Periodic Reporting for period 2 - ECP (European Composite Power Pylon)
Reporting period: 2020-11-01 to 2022-10-31
The EU electricity grid is undergoing major expansions to accommodate the switch to renewable sources and more decentralized energy production.
Therefore the main drivers for the ECP project and for the Composite Pylon demand are (problem):
1. the need for expansion of the electricity transmission networks throughout EU
2. the landscape impact and public opposition to the traditional lattice towers.
The overall environmental impact of composite materials is smaller than the steel galvanized lattice structures. As fibre reinforced polymer is environmentally inert, it could even be in environmentally sensitive areas. As a result, new OHTL construction projects, previously subject to strong community opposition, can now be realized, enabling a wide and faster implementation of projects expanding the distribution of alternative/renewable energy sources. Therefore, the adoption of the Composite Pylon will have direct and indirect societal and environmental impacts.
What is the overall objectives:
The objective of the ECP project is to bridge the current gaps in the innovation process for a compact, cost-effective, aesthetically pleasant electrical transmission system – the Composite Pylon – for the OHTLs market.
This objective is driven by the expectation of achieving a successful commercial launch by 2022.
Although the Composite Pylon design is already developed and protected by BYS, the full potential and the expected high impact in the OHTL sector will only be achieved by completing the maturation and demonstrating its technical performance, cost-effectiveness and visual appearance. Several market entrance barriers need to be overcome to release Composite Pylon’s full potential and at the same time, secure business growth and scale-up.
These include:
(1) achieve final product specifications and certification and optimize the manufacturing process;
(2) document technical performance and economic benefits to overcome intrinsic market skepticism to new products;
(3) raise awareness and acceptance of Composite Pylon’s benefits to mobilise all stakeholders, including TSOs, general public, environmental and land owners’ associations, policy and opinion makers.
Therefore the main drivers for the ECP project and for the Composite Pylon demand are (problem):
1. the need for expansion of the electricity transmission networks throughout EU
2. the landscape impact and public opposition to the traditional lattice towers.
The overall environmental impact of composite materials is smaller than the steel galvanized lattice structures. As fibre reinforced polymer is environmentally inert, it could even be in environmentally sensitive areas. As a result, new OHTL construction projects, previously subject to strong community opposition, can now be realized, enabling a wide and faster implementation of projects expanding the distribution of alternative/renewable energy sources. Therefore, the adoption of the Composite Pylon will have direct and indirect societal and environmental impacts.
What is the overall objectives:
The objective of the ECP project is to bridge the current gaps in the innovation process for a compact, cost-effective, aesthetically pleasant electrical transmission system – the Composite Pylon – for the OHTLs market.
This objective is driven by the expectation of achieving a successful commercial launch by 2022.
Although the Composite Pylon design is already developed and protected by BYS, the full potential and the expected high impact in the OHTL sector will only be achieved by completing the maturation and demonstrating its technical performance, cost-effectiveness and visual appearance. Several market entrance barriers need to be overcome to release Composite Pylon’s full potential and at the same time, secure business growth and scale-up.
These include:
(1) achieve final product specifications and certification and optimize the manufacturing process;
(2) document technical performance and economic benefits to overcome intrinsic market skepticism to new products;
(3) raise awareness and acceptance of Composite Pylon’s benefits to mobilise all stakeholders, including TSOs, general public, environmental and land owners’ associations, policy and opinion makers.
The work plan for ECP is organized into a total of 7 Work Packages (WP) , which have been planned to fulfil the objectives and to ensure an effective demonstration of the Composite Pylon concept.
The work plan has been carefully designed to minimize risks of introduction of the novel pylon into the market and to enable a cost-efficient development route.
WP1 Project management [Months: 1-36]
The project has formally started on 01.11.2019 when the Grant and the Consortium Agreement was signed by all partners. BYS have been coordinating and planning meetings, ensuring project schedule is met, including the review of reports against economic, industrial and operational objectives and targets. RPC and VAL have been in contact with subcontractors and end-users and have been overseeing all tests and adaptation tasks.
WP2 - Design specifications and technical requirements [Months: 1-3]
The consortium has liaised with TSOs (Amprion, Energinet, REE, JPower, ELIA, Tennet etc) to benefit from their practical expertise in OHTL deployment.
During this task, the team have been establishing 1) the initial transmission system design specifications according to the TSOs requirements; 2) the technical requirements for corona shield design, wire design; 3) the verification tests according to the TSOs’ requirements.
WP3 - Technical refinement, testing and manufacturing optimization [Months: 2-24]
The following goals have been achieved: 1) Re-assessment of system design and specifications; 2) Preliminary evaluation through testing of mechanical and electrical performance; 3) Concluding on the Composite Pylon’s design that will be showcased during demonstrations.
WP4 - Preparation of full-scale demonstration [Months: 6-24]
Manufacturing and validating prototypes for demonstration and performing qualification testing is successfully finalized.
WP5 - Technical refinement, qualification testing and demonstrations
The evaluation of demonstration results are documented for future modifications and to establish guidelines to optimize the Composite Pylon modular production and assembling to establish the final product specifications.
Having the crossarm electrically and mechanically type tested at laboratories in Germany and the Czech Republic data is received and documented.
Furthermore, the pylon elements are transported, delivered, assembled and prepared for demonstration.
