34-41] Lead Story - SPML Infra · PDF fileMadhya Pradesh. Apart from this, BHEL also supplied other key equipment like 1,200kV insulators. Vijai Electricals Ltd:This Hyderabad-based

34 Electrical Monitor April 2014

Lead Story

The development of India’spower sector—in bothqualitative and quantitativeterms—will be the principal

determinant of India’s socioeconomicdevelopment. Power transmission anddistribution have received much lesserattention as compared with powergeneration. In fact, power shortageshave traditionally been addressed byramping up power generation capacity.It is only over the past few years that

attention is being directed to improvingthe technical and commercial efficiencyof power generated by duly addressingcritical issues in the power T&D space.

On the power transmission front,one of the means to achieve greaterefficiency is the introduction of high-voltage lines. Today, commercial linesexist up to 765kV, and apart from AC(alternating current) technology, thereis widespread deployment of DC(direct current) lines. In terms of high

voltage direct current (HVDC) lines,India is establishing lines with ultrahigh voltages of even ±800kV. Anoutstanding aspect of India’s powertransmission endeavours has been theeffort to set up ultra high voltagepower transmission lines at 1,200kV—the highest voltage level anywhere inthe world as yet.

Though India has yet to establish1,200kV power transmissiontechnology on a commercial scale, a

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Electrical Monitor April 2014 35

good beginning has been made bysetting up testing facilities. The BinaUHVAC test station in MadhyaPradesh is the result of the concertedeffort of Central transmission utilityPower Grid Corporation of India,Central Power Research Institute(CPRI) and 35 Indian suppliers. Whatis encouraging to note is that theUHVAC test station is based largely onindigenous technology.

Seeds of the UHVAC enterprise were

India is set to deploy 1,200kV power transmission lineson commercial basis, making it the highest voltage levelin the world. Boosting India’s prospects is the successfulimplementation of the 1,200kV test station at Bina inMadhya Pradesh. VENUGOPAL PILLAI looks into variousaspects of ultra high voltage power transmission anddiscusses challenges that India will need to contend withbefore 1,200kV power transmission can become asustainable reality.

India steps up to

1,200kV

PHOTO: SUPREME & CO

PHOTO: SUPREME & CO



Lead Story

sown in 2007 when a Project SteeringCommittee was formed under theleadership of PGCIL and with membersfrom Central Electricity Authority(CEA), industry body IEEMA, CPRI,and leading Indian electricalequipment manufacturers. TheUHVAC Bina test station represents aninteresting manifestation of thepublic-private partnership (PPP)philosophy. When PGCIL announcedthe 1,200kV venture, severalequipment manufacturers came up insupport. For the 35 manufacturersinvolved in this project of nationalimportance, it was not merely a“contract” awarded by PGCIL, but anopportunity to contribute to a nationalcause. All the equipments for thestation like transformers, circuitbreakers, surge arrestors, insulators,etc were built indigenously. The Binatest station was dedicated to thenation on December 26, 2012. The testcentre includes two test bays, one1,200kV single-circuit line and one1,200kV double-circuit line. The testlines are around 2 km long.

The following is a brief description ofselect participants in the successfulcommissioning of the 1,200kV Binatest station.

Bharat Heavy Electricals Ltd:Central PSU engineering companyBHEL supplied a 1,200kV transformerof 333MVA rating. This single-phaseauto transformer was developed withindigenous technology andmanufactured at its Bhopal plant in

The choice between alternating current (AC) and direct current (DC) has been one of themost interesting aspects in the study of electricity. Thomas Alva Edison was an activeproponent of DC. On the other hand, other notable physicists of their time – Nikola Tesla

