The development of the new generation ground wire for lightning protection

1
The development of the new generation ground wire
for lightning protection of overhead
transmission lines
2
Motivation of new product creation
Market demand in production, close to lifetime to
the core elements of the overhead transmission
lines, both current and prospective without
substantial rise in price products.
Ground wire creation,which provides an effective
lightning protection of overhead transmission
from maximum true power lightning strokes
Provision of ground wires life duration not less
than 40 years, guarantee period on overhead
transmission lines not less than 4 years.
Provision of ground wires operability under the
condition of its factual exploitation operations
of all spectrum of the main types of loads.
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1 STAGE
The estimation of the basic technical features
of steel-wire robes according to the GOST
3062-3064, which were used on the overhead
transmission lines as ground wires.
Methods
Estimation of consumers requests
Weather exposure test of lightning stroke
Aging test
Estimation of strength characteristics
To realize all system researches, were involved

Engineering Centre FGC UES,ORGRES, Production and
Commercial Firm Eletroservice, MPEI and other
organizations.
4
Testing technique of lightning stroke

• Researches were conducted on the bench tester
  Current generator of lightning
  quaternary(GTM-4), which is certified by the High
  voltage electrical equipment test center of the
  State unitary enterprise (accreditation
  certificate ? ROSS RU.0001.21MB07 - 09.06.1999 ).
  Certificate ? 7-03-07 - 15.03.2007. Generator
  GTM-4 is capable of generating 4 current
  components with the following parameters
• Component ? (current impulse of the first back
  discharge)height to 200 ? 10 ?? ,with action
  integral (??2dt) - 2106?20?2? and exposure
  time to 500 MKS.
• Component ? (transitory amperage) with average
  amplitude 2 ? 10 ?? width to 5 ?? and
  transferred charge 10 ? 10 C.
• Component ? (DC current) amplitude from 200 to
  800 ? width from 0,25 to1c and with transferred
  charge to 200 ? 20 C.
• Component D (recharge current)with amplitude 100
  ? 10 ??, action integral 0,25106?20?2? and
  exposure time to 500 MKS.
• Description of the generator component
  corresponds to the IEC 60794-4-11999
  requisitions, appendix F.
• Measure of the impulse signal were certified and
  tested according to the repetitive metrological
  testing shunt ???-1 ?002 C.t. 1,5, R? 1,16
  ???, attack time no more than 200 ns,was checked
  22.05.2007.,digital-readout oscilloscope
  Tektronix TDS-2012,accuracy class. 2,0, was
  checked 30.05.2007.
• Registration of testing results were made by
  digital camera (comes with a CD supplement).

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Tests results of ground wire ?1 JSC BMK
production.
Discharge?1,charge 55C
Discharge ?2,charge 55C
Discharge?3,charge 55C
Discharge ?4,charge 70C
Discharge ?5,charge70C
Discharge ?6,charge 70C
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Discharge?8,charge 85C
Discharge ?7,charge85C
Discharge?10,charge 110C
Discharge?9,charge 85C
Discharge?11,charge110C
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Tests results of ground wire ?2,JSC Silur
production
Discharge?1,charge 55C
Discharge?2,charge 55C
Discharge?3,charge 55C
Discharge?4,charge 70C
Discharge?6,charge70C
Discharge?5,charge70C
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Discharge?13,charge130C
Tests results of ground wires ?2, CoLtd
VolgoMetiz production
Discharge ?1,charge55C
Discharge ?2,charge55C
Discharge?3,charge55C
Discharge ?4,charge 70C
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Discharge?11,charge 110C
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General regimes of aging tests, equipment set and
run time within one cyclic process (Testing
laboratory Khotkovo-Test,25.05.2006.).
Outfit Tests schedule Tests schedule The duration of samples exposure in one cycle, h
Outfit Temperature, ? ? Relative humidity, The duration of samples exposure in one cycle, h
Moisture chamber 402 973 2
Sulfur dioxide gas chamber (concentration SO2 - 51mg/m3) 402 973 2
Heating and freeze cabinet Minus (303) Not normalized 6
Artificial weather apparatus irrigation regime 3 min, without irrigation 17 min. 603 Not normalized 5
Freeze chamber Minus(603) Not normalized 3
Exposure to air 15-30 No more than 80 6
Total 24
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Aging tests results (Testing laboratory
Khotkovo-Test,25.05.2006.)
Samples Number of cycles Corrosion damage area, Lesion,point (GOST 9.311-87)
Steel rope GOST3063, JSC Silur -application technique zinc covering HD galvanizing 40 0,34 ?38
Steel rope GOST3063, JSC Silur -application technique zinc covering HD galvanizing 50 6,3 ?34
Steel rope GOST3063, JSC Silur -application technique zinc covering HD galvanizing 60 28 ?32
Steel rope GOST 3063,JSC Volgometiz- application technique zinc covering galvanization 40 No lesion No corrosion attack
Steel rope GOST 3063,JSC Volgometiz- application technique zinc covering galvanization 50 No lesion No corrosion attack
Steel rope GOST 3063,JSC Volgometiz- application technique zinc covering galvanization 60 No lesion No corrosion attack
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Basic conclusions about the study of steel ropes
according to GOST 3062 -3064
The increase of working time in the process of
galvanization (JSC Sevestal-metiz
technology).
The increase of lightning stroke durability in
the process of the increase of preformation
degree (JSC Severstal-Metiz technology).
Total loss of service outage in the process of
cumulative effect of discharge within the range
40-85 C.
The reduction of the aggregate breaking tension
after the lightning exposure of all represented
steel ropes.
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The development of ground wires for overhead
transmission lines according to the STO
(Standards of organization) 71915393TU
(Specifications) 0622008
2 Stage
Development peculiarity Novelty design of the
ground wire according to 71915393TU
(Specifications) 0622008(ground wire)for the
electric power transmission protection from
direct lightning strokes consists in the lay
consolidation technology, provision of line
contact wires and line contact of wires
provision, use of the wires outer layer of the
plastic straining to enlarge contact area between
outer and inner armor wires. This construction
provides the reduction of linear extension
(confirmation patent of the R.F.). Galvanical
method application of coating to a tolerance of
5 prevents zinc layer at increases current and
elevated temperature (short circuit), (it
increases service life, this product is different
from the previous one). Utilize technology of the
lay has no parallel in the Russian Federation,
the technology of application of zinc coating is
comparable to the technique, which is used by
Volgograd plant - JSC Severstal-Metiz in a
process of production cable and wire bridges.
Constructive result 40 years of service life
and 20 years of exploitation under the influence
of all types of loads.
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Producer Severstal-Metiz (Russia)
Cherepovets plant
The plant was found in 1965. It produces more
than 26000 types of production.


