INDIA S LARGEST TOWER TESTING FACILITY L&T TRANSMISSION LINE TESTING & RESEARCH STATION

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Shonda Young
6 years ago
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1 INDIA S LARGEST TOWER TESTING FACILITY L&T TRANSMISSION LINE TESTING & RESEARCH STATION (An ISO/IEC 17025:2005 NABL Accredited Laboratory)

765 kv Sipat Seoni transmission line Larsen & Toubro (L&T), a USD 13.

For over 70 years, L&T has been offering a gamut of advanced solutions, critical engineering services and products to diverse customers in India and abroad.

L&T Construction s leading edge capabilities cover every discipline of construction: civil, mechanical, electrical and instrumentation engineering and services extend to all core sector industries

Revolutionizing Power Over the years, L&T s Power Transmission & Distribution division has acquired extensive experience, knowledge and unmatched skills in executing critical power transmission

2 765 kv Sipat Seoni transmission line Larsen & Toubro (L&T), a USD 13.5 billion technology - driven engineering, construction and manufacturing organisation is one of the largest and most admired companies in India s Private Sector. For over 70 years, L&T has been offering a gamut of advanced solutions, critical engineering services and products to diverse customers in India and abroad. L&T Construction, the construction arm of Larsen & Toubro is the largest construction organisation in India and is ranked 27th among the world s top contractors (as per ENR, USA - August 2012). L&T Construction s leading edge capabilities cover every discipline of construction: civil, mechanical, electrical and instrumentation engineering and services extend to all core sector industries and infrastructure projects with single source responsibility. L&T possesses wide ranging capabilities and expertise to meet every requirement of power generation, transmission and distribution. Revolutionizing Power Over the years, L&T s Power Transmission & Distribution division has acquired extensive experience, knowledge and unmatched skills in executing critical power transmission projects for clients across the globe. Having executed more than 14,000 km of EHV power transmission lines in India and over 4000 km in the international markets, the company has a strong foothold and extends its services to 10 countries worldwide. For over two decades, L&T has been offering end-to-end EPC services that include design, manufacture, supply of towers, construction, testing and commissioning of EHV power transmission lines, and has established itself as a reliable partner in the transmission line industry. Scaling New Heights L&T s Transmission Line Testing & Research Station (TLTRS) is one of the largest tower testing station in India and the country s first private testing station to be accredited by National Accreditation Board for Testing & Calibration Laboratories (NABL). TLTRS since its inception in November 2009 has completed testing of towers for many International clients from Spain, Oman, Abu Dhabi and Egypt. This state-of-the-art testing station is established in an area of 25 acres at Kanchipuram (near Chennai) for testing various voltages of transmission line towers. TLTRS conforms to international design specifications and can test the adequacy of all components of the transmission line structures and their connections to withstand the design loads specified for the test structure under stimulated conditions. In addition, it provides insight into actual stress distribution of unique configurations, fit-up verification and performance of the structure. It is equipped with facilities to perform tests on square or rectangular base lattice towers, monopoles, tubular structures and guyed towers for capacities up to 1200kV. Apart from analyzing the accuracy of assumptions made in design calculation, this testing bed also ensures that the towers meet the desired performance criteria. The strategically located control room, the largest of its kind in the country (17,500sq.ft ground + two floors), is equipped with unobstructed viewing gallery (3,500sq.ft) for 360 degree view. This enables engineers to have better control of the entire testing process. The control room is equipped with high-capacity (100t) digital UTM (Universal Testing Machine) for load cell calibration of tower members. This facility also boasts of a specially designed builtin data acquisition and control system, with the latest equipment for operational support. A jumbo tower crane, spanning the entire area of erection and testing operations expedites the testing process.

The SCADA system coupled with auto, semi-auto and manual operation controls the movement of Hassles of shifting assembled tower members from the manufacturing facility to the testing Specialised

Digital theodolites and strain gauge cells of varied capacities are used for load/deflection measurement in different conditions.

Modifications envisaged in tower members during failure of the testing process are carried out quickly. This proto-fabrication facility (500 ton per month) is set up in an expanse of 19,500sq.

