PBP Preissinger Isobus Technology Capabilities Version 2

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

pbp P r e i s s i nger GmbH & Co.KG • Haup t s t r . 34 • D96123 L i t z end or f /German y

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pbp Preissinger GmbH & Co. KG persönlich haftende Gesellschafterin: Tel.: +49(0)9505950105Raiffeisenbank Hallstadt

Hauptstrasse 34 pbp Preissinger Verwaltungs GmbH Fax: +49(0)9505418 KontoNr.: 580 2016 (BLZ 770 630 48)

D96123 Litzendorf/Germany Sitz: LitzendorfEMail: pbppreissinger@tonline.deIBAN: DE64770630480005802016

Sitz: Litzendorf Amtsgericht: Bamberg HRB 3857 Internet: www.pbppreissinger.deSWIFTCODE: GENODEF1HLD

Amtsgericht: Bamberg HRA10480 Geschäftsführer: Norbert Preissinger U.St.IDNr.: DE 814212178SteuerNr.: 207/172/07603

ISOBUS

BUSBAR

CAPABILITIES

MEDIUM VOLTAGE AND LOW VOLTAGE “ ELECTRIC PIPE”

•Safe •Available •Reliable

mailto:[email protected]

http://www.pbp-preissinger.de/



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EXECUTIVE SUMMARY.............................................................................................................................IV

TABLES ......................................................................................................................................................V

INTRODUCTION & BACKGROUND............................................................................................................ 1

1 COMPONENT 1 THE BUSBAR.......................................................................................................... 6

1.1 CONDUCTORCAPABILITIES.........................................................................................................................7 1.2 BUSBARCAPABILITES ................................................................................................................................9

2 COMPONENT 2 THE CONNECTING CYLINDER.............................................................................. 10

2.1.1 Connecting Cylinder Capability ....................................................................................................... 10

3 COMPONENT 3 THE FLANGE ......................................................................................................... 11

3.1.1 Capability .......................................................................................................................................... 11

4 COMPONENT 4 BUSBAR – BUSBAR CONNECTION UNDER THE CYLINDER............................. 13

4.1.1 Connection capabilities .................................................................................................................... 13 4.1.2 Flexible Connection detail................................................................................................................ 14

5 COMPONENT 5 NUTS BOLTS & SPRING WASHERS.................................................................... 17

5.1.1 Nuts Bolts & Washers Capabilities.................................................................................................. 17

6 FIXING & PENETRATION COMPONENTS ...................................................................................... 18

6.1 FIXINGDESIGN SUPPLIED BY BUSBAR MANUFACTURER .............................................................................. 18

7 MANUFACTURE AND QUALITY ...................................................................................................... 21

7.1 VALUE ENGINEERING THE BUSBARS &CYLINDERS ................................................................................... 23 7.1.1 Conclusion ........................................................................................................................................ 26

7.2 EPOXY RESIN IMPREGNATED PAPER INSULATION ...................................................................................... 27 7.3 COMPONENT CAPABILITYOUTER SHEATH ................................................................................................ 30

8 HANDLING & STORAGE.................................................................................................................. 31

9 ACRONYMS AND ABBREVIATIONS................................................................................................ 32

10 APPENDIX ........................................................................................................................................ 33





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Executive Summary

1. World wide there are scores of Busbar & Busduct suppliers, however PBP Preissinger use Epoxy Resin Impregnated Paper as a composite insulation medium. Design, manufacture and installation processes ensure an installed product with a lifespan of 35 50 years, which is basically “fit and forget.”

2. ERIP Busbars are a technology transfer from Bushing technologies developed in the late 50’s. Since then literally thousands of RIP & later ERIP references have been obtained world wide in extreme environmental conditions ranging from arctic through tropical to desert.

3. PBP references include Petrochemical plants, Chemical industry, Utilities, Offshore Marine & Railway projects. The client list comprises the household names, ABB, Alstom, Areva, Schneider and Siemens. Two of these clients manufacture and supply their own air insulated Busduct systems.

4. Value engineered ERIP Busbars provide a partial discharge free according to IEC 60 137, touch safe, available, reliable, minimal maintenance, power distribution network which can withstand both shock and vibration.

