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374
Fig
gure 1. Enerrgy Gatewa
ay transmisssion expansiion map.
Some of the propossed Energy Gateway
G
trannsmission linnes will be 2230 kV and
345
5 kV. The vast
v majority
y of the totaal project, hoowever, willl be construucted at 500
kV utilizing thiis new steel lattice towerr family. Thhe companys requiremeent for longterm
m reliability
y affirms thee need of a well designned and econnomically vviable tower
fam
mily.
orps most recent
r
constrruction of a 500 kV latttice tower trransmission
PacifiCo
linee was in 199
91. That tow
wer family did
d not meeet the presennt code requuirements or
elecctrical capaccity of the Energy
E
Gateeway prograam. A new
w structure ffamily was,
therrefore, desig
gned to meeet all curren
nt industry aand companny design standards for
mecchanical an
nd electricall loading, as well as environmeental and cconstruction
requ
uirements off this planneed transmissiion developm
ment.
STR
RUCTURE
E REQUIRE
EMENTS
Some off the main 500 kV latticee tower desiign parameteers are listedd below:
Double
D
circu
uit towers to
o be used to m
meet certainn needs
Single
S
circuiit towers to be
b the majorrity of the linne constructiion
Triple-bundl
T
led 1949.6 kcmil
k
42/7 A
ACSR/TWD Athabaska cconductor
Line
L tension
ns approximaately 20,000 pounds per sub-conducctor
Reference
R
grround clearaance of 35 feeet
Regional
R
eleevations reacching 10,0000 feet above sea level
Typical
T
max
ximum towerr height of 2200 feet
Typical
T
rulin
ng span of 1,300 feet
Comply
C
with
h National Electric
E
Safeety Code C2--2007 (NESC
C)
Meet
M Design
n of Latticed
d Steel Transsmission Struuctures (ACSE 10-97)
375
376
1949.6 kcmil ACSR/TW Athabaska as the conductor which met the ampacity
requirements and provided good performance in limiting electrical losses.
Mechanical Loading Criteria
The towers were designed to meet or exceed NESC loading requirements and
ACSE 10-97 design requirements. They were also designed to accommodate the
widely varying climate which exists along this lengthy project.
The towers were originally designed for use on the Mona-Oquirrh project, the
first 500 kV project of Energy Gateway. The Mona-Oquirrh project in central Utah
includes a seventy mile 500 kV section between Tooele and Juab Counties. This 500
kV segment is presently being constructed with the newly designed lattice towers.
For Mona-Oquirrh, a family of five double circuit, and a family of five single circuit
towers was developed (see Table 1).
Table 1: Original Tower Family Designed for the Mona-Oquirrh project.
Single Circuit
Tower Type
Double Circuit
Tower Type
S5A
S5B
S5C
S5D
S5E
D5A
D5B
D5C
D5D
D5E
Tower Description
Typical tangent tower
Tangent or small angle long span tower
0-8 degree running angle tower
0-45 degree dead-end angle tower
45-90 degree dead-end angle tower
377
Weather studies were contracted to establish correct tower wind and ice loads.
Some areas within the vast project limits show higher wind and ice loads than others,
mostly varying directly with elevation. Based on the varying weather-related loads,
the typical tangent S5A tower was supplemented by a companion S5A1 tower to be
used in areas of lower climatic loads. The two typical tangent towers, S5A and S5A1,
allow optimizing design to the projects varying climate. They provide a cost benefit
by using towers with the appropriate capacity at each location. Millions of dollars
will be saved in the total Energy Gateway project by supplementing the tower family
with appropriate additional towers. Even more towers may be developed as
engineering and cost-saving opportunities present themselves.
Transposition Towers Included
Voltage imbalance can occur on transmission lines of significant length. The
imbalance can be rectified by rolling (or transposing) the phases at points along the
line. The transpositions are based on the low-angle dead-end towers and impose a
phasing roll from the back side to the ahead side of the tower. Rigid bus was used to
maintain appropriate electrical clearances with the long jumpers required to move the
phases. (See Table 2 for all added towers).