and George Westinghouse – advocated the use of alternating current. AC ultimately won overDC as the generally preferred mode of electricity transmission in what was famously knownas the “War of the Currents” in the 1880s. However, the world today realizes that it not a matterof “AC or DC” but “AC and DC”. The use of AC or DC, whether it is for low or ultra high voltage,depends on the situation on hand. In the context of high- and ultra high voltage powertransmission, India is a classic example of how it is creating a judicious mix of AC and DCpower transmission infrastructure. Even as EHV and UHV transmission is taking placethrough the AC mode, there is a conscious effort to build high voltage direct current (HVDC)lines for voltages as high as 800kV. China too has factored the use of both AC and DC ultrahigh voltage lines in its national power transmission plan.Over long-distance power transmission, both UHVAC and UHVDC offer comparable advantages.However, when it comes to equipment (e.g. transformers and circuit breakers), there is morecollective expertise with AC systems than DC systems. AC transmission lines can connect loadsat different points en route, while the same for DC systems is very expensive or even impracticable.Line costs for HVDC systems are said to be lower than HVAC systems, simply because DC systemsneed fewer number of conductors. However, there are specific applications – like subsea links –where DC enjoys distinct technical advantages. HVDC has a solid advantage in that it allows power transmission across asynchronous AC systems(operating at different frequencies). This, experts feel, leads to grid stability. In the Indian contexttoo, the southern grid, operating at 60Hz, was connected to the national grid using HVDCinterconnectors. This was before the AC link (Sholapur-Raichur) came up in January this year. Antonio Ardito, Chief Engineer, Consulting Division of Italy-based testing laboratory CESI, inan interaction with Electrical Monitor noted that competition between UHVAC and UHVDC isintensifying of late. Ardito said that technology relating to converters (used in HVDCtransmission) has developed significantly over the recent years. This has resulted in lowercapital costs of HVDC lines. “This makes HVDC more attractive from both a technical andeconomic standpoint,” he felt. While ±800kV DC transmission is in commercial operation,the technology for 1,000kV DC has also been developed, he observed.All in all, there cannot be ultra high voltage power transmission corridors using AC or DCalone. A combination of the two, depending on project conditions, is what a transmissionnetwork should deploy.

AC & DC: A winning combinationPHOTO: CTC GLOBAL


Madhya Pradesh. Apart from this,BHEL also supplied other keyequipment like 1,200kV insulators.

Vijai Electricals Ltd: ThisHyderabad-based company alsosupplied a 1,200kV auto transformer of333MVA rating. Like BHEL, this single-phase transformer was developed withindigenous technology and wasproduced at the Rudram works nearHyderabad.

Crompton Greaves: AvanthaGroup company Crompton Greaves(CG) dispatched a 1,200kV capacitivevoltage transformer for the Bina UHVtest station. Rolling out of the Nashikplant in Maharashtra, the mammothtransformer was developed with in-house technology.

Larsen & Toubro: This privatesector engineering giant was alsoinvolved in the 1,200kV powertransmission regime. In late 2009,Larsen & Toubro established India'slargest transmission line researchcentre at Kancheepuram in TamilNadu. The centre is equipped to testtransmission towers of up to 95mheight required for 1,200kV powertransmission lines. This testingstation, according to a statement byL&T, enables to design and validateinnovative configurations withoutany limitations on size, shape andmagnitude of loading, which iscurrently not possible in the industry.

Siemens: Siemens developed a1,200kV circuit breaker for the Binatest station. This apart, Siemens also

supplied surge arrestors of 1,200kVrating. A Siemens official told ElectricalMonitor that these arresters weredesigned and tested at Siemens’ Berlinand Cologne facility in Germany.

Alstom India: Formerly known asAreva T&D, Alstom India supplied a1,200kV capacitive voltagetransformer for the Bina test station.This equipment was developed at theHosur plant in Tamil Nadu. Alstom hasalso planned to make other 1,200kVgear including digital currenttransformers.

KEC International: RPG Groupcompany KEC International wasinvolved in the Bina test station as theEPC contractor for the 1,200kV

double-circuit line. The line involveshandling of towers each weighingmore than 400 tonnes and with aheight of 130m. In an exclusiveinteraction with Electrical Monitor,Ramesh Chandak, MD & CEO, KECInternational Ltd expressed pride inbeing associated with this landmarkproject. (Full interaction presentedelsewhere in this story.)