5. “Side effects” of deploying ERIP Busbar technology are that substantial cost savings can be made.

• When a purchaser compares acquisition & installation costs of the Busbar distribution system against the acquisition & installation costs of cable then this claim is backed by hard facts. The break even factor for ERIP Busbar against cable is reached at amperages ≥1400A.

• When total lifecycle costs are calculated ERIP Busbars are always cheaper than cable.





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Tables

Table 1 Shock withstand force in Newton of sample Busbars components & fixings. .............. 2

Table 2 Material Properties of ECu and E AlMgSi....................................................................... 7

Table 3 ECu & EAl trade offs ......................................................................................................... 8

Table 4 Ambient Temperature and conductor dimensioning ...................................................... 26

Table 5 Busbar Insulation Capabilities ......................................................................................... 29

Table 6 Acronyms, Abbreviations and terms.............................................................................. 32





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Introduction & background

Safety & lifespan of the distribution network

1. Electrical distribution systems generally represent a significant investment and are a key component of the power delivery system.

2. Complex electrical distribution systems are comprised of Networks of conductors that distribution power to various locations, and provide the physical means by which electricity is distributed from source to loads.

3. It is the task of all distribution accessories to reinstall the required insulation /ensure operating safety between:

Conductor – conductor connection.

Conductor – equipment terminations.

4. The issues of correct design /installation of connections, terminations & penetrations are core to operational safety, reliability availability, and additionally to the lifespan of the conductor networks.

5. This means that the safety, availability and reliability and lifespan of the distribution system are also directly dependant upon the quality of the chosen connectors and penetrations, together with the correct selection and installation of chosen connectors and penetrations.





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Partial Discharge Free according to IEC 60 137 Partial discharge is an important MV safety issue quite simply because this phenomenon can lead to catastrophic failure of equipment and loss of life.

Or in a milder case, PD activity within insulation layer can lead to premature insulation aging and consequent replacement of the distribution system /parts of the distribution system.

PBP Preissinger ISOBUS Busbars are partial discharge free according to IEC 60 137

Robust Shock Proof System

MV & LV Busbars components and fixings were Naval shock tested at Qinetiq Rosyth to 63 mm maximum displacement followed by > 200g shock followed by 450g.

These tests took place in May 2004.

Busbars components and fixings withstood and tested as electrically perfect after quite extreme shock events.

Table 1 Shock withstand force in Newton of sample Busbars components & fixings.

Shock level Busbar Voltage

And Amperage

Weight per meter in kilograms

Length tested in meters

Force in Newton

200g * 12kV 3150A 25 1.6 80,000

450g * 12kV 3150A 25 1.6 180,000

200g 12kV 2500A 19 Busbar

10 cylinder

2 96,000

200g <3.6kV 4000A 25kg 2 100,000

* Withstood and electrically perfect after 63 mm followed by >200g followed by 450g.

USA Naval acceptance testing for shock & vibration completed





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MV & LV ISOBUS Length and shape of Busbars Determined by the dimensions of the autoclave or impregnation oven, which is 8m X 2m X 2m The maximum bent length is therefore limited as shown in the sketch below. A single straight Busbar can be up to 8 meters long . For longer busbar connections, connecting cylinders are required. These insulated cylinders fit single Busbars together to the complete busbar system. The length of a run is unlimited.

Fig 1

Connections into SF6 36kV and 2,500A connection

Switchgear container in Petrochemical Plant showing Busbars and connecting cylinders

Fig 2





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Busbar Geometric Arrangement & bending radii

Fig 3 Trefoil Busbar arrangement

Land project 12kV 2,500 A busbar feed in 12kV 350 A feed out

“ Electric Pipe “ Distribution System has

üVery small bending radii

üCompact outer diameter

üA very small space envelope. This allows clear access at installation and is particularly important with LV Busbars which

carry high current.

ü1 Busbar can distribute up to 7,000A. üWe have completed projects with 12,000A carried in 2 Busbars





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Busbar Geometric arrangement and EMC/EMI The 3 phases can be installed in different geometric arrangements as shown in fig 5. The geometric arrangement has a direct effect on the level of magnetic emissions ( magnetic flux density) These are shown in descending order of magnetic emissions.

