Development of Low Wind-Pressure Insulated Wiresby Toshio Matsumura *, Toshiki Yura *, Naoshi Kikuchi *2, Tetsuo Matsumoto *3,
Hitoshi Takeuchi *4, Kunio Iwasaki *5 and Yasuhiro Tominaga *5

Low wind-pressure insulated wires with a furrowed surface have been developed
as a means to reduce the design load for electric poles and to suppress thereconstruction costs of electric poles at the time of restringing. It was demonstrated that the low
wind-pressure wires not only enabled to reduce the wind load by more than 15 % compared toordinary wires, but also were provided with excellent resistance against snow accretion.
Moreover, in terms of basic performance such as electric characteristics, ease of stringing andadaptability for accessories, these wires were confirmed to be equivalent to ordinary wires.

ABSTRACT1.

INTRODUCTION

The design load for electric poles of power lines tends toincrease due to the expanding electric power demands,causing the increase of facility costs. Because the design
load greatly depends on the wind load on the strung wires,
reduction of the wind load on the wires is expected todecrease the design load, thereby enabling to suppress
the facility costs.
Until now, the study on wind pressure reduction has
been focused on overhead transmission lines, in which
several effective wire shapes have been found 1)~3). Thus
wire shapes that are effective in reducing wind load havebeen investigated for wires 27 to 38 mm in diameter, while
the study on overhead distribution lines using smaller
wires 10 to 25 mm in diameter is still insufficient.
In this paper, wire shapes that are effective in reducing
wind load have been studied with emphasis on insulated
wires for overhead distribution lines using smaller wires,
thereby achieving the development of practical insulated
wires with low wind loads. Their characteristics will bereported in this paper.

2.

INVESTIGATION ON WIRE CROSS SECTIONS

2.1 Mechanism of Wind Load Reduction
Mechanism of wind load reduction manifested by golf ballswith a dimpled surface is well known, so that the samemechanism is applied to the wires to be developed at thistime. Figure 1 shows the mechanism of wind load reduction on the wires. When the surface is furrowed, vortex isgenerated in the interior of the furrows. This reduces theshearing stress on the bottom of the boundary layer of airflow, mitigating the wind speed reduction at the boundary,and thus displacing the separation point to the leeward.
This displacement decreases the number of vortex generated leeward reducing the pressure difference between
the windward and the leeward of the wire, and eventually
the wind load.
2.2 Wind Tunnel Experiment on Wire Models
2.2.1 Wire Models
In terms of overhead transmission lines, a wire shape withplural twisted grooves that are provided longitudinally on
the wire surface is reported to be effective in reducing thewind load 1). This shape, however, is insufficient for wires
with smaller diameters to achieve ample reduction of windload with a design wind speed of 40 m/sec. Moreover, aspecial facility would be needed to form twisted grooves at
extruding the insulated wires. Taking easy implementationof extrusion into consideration, various shapes of insulated wires for overhead distribution lines (e.g., 6-kV OC-I 80

Separation point

Air flow

Separation point*

Technical Research Center, The Kansai Electric Power Co.,Inc.
*2 Engineering Dept., Power Transmission Engineering Div.
*3 Ecology and Energy Laboratory*4 Optical Components Dept., FITEL Products Div.
*5 Engineering Dept., Power Cables Div.

Air flow

Figure 1

Mechanism of wind load reduction.

38

2.2.2 Method of Wind-Tunnel Test
Figure 3 shows the test equipment configuration. In thewind tunnel tests, a closed fuselage for measurement was
installed at the air outlet, and a detector head for 3-component force measurement was used. Measured results
were converted, according to the Reynold's number equation, to the wind speed for a wire diameter of 15.6 mm corresponding to 6-kV OC-I 80 mm2, assuming an atmospheric condition of either 15°C, 1013 hPa or a typhoon in
high-temperature seasons.

