p r e i s s i n g e r b u s b a r p r o d u c t i o n

p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

ISOBUS BUSBAR CAPABILITIES

Safe Available Reliable

MEDIUMVOLTAGEANDLOWVOLTAGE ELECTRICPIPE

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EXECUTIVESUMMARY.............................................................................................................................IV TABLES ......................................................................................................................................................V INTRODUCTION&BACKGROUND............................................................................................................ 1 1 COMPONENT1THEBUSBAR.......................................................................................................... 6 1.1 1.2 2 CONDUCTOR CAPABILITIES ......................................................................................................................... 7 BUSBAR CAPABILITES ................................................................................................................................ 9

COMPONENT2THECONNECTINGCYLINDER.............................................................................. 10

2.1.1
3

ConnectingCylinderCapability ....................................................................................................... 10

COMPONENT3THEFLANGE ......................................................................................................... 11

3.1.1
4

Capability .......................................................................................................................................... 11

COMPONENT4BUSBARBUSBARCONNECTIONUNDERTHECYLINDER............................. 13

4.1.1 4.1.2
5

Connectioncapabilities .................................................................................................................... 13 FlexibleConnectiondetail................................................................................................................ 14

COMPONENT5NUTSBOLTS&SPRINGWASHERS .................................................................... 17

5.1.1
6

NutsBolts&WashersCapabilities.................................................................................................. 17

FIXING&PENETRATIONCOMPONENTS ...................................................................................... 18 6.1 FIXING DESIGNSUPPLIEDBYBUSBARMANUFACTURER .............................................................................. 18

MANUFACTUREANDQUALITY ...................................................................................................... 21 7.1 7.2 7.3

7.1.1

VALUE ENGINEERINGTHEBUSBARS& CYLINDERS ................................................................................... 23 Conclusion ........................................................................................................................................ 26 EPOXYRESINIMPREGNATEDPAPER INSULATION ...................................................................................... 27 COMPONENTCAPABILITY OUTERSHEATH ................................................................................................ 30

8 9 10

HANDLING&STORAGE .................................................................................................................. 31 ACRONYMSANDABBREVIATIONS................................................................................................ 32 APPENDIX ........................................................................................................................................ 33

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ExecutiveSummar y
1. WorldwidetherearescoresofBusbar&Busductsuppliers,howeverPBPPreissinger useEpoxyResinImpregnatedPaperasacompositeinsulationmedium.Design, manufactureandinstallationprocessesensureaninstalledproductwithalifespanof 3550years,whichisbasicallyfitandforget. ERIPBusbarsareatechnologytransferfromBushingtechnologiesdevelopedinthe late50s.SincethenliterallythousandsofRIP&laterERIPreferenceshavebeen obtainedworldwideinextremeenvironmentalconditionsrangingfromarcticthrough tropicaltodesert. PBPreferencesincludePetrochemicalplants,Chemicalindustry,Utilities,Offshore Marine&Railwayprojects.Theclientlistcomprisesthehouseholdnames,ABB, Alstom,Areva,SchneiderandSiemens.Twooftheseclientsmanufactureandsupply theirownairinsulatedBusductsystems. ValueengineeredERIPBusbarsprovideapartialdischargefreeaccordingtoIEC60 137,touchsafe,available,reliable,minimalmaintenance,powerdistributionnetwork whichcanwithstandbothshockandvibration. SideeffectsofdeployingERIPBusbartechnologyarethatsubstantialcostsavings canbemade. Whenapurchasercomparesacquisition&installationcostsoftheBusbardistribution systemagainsttheacquisition&installationcostsofcablethenthisclaimisbackedby hardfacts.ThebreakevenfactorforERIPBusbaragainstcableisreachedat amperages1400A. WhentotallifecyclecostsarecalculatedERIPBusbarsarealwayscheaperthan cable.

2.

3.

4.

5.