Parallel

Trefoil

2X 3 Phase Cross over

Fig 4 Within any project, combinations of all 3 arrangements are possible, depending on project requirements for magnetic emission levels and space requirements.

PBP Preissinger ,has its own BField software which allows the calculation of B field emissions where client /project require this information.

Busbars emit no electric field due to the earthing /shielding layers.





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1 COMPONENT 1 THE BUSBAR

Fig 5

Either ECopper or EAluminium possible. Choice of conductor depends on the specific project requirements. The material and electrical properties for both are listed in the tables below.

Component 1 Busbar ECopper





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1.1CONDUCTOR CAPABILITIES

Table 4 shows material properties of ECu and EAlMgSi.

Both are used in ERIP Busbar production

Choice of conductor material is project specific .

Table 2 Material Properties of ECu and E AlMgSi

Unit ECu

Copper

EAl

Aluminium

AlMgSi

Al Alloy

Density kg/dm 3 8,9 2,7 2,7

Tensile Strength (hard... annealed) N/mm 2 450...240 180...80 310

Elongation at break (hard... annealed) % 1...35 2...35 3

Modulus of elasticity kN/mm 2 120 70 70

Melting point 0 C 1083 658 658

Coef. of thermal expansion 10 6 / 0 C 16,6 23,8 23,0

Temperature coef. of resistance +20 0 C 1/ 0 C 0,0039 0,0040 0,0036

Conductivity at +20 0 C IACS % 97...100 61...62 53

Resistivity at +20 0 C mm 2 /m 0,01786 0,02857 0,03280





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ECu versus EAl .Copper conductors are given the value 1 And Aluminium equivalent values shown alongside.

Table 3 ECu & EAl trade offs

Conditions Copper Aluminium

Same crosssection 1 1

* Weight 1 0,3

* Conductivitiy 1 0,625

* Current carrying capacity 1 0,8

Same conductivity 1 1

* Cross sectional area 1 1,6

* Diameter 1 1,3

* Weight 1 0,49

Same temperature rise 1 1

* Cross sectional area 1 1,4

* Diameter 1 1,17

* Weight 1 0,42

As can be seen from tables 1 & 2, trade off between ECu and EAl is possible based on material properties.





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1.2 BUSBAR CAPABILITES

•

Fig 7

• Touch safe

• Ambient temperature range from < –50°C > + 50°C

35 – 50 year lifespan

• No phase to phase short circuit

• 1 Busbar can distribute up to 7,000A. 1 Busbar per phase.

• Partial discharge free according to IEC 60 137

• Minimal maintenance

Fig 6





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2 COMPONENT 2 THE CONNECTING CYLINDER

Fig 8

2.1.1 Connecting Cylinder Capability

Medium Voltage Busbar – cylinder connection showing earth and capacitive grading.

Fig 9

Earth layer ensures voltage free surface and touch safety

Concentric Copper stocking (35mm² )Withstand 6.3kA 1 sec in case of short circuit

Equal and opposite capacitive grading layers ensure an electrically stress free connection.

Therefore no flashover possible.

Component 2 Cylinder





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3 COMPONENT 3 THE FLANGE

3.1.1 Capability

The flanges ensure that the live, graded ends of the busbars are covered and the complete busbar run is touch safe. Flanges are available in degree of protection from IP30 up to IP68.

This Component generally provides touch safe, operational safe sealed penetrations into switchboards, transformers, generators (not the bulkhead, deck or deckhead penetrations)

Flanges are available in both stainless steel and bellows type.

Component 3 Flange

Fig 10





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Flanges are available in all sizes and chosen to provide a complete seal between Busbar and equipment. They are also chosen to meet the environmental challenges. Flanges are therefore available in degree of protection up to IP68. Detailed flange drawings are supplied below.

Typical example of sealing flange IP44: Typical example of sealing flange IP65:

( Degree of protection of a typical switchboard.)

Fig 11

Fig 12 Fig 13





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4 COMPONENT FOUR BUSBAR – BUSBAR CONNECTION UNDER THE CYLINDER

Fig 14

showing 12mm hexagonal bolts and spring clamps.