16-ridge model

24-ridge model

2.2.3 Results of Wind-Tunnel Test on Wire Modelsa) Effects of the number of ridge
Figure 4 shows the relationship between drag coefficientand wind speed for each wire model. The drag coefficientof every model is seen to have reduced compared to theordinary wire at wind speeds of around 40 m/sec,
decreasing in the order of 16-, 24- and 30-ridge.
The degree of the drag coefficient reduction is about 40% for the 30-ridge model, a sufficient effect of reduction. A
tendency can be seen that, as the number of ridge
increases, both the wind speed at which the drag coefficient begins to drop and the wind speed at which the coefficient shows a minimum shift to the region of lower windspeed, and moreover, the minimum value of the dragcoefficient decreases. From these results and in view ofapplication to the wires of around 15 mm in diameter, it isConverted to outer diameter d=15.6 mm

1.5Ordinary wire (circular cylinder)
16-ridge model
24-ridge model
30-ridge model

1.4

Drag coefficient (Cd)mm2, 15.6 mm in diameter) with a plurality of parallel furrows and ridges that are provided longitudinally on thewire surface were investigated in this study. We began bywind tunnel tests using wire models prepared by shaping
an aluminum block in order to confirm the wire shapesthat were effective in reducing wind loads.
Figure 2 shows cross sections of wire models used in
the tests. The number of ridge was changed to study its
effect on drag coefficients and, with 24-ridge and 30-ridge
models, the height of the ridge was also changed to see
the effects.

30-ridge model

1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0

33 mm

Figure 2

23 mm

10.0

20.0

30.0

40.0

50.0

60.0

Wind speed (m/sec)

23 mm

Cross sections of wire models for wind tunnel test.

Figure 4

Relationship between drag coefficient and windspeed for wire models.

Detector head for 3-component force

Wind tunnel air outlet,
1 m by 1 m in size

940 mmClosed fuselage
for measurement

Stabilizing fuselage
Adding andcalibrating circuits

Goettingen type manometer

CL direction

Schematic of 3-component
force measurement

Wire sample

Cy direction(Wire axis direction)

Air flow

Cd direction

DC amplifier

A/D board
Detector head for 3-component force

Figure 3

39

PC

Equipment for wind tunnel test.

Furukawa Review, No. 21

2002Converted to outer diameter d=15.6 mm

1.4
1.3

Ridge height: high;Furrow's root radius R: small

1.2

20.0

Wind load (N/m)

Drag coefficient (Cd)25.0

24-ridge model

Ridge height: medium;
Furrow's root radius R: medium

1.1

Ridge height: low;
Furrow's root radius R: large

1.0
0.9
0.8

Assuming typhoon in high-temperature seasons
Ordinary wire(circular cylinder)
16-ridge model
24-ridge model
30-ridge model

100%
68%

15.0

79%

10.0
65%
5.0

0.7
0
20.0

0.6
0

10.0

20.0

30.0

40.0

50.0

Effects of ridge height and furrow's root radius for
24-ridge model.

50.0

Figure 7

Calculated wind load on wire models, converted toOC-I 80 mm2.

Converted to outer diameter d=15.6 mm

1.430-ridge model

1.3

Drag coefficient (Cd)40.0Wind speed (m/sec)

Wind speed (m/sec)

Figure 530.0

Ridge height: high;Furrow's root radius R: small

1.2

Ridge height: medium;
Furrow's root radius R: medium

1.1

Ridge height: low;
Furrow's root radius R: large

1.0
0.9
0.8

Photo 1

0.7

Low wind-pressure insulated wire, 6-kV OC 150 mm2.

0.6
0

10.0

20.0

30.0

40.0

50.0

Wind speed (m/sec)

Figure 6

Effects of ridge height and furrow's root radius for
30-ridge model.

considered that the 30-ridge model represents the mostsuitable shape, which provides smaller drag coefficients at
a wide range of wind speeds involving 40 m/s.
b) Effects of ridge height
Figures 5 and 6 show the relationships between dragcoefficient and wind speed when the height of ridge andthe furrow's root radius R are changed for 24-ridge modeland 30-ridge model, respectively. The 24-ridge modelshows small differences in the drag coefficient when theridge height is medium or high, but when the ridge height
is low, the wind speed at which the drag coefficient begins
to decrease is seen to shift to the high wind speed range.
The 30-ridge model has been confirmed to show a relatively weak influence of ridge height on the drag coefficient. Thus, it is anticipated that the 30-ridge model
achieves a stabilized effect of wind load reduction, whensuch practical issues as dimensional changes during insulation extrusion together with wire geometry changes due
to dust accretion after stringing are taken into account.
c) Wind load reduction ratio on practical wires
In order to provide surface furrows on the insulation layer
while ensuring an insulation thickness equivalent to ordinary wires, the outer diameter of the wire has to be larger
than that of an ordinary wire. The wind load of each wiremodel has been calculated allowing for this diameterincrease, in which it was assumed that the wire size to be
OC-I 80 mm2 and atmospheric conditions to be 23°C 960

hPa, a typhoon in high-temperature seasons. The results
are shown in Figure 7. It has been confirmed that a sufficient wind load reduction can be expected regardless ofincreased diameter and that the 30-ridge model is mostefficient in wind load reduction.