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Tables
Table1ShockwithstandforceinNewtonofsampleBusbarscomponents&fixings. .............. 2 Table2MaterialPropertiesofECuandEAlMgSi....................................................................... 7 Table3ECu&EAltradeoffs ......................................................................................................... 8 Table4AmbientTemperatureandconductordimensioning ...................................................... 26 Table5BusbarInsulationCapabilities ......................................................................................... 29 Table6Acronyms,Abbreviationsandterms.............................................................................. 32

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Intr oduction&backgr ound

Safety&lifespanofthedistributionnetwork 1. Electricaldistributionsystemsgenerallyrepresentasignificantinvestmentandareakey componentofthepowerdeliverysystem. 2. ComplexelectricaldistributionsystemsarecomprisedofNetworksofconductorsthat distributionpowertovariouslocations,andprovidethephysicalmeansbywhichelectricity isdistributedfromsourcetoloads. 3. Itisthetaskofalldistributionaccessoriestoreinstalltherequiredinsulation/ensure operatingsafetybetween: Conductorconductorconnection. Conductorequipmentterminations. 4. Theissuesofcorrectdesign/installationofconnections,terminations&penetrationsare coretooperationalsafety,reliabilityavailability,andadditionallytothelifespanofthe conductornetworks. 5. Thismeansthatthesafety,availabilityandreliabilityandlifespanofthedistributionsystem arealsodirectlydependantuponthequalityofthechosenconnectorsandpenetrations, togetherwiththecorrectselectionandinstallationofchosenconnectorsandpenetrations.

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PartialDischargeFreeaccordingtoIEC60137 PartialdischargeisanimportantMVsafetyissuequitesimplybecausethisphenomenoncanlead tocatastrophicfailureofequipmentandlossoflife. Orinamildercase,PDactivitywithininsulationlayercanleadtoprematureinsulationagingand consequentreplacementofthedistributionsystem/partsofthedistributionsystem. PBPPreissingerISOBUSBusbarsarepartialdischargefreeaccordingtoIEC60137 RobustShockProofSystem MV&LVBusbarscomponentsandfixingswereNavalshocktestedatQinetiqRosythto63mm maximumdisplacementfollowedby>200gshockfollowedby450g. TheseteststookplaceinMay2004. Busbarscomponentsandfixingswithstoodandtestedaselectricallyperfectafterquiteextreme shockevents.

Table1ShockwithstandforceinNewtonofsampleBusbarscomponents&fixings.
Shocklevel BusbarVoltage AndAmperage
200g* 450g* 200g 12kV3150A 12kV3150A 12kV2500A

Weightper meterin kilograms

25 25 19Busbar 10cylinder

Lengthtested inmeters
1.6 1.6 2

Forcein Newton
80,000 180,000 96,000

200g

<3.6kV4000A

25kg

100,000

*Withstoodandelectricallyperfectafter63mmfollowedby>200gfollowedby450g. USANavalacceptancetestingforshock&vibrationcompleted

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pbp

MV&LVISOBUS LengthandshapeofBusbars Determinedbythedimensionsoftheautoclaveorimpregnationoven,whichis8mX2mX2m Themaximumbentlengthisthereforelimitedasshowninthesketchbelow. AsinglestraightBusbarcanbeupto8meterslong. Forlongerbusbarconnections,connectingcylindersarerequired. TheseinsulatedcylindersfitsingleBusbarstogethertothecompletebusbarsystem. Thelengthofarunisunlimited.

Fig1
ConnectionsintoSF636kVand2,500Aconnection

SwitchgearcontainerinPetrochemicalPlantshowingBusbarsandconnectingcylinders

Fig2

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BusbarGeometricAr rangement&bendingradii

Fig3TrefoilBusbararrangement

Landproject12kV2,500Abusbarfeedin12kV350Afeedout

ElectricPipe DistributionSystemhas Verysmallbendingradii Compactouterdiameter Averysmallspaceenvelope. ThisallowsclearaccessatinstallationandisparticularlyimportantwithLVBusbarswhich carryhighcurrent. 1Busbarcandistributeupto7,000A. Wehavecompletedprojectswith12,000Acarriedin2Busbars

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BusbarGeometricarrangementandEMC/EMI The3phasescanbeinstalledindifferentgeometricarrangementsasshowninfig5. Thegeometricarrangementhasadirecteffectonthelevelofmagneticemissions(magneticflux density) Theseareshownindescendingorderofmagneticemissions.