4.1.1 Connection capabilities

High Flexible Braided Copper Connection

Component 4 Can be Copper

laminate or Copper High Flex

Fig 15

Does not transmit vibration

Compensates thermal expansion

Compensates build tolerances

MV 100mm and 5° each cylinder

Allows movement in all three axes





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High Flex is the standard connection from Busbar – other equipment. This eases installation and enables the Busbar runs to be routed in close proximity to the equipment.

High flex connectors are fully compatible with every type of switchgear available world wide Alstom, ABB, Siemens, Schneider, Areva etc.

High flex braids allow compensation of build tolerances in all 3 orthogonal axes.

4.1.2 Flexible Connection detail

Press welded Copper Laminate Flexible

Copper laminated flexibles are welded together at each end utilizing press welding technology. Press welding provides superior technical characteristics that result in the following advantages:

smaller cross sections for same amperage

cooler terminals by reduced power losses

Press welding solidifies both ends of the package of copper laminates. The package is then positioned between graphite electrodes, which are then heated by high electrical currents. The fusion of the laminates into a solid terminal occurs at a temperature level of approx. 1000°C / 1800°F just below the melting point of copper

In this phase a terminal is created which can be drilled, bent or machined in the same way as a solid bar. Press welding technology is "stateoftheart".

The press welding process is well established in Europe as the optimal technology for welding packaged copper laminates. Press welding can be used for a limited number of materials like copper, copper alloys, nickel, chrome, etc. Other processes such as MIG or TIGwelding allow

Fig 16





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also to produce flexible connections but at a higher resistance when compared to press welding. Press welding has lowest connection resistance because no additional weld metals or auxiliary matter is used in the weld.

This type of connection is extensively used in land power projects.





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Compressed Braid Copper Flexible

The Copper braided flexible is used in applications that require movement in 3 orthogonal axes. The copper braids consist of wires with a thickness between 0.07 mm and 0.3 mm. Technically the high flex connectors are machine braided single wires. The copper braid is held together by a copper tube which is then mechanically compressed from all four sides using a special double press system. Most manufacturers generally compress from the top thereby allowing the sides to bend out. The result of this technology is a highly compressed terminal palm with lower short and longterm resistance than comparable products.

Compressed Braid flat ……………Compressed Braid round

A range of project specific contact surfaces can be delivered

Polished Silverplated Tinplated

Fig 19

Fig 17 Fig 18





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5 COMPONENT 5 NUTS BOLTS & SPRING WASHERS

Fig 20

5.1.1 Nuts Bolts & Washers Capabilities Simplicity All sections are simply bolted together. No special tools necessary to install the Busbar Distribution system.

Naval tested Our standard range of Nuts Bolts and Spring Washers were tested to 63mm maximum displacement and over 200g shock at Qinetiq. There was no loosening due to vibration /shock under the connecting cylinders.

Standard Spring washers are used in the automotive, aircraft and railway industries Where Nuts Bolts & washers must be vibration proof over many years.

In our 15 years supply and over 780 projects world wide, we have never had a single project where Nuts and bolts vibrated loose.

Component 5 Nuts Bolts & spring

washers





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6 FIXING & PENETRATION COMPONENTS

6.1FIXING DESIGN SUPPLIED BY BUSBAR MANUFACTURER

Fixing systems for Busbars are dimensioned and designed according to the following two parameters.

• Short circuit current

• Natural frequency

Parameters 1 and 2 are designed on a special computer programme in house. The design of fixings is done by PBP Preissinger and a distribution system “meccano” kit is delivered comprising all necessary components for the individual project..

The kit comprises, first fixing components Aluminium /stainless steel profiles. Busbars, cylinders flexible connections and all components Technical drawings and instructions.

