transmission - Hubbell Power Systems

Transcrição

transmission - Hubbell Power Systems
®
TRANSMISSION
TOWERS IN BRAZIL
A Case History: Helical Piles & Guy Anchors
w w w. h u b b e l l p o w e r s y s t e m s . c o m
10,000 TOWERS
The Rio Madeira Project in Brazil
One of the largest power lines in the world is being
built in Brazil and Chance® helical piles and guy
anchors made by Hubbell Power Systems, Inc. (HPS)
are helping support the transmission towers in a
diverse array of terrains and soil conditions.
Brazil’s demand for electricity is growing by about 4.5% per year. That means by 2021, overall demand will rise from today’s load of
472,000 GWh to a whopping 736,000 GWh—a 56% increase.
To meet this demand, the Brazilian government is building or plans to build as many as 48 new power plants over the next 10 years.
Brazil is crisscrossed by rivers and all 48 plants will be hydroelectric with a combined generating capacity of 42,157 MW of power. Most
of that (80%) will be generated by 18 new dams in the Amazon River Basin.
Two are already built. The Jirau dam produces 6.5 GW and Santo Antonio dam produces 6.3 GW of power. Both are in the Port Velho area.
There is just one problem.
In Brazil, the power-hungry East and Southeast is separated from the massive hydro generating plants in the Northwest by 1,475
miles (2,375 kilometers) of rugged terrain and smaller rivers. So, in addition to building new power plants, Brazil is also in a frenzy of
transmission line construction. One of the largest ventures, the Rio Madeira Project, is currently under construction.
2
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NBTE--formed by Abengoa (51%), Eletrosul (24.5%), Eletronorte (24.5%).
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me
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an
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13
10
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do
o
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Ri
R
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i
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et
R.
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Rio das Éguas
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CACHOEIRA
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SãoSIMÃO
Simão
SÃO
S.
Domingos
O
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ILHA
io
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Brilhante (10)
10
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RI
Ri
o
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ã
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o
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o
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12
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10
10
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12
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PCH S
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11
11
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Natal III (11)/
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12
12
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i Picos
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FR
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R
n
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io
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aribe
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12
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11
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10
16
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lin
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10 PARAÍSO
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10
Rio Pardo (11)
Campo Grande /
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10
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io
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11
11
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10
10
15
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R
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ri
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Fortaleza / Fortaleza II / Pici II /
Delmiro Gouveia / Aquiraz II (12) / Maracanaú (16)
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u
10
Rio
Balsa
bá
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Nicolau
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a
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11
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do Tocantins
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les
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-15º
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ba
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cur
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10
TUPIRATINS
ILHA DO
BANANAL
on
Sui
TERMOCEARÁ
Pecém II (12)
Sobral III
CEARÁ
Rio
A
io
TOCANTINS
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a
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JUBA I, II
Piripiri
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16
Balsas(10)
R
MATO GROSSO
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Sep
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R
Ri
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Ri
10
10
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TERESINA
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10
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10
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10
Parecis (10)
Porto
Franco
ESTREITO (11)
Araguaína
O
Ponta dos Patos
Icaraizinho
Massapê II
m
e
11
Tocantinópolis
RI
Acaraú II (12)
Praia Formosa
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11
16
UA
14
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g
10
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10
ri
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18
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IA
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12
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XI
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15
12
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Ri
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15
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15
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Ilha do Caju
Ilha das Canárias
Ilha Grande de Santa Isabel
12
Carajás
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São Luís I / São Luis II
12
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ru
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ara
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R
11
l
Encruzo Novo (12)
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Tailândia
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Ri
to
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sé
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Work on the first line began in 2011 and is nearing completion. Work on
the second, parallel line started in middle of 2012 and should be completed
in 2013. It will take 6,500 workers to finish and will cost approximately $1.8
billion USD (about $3.5 billion Reais).