Parallel

Trefoil

2X3PhaseCrossover

Fig4
Withinanyproject,combinationsofall3arrangementsarepossible,dependingonproject requirementsformagneticemissionlevelsandspacerequirements. PBPPreissinger,hasitsownBFieldsoftwarewhichallowsthecalculationofBfieldemissions whereclient/projectrequirethisinformation. Busbarsemitnoelectricfieldduetotheearthing/shieldinglayers.

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Component1 Busbar ECopper

COMPONENT1THEBUSBAR

Fig5
EitherECopperorEAluminiumpossible.Choiceofconductordependsonthespecificproject requirements.Thematerialandelectricalpropertiesforbotharelistedinthetablesbelow.

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1.1CONDUCTORCAPABILITIES

Table4showsmaterialpropertiesofECuandEAlMgSi. BothareusedinERIPBusbarproduction Choiceofconductormaterialisprojectspecific.

Table2MaterialPropertiesofECuandEAlMgSi
ECu Unit Copper Density TensileStrength(hard... annealed) Elongationatbreak (hard...annealed) Modulusofelasticity Meltingpoint Coef.ofthermal expansion Temperaturecoef.of resistance+200C Conductivityat+200C IACS Resistivityat+200C
3 kg/dm

EAl Aluminium
2,7

AlMgSi AlAlloy
2,7

8,9

2 N/mm

450...240

180...80

310

%
2 kN/mm

1...35

2...35

120 1083

70 658

70 658

6 10 /0C

16,6

23,8

23,0

1/0C

0,0039

0,0040

0,0036

%
2 mm /m

97...100

61...62

53

0,01786

0,02857

0,03280

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ECuversusEAl.Copperconductorsaregiventhevalue1AndAluminiumequivalentvalues shownalongside.

Table3ECu&EAltradeoffs
Conditions Samecrosssection *Weight *Conductivitiy *Currentcarryingcapacity Sameconductivity *Crosssectionalarea *Diameter *Weight Sametemperaturerise *Crosssectionalarea *Diameter *Weight Copper 1 1 1 1 1 1 1 1 1 1 1 1 Aluminium 1 0,3 0,625 0,8 1 1,6 1,3 0,49 1 1,4 1,17 0,42

Ascanbeseenfromtables1&2,tradeoffbetweenECuandEAlispossiblebasedonmaterial properties.

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1.2BUSBARCAPABILITES Touchsafe Ambienttemperaturerangefrom<50C>+ 50C Nophasetophaseshortcircuit 1Busbarcandistributeupto7,000A.1Busbarper phase. PartialdischargefreeaccordingtoIEC60137 Minimalmaintenance

3550yearlifespan

Fig6

Fig7

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pbp

COMPONENT2THECONNECTINGCYLINDER

Component2 Cylinder

Fig8

2.1.1

ConnectingCylinderCapability
Earthlayerensuresvoltage freesurfaceandtouchsafety ConcentricCopperstocking (35mm)Withstand6.3kA1 secincaseofshortcircuit

MediumVoltageBusbarcylinderconnectionshowingearthandcapacitivegrading.

Equalandoppositecapacitivegradinglayers ensureanelectricallystressfreeconnection.

Therefor enoflashoverpossible.

Fig9

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pbp

COMPONENT3THEFLANGE

Component3 Flange

Fig10

3.1.1

Capability

Theflangesensurethatthelive,gradedendsofthebusbarsarecovered andthecompletebusbarrunistouchsafe. FlangesareavailableindegreeofprotectionfromIP30 uptoIP68. ThisComponentgenerallyprovidestouchsafe,operationalsafesealedpenetrationsinto switchboards,transformers,generators(notthebulkhead,deckordeckheadpenetrations) Flangesareavailableinbothstainlesssteelandbellowstype.