Fig 21





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Fig 22





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Fig 23

Earth Top of connecting cylinder

Busbar clamp

To withstand short circuit forces

Fixing system

Either Stainless Steel or Aluminium

Crosssection

Busbar

ECopper





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7 MANUFACTURE AND QUALITY

The following is the step by step manufacturing process

•Pre manufacture all raw materials quality checked

•Measurement of specific resistance :conductors & capacitors

•Verification of purity & tearing strength test :insulating paper

•Viscosity, viscosity rise (temperature as parameter) gelation time: impregnating resin

The basic conductor tube is wrapped with crepe paper and layers of semi conducting paper provide the capacitive grading layers. ( 12kV has 3 capacitive grading layers, 24kV has 4, 36 kV has 6) The earth layer has a withstand of 6.3kA .It comprises Aluminium foil wrapping overlaid with copper earth stocking (35mm² ) supplied as standard. Where there is a client or project requirement the Cu layer can be denser.

Fig 24





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Drying process the prepared Busbar lengths are placed in the autoclave at 90°C temperature with vacuum of 1 Torr .This takes 24hours Impregnation process Next stage is impregnation of the epoxy resin under vacuum and reduced temperature (around 45°C ) Insulation curing and hardening Next is curing and hardening process which takes place at 120°C Controlled cooling The final process is the controlled cooling to room temperature, which takes around 48 hours The entire process takes one full week.

•Impregnation process, in autoclave is checked by the following measurements

•Conditioning (degassing) of the resin compound

•Temperature inside the vacuum oven

•Continuous control of vacuum process

•Gelation temperature / time post curing temperature time

Electrical testing of the Busbars and Cylinders Each and every section of Busbar and Cylinder is individually tested in our high voltage test lab Adjacent to autoclave. (we can test up to 72.5kV )

•Post Manufacture High Voltage testing each individual Busbar section & MV connecting cylinder

•Power frequency test

•Partial discharge test according to IEC 60 137

(eg) a 36kV nominal voltage is progressively tested up to 85kV for 1 minute

•Capacitance measurement

•Tan delta measurement





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7.1VALUE ENGINEERING THE BUSBARS & CYLINDERS Safety Reliability availability by design.

The Epoxy Resin Impregnated Busbar & HV connecting cylinder “The electrical current in a conductor causes a voltage drop and power losses. The temperature rise in the conductor caused by the losses must be kept within certain limits in order not to shorten the service life of the conductor (through thermal stressing of the insulation layer ) The temperature limit varies with the type of conductor, or more precisely the type of insulation. The best way to keep the temperature within limits specified for the type of conductor, is to choose the conductor crosssection so that the conductor and its surroundings with the actual continuous load, achieve thermal balance at a temperature below or equal to the temperature limit recommended”

Value engineering of the Busbar product starts with very detailed project data capture from the client. The next stage is to input this data into a computer programme that calculates and dimensions both conductor and insulation layer, to ensure that the maximum conductor temperature is < 90°C.

This is to ensure that the insulating layer which is class E120 or 120°C , is not thermally stressed above the 120°C limit.

Two graphs are produced, one showing temperature rise at rated current, and one with temperature rise at short circuit current.

Busbars are dimensioned at this stage of design both in terms of conductor outer diameter and thickness of insulation.

The following tables and graphs are the calculations for Areva & Network Rail project.





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Fig 25

The following graph is produced.





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The Blue line represents the conductor temperature over time The Magenta line represents the outer sheath temperature over time.

Fig 26





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7.1.1 Conclusion

Table 4 Ambient Temperature and conductor dimensioning

Temperature Conductor Dimension in mm Outer Dimension in mm 30° 25 70

(ERIP Insulation is class E120 ) = 120°C Insulation working temperature up to 120°C . As seen from above graphs, Busbars are dimensioned for this project to operate at < 90°C conductor And < 50°C outer sheath temperature.

This means that Busbar insulation is never subject to thermal stressing. The calculation must take into account connecting cylinders, due to the thermal insulating properties of the cylinders. As defined by IEC 60 137. Maximum temperature across the flexible connection is 115°C .

Our margin of safety to ensure long product life span sets the temperature to < 90°C.

(Thermal stressing shortens the lifespan of any distribution system because it degrades the insulation layer)





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7.2 EPOXY RESIN IMPREGNATED PAPER INSULATION The insulation is dimensioned according to test voltage & impulse test voltage. On land these are chosen to guarantee a minimum lifespan of 30+ years ERIP Has been used as core insulation layer in thousands of projects world wide dating back to the Early 60’s for Busbars and the early 50’s for Bushings. RIP and later ERIP Busbar technology was a technology transfer from Bushings. Standards which apply to ERIP Busbars is therefore Bushing standard IEC 60 137 formerly IEC 137.