R
No
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11
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ru
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má
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12
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JARDIM DO OURO (19)
DARDANELOS (10)
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co
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Rio
12
15
BELO MONTE (15)
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par
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11
11
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15
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11
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13
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Universidade (13) M
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S. ANTÔNIO (12)
SAMUEL
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ri
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VELHO
au
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oj
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Cach. do
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CHACORÃO (19)
12
12
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Rurópolis
SÃO LUIS DO TAPAJÓS(16)
JATOBÁ (19)
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RIO
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s
Rio
P
Inauin
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a
-10º
Tapajós
Miramar (12)
Santa Maria/Castanhal
Maria
(10)
BELÉM
Guamá
RÁ
P Ado
Vila
Conde
RIO
Santarém
Itaituba
EQUADOR
ILHA
DE MARAJÓ
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Grande
de Gurupá
12
R Laranjal (12)
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xi
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12
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ru
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ri
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D
SISTEMA ELÉTRICO BRASILEIRO
CONFIGURAÇÃO 2019
Ilha Caviana
AS
ON
AZ
M
A
CACHOEIRA DOS PATOS (19)
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12
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Iranduba(11)
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ac
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AMAZONAS
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12
12
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11
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DIRETORIA DE PLANEJAMENTO E ENGENHARIA
SUPERINTENDÊNCIA DE TRANSMISSÃO
DEPARTAMENTO DE PLANEJAMENTO DE TRANSMISSÃO
Cabo Norte
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Ara
SANTANA
Macapá (12)
JA
12
un
12
Itacoatiara (12)
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Lechuga (12)
MANAUS
R
R
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Oriximiná (12)
am
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12
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12
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When finished, it will be the largest transmission
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The Project will cross five Brazilian states, be supported by 10,000 towers and
have approximately 47,200 miles (76,000 km) of conductor (ACSR 40/25mm).
The two lines will transmit 12.8 GW of power 1,475 miles (2,375 km) from
Port Velho to São Paulo.
-5º
OCEANO
12
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-45º
-50º
ía
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COLÔMBIA
line in Brazil and one of the largest in the world.
-55º
Ba
-70º
5º
A
Being built by a consortium of companies, the Rio Madeira Project consists
of two 600 kV DC transmission lines.
Jaguarão
Lagoa Mirim
Escala 1 : 5.000.000
50
Marmeleiro
Lagoa Mangueira
URUGUAI
-70º
-65º
-60º
0
50
100
150
200
250 km
Projeção Policônica
Meridiano Central: 54 W. Gr.
08/2010
S.Vitória do Palmar
Chuí
Fonte: PDE 2010/2019 - MME
-75º
-55º
-50º
-45º
-40º
Obs: Algumas datas foram atualizadas de acordo
com os Leilões de Transmissão da Aneel
-35º
Three companies are building the lines: Alta Energia (33%), Schahin (34%) and Toshiba (33%).
Support for all Terrains
Terrain and soil conditions vary greatly over the course of the line. As a result,
tower designs vary: About 80% are single pivot, guyed towers, supported by
helical anchors. About 20% are self-supporting (four legged) towers. The type
of tower chosen for each location depended on geography (soil conditions)
and line route (curves).
Some towers are in very remote locations making construction access difficult.
When possible, center pivot, guyed towers were used, which lend themselves to
the use of helical anchors.
There are three manufacturers in Brazil that produce helical anchors, but in lower
quantities than HPS produces Chance® anchors. In February 2011, representatives
of HPS Delmar facility in Brazil met with Alta Energia and Schahin.
Some tower locations were very remote and a challenge to access.
Delmar is an HPS factory and distribution point for such products as arresters, cutouts and substation switches. The plant is located in
Tatui, São Paulo. Delmar has been in business for more than 40 years and was acquired by HPS in 2005.
HPS suggested the tower-foundation contractors consider Chance® helical piles as an option and provided samples for testing along
with quality reports and test results (including torsional loads). The contractors installed the sample helical piles down and performed
compression and tension tests. They also contacted for reference other companies using Chance helical piles.
