Brief Write-up on GAP Type Conductors

& Advantages over Conventional ACSR

Conductor

Author:
Prasad Pachegaokar
Jitendra Rajput

APAR INDUSTRIES LIMITED

AN ISO 9001, ISO 14001 & OHSAS 18001 COMPANY
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White Paper on GAP Type Conductor Introduction: GAP Type Conductor

Research in Japan in the 1960s produced a series of aluminum-zirconium

alloys that resisted the annealing effects of high temperatures. These alloys
can retain their strength at temperatures up to 230C (446F). The most
common of these alloys TAl, ZTAl and XTAl are the basis of a variety of
high-temperature conductors.

The thermal expansion coefficients of all the conventional steel-cored

conductors are governed by both materials together, resulting in a value
between that of the steel and that of the aluminum. This behavior relies on
the fact that both components are carrying mechanical stress.

Developed in Japan during the 1970s, Gap-type ZT-aluminum conductor steel

reinforced (GTACSR/GZTACSR) uses heat-resistant aluminum over a steel
core. It has been used in Japan, Saudi Arabia and Malaysia, and is being
extensively implemented by National Grid in the UK. The principle of the Gap-
type conductor is that it can be tensioned on the steel core alone during
erection. A small annular Gap exists between a high-strength steel core and
the first layer of trapezoidal-shaped aluminum strands, which allows this to be
achieved. The result is a conductor with a knee-point at the erection
temperature. Above this, thermal expansion is that of steel (11.5 microstrain
per Degree Celsius), while below it is that of a comparable ACSR
(approximately 19-20). This construction allows for low-sag properties above
the erection temperature and good strength below it as the aluminum alloy
can take up significant load.

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White Paper on GAP Type Conductor Construction: GAP Type Conductor

Extra high strength steel core is in the center and (Super) thermal-resistant
aluminum alloy is supplied in conductor part. To maintain the gap between
the steel core and aluminum inner layer, the inner layer wires are trapezoid
shaped. The thermal-resistant grease is filled to the gap to avoid friction
between the steel core and aluminum inner layer. The aluminum layer and
steel core move independently.

Steel core carries the load of the conductor (Including Alu.)

Limiting the sag increase with the increase of by thermal expansion co-efficient
above knee point related to the steel core.
Combination of (super) thermal-resistant aluminum alloy & Gap construction
offers excellent sag & current carrying characteristics.
Maintaining the mechanical strength of conductor with continuous operating
temperature up to 210 0 C.
Transfer tension by using innovative stringing technology.

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White Paper on GAP Type Conductor Advantages: GAP Type Conductor

Current carrying capacity:

0
Gap type thermal resistance Alu. Alloy conductors CCC under 150 c is up to
2.0 times ACSR under 75 0 c.
0
Gap type thermal resistance Alu. Alloy conductors CCC under 210 c is 2.0 to
2.5 times ACSR under 75 0 c.

Advantages:

Double the current carrying capacity for the same size conductor.
No modification or reinforcement required for existing towers.
Low cost and short construction period.

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White Paper on GAP Type Conductor Accessories: GAP Type Conductor

Accessories of Gap Type Conductor:

H/W Particular GTACSR/GZTACSR COMMENT

Tension Clamp Larger -
Compression Type
Compression Joint Not Applicable -

Suspension Clamp Bolted Type Armor Grip Type

Damper Standard Standard

In case of replacing an existing transmission line, only compression type dead-

end clamp should be changed. Other accessories can be re-used.

Why are compression fitting larger?

Low D.C. Resistance Reduce Current Heating

Larger Diameter Enhance Heat Radiation.
Temperatures of fitting are equivalent to conventional ones.

Installation:

Installation method of GTACSR/GZTACSR is basically the same as

conventional ACSR.
Only at the time of sagging, A special sagging method is required to apply all
the tension to the steel core.

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White Paper on GAP Type Conductor

REGD. CUM MKTG. OFFICE

301, PANORAMA COMPLEX, R.C.DUTT ROAD,

VADODARA 390 007
TEL.: (++91) (265) 2322798,
FAX: (++91) (265) 2330309,
(M): 09909020626
E-mail: ppachegaokar@apar.com;

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