3.

CHARACTERIZATION OF PROTOTYPE
WIRES

3.1 Prototype Wires
It was demonstrated in the experiments based on aluminum models that the 30-ridge model achieved efficient
wind load reduction, so that prototype wires of different
sizes were fabricated using actual manufacturing facilities.
Photo 1 shows a low wind-pressure insulated wire, 6-kV
OC 150 mm 2 , thus fabricated. Using these prototype
wires, wind load measurements at wind tunnel tests andthat during rainfall were carried out, and their resistanceagainst snow accretion was also evaluated.
3.2 Wind Tunnel Test
The equipment shown in Figure 3 were used in the windtunnel tests of prototype wires. Rigidity of test samples
was secured by a sample preparation process in which
the insulation layer of a prototype wire was removed andsubsequently reinstalled on a stainless steel shaft to makea sample.
Figures 8 and 9 show the wind speed vs. wind load relationship of 600-V OW-I 38 mm2 and 22-kV OC-W 150
mm2, respectively.
For all the cable sizes, the prototype of low wind-pres-40

At 40 m/sec, during rainfall
1.0

Ordinary wire (circular cylinder)
Model of low wind-pressure wirePrototype of low wind-pressure wire

Drag coefficient (Cd)Wind load per unit length (N/m)

Assuming typhoon in high-temperature seasons

20.0

100%

10.0
73%
67%

0.8

0.6
600 V OW-38 mm2

0
10.0

20.0

30.0

40.0

50.0

0

Figure 8

Relationship between wind load and wind speed on
600-V OW-I 38 mm2 samples.

20.0

At 40 m/sec, during rainfall
1.0

Drag coefficient (Cd)Wind load per unit length (N/m)

15.0

22 kV OC-150 mm2

100%
72%

20.0

10.0

Figure 10 Relationship between precipitation and drag coefficient for 600-V OW-I 38 mm2.

Assuming typhoon in high-temperature seasons
Ordinary wire (circular cylinder)
Model of low wind-pressure wirePrototype of low wind-pressure wire

30.0

5.0

Precipitation (mm/10 min)Wind speed (m/sec)

70%
10.0

0.8

0.6

0
10.0

20.0

30.0

40.0

50.0

Wind speed (m/sec)

Figure 9

Relationship between wind load and wind speed on
22-kV OC-W 150 mm2 samples.

sure wire shows a similar wind load changes as for thealuminum model, demonstrating that the surface conditionand dimensional accuracy of wires actually fabricatedwere satisfactory in achieving an effect of wind load
reduction that is equivalent to the shaped aluminum models. Thus the 30-ridge shape was validated to be sufficiently applicable to practical insulated wires.
Other wires of different sizes were also proved to provide the same level of wind load reduction as for the aluminum models.
3.3 Drag Coefficient Measurements during Rainfall
To clarify the effect of rainfall on the low wind-pressure
wires, their drag coefficients were measured in whichwater drop spray was used to simulate rainfall. In theexperiment, a pipe for water drop formation was installedon the windward of the measurement fuselage of windtunnel test equipment shown in Figure 3, and drag coefficients at a wind speed of 40 m/sec were measured whilea specified amount of water drop was sprayed simulating
rainfall. Figures 10 and 11 show the precipitation vs. dragcoefficient relationships of 600-V OW-I 38 mm2 and 22-kV
OC-W 150 mm2, respectively.
The drag coefficient for either wire is seen to increase
considerably at a light precipitation rate of about 1
mm/10min, and gradually increases as precipitation
increases. The drag coefficient increase due to rainfall is