Between Schahin Engenharia and Alta Energia, both tension (SS200-square shaft) and compression (RS3500 round shaft for self support
tower) were performed in Brazil under the supervision of HPS engineers.
3
Fully satisfied, the contractors placed their first order in August 2011. Of the helical piles used on the first line, 50% are Chance® brand.
The first line of the Rio Madeira project has 4300 towers. Of that, 3440 are guyed towers, with 1800 supported by Chance SS200 helical
piles. Of 860 self-supporting towers, 250 are supported by Chance RS3500 helical piles.
Advantages Add Up
Brazilian utilities and contractors have been using concrete, driven-pile and precast tower foundations for several years. While
technically efficient, these approaches have some disadvantages.
Comparison of Foundation Types
concrete/precast/driven pile
helical pile
• Requires a lot of cement
• Requires no cement
•Requires a lot of water
• Requires no water
•Requires large earth moving equipment
• Requires small tractor or backhoe with drive head
•Requires large workforce
• Requires small workforce
•Significant vibration (Driven Pile)
• No vibration
•Large impact on environment
• Very little impact on environment
•Difficult to install in some weather conditions
• Can be installed in any weather conditions.
Since most of the towers are in remote locations, helical piles worked very well, and can be used in diverse soil conditions. Very sandy
soil at some sites along the route would impede the installation of concrete foundations. Holes dug in sandy soil tends to cave in and
require not only shoring but larger mass. Transportation obstacles to other sites would have impaired delivery of concrete and all its related
equipment. These problems were overcome by helical piles, requiring one relatively small installation machine and fewer workers. This
resulted in significantly lower total labor costs to install helical piles compared to a large concrete foundation for a single tower.
Extension rods allow the drive head to drill the helical piles deeply into the ground, until
the proper torque is reached.
4
www.hubbellpowersystems.com
Helical foundations are easier and faster to install than traditional,
concrete foundations. They also require significantly less material
and far fewer workers.
Testing and Confidence
After installation, the contractors tested the majority of the helical piles. On the four legged towers that rest on helical piles, the
contractors tested one of the five to seven piles for each leg. On the center pivot towers, the contractors tested every guyed foundation.
Testing was necessary for two reasons. First, the Brazilian government required it as part of
the construction contract. Second, this was the first time the contractors had worked with this
type of foundation system and they wanted to confirm the piles would work in the various
soil conditions.
Testing did reveal a few problems that illustrate the importance of having accurate soil
information. At some sites, soil conditions were deceiving. At one such location, a helical pile
had been installed to the correct torque resistance, but testing pulled it out. To remedy that,
the contractor simply installed the helical pile deeper. At another site, subterranean cavities
forced the engineers to abandon a center pivot design and put in a self-supporting tower
due to those soil conditions.
All problems were resolved by correcting testing procedures, changing the tower design or
readjusting drilling depths (torque).
Circuitous Delivery Route
Extensive testing was done on the helical
piles, including tension tests.
HPS manufactures Chance® helical piles in Centralia, Missouri, but the product needed to
go to the wilds of Brazil. This required an interesting materials delivery route.
First packed in crates in Missouri, the helical piles then shipped to a US port and by sea to
Santos, the largest port in Brazil. From there, shipments were delivered by trucks over the
150 miles (240 km) to the HPS Delmar facility. From there, the materials were transported to
staging areas and construction sites across Brazil — including some destinations as far as
1,800 miles (3,000 km).
There were no shipping or delivery problems. Everything arrived on time. Orders were
placed well in advance, so HPS could plan manufacturing and transportation. At first, sources
in Brazil made deliveries sooner than HPS. By the end of the project, Chance® helical piles
were delivered ahead of schedule and faster than those of local competitors.
This high level of service and product performance bodes well for future projects to employ
Chance® helical piles and guy anchors. Their value as a solution for difficult site and soil
conditions was well received.
Contractors also ran compression tests.
The international and interpersonal experience of this iconic undertaking
established strong ties between all parties involved. Those relationships
formed a working foundation certain to continue building in concert with
Brazil’s next power line ventures.