WP6 - Product intelligence and certification
A comparison is made between Standard towers and the composite tower regarding CO2 footprint based on weight on the individual parts.
The result document that the composite tower is having half (57%) the impact on the environment.
The results of this study are useful in targeting areas where improvement can be made, providing knowledge to be able to integrate climate and environmental aspects into the decision-making process. LCA / CO2 assessments can thus serve as a powerful tool in environmental management systems, fulfilling new requirements of the ISO 14001:2015 standard which requires an integration of life cycle thinking to all stages of an organization’s activities; from design and development stages, procurement, operation, and maintenance to end of life stages.
WP7 - Market intelligence, dissemination & communication [Months: 1-36]
The communication and dissemination activities has been achieved by preparing a market dissemination and communication plan (presentations, posters, webinars, newsletters, etc.), by creating marketing material (presentations, posters, brochures etc.) and finally by participating in conferences.
Several real-life presentations and inspections are executed at the demonstration site - having 3 full scale pylons installed - illustrating a realistic setup for 2x400kV transmission.
The work plan has been carefully designed to minimize risks of introduction of the novel pylon into the market and to enable a cost-efficient development route.
WP1 Project management [Months: 1-36]
The project has formally started on 01.11.2019 when the Grant and the Consortium Agreement was signed by all partners. BYS have been coordinating and planning meetings, ensuring project schedule is met, including the review of reports against economic, industrial and operational objectives and targets. RPC and VAL have been in contact with subcontractors and end-users and have been overseeing all tests and adaptation tasks.
WP2 - Design specifications and technical requirements [Months: 1-3]
The consortium has liaised with TSOs (Amprion, Energinet, REE, JPower, ELIA, Tennet etc) to benefit from their practical expertise in OHTL deployment.
During this task, the team have been establishing 1) the initial transmission system design specifications according to the TSOs requirements; 2) the technical requirements for corona shield design, wire design; 3) the verification tests according to the TSOs’ requirements.
WP3 - Technical refinement, testing and manufacturing optimization [Months: 2-24]
The following goals have been achieved: 1) Re-assessment of system design and specifications; 2) Preliminary evaluation through testing of mechanical and electrical performance; 3) Concluding on the Composite Pylon’s design that will be showcased during demonstrations.
WP4 - Preparation of full-scale demonstration [Months: 6-24]
Manufacturing and validating prototypes for demonstration and performing qualification testing is successfully finalized.
WP5 - Technical refinement, qualification testing and demonstrations
The evaluation of demonstration results are documented for future modifications and to establish guidelines to optimize the Composite Pylon modular production and assembling to establish the final product specifications.
Having the crossarm electrically and mechanically type tested at laboratories in Germany and the Czech Republic data is received and documented.
Furthermore, the pylon elements are transported, delivered, assembled and prepared for demonstration.
WP6 - Product intelligence and certification
A comparison is made between Standard towers and the composite tower regarding CO2 footprint based on weight on the individual parts.
The result document that the composite tower is having half (57%) the impact on the environment.
The results of this study are useful in targeting areas where improvement can be made, providing knowledge to be able to integrate climate and environmental aspects into the decision-making process. LCA / CO2 assessments can thus serve as a powerful tool in environmental management systems, fulfilling new requirements of the ISO 14001:2015 standard which requires an integration of life cycle thinking to all stages of an organization’s activities; from design and development stages, procurement, operation, and maintenance to end of life stages.
WP7 - Market intelligence, dissemination & communication [Months: 1-36]
The communication and dissemination activities has been achieved by preparing a market dissemination and communication plan (presentations, posters, webinars, newsletters, etc.), by creating marketing material (presentations, posters, brochures etc.) and finally by participating in conferences.
Several real-life presentations and inspections are executed at the demonstration site - having 3 full scale pylons installed - illustrating a realistic setup for 2x400kV transmission.
Having investigated, tested, optimized, installed and evaluated three full scale pylons using composite crossarms for 400kV this is the conclusion:
New Composite Pylon will enable innovative visual expressions and at the same time - through the integration of insulators in the pylon design - reduce the size of the pylons. Moreover, as the pylons are smaller and compact, they will reduce the footprint associated to the manufacturing and transport to the installation sites. Furthermore, the use of mono-pile foundations leads to significant reduction in construction costs. The overall environmental impact of composite materials is smaller than the steel galvanized lattice structures. As fibre reinforced polymer is environmentally inert, it could even be in environmentally sensitive areas. As a result, new OHTL construction projects, previously subject to strong community opposition, can now be realized, enabling a wide and faster implementation of projects expanding the distribution of alternative/renewable energy sources.
Therefore, the adoption of Composite Pylon will have direct and indirect societal and environmental impacts.
New Composite Pylon will enable innovative visual expressions and at the same time - through the integration of insulators in the pylon design - reduce the size of the pylons. Moreover, as the pylons are smaller and compact, they will reduce the footprint associated to the manufacturing and transport to the installation sites. Furthermore, the use of mono-pile foundations leads to significant reduction in construction costs. The overall environmental impact of composite materials is smaller than the steel galvanized lattice structures. As fibre reinforced polymer is environmentally inert, it could even be in environmentally sensitive areas. As a result, new OHTL construction projects, previously subject to strong community opposition, can now be realized, enabling a wide and faster implementation of projects expanding the distribution of alternative/renewable energy sources.
Therefore, the adoption of Composite Pylon will have direct and indirect societal and environmental impacts.