Supreme & Co: Kolkata-basedSupreme was an active supplier ofcritical hardware for the Bina teststation. In an earlier interaction withElectrical Monitor, the company saidthat it had supplied nearly 80 per centof the hardware used in the UHVACcentre. Some key equipment included


Several countries, since the 1970s, have been planning to develop ultra high voltage AClines for efficient power transmission. Two countries that were successful in puttingUHVAC lines in commercial operations include Russia and Japan. (Also see Box:

Italy’s Experience)In 1985, Russia (erstwhile USSR) energized a 500-km section of the 900-km 1,100kV UHVAC

line between Ekibastuz and Kokchetav substation. The remaining 400-km line between Kokchetvaand Kustanai was energized in 1998. The line was operated at 1,100kV only for a brief period oftime and today, the UHVAC line has an operational voltage of 550kV. This drop in voltage resultedfrom lower electricity transfer demand, among other reasons.

Japan has been working on UHV technology since the early 1970s in an attempt to findsolutions to upgrade its then existing 550kV power transmission network. Bulk of the research wasconducted by Tokyo-based Central Research Institute of Electric Power Industry (CRIEP), inassociation with power utilities. Tokyo Electric Power Company, in 1993, completed the 190-km1,100kV North-South route linking the nuclear power station on the Sea of Japan to themetropolitan region. The 240-km East-West route connecting power plants on the Pacific Oceanwas built in 1999, designed for the same nominal voltage of 1,100kV. However, for much of theircommercial life, the lines have operated at 550kV voltage.

Early adopters: Russia & Japan PHOTO: CESI, ITALY

PHOTO: CPRI



Lead Story

corona control rings, clamps,connectors, etc.

Hivelm Industries: This Chennai-based company that is a unit ofDigivision Electronics Ltd designedand developed a 1,200kV isolator forthe Bina test station. The isolator wasshipped to Bina in August 2012.

As of now, the Bina UHVAC stationis under testing. Going by industryplayers, the results have beensatisfactory. Testing is expected to goon for another couple of years afterwhich India can embark on setting up1,200kV lines at the commercial level.When it comes to 1,200kV lines, Indiahas established its competence in

manufacturing equipment andhardware. The next phase—and ofcourse the most critical one—is tostudy “live line” conditions, which is toinvestigate the working of 1,200kVlines at full load on a sustained periodof time. The impact of full load is alsobeing studied on the equipment andhardware. Depending on the results ofthis study, suitable modifications mayneed to be made for future projects.

THE NEED FOR UHVACIndia, due to its intrinsic conditions,makes a very good application area forultra high voltage power transmission.India’s current installed capacity is

around 2.3 lakh mw and by 2027,installed capacity is likely to touch 7lakh mw, necessitating the transfer of 5lakh mw worth of power capacity.

Power transmission is very land-centric activity and land—as asubject—has always had a difficulttime. Erecting power transmissionlines involves obtaining the ever-elusive right of way. Securing RoW forlines passing through sensitive areaslike forests or mines or through privateland has been a big deterrent. OnceRoW is obtained, it makes technicaland commercial sense to harness it tothe fullest. The difference in RoWrequirement for a 400kV line and a

TTeellll uuss aabboouutt KKEECC IInntteerrnnaattiioonnaall’’ss rroollee iinn tthhee11,,220000kkVV BBiinnaa tteesstt ssttaattiioonn..

As part of PGCIL’s 1,200kV test station atBina, KEC played a vital role of constructingthe 1,200 kV double circuit (D/C)transmission test line. This is the first1,200kV D/C transmission line in the world.Each tower weighed more than 400 tonnesand had a height of 130m.

WWhhaatt wweerree tthhee mmaajjoorr cchhaalllleennggeess tthhaatt KKEECCccoonntteennddeedd wwiitthh wwhhiillee eexxeeccuuttiinngg tthhee pprroojjeecctt??

The foundation activity involved hugeconcreting volume—exceeding 500 cubicmetres (cum) in each foundation. Erection ofthese mammoth towers was indeed achallenging task. We decided to use acombination of conventional and innovativemechanization techniques for this work. Wedeployed a central crane and a 3.5-tonnepuller along with heavy-duty pullers to carryout the tower erection. To expedite theproject – in view of its importance to PGCIL

and to the nation – a special 150-tonnecrane with an 80m boom was also mobilizedat the site in February 2012. Manpowermobilization at the peak of project progresswas about 400 workers at the site.

