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B1_108

CIGRE 2012

Design and Installation of One Section of Anhanguera - Casa Verde Underground Transmission Line - 138 kV, Using Special "T" Joints

Karabolad, E.F (*) EDS Engenharia Brazil Thomaz, R.D.Jr EDS Engenharia Brazil

Louredo, N.H.G.R de EDS Engenharia Brazil

Souza, I.P Pfisterer Brazil Silvestre, G.C AES Eletropaulo Brazil

SUMMARY AES Eletropaulo, a Brazilian utility responsible for Sao Paulo city electric distribution system, had a real challenge to turn feasible the Underground Transmission Line UTL Anhanguera Casa Verde. The route of this line runs along a right of way where there are nowadays, four overhead transmission lines: two of 230 kV, one of 88 kV and other of 138 kV. The route profile is very rough and plenty of several types of physical interferences like two very crowded highways, streams and rock outcrops. The best solution according to the ampacity studies was to install two cables per phase, per circuit, aluminum conductors with 1200 mm2 cross section along the majority of the cable route, and one cable per phase, per circuit, copper conductors with 1600 mm2 cross section in the section localized inside the Anhanguera substation, crossing the equipment yard and entering in the power cables basement. Single point bonding special grounding system was employed in the section of the line with 1x 1600 mm2 copper conductor, and cross bonding special grounding system was used along the portion of the route with 2 cables of 1200 mm2 aluminum conductors. The aluminum conductor option was to reduce overall costs and mechanical forces during the laying services. The power cables were installed on two trenches, one circuit per trench. Considering the trench dimensions and mechanical forces during laying services the underground line installation became very difficult and costly. The gas insulated substation (GIS) Anhanguera is a three phase per tube type, allowing just one power cable connection per phase. Thus, became necessary to install one double to single power cable transition to make the physic connection from one cable conductor with 1600 mm2 to two cable conductors with 1200 mm2 in each phase per circuit. The first alternative using a set of outdoor terminations resulted completely unfeasible, since doesnt exist available area to install eighteen outdoor terminations units inside Anhanguera substation property. The alternative chosen was the usage of the special plug-in joint box called T joint. Their dimensions presented the best alternative to the available physical space in Anhanguera power cables basement. This paper presents this accessory installed in the underground transmission line, showing its role related to changes on the special edseng@uol.com.br

grounding systems, and how the steel boxes that contain the special SF6 T joints were placed into an underground chamber with natural ventilation. KEYWORDS High Voltage, Transmission Line, Underground Cable, T Joint

INTRODUCTION The system with the technology "plug-in/out" had a great evolution in the last 30 years. Its main advantage is to allow various geometric configurations in systems of high voltage cables with few components. The "T joint" box type plug-in/out used in this design consists of a single body equipment fully assembled and tested in factory. The main advantage of this accessory stands out for its simple assembly, ability to be connected dry for added security, the great flexibility in installation, and converting or multiplication of an electrical system. The "T Joint box is made of stainless steel plates, totally insulated, touch-proof, maintenance free, high resistance to short circuit, using SF6 gas insulation, and can be used in harsh environmental conditions. The "T Joint" will be monitored through a modified gauge with remote monitoring capability. This gauge has a dual function: electric alarm and quick action. The Figure 1 shows details of the T joint.

Plug in connected View from the 1200mm power cables

Plug in connected View from the 1600mm power cables FIGURE 1

These joints enable a variety of situations such as: A second input being connected to the GIS; To allow the connection and disconnection of a cable affected by a failure to be exchanged or repaired without handling SF6 gas; To allow the derivation of the main line like in the design of the underground transmission line in 110 kV between the power plant and substation Belchatw Kleszczw, Poland [1], [2]; To increase the security of the energy supply to a large area of consumers like it was installed by Balfour Beatty Power Networks in a new line voltage class of 72.5 kV, which allowed the necessary division of the main line in Northern Britain in the town of Middlesbrough; To allow the transition bare cable to insulated cable, such as the substation in La Reja, Buenos Aires, Argentina. The system needed to make the transition from a bare wire to two insulated cables of 138 kV in the same connection and in the same space.
GENERAL BENEFITS INTRODUCED BY THE USE OF PLUG IN-OUT TYPE TJOINTS The advantages of the T-Joint with the plug-in type cable termination systems are:

Easy assembly and disassembly; The plug-in capability of the system enables the cable to be quickly and easily disconnected from the system component in the case of a fault; A considerably reduced installation length of 50% compared with conventional design; There is no necessity of unsealing or opening the T-Joint due to the fact that the bushing is already fitted in the factory, eliminating the costly and troublesome SF6gas insulation works during the installation process; Any desired spatial arrangement can be done, i.e. horizontal, vertical and even angled arrangements from top or bottom are possible because the T-Joint uses plug in type cable termination systems with solid insulating materials. Thus, it is not necessary to know previously the geometries of the installation for cable connections; Assembly times are considerably reduced compared with conventional joints / terminations; The use of pre-fabricated and tested components provides a high level of safety and reliability; Assembly errors are minimized due to the technique of connection between the cable and joint, which justifies the technological innovation of this high voltage T-Joint type.

COMPARISON OF THE OUTDOOR TERMINATIONS SYSTEM AND T JOINTS ALTERNATIVES

This project considered two alternatives to connect the section of the line with one cable per phase, 1600 mm2 cooper conductor and the section of the line with two cables per phase, 1200 mm2 aluminium conductor. The first alternative it was to connect the both sections of the line through an arrangement of eighteen outdoor terminals, installed inside the Anhanguera substation yard. This solution occupied a large area of the substation and created great difficulties to the maintenance of the other equipments if it was necessary to remove them. The other alternative it was to connect the sections of the line through six T joints assembled inside vaults. Specifically for this project, the cost of the conventional alternative with 18 outdoor terminations, 18 steel structures for fixing termination equipment, civil works, foundations, assembly and others accessories were between 12 and 15% less than the alternative with "T" Joints. Although the cost of the alternative using T joints was more expensive than the alternative with outdoor terminals, it was the chosen alternative because the space into de substation it was not enough to install the terminals without prejudice for the maintenance of the substation.

IMPLICATIONS OF THE INCLUSION OF THE T JOINTS ON THE UNDERGROUND TRANSMISSION LINE: UTL ANHANGUERA CASA VERDE During ampacity calculations, it was found that to meet the transmission capacity of the Underground Transmission Line - UTL Anhanguera - Casa Verde it was necessary two cables per phase, per circuit, in aluminium conductors with cross section of 1,200 mm2 in crossbonding special grounding system, and one cable with copper conductor per circuit with 1600 mm2 cross section in the line portion localized at the basement of the Terminal Substation Anhanguera with single point bonding special grounding system. The line portion installed with cable conductor of 1,600 mm2, in the original condition, stretched along the basement of Terminal Substation Anhanguera, with a length of approximately 150 m from the terminals of GIS to the external terminals on the patio. The Figure 2 shows the cables at the basement of the substation. 4

GIS Terminals Connection

Power cables into the basement of Anhanguera 138kV substation FIGURE 2

Once the area in question could not support the 18 terminals, the alternative has emerged to enable the continuity of the line using "T joints". The Figure 3 shows a general view of the joints.

T-Joints into the concrete Box side of 1200 mm2 power cables

T-Joints into the concrete Box side of 1600 mm2 power cables

FIGURE 3 With the insertion of the T joints and knowing that it was necessary to consider the installation as a whole, the designers searched for the most suitable place to install them in the area inside the substation Anhanguera. The most suitable location is far from the GIS terminals about 40 meters. The definition of this length is due to the fact that at this point there was enough space for the installation of the steel boxes containing the plug-in/out terminations. The special grounding systems were configured like described below and showed in the Figure 4. The single point bonding grounding system was used between the GIS terminals, at the beginning of the line, and the T Joints, with 40m long. The surge voltage limiters (SVLs) were connected at the 1600 mm2 conductor cable end, and the grounded end it was in the 2 x 1200 mm2 conductor cable side. The SVLs voltage class installed in the single point bonding system is 4.5 kV. The crossbonding grounding system was installed between the T joints and the end of the line, at the Transition Substation Anhanguera, with a total length of 4,640 m.