During failure, a fullfledged design office at the testing station complements the fabrication unit in preparing the revised drawings and manufacturing tower members for replacement in the least

3 The SCADA system coupled with auto, semi-auto and manual operation controls the movement of Hassles of shifting assembled tower members from the manufacturing facility to the testing Specialised Testing Capabilities design and testing. Plans are afoot to develop and acquire new concepts applying advanced technology, winches. Digital theodolites and strain gauge cells of varied capacities are used for load/deflection measurement in different conditions. Yet another unique feature of this testing centre is the prototype fabrication unit for carrying out fabrication / proto-assembly of test towers. Modifications envisaged in tower members during failure of the testing process are carried out quickly. This proto-fabrication facility (500 ton per month) is set up in an expanse of 19,500sq.ft and is equipped with a CNC machine to expedite the process. station are duly eliminated by using this proto-fabrication unit. During failure, a fullfledged design office at the testing station complements the fabrication unit in preparing the revised drawings and manufacturing tower members for replacement in the least possible time. The design engineers can also assist customers with 3D structural analysis and detailing whenever required. TLTRS is the only testing centre in India, where fullfledged fabrication facility is available within the station premises. z Computerised central loading and monitoring system to simulate the actual loading z Freedom for design engineer to choose any shape of tower to achieve optimization z Electrically operated winches with dual-speed variable frequency drives enable smooth loading z Sophisticated in-house touch-screen based SCADA software ensures accuracy in testing z Towers up to 1200kV with 95m height can be tested configurations and materials for different size and shape in the transmission line field. TLTRS bagged the prestigious D.L.Shah - Quality Council of India - Award 2013 for implementing new technology 400 kv multi circuit narrow base NMA tower z Towers can be tested to exceptional heavy loading (1000t per leg) and large base width (up to 35m) z Web casting to facilitate the overseas customers to view the tower testing in LIVE in turn saving cost and valuable time z Usage of Tower Rigging software - Ability to adopt various tower configurations i.e. Square, Triangular, Tubular and Rectangular As part of its R&D efforts, TLTRS constantly upgrades its knowledge and expertise in transmission line With a gamut of operations under a single roof from design, detail engineering and manufacturing of towers in ISO & OHSAS certified factories at Pudhucherry and Pithampur including testing of towers in its own centre to turnkey construction of transmission lines L&T is poised to meet challenges and set indelible benchmarks in the transmission line industry

Test Bed Highlights Independent testing facility for testing insulators up to 1200kV z Maximum Test Tower Base Width 35m x 35m z Maximum Test Tower

Wire Load 100t per point z Maximum Longitudinal Wire Load 70t per point Maximum V-String Insulator Span : 22 m Maximum I-String Insulator Span : 22 m

Electrically operated winch Load Measurement System : Strain gauge type load cell Load Cell Verification : 1000 kn digital UTM Test pad Dimensions :

5t capacity Electrically Operated Winches z Load Measurement System Strain Gauge Type Load Cell Highest tower tested till date - 80.

4 Test Bed Highlights Independent testing facility for testing insulators up to 1200kV z Maximum Test Tower Base Width 35m x 35m z Maximum Test Tower Height 95m z Maximum Compression / Uplift per Leg 1000t z Allowable Overturning Moment 70,000t-m z Maximum Cross Arm Spread 70m z Maximum Transverse Wire Load 100t per point z Maximum Longitudinal Wire Load 70t per point Maximum V-String Insulator Span : 22 m Maximum I-String Insulator Span : 22 m Insulators can be tested up to : 1200 kv Maximum Test Load : 1000 kn Configuration : V-String, I-String, Y-String Load Application System : Electrically operated winch Load Measurement System : Strain gauge type load cell Load Cell Verification : 1000 kn digital UTM Test pad Dimensions : 22.5 m x 22.5 m Insulator testing z Maximum Vertical Wire Load 60t per point z Load Application System 65 Nos. 5t capacity Electrically Operated Winches z Load Measurement System Strain Gauge Type Load Cell Highest tower tested till date m high 400 kv multi circuit twin tower First 765 kv DD type tower tested z Material Testing and Calibration 100t digital UTM z Tower Erection through Tower Crane Heaviest tower tested till date 193 MT T-60 type, 500 kv tower

www.lntecc.com Headquarters: P.B.No. 979, Mount Poonamallee Road, Manapakkam, Chennai - 600 089. Tel.: +91-44-2270 5000 Fax: +91-44-2270 5494 (Mr. C.S.

5 Headquarters: P.B.No. 979, Mount Poonamallee Road, Manapakkam, Chennai Tel.: Fax: (Mr. C.S.Reddy - csr@lntecc.com) Testing Station: NH-4, Bangalore Highway, Neeravalur Village, Kanchipuram, Tamil Nadu (Mr. K. Srinivasan - ksvasan@lntecc.com)

Building Customer Confidence & Sustainability Initiatives in Transmission Line Testing

Building Customer Confidence & Sustainability Initiatives in Transmission Line Testing Key words: TLTRS (Transmission Line Testing & Research Station), RIGGING, RIGGING, CHART, SCADA (Supervisory Control