GGiivveenn tthhaatt tthhee BBiinnaa UUHHVVAACC ssttaattiioonn hhaass bbeeeennaa nnaattiioonnaall llaannddmmaarrkk,, wwhhaatt ssppeecciiaall ttrreeaattmmeenntt–– ssoo ttoo ssppeeaakk –– ddiidd KKEECC ggiivvee ttoo tthhee pprroojjeecctt??

Yes, we gave special attention to safety inview of the enormity of the task and safetyhazard it imposed. We are proud to share thatwe have no incident reported from site tilldate. This was ensured with the use ofspecial safety equipments andcommunication devices.

Being a landmark project of PGCIL, theproject was keenly and closely watched bythe industry, government and of coursePGCIL. There were regular visits of seniorPGCIL officials including its CMD.

We can say proudly that we were part ofthe first 1,200kV test project in the world!

We are proud to be part of the world’s first 1,200kV test projectKEC International Ltd was involved in setting up the 1,200kV double-circuit line that was a crucial component of the Bina UHVAC teststation. We have Ramesh Chandak recalling the experience andsharing his elation in being part of a landmark project.

—RRaammeesshh CChhaannddaakk,, Managing Director & CEO, KEC International Ltd


1,200kV is not significant. However,the benefits of being able to transmithuge quantum ultra high voltage linescannot be overlooked. A 400kV line cantypically transmit 400 mw of power.When one moves to 800kV, thequantum of power transfer is between1,200 mw and 2,400 mw. When onegraduates to 1,200kV lines, powertransmission of 6,000-8,000 mw istechnically possible. Ultra high voltagepower transmission, despite thechallenges, will be an area that Indiawill need to keenly explore.

One more reason why UHVtransmission is warranted is because ofthe power demand-supply situation.Power generation centres are typicallyin eastern and northeast regions whileconsumption centres are spread acrossrest of India – north, west and south. Ingeneral, generation hubs are limitedconsumers, warranting the need forcarrying power across long distances.One more application for high-voltagelines stems from India’s plan to importpower from hydropower-richneighbours like Bhutan and Nepal.

Thus, we see that ultra high voltagepower transmission is indispensable.However, the choice of AC and DC willdepend on the specific projectconditions (See Box: AC or DC). In theIndian context, UHVAC has a solidadvantage in that it is cheaper to buildas converters used in HVDC lines areexpensive. According to AntonioArdito of Italy-based CESI, UHVACallows easy and cheap connection oflower voltage networks. It also ensuresavailability of large synchronizingpower during major networkperturbation. Speaking to ElectricalMonitor, Hitesh Mundhada, RegionalDirector -- India & Middle East, CTCGlobal, noted, “1,200kV is like a supertransmission highway used forinterregional connections; for exampleevacuating bulk power from NE regionthrough the very narrow (Chicken’sNeck) area. Through higher AC voltagelevels like 1,200kV which are electricalcompaction of transmission lines, unitcost of ROW per block of power isgreatly reduced compared to lower ACvoltage levels.”

The first commercial 1,200kV line inIndia, by current thinking, is going to

be the 400-km Wardha to Aurangabadline in Maharashtra. Currently, the lineis 400kV but will be scaled up to1,200kV over the next 2-3 years. Workon this line will of course take placewhen detailed tests are done at the1,200kV Bina pilot project.

CHALLENGESThe technical and commercialadvantages of 1,200kV are significantbut there are countervailing challenges.India has acquired some expertise inproducing key UHVAC equipment liketransformers, circuit breakers, etc. Theability to construct 1,200kV lines hasalso been established. The critical issue,as discussed earlier, is keeping a 1,200kVline fully charged over long periods of

time. The highest-rating AC powertransmission line currently operationalin the world is a 1,100kV line by China.This line has been in operation onlysince recently; the collective globalexperience of fully-charged live lines istherefore relatively limited.