Orel plant
The plant was found in 1967. it produces more
than 11000 types of production.
The plant was found in 1954. It produces more
than 1500 types of steel ropes and wires.
Volgograd plant
Authorized provider and developer of the rope and
wire production Co Ltd Energoservice.
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Basic conclusions about the researches of
lightning stroke.
Charge, C (Coulomb) Tension reduction, kgf (kilogram-force) Result of effect
110 no Surface fusion in the discharge zone in zone in area 10?15 mm
147 no Surface fusion in the discharge zone in zone in area 10?15 mm
55 no Electrode touched the surface of pattern during the process of discharge
55 no Surface fusion in the discharge zone in zone in area 10?10 mm
)
Conclusion The ground wires patterns are
stable to lightning stroke (with transferred
charge 55C and 110C) and also have high stable to
a lightning current effect (with transferred
charge 147 C),which has total occurrence
probability 1,2 , in negative and positive
lightning. It ought to be noted, that such a high
lightning resistance of the proved ground wires
is connected with its improved construction,
which is different from the ground wires
construction and is used today in overhead
transmission lines. There is no strength
reduction after stoke.
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• Basic results of the ground wires approval tests
  according to STO (Standards of organizations)
  71915393TU (Specifications) 0622008 for the
  overhead transmission lines.
• List of testing full testinglightning stroke,
  mechanical (disruption, after the lightning
  stroke) eolian vibration ,an attack of wind
  load, and stableness to short-circuit current.
• New ground wires construction was developed
  especially for the protection of overhead
  transmission lines from lightning strokes, it was
  made with the use of current rope technologies
  and it has following peculiarities
• Total resistance to lightning stroke in the load
  range 98,8.
• High corrosion resistance at the expense of
  galvanic coating with 5 tolerance and reduction
  of the total contact area of the ground wires
  surface with environment.
• Increased breaking strength (against ropes) -
  (180kg/mm2 200kg/mm2), it provides reliability
  growth, it is especially important for the anchor
  poles and during the glaze formation.
• Extended service life almost in 2 and 5 times is
  a guaranteed service, in comparison with the
  standard rope.
• Applied technology, in the process of production
  of the ground wires lay according to the STO
  (Standards of organization) 71915393TU
  (Specifications) provides reduction of the
  extension strain, which decreases sagging in the
  process of exploitation.
• There is no strength reduction, no disruptions or
  melting wires to base metal, after lightning
  strokes 147 C (coulomb). .

