Mumbai’s Power Lifeline Gets An Upgrade With APAR’s HTLS Conductors
Current Affairs: APAR’s High-Voltage Success Stories - Case Study #2
APAR is at the forefront of powering India’s energy infrastructure. As the world’s largest global aluminium and alloy conductor manufacturer, APAR has integrated to turnkey solutions —bringing not just products, but complete, high-performance energy systems to the heart of the nation’s power grid.
Connecting diverse and challenging terrains across India, we have successfully supplied over 63,000 KM of in High-Temperature Low Sag (HTLS) conductors.Our expertise in HTLS conductor technology enables us to deliver innovative solutions for enhancing power transmission infrastructure. With this vast deployment, APAR has ~50% market share in re-conducting projects across India. A recent project that exemplifies our focus on setting new benchmarks is the 400kV Kalwa-Padgha line upgrade, a critical artery in Mumbai’s power network, executed in collaboration with Maharashtra State Electricity Transmission Company Limited (MSETCL).
Meeting Mumbai’s Growing Energy Demands
The 400kV Kalwa Padgha line serves as the lifeline for Mumbai and its suburban region, playing a vital role in delivering 4100 MW of power to the system. Recognising the need to enhance the line’s capacity and reliability, MSETCL partnered with APAR to upgrade circuits 1 & 2 using High-Performance ACCC conductors. This upgrade significantly enhances the line capacity from 2000 MW to 4200 MW, reducing congestion and over-dependence in the Mumbai Metropolitan Region (MMR). The result: enhanced power flow, greater transmission efficiency, and a more resilient grid for one of India’s most energy-intensive cities.
APAR’s contributions to historic development
Navigating Challenges – Technology to the rescue
The Kalwa Padgha project presented several challenges, including hilly terrain in Mumbra Hills, congested locations, and severe Right-of-Way (ROW) issues in Padgha, Ambernath, Silphata, Mumbra, and Airoli. The route also involved numerous road crossings, line crossings, and railway and river crossings, as well as crossings over the Samruddhi Highway and the National High-Speed Rail Corridor (NHRCL). To overcome these obstacles, APAR implemented innovative technology-driven solutions such as:
- LDRS Drone Survey:APAR leveraged LDRS drone survey technology for precise route planning and obstacle identification, ensuring efficient project execution and minimising environmental impact.
- ACCC Conductors via CTC-Global Partnership:The project benefited from APAR’s technology tie-up with CTC-Global, USA, utilizing advanced ACCC (Aluminium Conductor Composite Core) conductors, which enhance power transmission efficiency and capacity.
- Live-Line Network Diversions: Utilizing Emergency Restoration System (ERS) towers and live-line stringing techniques to minimize disruption during the upgrade process. The ERS was introduced three times to achieve desired outages in patches.
- Specialised Tower Designs: Incorporating two new towers and height rising of two existing towers to address specific ROW challenges and ensure optimal conductor clearance. The Airoli-Khatai Naka highway bridge crossing section also saw the installation of two new monopoles.
- Community Engagement: Tackling ROW issues through combined efforts to address community concerns in areas like Ghotsai Gaon, Taluka Kalyan.
A Testament to Collaboration and Expertise
“The 400kV Kalwa Padgha project was a critical undertaking for the reliable power supply of Mumbai and the MMR. The project’s success hinges on the innovative solutions implemented by the APAR team. Securing ROW in densely populated areas presented significant challenges, and the team demonstrated exceptional skill in navigating these complexities. The successful execution of multiple live-line network diversions using ERS techniques was a remarkable achievement, minimising disruption to power supply for millions of consumers. This project is a testament to the collaborative spirit between APAR and MSETCL. We commend the team’s dedication, expertise, and commitment to delivering a project that strengthens Mumbai’s power infrastructure while minimising impact on the city’s residents.”
By Mr. Vijay Aware, Superintending Engineer at MSETCL
Driven by technical expertise, innovative problem-solving, and strong partnerships, APAR delivers secure and reliable power solutions. The Kalwa Padgha upgrade exemplifies this dedication, showcasing how we enhance power infrastructure and contribute to a sustainable future for the communities we serve.
Current Affairs: APAR’s High-Voltage Success Stories
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