Electrical Monitor got in touch withsome industry players to understandthe challenges ahead of India in itsquest of running 1,200kV lines oncommercial basis. Harish Agarwal,CEO, Supreme & Co, felt thatbreakdown and outage managementof UHVAC lines could be challenging asIndia has yet to acquire experience inthis regard. “Sudden loss of line owingto big natural calamities, if they occur,will result in loss of huge quantum of


China is also pursuing ultra high voltage power transmission to carry electricity from remotegeneration centres. China has been adopting both AC and DC modes of transmission,much like India. As far as ultra high voltage AC transmission is concerned, China began

preliminary work in 2004-05. Currently, the 1,000kV Jindongnan Nanyang-Jingmen line, whichbegan operations in January 2009, is the highest-capacity AC line in China. Though it has anominal voltage of 1,000kV, it has recorded its highest operational voltage of 1,100kV. Itstransformational capacity stands at 6,000MVA.

The 650-km long line has two segments—a 360-km line from Jindognan in the northernprovince of Shaanxi to Nanyang, and a 290-km line from Nanyang to Jingmen in the centralprovince of Hubei. The project includes a 3.7-km line crossing the Yellow river and a 2.9-km linecrossing the Hanjiang River. The UHVAC line, completed in November 2008, was built by China’slargest transmission utility State Grid Corporation of China, with an investment of around $1 billion.

Approved by China’s National Development & Reform Commission in August 2006,construction work started at the end of the same year. It was put into commercial operationson January 6, 2009, after 168 hours of trial run. The line was built with indigenoustechnology and equipment.

UHVAC in China



Lead Story

power. Emergency restoration canpresent a challenge as such solutionstoday are available only up to 800kV,”noted Agarwal.

Rishabh Sethi, Chief OperatingOfficer, SPML Infra Ltd, also pointedout some technical issues in UHVAClines. SPML Infra is a leadingmultifarious EPC contractor withsignificant expertise in power T&D.Sethi observed, “The electrical concernin these kinds of ultra-high voltage linesis the corona effect that could lead tohuge loss of power duringtransmission.” He also pointed outIndia will generally have to upgrade itsmanufacturing and fabricationfacilities to cater to the UHVAC regime.

Hitesh Mundhada, RegionalDirector – India & Middle East, CTCGlobal, was of the opinion that Indiashould expedite the creation of testingfacilities for 1,200kV otherwise itwould need to import costly UHVequipment. He also expressed that dueto high electromagnetic fields, therecould be an impact on environmentand health. Concurring broadly withthis view was Harish Agarwal who feltthat “Biological effect in the vicinity ofUHV lines, owing to induction, maypose some challenge.”

Siemens that supplied circuitbreakers for the 1,200kV Bina teststation expressed apprehension abouttesting of high-voltage equipment. ASiemens spokesperson said, “Generallythe procedure for development of UHVcircuit breakers is comparable to thedevelopment of those for lower voltagelevels. However, one of the majorchallenges is the availability of suitabletest fields (test equipment) to test thebreakers during the development andto perform the necessary type tests atthese high voltage levels.”

Given that obtaining right-of-waycan be very challenging in the contextof India, Harish Agarwal observed thatsecuring RoW in absolute terms maybe challenging even if the ratio of RoWto power transmitted were favourablylow.

CONCLUSIONIndia’s plans for power generationcapacity hinge on the setting up oflarge-sized plants. The ultra mega

The experience of Italy in ultra high voltage power transmission is very interesting. TheEuropean country started development of UHVAC technology way back in the 1970s, inanticipation of bulk power transmission requirements over long distances. Interestingly

enough, by 1997, Italy found no commercial application for UHVAC lines as following a systemicchange in its power demand-supply situation.

Italy-based CESI, the independent global centre of expertise and provider of technical andengineering services to customers throughout the energy value chain, was closely involved in thedevelopment of 1,000kV UHVAC technology in that country. Antonio Ardito, Chief Engineer ofCESI’s Consulting Division, recounted Italy’s UHVAC experience in an exclusive exchange withElectrical Monitor. His narration is summarized below.