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• Main points of specifications to the ground wire
  ??-?-O?- ?-? STO (Standards of organization)
  71915393-TU (Specifications) 062-2008, which
  realization is guaranteed by plant JSC
  Severstal-Metiz
• Ground wires should be up to quality of the
  standard and STO (Standards of organization)
  56947007-29.060.50.015-2008 Technical
  requirements JSC FGC UES.
• Ground wires ( marking groups 1770n/mm2
  (180kgf/mm2), 1870n/mm2 (190kgf/mm2), 1970n/mm2
  (200kgf/mm2)) are made from galvanized wire,
  according to the GOST 7372-79, gauge of zinc
  covering should correspond to the ??(extra
  hard) group with the positive tolerance 5.
• Ground wires are made length at least 500
  meters.
• Ground wire should be resistant to impulse of
  the lightning discharge, which size (in
  Coulombs) is defined by the ground wire
  suspension, according to the consumer
  requirements and is installed by manufacturer (if
  it has an appendix tensile load, according to
  the STO (Standards of organization)
  56947007-29.060.50.015-2008 Technical
  requirements JSC FGC UES , at least 85C.
• Ground wire should be resistant to the thermal
  influence of short circuit current,appearing in
  the process of the ground wires exploitation
  with single and double phase to earth fault,
  which size and time is installed by manufacturer
  according to the STO (Standards of organization)
  56947007-29.060.50.015-2008 Technical
  requirements JSC FGC UES.
• (Lightning protection premium quality extra
  hard nonspinning straighten)

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• Ground wire should be resistant to the eolian
  vibration at least 100 million cycles, which
  frequency should correspond to resonating
  frequency with wind speed from 4 to 8 ms
  (Frequency 830/diameter of the ground wire in
  mm 10 Hz),with appendix of the tension load,
  which is installed by manufacturer, according to
  the STO (Standards of organization)
  56947007-29.060.50.015-2008 Technical
  requirements JSC FGC UES.
• Ground wire should be resistant to the pitching
  (eolian vibration), in the process of its
  exploitation and under the influence of crosscut
  wind flow, alternate aerodynamic lift is
  appeared, which can create self-sustained
  oscillations, with the correlation of parallel
  and torsion motions of rope, STO
  (Standards of organization) 56947007-29.060.50.015
  -2008 Technical requirements JSC FGC UES.
• All others technical requirements should
  correspond to the GOST requirements 3241-91 and
  STO (Standards of organization)
  56947007-29.060.50.015-2008 Technical
  requirements JSC FGC UES.
• In accordance with article13.2, Technical
  requirements JSC FGC UES guarantee service
  life of the ground wires should form at least 20
  years, from the moment of commencement of
  operation.

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Overhead transmission lines
Ground wires (Lightning protection),which were
made in accordance with the technical
requirements STO (Standards of organization)
71915393-TU (Specifications) 062-2008, are meant
for the overhead transmission lines protection
from lightning strokes, diameters of which from 8
to 22,5mm and resistance from 1770 n/mm2 to 1970
n/mm2, are galvanized according to the ??(extra
hard) group with a tolerance of 5. The
advantages of lightning protection (except high
density and better corrosive resistance) is a
heightened sturdiness to the lightning pulse
influence from 85C and higher. Lightning
protection (in contrast to steel ropes) survive
even in the zones with heightened probability
value of lightning discharges, during the
guaranteed service life 20 years. Sole
manufacturer and patent holder JSC
Severstal-Metiz. Dealer and developer Co Ltd
Energoservice. Sign of implementation
Lightning protection. Agency output minimum 350
tons monthly. Standard-size spectrum 8,0-22,5mm
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Ground wires for the overhead transmission lines
and lightning strokes protection STO
(Standards of organization) 71915393 TU
(Specifications) 062-2008 Construction 1 ? 36
(1 7 7/7 14)
Diameter, mm Projected area of sectional view of all wires in lightning protection , mm2 Estimated weigh 1000 m of oiled lightning protection , kg Marking group 1770 n/mm2 Marking group 1870 n/mm2 Marking group 1970 n/mm2
Actual aggregate breaking strength of all wires - g, n (not less than) Actual aggregate breaking strength of all wires - g, n (not less than) Actual aggregate breaking strength of all wires - g, n (not less than)
8,0 44,54 366 78400 82300 87200
9,2 59,06 490 103800 109700 115600
10,0 69,67 575 122500 129300 136200
11,0 83,59 695 147000 154800 163600
12,5 107,97 886 190100 200900 210700
13,0 118,55 974 208700 220500 232200
14 135,88 1125 239100 252800 265500
15 157,79 1295 278300 293000 308700
16 180,61 1480 318500 336100 353700
17 201,59 1660 354700 375300 394900
18,5 240,72 1980 424300 447800 471300
21 309,35 2540 544800 575200 605600
22,5 354,29 2910 624200 659500 693800
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Severstal-Metiz and Energoservice express
gratitude for kind attention! We are always glad
to cooperate!