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pbp

Fig11
FlangesareavailableinallsizesandchosentoprovideacompletesealbetweenBusbarand equipment.Theyarealsochosentomeettheenvironmentalchallenges.Flangesaretherefore availableindegreeofprotectionuptoIP68.Detailedflangedrawingsaresuppliedbelow. TypicalexampleofsealingflangeIP44: (Degreeofprotectionofatypicalswitchboard.) TypicalexampleofsealingflangeIP65:

Fig12

Fig13

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p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

COMPONENTFOURBUSBAR BUSBAR CONNECTIONUNDERTHECYLINDER

Component4 CanbeCopper laminateorCopper HighFlex

Fig14 showing12mmhexagonalboltsandspringclamps.

4.1.1

Connectioncapabilities

HighFlexibleBraidedCopperConnection Doesnottransmitvibration Compensatesthermalexpansion Compensatesbuildtolerances MV100mmand5eachcylinder

Fig15

Allowsmovementinallthreeaxes

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

HighFlexisthestandardconnectionfromBusbarotherequipment.Thiseasesinstallationand enablestheBusbarrunstoberoutedincloseproximitytotheequipment. Highflexconnectorsarefullycompatiblewitheverytypeofswitchgearavailableworldwide Alstom,ABB,Siemens,Schneider,Arevaetc. Highflexbraidsallowcompensationofbuildtolerancesinall3orthogonalaxes.

4.1.2

FlexibleConnectiondetail

Fig16

PressweldedCopperLaminateFlexible Copperlaminatedflexiblesareweldedtogetherateachendutilizingpressweldingtechnology. Pressweldingprovidessuperiortechnicalcharacteristicsthatresultinthefollowingadvantages: smallercrosssectionsforsameamperage coolerterminalsbyreducedpowerlosses Pressweldingsolidifiesbothendsofthepackageofcopperlaminates.Thepackageisthen positionedbetweengraphiteelectrodes,whicharethenheatedbyhighelectricalcurrents.The fusionofthelaminatesintoasolidterminaloccursatatemperaturelevelofapprox.1000C/ 1800Fjustbelowthemeltingpointofcopper Inthisphaseaterminaliscreatedwhichcanbedrilled,bentormachinedinthesamewayasa solidbar.Pressweldingtechnologyis"stateoftheart". ThepressweldingprocessiswellestablishedinEuropeastheoptimaltechnologyforwelding packagedcopperlaminates.Pressweldingcanbeusedforalimitednumberofmaterialslike copper,copperalloys,nickel,chrome,etc.OtherprocessessuchasMIGorTIGweldingallow
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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

alsotoproduceflexibleconnectionsbutatahigherresistancewhencomparedtopresswelding. Pressweldinghaslowestconnectionresistancebecausenoadditionalweldmetalsorauxiliary matterisusedintheweld. Thistypeofconnectionisextensivelyusedinlandpowerprojects.

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p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

CompressedBraidCopperFlexible TheCopperbraidedflexibleisusedinapplicationsthatrequiremovementin3orthogonalaxes. Thecopperbraidsconsistofwireswithathicknessbetween0.07mmand0.3mm.Technicallythe highflexconnectorsaremachinebraidedsinglewires.Thecopperbraidisheldtogetherbya coppertubewhichisthenmechanicallycompressedfromallfoursidesusingaspecialdouble presssystem.Mostmanufacturersgenerallycompressfromthetoptherebyallowingthesidesto bendout.Theresultofthistechnologyisahighlycompressedterminalpalmwithlowershortand longtermresistancethancomparableproducts.

Fig17

Fig18

CompressedBraidflatCompressedBraidround Arangeofprojectspecificcontactsurfacescanbedelivered

Polished

Silverplated

Tinplated

Fig19

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
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pbp

5
Fig20

COMPONENT5NUTSBOLTS&SPRINGWASHERS
Component5 NutsBolts&spring washers

5.1.1

NutsBolts&WashersCapabilities

Simplicity Allsectionsaresimplyboltedtogether.NospecialtoolsnecessarytoinstalltheBusbar Distributionsystem. Navaltested OurstandardrangeofNutsBoltsandSpringWashersweretestedto 63mmmaximumdisplacementandover200gshockatQinetiq. Therewasnolooseningduetovibration/shockundertheconnectingcylinders. StandardSpringwashersareusedintheautomotive,aircraftandrailwayindustries WhereNutsBolts&washersmustbevibrationproofovermanyyears. Inour15yearssupplyandover780projectsworldwide,wehaveneverhadasingleproject whereNutsandboltsvibratedloose.