Table 2. Supplemental towers added to the family
Tower Type
S5A1
S5C1
S5C2
S5DT
Tower Description
Light loaded tangent tower
8-16 degree running angle tower
16-24 degree running angle tower
0-45 degree dead-end phase transposition tower
378
the cost of fulll scale testiing. On larrger projectts, however,, it is muchh more cost
effeective to fullly test a toweer and use its full designn potential.
It was also determ
mined for En
nergy Gatew
way that moost, but not all, towers
wou
uld be load tested. Man
ny similaritiies exist in tthe loads, geeometry, meember types
and
d connection
ns between ceertain towers. These sim
milarities woould give asssurance that
the two towers would behaave in similaar ways evenn if not subjjected to fulll scale load
testting. Throu
ugh testing, significant findings weere made onn tested tow
wers. These
werre applied to
o the similar tower that was
w not testedd.
Tow
wer Test Prrocedure
Beginniing with the D5A tang
gent tower, nine of thhe fifteen toowers were
sub
bjected to fulll scale load
d testing performed by tthe tower deesign firm. Each tested
tow
wer was placced under a minimum
m
off ten separatte load casess at a facilitty dedicated
to this purposse. Due to
o the projeect schedulee and the widely varrying tower
cap
pabilities, fiv
ve different test facilitiees were usedd by the tow
wer design fi
firm. These
faciilities were in
i Belo Horizonte and Sao
S Paulo, B
Brazil; Johannnesburg, Soouth Africa;
and
d Nagpur, In
ndia. PaciffiCorp engin
neers witnesssed each teest along wiith owners
eng
gineers upon request.
Each tesst facility haas common features
f
(seee Figure 2). A test bed w
with an X
shaaped variablee foundation
n allows tow
wers to be anchored too the groundd. A wide
testting tower is
i located att one axis for
f applyingg longitudinnal loads annd at ninety
deg
grees is a more
m
slender testing tow
wer for transsverse loads. A control room and
obsservation areea is located at a safe distance aw
way from tthe actual teesting area.
Fig
gure 2. D5A test in Belo
o Horizonte,, Brazil, and
d S5C2 test in Nagpur, India.
Test loaads were imp
posed by a series
s
of cabbles attachedd to the tow
wer at points
wheere they wou
uld occur un
nder actual service
s
condditions. Wiree tension, w
wind on wire
and
d weight of wire
w were ap
pplied at con
nductor attacchment pointts (see Figurre 3). Wind
on structure waas simulated through cab
bles applied aat various jooints on the ttower body.
w a calibrrated load ceell which in tturn was connnected to a
Eacch load cablee was fitted with
gag
ge in the con
ntrol room displaying the
t load vallue. Each caase imposedd significant
load
ds to differen
nt areas of th
he tower. PL
LS-Tower shhowed the toower area afffected most
und
der each load
d case and peercentage off allowable uuse for each member.
379
The loaads were inccreased on each cable gradually by means off manual or
auto
omatic wincches. Load cases proceeeded by briinging all appplied loadss up to fifty
percent of maximum design
n. This incrrement was ffollowed by 75 percent, 90 percent,
95 percent,
p
and
d finally, 100
0 percent of maximum. Only after eevery gage w
was verified
to meet
m
the req
quired load was that inccrement connsidered com
mplete. Aftter all loads
reacched 100 perrcent of desiign load, a five
fi minute w
waiting periood began. Iff no damage
occcurred to the tower durin
ng the test orr during waiiting periodss, that loadinng case was
decclared compllete.
Depend
ding on the complexity
c
of
o a given looad case, thee weather annd the speed
of the
t testing faacility, betw
ween one and
d six load caases were perrformed eacch day. The
tow
wer design an
nd test firm suggested
s
th
hat witnessess allow time in their travvel plans for
delaays that can occur. Som
me are planneed, like channges in riggiing between some tests,
and
d some are no
ot planned, such
s
as locallized membeer failure or inclement w
weather.
