85111,85–5,551,853 000
25/4,262,3112,3–6,92,33 000
35/6,262,8112,8–8,42,83 000
50/863,2113,2–9,63,23 000
70/1163,8113,8–11,43,82 000
70/72182,21192,2215,4112 000
95/1664,5114,5–13,54,51 500
120/19262,4271,85115,155,552 000
120/27302,2272,2115,46,62 000
150/19242,8271,85116,755,552 000
150/24262,7272,1117,16,32 000
150/34302,5272,5117,57,52 000
185/24243,15272,1118,96,32 000
185/29262,98272,3118,826,92 000
185/43302,8272,8119,68,42 000
205/27243,3272,2119,86,62 000
240/32243,6272,4121,67,22 000
240/39263,4272,65121,557,952 000
240/56303,2273,2122,49,62 000
300/39244272,65123,957,952 000
300/48263,8272,95124,058,852 000
300/66303,52192,1224,510,52 000
300/67303,5273,5124,510,52 000
330/30482,98372,3124,786,92 000
330/43542,8372,8125,28,42 000
400/18423,4371,85125,955,551 500
400/51543,05373,05127,459,151 500
400/64264,37273,4127,6810,21 500
400/93304,152192,5229,112,51 500
450/56543,2373,2128,89,61 500
500/26423,9372,21306,61 500
500/64543,4373,4130,610,21 500
550/71543,6373,6132,410,81 200

Table 3. KUSIL-(ApS, -TAApS-1, -TAApS-3)

Nominal cross-section, mm²Aluminum or aluminum alloy part of the wireSteel coreNominal diameter, mmConstruction length, m, not less than
Number of wires and equivalent diameter, mmNumber of layersNumber of wiresNominal wire diameter, mmNumber of layersWireCore
120/198(2,78) + 12(2,78)271,85113,785,552 000
150/248(3,11) + 12(3,11)272,1115,576,32 000
150/348(3,11) + 12(3,11)272,5115,977,52 000
185/248(3,45) + 12(3,45)272,1116,886,32 000
185/298(3,45) + 12(3,46)272,3117,116,92 000
185/438(3,47) + 12(3,45)272,8117,778,42 000
240/328(3,93) + 12(3,94)272,4119,237,22 000
240/398(3,93) + 12(3,93)272,65119,527,952 000
300/398(4,39) + 12(4,43)272,65121,467,951 800
300/678(4,43) + 12(4,38)273,5122,5310,51 800
330/438(4,60) + 12(4,60)272,8122,538,41 700
400/518(5,06) + 12(5,10)273,05124,779,151 500
500/648(5,67) + 12(5,71)273,4127,6910,21 400

Table 4. KUSIL-(ZApS, -ZTAApS-1, -ZTAApS-3)

Nominal cross-section, mm²Aluminum or aluminum alloy part of the wireSteel coreNominal diameter, mmConstruction length, m, not less than
Number of wires and equivalent diameter, mmNumber of layersNumber of wiresNominal wire diameter, mmNumber of layersWireCore
185/22272117,8262 000
210/32272,4119,047,22 000
240/32272,4120,567,21 800
265/43272,8122,698,41 800
310/43272,8124,428,41 800
370/80273,8127,3411,42 000
410/50273127,5992 000
435/50273128,892 000
550/50273129,391 800
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