41

0

5.0

10.0

15.0

20.0

Precipitation (mm/10 min)Figure 11 Relationship between precipitation and drag coefficient for 22-kV OC-W 150 mm2.

larger for 600-V OW-I 38 mm2 with a smaller outer diameter. The increase in drag coefficient due to rainfall may be
attributable to a phenomenon such that raindrops adhere
to the wire surface resulting in apparent changes in surface configurations, thereby suppressing the effect of windload reduction.
In view of the 10-min precipitation data gathered at
AMEDAS observation locations during 1994 to 1999, a
precipitation rate of 15 mm/10min at a wind speed of 40
m/sec is sufficiently high, so that an evaluation test using
a precipitation rate of 20 mm/10min would result in a suitable tolerance even when assuming typical typhoons.
Table 1 shows comparisons of wind loads at a windspeed of 40 m/sec with and without rainfall. It is seen thatthe prototype wires present, compared to ordinary wires, awind load reduction of about 15 % at a precipitation rate of
20 mm/10min, while they present a wind load reduction of
about 30 % under the condition of no precipitation.
3.4 Snow Accretion Resistance Test
Figure 12 shows equipment configuration for snow accretion resistance test. With this equipment, while a fan
sends wind against wire samples, spray damping is used
to moisten the snow that passes through a sieve thereby
accelerating snow accretion. A video camera was used tomonitor snow accretion, and the frequency with which thesnow that had accreted on the sample fell down was

Furukawa Review, No. 21

2002

Table 1

Wind loads on prototype wires at a wind speed of 40
m/sec, represented in percentage over ordinary
wires.

Snow

Vibrator

Video camera

Sieve
Voltage Wire type Wire size

Wind load underWind load under precipitationno precipitation (%)

of 20 mm/10 min (%)

67

85

62

76

600 V

OW-I

38 mm2

600 V

OW-I

60 mm2

600 V

OW-I

100 mm2

65

79

6 kV

OC

5 mm

Unmeasurable

Unmeasurable

6 kV

OC-I

80 mm2

65

77

6 kV

OC-W

150 mm2

62

73

22 kV

OC-W

150 mm2

70

79

Fan

Spray machine

Figure 12 Equipment for snow accretion resistance test.

Table 2

employed as a measure of snow accretion resistance.
Table 2 shows the results of evaluation of snow accretion resistance including those of a snow accretion resistant wire with fins. Snow accretion resistance was evaluated based on the fall times of accreted snow that took
place during 10 minutes of snowfall and averaged overfour experiments.
Whereas snow accreted on the surface of ordinary wiregrew into a pipe-shaped snow, snow on both the low
wind-pressure insulated wires and the snow accretion
resistant wire with fins fell down immediately without growing. The low wind-pressure insulated wires are seen tohave more fall times of snow compared to the snow accretion resistant wire with fins. Thus, the former wire compares favorably with the latter wire in terms of snow accretion resistance, and this result may be attributable to amechanism such that the furrowed wire surface effectively
suppresses the growth resulting from the rotation ofaccreted snow.
Furthermore, prototype wires were strung in an actual
test field with a line span of 45 m to evaluate its snow
accretion, in which it was confirmed that the low windpressure wires are superior to ordinary wires in snow
accretion resistance.
Evaluation of Basic Characteristics as Electrical
Wire
Various basic characteristics of prototype wires were evaluated in order to confirm that the change of the wire surface configuration did not have adverse influences on thebasic characteristics of original electrical wires.

Wires

Test results of snow accretion resistance of various
wires.

Low wind-pressure
insulated wire
Snow accretion resistantwire with fins
Ordinary wire

Fall times of accreted

Voltage Wire type

Size

6 kV

OC

5 mm

2.5 times

6 kV

OC-I

80 mm2

1.5 times

6 kV

OC-W

150 mm2

2.0 times

6 kV

OC

60 mm2

0.8 times

6 kV

OC

5 mm

No fall*snow in 10 min* Accreted snow on the ordinary wire did not fall but grew into a pipe
-shaped snow.

including stripping jig, which was then followed by actual
overhead stringing. As a result, it was confirmed that thewires were as easy to handle as ordinary wires.
3.5.3 Evaluation of Adaptability to Accessories
22-kV OC 150 mm2, 6-kV OC 80 mm2 and 5 mmφ prototype wires were evaluated for their adaptability to overhead stringing accessories such as hot-melt joint coverand shrinking joint cover, whereby almost all of theseaccessories as they are now proved to be adaptable for
use.