Fig
gure 3. D5E NESC Heavy test, and
d top section
n failure, Johannesburgg, SA.
The purrpose of perrforming thee tower testt is to provee every tow
wer member
cap
pable of with
hstanding alll design load
d cases. Sevveral towers sailed throuugh the fullscale tests with
hout any issu
ues at all. Some experieenced localizzed failures on arms, at
con
nnection poin
nts or in stru
ucture lacing members (ssee Figure 4)).
Fig
gure 4. Toweer D5A loca
al arm failurre and comp
plete failuree under 1100% load.
380
381
Any local failures brought about immediate redesign of that tower section.
Although retesting of failed parts resumed as quickly as possible, time was required
for forensic analysis of the failure, redesign, disassembly of affected members,
fabrication of replacement parts, safe installation of new members and retesting of the
modified design. Delays of several days, and sometimes weeks, occurred depending
on the severity of a failure. Complete testing results are shown in table 3.
Destructive Testing
It is desirable to know the load case that may bring the tower closest to its
design potential. One load case was selected for each tower, representing the most
severe loads to significant tower members. This case was performed last with loads
reaching 110 percent of maximum design. This limit was selected because of test bed
limits and to avoid significant damage to the test facility.
Since this load case exceeded the tower design limit, failures were expected.
Some towers did fail as loads exceeded design limits. Optimal results of destructive
testing would be seen when all towers reach at least 100 percent of design loading
(which they did), but with just some exceeding the destructive test level. This would
prove the adequacy of all towers while showing they are not over-designed.
Table 3. Tower testing locations and results
Tower Testing
Type
Location
Testing Issues
Destructive Test
Result
Final
Result
D5A
Belo Horizonte,
Brazil
Complete failure at
110% of Ultimate
Passed
D5C
Sao Paulo,
Brazil
Passed
D5E
Johannesburg,
South Africa
Passed
S5A
Belo Horizonte,
Brazil
Passed
S5C
Sao Paulo,
Brazil
Passed
S5D
Belo Horizonte,
Brazil
Passed
S5A1
Belo Horizonte,
Brazil
Local failure at
110% of ultimate
Passed
S5C1
Belo Horizonte,
Brazil
Arm failure,
successfully retested
Complete failure at
110% of ultimate
Passed
S5C2
Nagpur, India
While some
s
towerss experienceed minor faailures durinng normal teest loading,
they
y were satisfactorily reteested after lo
ocalized reddesign. All rretested tow
wers reached
at least 100 perrcent of max
ximum load. Some toweers failed duuring the desttructive test
phaase and some did not. The
T design of
o the 500 kkV towers fo
for PacifiCorrps Energy
Gatteway program has been
n considered
d fully succeessful basedd on the resuults of these
tow
wer tests.
Full scaale load tessts provide significant benefit to a transmissiion project.
Eng
gineers can be
b assured th
hat the toweers they incllude in the liine design w
will perform
as intended,
i
meeting the full
fu design lo
oads. They also know that all connnections fit
together and wo
ork in a com
mpatible man
nner with all hardware.
TO
OWER PRO
OTOTYPE TESTS
T
Some to
owers within
n this family
y were not subjected too load tests. Similarity
betw
ween certain
n towers jusstified this as
a a prudent decision. T
These towerrs, although
not load tested,, were fit-tessted or proto
otype tested.. Followingg design, alll symmetric
porrtions of thee tower werre fabricated
d and assem
mbled on thee ground too verify the
proper fit of meembers and connectionss. All leg annd body exteensions weree assembled
ng with all basic
b
tower sections. The high loadds on dead-eend towers rrequired the
alon
maiin leg memb
bers to be deesigned using four anglees per leg in a cruciform
m shape. Fit
verification is a must for th
hese and otheer complicatted tower secctions. Thesse prototype
testts were perfformed both by the tow
wer designer in Monterrey, Mexico and by the
tow
wer supplier for
f the Monaa-Oquirrh prroject in Ankkara, Turkeyy (see Figuree 5).
Fig
gure 5. Com
mplex parts seen
s
during fit test, Moonterrey, Mexico.