The installed length using the crossbonding system can be seen in the diagram of the Figure 4. Two complete sections of sectionalized cross bonding system, also called Kirke-Searing bonding and one section of modified sectionalized crossbonding [3]. The first complete section of sectionalized cross bonding has 1560 meters long and the second has 1590 meters long. The major sections of the cross bonding system are divided into three equal length minor sections. The portion of the underground transmission line with modified sectionalized crossbonding is 1490 m long. It was designed with 4 minor sections, using the concepts of the reference [3], and it was used due to the crossing of a highway, whose right of way reaches approximately 300 meters width, which forced the displacement of split joint boxes. At the points with sectionalized joints the cable sheaths are connected using suitable link boxes provided with surge voltage limiters (SVLs) 9.0 kV voltage class.
Anhanguera Terminal Substation T Joints

Anhanguera Transition Substation

FIGURE 4: Anhanguera-Casa Verde underground transmission line special grounding system diagram THE T JOINTS GAS CONTROLLING AND MONITORING SYSTEM The control of the joints gas is done through a remote continuous monitoring system. The system has a gas (SF6) density indicator equipment compose of a pressure gauge and alarm contacts installed in T Joint. 6

The gauges are hermetically sealed to avoid the influence of temperature fluctuation due to air pressure and altitude differences. The monitoring system has 2 types of alarm. One, that is intermittent, signalizes down gas pressure levels, and the other acts as a "trip" to critical levels of gas pressure. DESCRIPTION OF CONCRETE BOX WHERE ARE SHELTERED THE STEEL BOXES The six units of boxes made of stainless steel of the joints are installed directly on the bottom of a concrete chamber 16 m long, 6 m wide and a final clearance around 1.30 m. See Figure 5. The camera is closed by 63 units of steel ASTM A-36 grilles. The weight of each unit is equal to 100 kg. The bars of the grille have an inclination of 45, directed to the north face, and it was designed to reduce the direct insolation on the conductor cables.

FIGURE 5: Steel grid floor beams inclined at 45 On the bottom of the chamber there is a drainage system, since the chamber is exposed to rain water penetration. All the fixing hardware existing into the chamber is properly grounded. The grounding system is composed of loops of bare cooper cables of 120 mm2 installed in the bottom of the vault. In the top of the vault are installed equalization rings of bare cooper conductor of 95 mm2. The equalization loop cable is installed in the corners of fixing metal bars. The stainless steel boxes of the T joints are positioned in the chamber along six parallel lines, each unit lagged of the other. The connections of the cables in the T joints have a distance of approximately 24 m of the GIS terminals. CONCLUSION This kind of joint was first used in Brazil in the Underground Transmission Line Anhanguera Casa Verde that is the vital importance to the electrical system of AES Eletropaulo utility. This line has a transmission capacity of 300 MVA per circuit operating in 88 kV. The use of the T joints technically made feasible the cable system in question, although it is important to enhance that its cost was between 12 to 15% greater than the conventional alternative using eighteen units of outdoor terminals. Currently there are 130 T joints in voltage classes of 72.5 to 245 kV, installed in several countries that began their operation between the years 1994 and 2010, maintenance-free and with no damage reported. 7

It is important to mention that the T joints can be used also to the transition between paper impregnated cables and cables with extruded insulation. BIBLIOGRAPHY
[1] http://www.pfisterer.com/pdf_anwendung/druck_100.pdf [2] http://www.energoprojekt.krakow.pl/?ac=ProductsView&cId=2 [3] IEEE Guide for the Application of Sheath-Bonding Methods for Single-Conductor Cables and the Calculation of Induced Voltages and Currents in Cable Sheaths - Institute of Electrical and Electronics Engineers, New York, USA November 1987. [4] Technical Brochure 177 Accessories for HV Cables with Extruded Insulation CIGRE WG 21.06,2001 [5] Technical Brochure 415 Test Procedures for HV Transition Joints CIGRE WG B1.24, Electra 250, June 2010 [6] Plug-in type connection techniques on encapsulated components on high-voltage equipment up to Um = 245 Kv. Schuster, M., Pfisterer Kontaktsysteme.