In the early 1970s, Enel, the then Italian national electricity board, decided to develop UHVACtechnology (at 1,000kV level) as a consequence to rapid and stable growth in electricityconsumption, which was doubling every ten years. During this period, there was a gradual increasein capacity of power generation plants (mainly thermal), matched by increase in network voltagefrom 380kV to 420kV. It is interesting to note that Italy then had envisaged around four mega nuclearpower generation plants, each with capacity of 5-6 GW. Italy was convinced that higher voltage lineswould allow land occupied by overhead lines to be kept within acceptable limits, and that therewould be significant savings in terms of both investment and technical losses.

Italy did not pursue HVDC as its plan envisaged four mega nuclear power plants with loadcentres located at relatively short distances of around 250 km. Secondly, HVDC technology wasthen only evolving, in other parts of the world like North and South America, and as such was veryexpensive. Italy’s 1,000kV UHVAC project was developed in two phases:

In the first phase, from 1970 to 1985, extensive theoretical studies and experimentalinvestigations were performed in CESI’s dedicated test facility at Suvereto and CESI’s laboratoriesin Milano. Experimental tests were conducted on a line span with prototypes of componentsdesigned and supplied by associated manufacturers. In the second phase, from 1985 to 1990, aplant was erected with commercially-conceived components including a 3-km overhead line, a0.5 km underground cable and all the substation apparatus and components (380/1000 kVautotransformer set, a complete SF6 switchyard and an air insulated switchyard) for a completeoperational test and full feasibility demonstration.

This feasibility demonstration project was operated up to 1997 and ultimately dismantled asthere was a radical change in Italy’s electricity landscape. The large nuclear power plantsenvisaged earlier were cancelled, making way for medium-sized (400 to 800 mw) gas-fired powerplants and a few coal-fired ones. Therefore the need to transmit large quantum of power over longdistances simply dropped off.

Italy’s Experience

Corona test cage of CESI’s UHV test facility at Suvereto, Italy


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power plant series (with each plant ofaround 4,000 mw) and gigawatt-sizednuclear power plants are key plans tothis effect. India will continue to dealwith large quantum of power thatneeds to be transmitted over longdistances. In this reckoning, the powertransmission backbone will need toincorporate ultra high voltage lines.Contentious issues like securing right-of-way will persist, once againnecessitating the deployment of ultrahigh voltage lines. Maximum powertransmission per unit right-of-way willbe the key mantra. In future, India willneed both AC and DC modes of ultrahigh voltage transmission, ensuringthat the individual advantages of bothtechnologies are exploited and awinning combination created. Expertsfeel that in the medium term, the bulktransmission network in India will

comprise 1,200kV UHVAC and±800kV HVDC lines. The sub-transmission network will have acombination of 756kV AC and±500kV lines.

The 1,200kV regime is new to India,and for that matter, to the world. Indiathus has to build self-sufficiency inevery department of UHVACinfrastructure—manufacturing,construction, testing, servicing, etc.UHVAC transmission at 1,200kV isperhaps a rare area where India willfind itself without global precedents toemulate. So far, the journey has beenquite satisfactory with Indiaestablishing a 1,200kV test station inless than five years, thanks to theoverwhelming and enthusiasticsupport of Indian enterprise. However,the key challenge will be to operatecommercial lines on a sustainable basis.

This will need much more effort thanwhat has been seen so far. A pilotproject, especially if it is that of aworld-first like 1,200kV powertransmission, is bound to be a euphoricexperience. What is now needed is thededication and commitment totransmute this pilot model tocommercial scale.

Creating facilities for manufacturingand especially testing of 1,200kVequipment on commercial scale will beof paramount importance. Withcommendable work done towardssuccessfully building the pilot model,India now has an open field todemonstrate its prowess on buildingcommercial 1,200kV lines. This willendorse its commitment in addressingthe often-neglected cause of improvingtechnical and commercial efficiency inthe power sector.


PHOTO: CESI, ITALY


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34-41] Lead Story - SPML Infra · PDF fileMadhya Pradesh. Apart from this, BHEL also supplied other key equipment like 1,200kV insulators. Vijai Electricals Ltd:This Hyderabad-based