5
®
Square Shaft guy anchors deliver
for heavy loads in tough soils
Load capacities to 200,000 lb.
Torque capacities to 20,000 ft-lb.
Five performance sizes are suited to a wide
range of soil conditions.
Chance® helical guying anchors and
foundation piles work together to provide
adequate lateral support and resistance to
overturning moments.
• Draw on our 100 years of anchoring
leadership in the industry
Guy Adapter
Extension
• Call on us for our expert anchorengineering application support
• Utilize our copyrighted HeliCAP® Helical
Capacity Design Software
Lead Section
• Get our unmatched manufacturing
capacity, capability and in-stock inventory
CHANCE® Square Shaft (SS) Helical Product Ratings
Product Series
Torque Rating
ft-lbs (Nm)
Ultimate Tension Strength*
kip (kN)
Uplift/Compression
Capacity Limit**
kip (kN)
SS5
5,500 (7 500)
70 (312)
55 (245)
SS150
7,000 (9 500)
70 (312)
70 (312)
SS175
10,500 (14 200)
100 (445)
110 (489)
SS200
16,000 (21 700)
150 (668)
150 (668) ***
SS225
23,000 (31 200)
200 (890)
200 (890) ***
* Based on Mechanical Strength of Coupling
** Based on Torque Rating – Uplift/Compression Capacity Limit = Torque Rating x Kt.
“Default” Kt for Type SS = 10 ft-1 (33 m-1)
*** Based on Mechanical Strength of Coupling Bolt
6
Higher Compression Capacities Available with Helical Pulldown® Micropile
®
Instant Foundation® helical piles
go places concrete piers cannot
Soil and load-matched capacities:
Any load. Anywhere.
To match a wide range of site conditions,
Chance® foundations include single-piece and
extendable designs.
Helix plates of mill-specified high-strength
steel distribute the up-lift and compression
forces.
The central shaft transfers horizontal shear,
torsion and bending loads to surrounding
soils.
Properly selected helical-pile foundation
groups can support virtually any
transmission structure loads in any soil
conditions.
CHANCE® Round Shaft (RS) Helical Product Ratings
Product Series
Torque Rating
ft-lbs (Nm)
Ultimate Tension Strength*
kip (kN)
Uplift/Compression
Capacity Limit**
kip (kN)
RS2875.203
5,500 (7 500)
60 (267)
49.5 (220)
RS2875.276
8,000 (10 846)
90 (400)
72 (320)
RS3500.300
13,000 (17 600)
120 (534)
91 (405)
RS4500.337
23,000 (31 200)
140 (623)
138 (614)
RS6625.280
40,000 (54 233)
200 (890)
200 (890)
RS8625.250
60,000 (81 349)
300 (1 334)
300 (1 334)
* Based on Mechanical Strength of Coupling
**Based on Torque Rating – Uplift/Compression Capacity Limit = Torque Rating x Kt
“Default” Kt for Type RS2875 Series = 9 ft-1 (30 m-1); for Type RS3500.300 = 7 ft-1 (23 m-1);
for Type RS4500.337 = 6 ft-1 (20 m-1);
for Type RS6225.280 = 5 ft-1 (13 m-1);
for Type RS8624.250 = 4 ft-1 (13 m-1);
7
About Hubbell Power Systems
Hubbell Power Systems (HPS) manufactures a wide
variety of transmission, distribution, substation, OEM and
telecommunications products used by utilities. HPS products
are also used in the civil construction, transportation, gas
and water industries. Our product line includes construction
and switching products, tools, insulators, arresters, pole line
hardware, cable accessories, test equipment, transformer
bushings and polymer precast enclosures and equipment pads.
Preprinted for a 2013 issue
of Hubbell
TIPS&NEWS
Hubbell has a policy of continuous product
improvement. We reserve the right to change
design and specifications without notice.
©Copyright
2013 Hubbell Incorporated
Printed in U.S.A.
CH06004E
www.hubbellpowersystems.com

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