3.5

3.5.1 Evaluation of Electrical Characteristics
Electrical characteristics of all prototype wires were evaluated with respect to insulation resistance, AC withstandvoltage, AC breakdown voltage and tracking resistance(for OC only), and it was confirmed that the wires were
provided with electrical characteristics equivalent to thoseof ordinary wires.
3.5.2 Evaluation of Ease of Stringing
In order to evaluate the ease of stringing of prototype
wires, 6-kV OC 150 mm2 and 6-kV OC 80 mm2 were evaluated for their adaptability to fittings and stringing tools

4.

VERIFICATION FIELD TEST

A verification field test was carried out at Cape
Shionomisaki in Wakayama Prefecture, using 6-kV OC
150 mm2 and 6-kV OC 80 mm2 prototype wires and ordinary wires.
Photo 2 shows the verification field test.
During the period from December 2000 to January
2001, winds perpendicular to the wires with a velocity of
about 25 m/sec were observed. Figure 13 shows the relationships between wind speed and maximum tension of
the 6-kV OC 150 mm2 prototype wire and the ordinary
wire, which were observed at a time instant close to the
maximum wind speed. Effects of tension reduction due tothe low wind-pressure shape can be identified to start at awind speed of 18 to 20 m/sec and above, whereby areduction of about 5 % in maximum tension has been

42

Low wind-pressure insulated wire,
6-kV OC 80 mm2

Load cell

Ordinary insulated wire,
6-kV OC 150 mm2

Ordinary insulated wire,
6-kV OC 80 mm2

Low wind-pressure insulated wire,
6-kV OC 150 mm2

Wind-direction andwind-velocity meter

Ambient temperature meter
Rain gage
Barometer

Photo 2

Verification field test at Cape Shionomisaki.

Maximum tension (kgf)215
Ordinary 150 mm2

210

Developed 150 mm2

to be equivalent to ordinary wires in terms of basic performance such as electric characteristics, ease of stringing
and adaptability to accessories.

REFERENCES
1) Ishikubo et al.: Study on wind load reduction of overhead transmission wires, Proc. IEEJ Energy Dept., p.580 (1995) (inJapanese)2) Ishikubo et al.: Study on wind load reduction of overhead transmission wires: Part 3, Proc. IEEJ Energy Dept., p.753 (1996) (inJapanese)3) Ishikubo et al.: Study on wind load reduction of overhead transmission wires: Part 3, Proc. IEEJ Electric Power and Energy
Dept., p.776 (1997) (in Japanese)
4) Tsutahara et al.: Flow around a circular cylinder with arc grooves
on its surface, Visualization Information, Vol.10, No.1, p.73 (1990)(in Japanese)
5) Eguchi et al.: Clarification on the mechanisms of wind load reduction on wires using fluidic experimentation, CRIEPI Report,
U96050 (1997) (in Japanese)
6) IEEJ Survey Committee for Electric Standards, Design Standards
for Structures for Electric Power Transmission, JEC-127-1979 (inJapanese)

Manuscript received on November 5, 2001.

205
200
195
190
185
5

10

15

20

25

Wind speed (m/sec)

Figure 13 Relationships between wind speed and maximum
tension of the developed and ordinary wires.

achieved.
Thus, the effectiveness of the prototype wires in windload reduction has been demonstrated by the field test,
while the wind speed range where the reduction effectappears approximately coincides with that encountered in
the wind tunnel test.

5.

SUMMARY

Various wire models with different surface furrows andridges have been evaluated for their aerodynamic characteristics, and a superior wire shape applicable to insulated
wires for overhead distribution lines has been found,which enables to efficiently reduce wind loads. Prototypesof these low wind-pressure insulated wires have been fabricated using actual manufacturing facilities, and havebeen subjected to evaluation experiments on their aerodynamic and snow accretion resistance characteristics. As aresult, it was demonstrated that the wires not only reduced
the wind load by more than 15 % compared to ordinary
wires, but also provided excellent resistance against snow
accretion. Selected wires of certain sizes were confirmed

43

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2002