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

FIXING&PENETRATIONCOMPONENTS

6.1FIXINGDESIGNSUPPLIEDBYBUSBARMANUFACTURER FixingsystemsforBusbarsaredimensionedanddesignedaccordingtothefollowingtwo parameters. Shortcircuitcurrent Naturalfrequency

Parameters1and2aredesignedonaspecialcomputerprogrammeinhouse. ThedesignoffixingsisdonebyPBPPreissingerandadistributionsystemmeccanokitis deliveredcomprisingallnecessarycomponentsfortheindividualproject.. Thekitcomprises,firstfixingcomponents Aluminium/stainlesssteelprofiles. Busbars,cylindersflexibleconnectionsandallcomponents Technicaldrawingsandinstructions.

Fig21

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

Fig22

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp
Busbarclamp Towithstandshort circuitforces

Fixingsystem EitherStainlessSteel orAluminium

Earth

Topofconnecting cylinder

Fig23

Crosssection Busbar ECopper

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

MANUFACTUREANDQUALITY

Thefollowingisthestepbystepmanufacturingprocess Premanufactureallrawmaterialsqualitychecked Measurementofspecificresistance:conductors&capacitors Verificationofpurity&tearingstrengthtest:insulatingpaper Viscosity,viscosityrise(temperatureasparameter)gelationtime:impregnatingresin Thebasicconductortubeiswrappedwithcrepepaperandlayersofsemiconductingpaper providethecapacitivegradinglayers. (12kVhas3capacitivegradinglayers,24kVhas4,36kVhas6) Theearthlayerhasawithstandof6.3kA.ItcomprisesAluminiumfoilwrappingoverlaidwith copperearthstocking(35mm)suppliedasstandard.Wherethereisaclientorproject requirementtheCulayercanbedenser.

Fig24

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

DryingprocessthepreparedBusbarlengthsareplacedintheautoclaveat 90Ctemperaturewithvacuumof1Torr.Thistakes24hours Impregnationprocess Nextstageisimpregnationoftheepoxyresinundervacuumandreducedtemperature (around45C) Insulationcuringandhardening Nextiscuringandhardeningprocesswhichtakesplaceat120C Controlledcooling Thefinalprocessisthecontrolledcoolingtoroomtemperature,whichtakesaround48hours Theentireprocesstakesonefullweek. Impregnationprocess,inautoclaveischeckedbythefollowingmeasurements Conditioning(degassing)oftheresincompound Temperatureinsidethevacuumoven Continuouscontrolofvacuumprocess Gelationtemperature/timepostcuringtemperaturetime ElectricaltestingoftheBusbarsandCylinders EachandeverysectionofBusbarandCylinderisindividuallytestedinourhighvoltagetestlab Adjacenttoautoclave.(wecantestupto72.5kV) PostManufactureHighVoltagetestingeachindividualBusbarsection&MVconnectingcylinder Powerfrequencytest PartialdischargetestaccordingtoIEC60137 (eg)a36kVnominalvoltageisprogressivelytestedupto85kVfor1minute Capacitancemeasurement Tandeltameasurement

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

7.1VALUEENGINEERINGTHEBUSBARS&CYLINDERS SafetyReliabilityavailabilitybydesign. TheEpoxyResinImpregnatedBusbar&HVconnectingcylinder Theelectricalcurrentinaconductorcausesavoltagedropandpowerlosses.Thetemperature riseintheconductorcausedbythelossesmustbekeptwithincertainlimitsinordernotto shortentheservicelifeoftheconductor(throughthermalstressingoftheinsulationlayer)The temperaturelimitvarieswiththetypeofconductor,ormorepreciselythetypeofinsulation.The bestwaytokeepthetemperaturewithinlimitsspecifiedforthetypeofconductor,istochoosethe conductorcrosssectionsothattheconductoranditssurroundingswiththeactualcontinuous load,achievethermalbalanceatatemperaturebeloworequaltothetemperaturelimit recommended Value engineering of the Busbar product starts with very detailed project data capture from the client. Thenextstageistoinputthisdataintoacomputerprogrammethatcalculatesanddimensions bothconductorandinsulationlayer,toensurethatthemaximumconductortemperatureis<90C.