Busbars have been installed in a wide range of environmental outdoor conditions. Ranging from < 50°C to >+55°C including Desert, tropical, petrochemical, arctic and coastal Environments. ERIP is considered state of the art among the small & select group of suppliers of Bushings in today’s market Bushing Sources: Trench Switzerland, ABB, Micafil

Insulation stabil i ty vs. time

0

40

80

120

160

200

1.E06 1.E02 1.E+02 1.E+06 1.E+10

time (s)

with

stand voltage (kV)

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

Fig 25





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“ECC Group S.E.A.T. University of Sunderland

Abstract A joint project in collaboration with a leading manufacture of high voltage bushings, this research is an investigation into the manufacturing process and testing of Epoxy Resin Impregnated Paper (ERIP) bushings. These use solid resin composite as a very high grade electrical insulation for the core material. Bushings of this type are used at the highest voltages encountered in power conversion and distribution systems. Mathematical Modelling of ERIP Processing: ERIP bushing cores are processed in large heated autoclave vessels, used for drying the base paper cores, impregnation with epoxy resin mix and curing of the resultant composite material. This section of the project concentrates on the production of a thermal mathematical model of the processing system, accounting for the heat transfer and evolution mechanisms involved. These include conduction, film convection and radiation effects together with the bulk heat generation by the resin exothermic reaction. Due to the complexity of the autoclave system, finite element software has been used for the [transient] analyses of the various process stages. All results are checked against data acquired from measurements made during actual process runs to accurately evaluate the model performance. “





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Busbar Insulation Capabilities

Both MV and LV Insulation is a composite of Epoxy resin impregnated paper Copper stocking earth Insulation class E (120°C)

The MV insulation comprises additionally capacitive grading (semi conducting paper layers) ensure even voltage stress through the insulation layer.

Table 5 Busbar Insulation Capabilities Insulation

Components Purpose Dimension MV

Material Epoxy resin impregnated paper layer

Guarantees void free PD free insulation IEC 60 137

Each Busbar and cylinder factory tested according to IEC 60 137.

Insulation thickness 22.5mm

dimensioned according to test voltage

Earth Layer Copper

stocking earth layer

To provide voltage free Surface of Busbar. Touch safety under power

(35mm² )Withstand 6.3kA 1 sec in case of short circuit

Capacitive grading Semi

conducting paper

To ensure even voltage gradient within insulating layer. Capacitive grading means smaller diameter Prevents flashover

36kV Busbar has 6 grading layers

Fire Both MV and LV insulation is completely selfextinguishing and contain no Halogens or other toxic substances.

A120 fire test In this test Busbars and Rockwool penetration material were tested The Busbars withstood 120 minutes. There were no toxic gases produced and the Busbars were shown to be self extinguishing.





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7.3COMPONENT CAPABILITY OUTER SHEATH

The Busbar outer sheathing can be colour coded according to customer requirements. Outer Sheath temperature is designed for this project to be < 50° C under power . Choice of sheath material as well as choice of IP ratings is shown below.

Within large projects there can be many different Zones with different environmental requirements.

The optimal outer sheath can be selected according to environmental conditions.

In one Busbar run, it is therefore possible to have both resin IP44 through IP66 and stainless steel or Aluminium IP68.

Metal outer sheath will provide Protection against mechanical damage from both Operations staff & rodents.

Degree of protection and selection of outer sheath must provide safety and environmental protection

Fig 26





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8 HANDLING & STORAGE

In accordance with the following regulations and policies

§ PBP General Assembly & Maintenance Instruction Manual for Installations

§ Local safety at work regulations.

§ Local electrical safety regulations





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9 ACRONYMS AND ABBREVIATIONS

Table 6 Acronyms, Abbreviations and terms

Acronym/Abbreviation/Term Description

ERIP Epoxy Resin Impregnated Paper

IP Degree of Protection

PD Partial Discharge





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10 APPENDIX



Documents

PBP Preissinger Isobus Technology Capabilities Version 2