382
383
Fig
gure 7. S5B interaction diagram. Several
S
load
d cases defin
ne useable eenvelope.
Addition
nal iteration
ns were perfformed to pprovide a neew curve foor each line
ang
gle incremen
nt. These currves allow optimizing
o
thhe spotting of towers ass a function
of the
t wind an
nd weight sp
pans. Perfo
orming this iterative toower analysiis was time
con
nsuming but the benefit in using tow
wers to theiir potential ssaved time aand money.
Thee points alon
ng the calcullated utilization curve caan be enteredd into PLS-C
CADD for a
quick line optim
mization. Due
D to the co
omplexity off lattice toweer analysis, without the
tow
wer utilization curve dataa line optimizzation wouldd be a nearlyy never-endiing task.
Creatin
ng interactio
on diagrams for Energyy Gateway towers show
wed longer
win
nd and weigh
ht spans cou
uld be achiev
ved than preeviously undderstood. Thhis is based
on looking at all
a load casees combined
d in a singlee chart. A sstudy complleted by the
Gatteway Westt owners engineer
e
sho
owed a signnificant prooject savings by using
inteeraction diag
grams to re-o
optimize som
me already sppotted line ssegments.
PR
ROJECT CO
ONSTRUCT
TION
The firsst of PacifiCo
orps Energy
y Gateway trransmission projects to uuse the new
fam
mily of 500
0 kV towerrs is the Mona-Oquir
M
rrh project. Tower ssupply was
com
mpetitively bid
b by PaciffiCorps EPC
C contractorr. The firstt tower shipm
ments were
receeived in the early fall off 2011 with erection begginning soonn after receippt. By June
201
12, more th
han 150 tow
wers had beeen erected (see figuree 8) with m
many more
fou
undations com
mpleted and
d ready for tower
t
erecti on to follow
w. Tower erection was
effiicient with very little complaint from
f
crews about fit oor assemblyy problems.
Acccess roads and
a construcction pads were
w
establishhed prior too installing ffoundations.
A mild
m winter also
a allowed
d the construcction to conttinue withouut major inteerruptions.
Foundattion installaation was sccheduled to begin earlyy enough annd maintain
such a pace thaat crews ereecting towerss would nott catch up too the foundaation crews.
Thee schedule was well maintained for both ffoundations and towerr erections.
Fou
undation creews kept weell ahead of tower settinng crews, aggain helped out by the
mild winter. Foundation
F
setting
s
jigs made
m
the oriientation andd setting of stub angles
progress quicklly and accurrately. Strin
nging of connductors andd shield wires began in
the spring of 20
012.
Fig
nty, Utah.
gure 8. Foun
ndation installation and
d completed
d towers in T
Tooele Coun
384
SUMMARY
The development of a family of steel lattice towers has been a challenging and
rewarding process. Our eyes were opened to the iterative and global facets of tower
type selection, design, inclusion of additional towers, testing, specifying, shipping and
construction of these towers. The experience has been good.
The tower family began with just those towers needed for the first project
which is small in comparison to the overall Energy Gateway project. Other specific
towers were added as the scale of the total project was considered. These towers will
enhance project engineering and economic optimization.
Full scale load and prototype testing of towers have benefitted planning and
construction. Interaction diagrams have further allowed optimization of tower use.
Seeing new towers under construction dotting the landscape signifies progress.
PacifiCorps Energy Gateway project is a very significant undertaking and
will greatly increase the capacity and reliability of this transmission system. Many
hands are working in many areas to move this project forward. This large scale
project is definitely a team effort. The development of this family of lattice towers is
playing an important part in the overall project, but it is just one of countless efforts
required to bring success to this venture.
It brings satisfaction to see two Energy Gateway line segments completed,
another under construction and others moving forward in planning, permitting, design
and procurement. Much has been accomplished so far, yet even more lies ahead for
the Energy Gateway project. We have seen the beginning, and having seen that, we
enthusiastically approach upcoming aspects of something big and something very
beneficial.
385