ThisistoensurethattheinsulatinglayerwhichisclassE120or120C,isnotthermally stressedabovethe120Climit. Two graphs are produced, one showing temperature rise at rated current, and one with temperatureriseatshortcircuitcurrent. Busbarsaredimensionedatthisstageofdesignbothintermsofconductorouterdiameterand thicknessofinsulation.

ThefollowingtablesandgraphsarethecalculationsforAreva&NetworkRailproject.

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
p b p P r e i s s i n g e r G m b H & C o . K G H a u p t s t r . 3 4 D 9 6 1 2 3 L i t z e n d o r f / G e r m a n y

pbp

Fig25

Thefollowinggraphisproduced.

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
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pbp

TheBluelinerepresentstheconductortemperatureovertime TheMagentalinerepresentstheoutersheathtemperatureovertime.

Fig26

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
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pbp

7.1.1

Conclusion

Table4AmbientTemperatureandconductordimensioning

Temperature 30

ConductorDimensioninmm OuterDimensioninmm 25 70

(ERIPInsulationisclassE120)=120C Insulationworkingtemperatureupto120C. Asseenfromabovegraphs,Busbarsaredimensionedforthisprojecttooperateat<90C conductor And<50Coutersheathtemperature. ThismeansthatBusbarinsulationisneversubjecttothermalstressing. Thecalculationmusttakeintoaccountconnectingcylinders, duetothethermalinsulatingpropertiesofthecylinders. AsdefinedbyIEC60137. Maximumtemperatureacrosstheflexibleconnectionis115C. Ourmarginofsafetytoensurelongproductlifespansetsthetemperatureto<90C. (Thermalstressingshortensthelifespanofanydistributionsystembecauseitdegradesthe insulationlayer)

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
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pbp

7.2EPOXYRESINIMPREGNATEDPAPERINSULATION Theinsulationisdimensionedaccordingtotestvoltage&impulsetestvoltage.Onlandtheseare chosentoguaranteeaminimumlifespanof30+years ERIPHasbeenusedascoreinsulationlayerinthousandsofprojectsworldwidedatingbackto the Early60sforBusbarsandtheearly50sforBushings. RIPandlaterERIPBusbartechnologywasatechnologytransferfromBushings. StandardswhichapplytoERIPBusbarsisthereforeBushingstandardIEC60137formerlyIEC 137.

Insulationstabilityvs.time
200

withstandvoltage(kV)

160 120 80 40 0 1.E06

36kVinsulation 30years 1min 185kVimp.voltage 85kV 36kV

1.E02

1.E+02

1.E+06

1.E+10

tim e(s)

Fig25
Busbarshavebeeninstalledinawiderangeofenvironmentaloutdoorconditions. Rangingfrom<50Cto>+55CincludingDesert,tropical,petrochemical,arcticandcoastal Environments. ERIPisconsideredstateoftheartamongthesmall&selectgroupofsuppliersofBushingsin todaysmarket BushingSources:TrenchSwitzerland,ABB,Micafil

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
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pbp

ECCGroupS.E.A.T.UniversityofSunderland Abstract Ajointprojectincollaborationwithaleadingmanufactureofhighvoltagebushings,thisresearch isaninvestigationintothemanufacturingprocessandtestingofEpoxyResinImpregnatedPaper (ERIP)bushings.Theseusesolidresincompositeasaveryhighgradeelectricalinsulationforthe corematerial.Bushingsofthistypeareusedatthehighestvoltagesencounteredinpower conversionanddistributionsystems. MathematicalModellingofERIPProcessing: ERIPbushingcoresareprocessedinlargeheatedautoclavevessels,usedfordryingthebase papercores,impregnationwithepoxyresinmixandcuringoftheresultantcompositematerial. Thissectionoftheprojectconcentratesontheproductionofathermalmathematicalmodelofthe processingsystem,accountingfortheheattransferandevolutionmechanismsinvolved.These includeconduction,filmconvectionandradiationeffectstogetherwiththebulkheatgenerationby theresinexothermicreaction.Duetothecomplexityoftheautoclavesystem,finiteelement softwarehasbeenusedforthe[transient]analysesofthevariousprocessstages.Allresultsare checkedagainstdataacquiredfrommeasurementsmadeduringactualprocessrunsto accuratelyevaluatethemodelperformance.

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pbp

BusbarInsulationCapabilities BothMVandLVInsulationisacompositeof Epoxyresinimpregnatedpaper Copperstockingearth InsulationclassE(120C) TheMVinsulationcomprisesadditionally capacitivegrading(semiconductingpaperlayers)ensureevenvoltagestressthroughthe insulationlayer. Table5 BusbarInsulationCapabilities
Insulation Components Material Epoxyresin impregnated paperlayer Purpose DimensionMV

Guaranteesvoidfree Insulationthickness22.5mm PD free insulation IEC 60 137 dimensionedaccordingtotestvoltage Each Busbar and cylinder factory tested according to IEC60137. Toprovidevoltagefree SurfaceofBusbar. (35mm)Withstand6.3kA1secin Touchsafetyunder caseofshortcircuit power Toensureevenvoltage gradientwithininsulating layer. Capacitivegradingmeans smallerdiameter Preventsflashover 36kVBusbarhas 6gradinglayers

EarthLayer Copper stockingearth layer Capacitive grading Semi conducting paper

Fire BothMVandLVinsulationiscompletelyselfextinguishingandcontainnoHalogensorother toxicsubstances.

A120firetest InthistestBusbarsandRockwoolpenetrationmaterialweretested TheBusbarswithstood120minutes.TherewerenotoxicgasesproducedandtheBusbarswere showntobeselfextinguishing.

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
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pbp

7.3COMPONENTCAPABILITYOUTERSHEATH TheBusbaroutersheathingcanbecolourcodedaccordingtocustomerrequirements.Outer Sheathtemperatureisdesignedforthisprojecttobe<50Cunderpower.Choiceofsheath materialaswellaschoiceofIPratingsisshownbelow.

Withinlargeprojectstherecanbemanydifferent Zoneswithdifferentenvironmentalrequirements. Theoptimaloutersheathcanbeselected accordingtoenvironmentalconditions. InoneBusbarrun,itisthereforepossible tohavebothresinIP44throughIP66and stainlesssteelorAluminiumIP68. Metaloutersheathwillprovide Protectionagainstmechanicaldamagefromboth Operationsstaff&rodents. Degreeofprotectionandselectionofoutersheath mustprovidesafetyandenvironmentalprotection

Fig26

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Tel.:+49(0)9505950105RaiffeisenbankHallstadt Fax:+49(0)9505418KontoNr.:5802016(BLZ77063048)

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p r e i s s i n g e r b u s b a r p r o d u c t i o n
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pbp

HANDLING&STORAGE

Inaccordancewiththefollowingregulationsandpolicies PBPGeneralAssembly&MaintenanceInstructionManualforInstallations Localsafetyatworkregulations. Localelectricalsafetyregulations

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persnlichhaftendeGesellschafterin: pbpPreissingerVerwaltungsGmbH

Tel.:+49(0)9505950105RaiffeisenbankHallstadt Fax:+49(0)9505418KontoNr.:5802016(BLZ77063048)

Sitz:LitzendorfEMail:pbppreissinger@tonline.deIBAN:DE64770630480005802016 Amtsgericht:BambergHRB3857 Geschftsfhrer:NorbertPreissinger Internet:www.pbppreissinger.deSWIFTCODE:GENODEF1HLD U.St.IDNr.:DE814212178SteuerNr.:207/172/07603

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ACRONYMSANDABBREVIATIONS

Table6Acronyms,Abbreviationsandterms Acronym/Abbreviation/Term ERIP IP PD Description EpoxyResinImpregnatedPaper DegreeofProtection PartialDischarge

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pbp

10

APPENDIX

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persnlichhaftendeGesellschafterin: pbpPreissingerVerwaltungsGmbH

Tel.:+49(0)9505950105RaiffeisenbankHallstadt Fax:+49(0)9505418KontoNr.:5802016(BLZ77063048)

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