Trends and Challenges of HV Cable Systems

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1 Trends and Challenges of HV Cable Systems Bruno Arnold Electrical Engineer FH Global Sales Far East, Latin America and India Pfisterer Business Unit PTS Cable

2 Trends and Challenges of HV Cable Systems Agenda Limited and expensive space for cable system and its substation Short outage and installation time, maintenance free More safety, easier installation and more reliability Higher power rating of cable systems

3 It is all about evolution

4 Trends and Challenges of HV Cable Systems Limited and expensive space for cable system and its substation Short outage and installation time, maintenance free More safety, easier installation and more reliability Higher power rating of cable systems

5 Limited and expensive space for cable system and its substation Approach: Compact plug accessories Cast Resin Joints up to 170 kv Connection Joints up to 550 kv El bow Joints up to 362 kv

at site Easy to install - pluggable IEC 62271-209 Transformer Dry type- no liquid insulation Same

6 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories GIS Dry type- no liquid insulation Bushing installed at factory No SF6 gas handling at site Easy to install - pluggable IEC Transformer Dry type- no liquid insulation Same components as GIS No oil works at site Easy to install - pluggable EN /DIN VDE Application

7 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories / cable connectors An Universal Connection Interface Transformer Testing: IEC Housing: EN Cable termination GIS Testing: IEC Housing: IEC Testing: IEC and IEC 62067

8 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories / cable connectors One solution for different applications - GIS and Transformer 550 kv 145 kv 24 kv

protection object Maximum electrical protection of equipment Pluggable technology Fast and easy installation Short outage time in case of

9 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories / surge arrester Dry pluggable surge arrester for transformers The surge arrester is installed directly on the GIS or transformer Shortest possible distance to protection object Maximum electrical protection of equipment Pluggable technology Fast and easy installation Short outage time in case of overload Dry insulation made from elastomer material: No pressure vessel No gas monitoring No clearance distance Dry pluggable surge arrester up to 145kV

for transformers Plug including contact and insulating part Polymer

10 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories / surge arrester Dry pluggable surge arrester for transformers Plug including contact and insulating part Polymer insulating part incl. field grading FRP tube housing Head flange incl. pressure release system

11 It is all about evolution

Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories Dry pluggable surge arrester up to 170kV (Case study) Country: Brasil Project: Comperj /

12 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories Dry pluggable surge arrester up to 170kV (Case study) Country: Brasil Project: Comperj / Petrol refinery Quantity: 26 pcs Voltage: Um 145 kv Year: 2013 Flexible transformer Interchangeability and relocation due to pluggable system Completely metal enclosed > Touchproof Protection at the core

13 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories Dry pluggable surge arrester up to 170kV (Case study) Country: Switzerland Client : EKZ Zürich Quantity: 8 pcs Voltage: Um 145kV Year: 2013 Easy to install meets installation experience. The technicians installed 8 Connex HV surge arrester 5-S in 2 days only.

BKW Bern Quantity: 12 pcs Voltage: Um 72.

14 Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories Dry pluggable surge arrester up to 170kV (Case study) Country: Switzerland Client : BKW Bern Quantity: 12 pcs Voltage: Um 72.5kV Year: 2012 Flexible transformer Easy to move at a new location, just plug-out then plug in Completely metal enclosed Touch proof design Less space required

Limited and expensive space for cable system and its substation Approach: Combined cable termination with surge arrester EST170SubSA termination with surge arrester up to 170kV Features and

15 Limited and expensive space for cable system and its substation Approach: Combined cable termination with surge arrester EST170SubSA termination with surge arrester up to 170kV Features and Application Space saving Dry type (NO liquid insulation) Easy installation on ground then lifting at final position Indoor and outdoor use with different pollution levels Perfect solution for earthquake regions Explosion poof

contact-resistance connections: Current capability up to 2500 A Surge Arrester Modularized height compensation

16 Limited and expensive space for cable system and its substation Approach: Combined cable termination with surge arrester ESTSub SA direct earthing ESTSub SAC- coil earthed / petersen coil Top bolt diameter 30, 40, or 50 mm Low contact-resistance connections: Current capability up to 2500 A Surge Arrester Modularized height compensation IXOSIL Cable termination Baseplate with multi-purpose hole pattern, rect. 270, 345, 400 mm Insulated or non-insulated mounting

termination with surge arrester up to 170kV (Case study) Client: Enmax

17 Limited and expensive space for cable system and its substation Approach: Combined cable termination with surge arrester EST170SubSA termination with surge arrester up to 170kV (Case study) Client: Enmax Calgary Canada Challenge: Installation on 30 meters Cable supplier: Taihan Korea 145kV

18 Trends and Challenges of HV Cable Systems Limited and expensive space for cable system and its substation Short outage and installation time, maintenance free More safety, easier installation and more reliability Higher power rating of cable systems

19 Short outage and installation time, maintenance free Approach : Compact pluggable accessories

Short outage and installation time, maintenance free Approach : Compact pluggable accessories Dry Pluggable Transformer Bushing up to 345kV Pluggable technology Very compact dimensions Fast and easy

20 Short outage and installation time, maintenance free Approach : Compact pluggable accessories Dry Pluggable Transformer Bushing up to 345kV Pluggable technology Very compact dimensions Fast and easy installation Short outage time in case of an damage Easy transportation Easy testing of transformer at factory Dry insulation made from elastomer material: Less weight Explosion proof Heat pipe technology for higher currents applicable No environment hazardous substances No loss of insulation media

Short outage and installation time, maintenance free Approach: Compact pluggable accessories Dry Pluggable Transformer Bushing up to 345kV Bushing

One integrated in the transformer (socket), the other consists of the conventional part and a plug connector Socket is permanently installed in the

21 Short outage and installation time, maintenance free Approach: Compact pluggable accessories Dry Pluggable Transformer Bushing up to 345kV Bushing Connector For conventional bushing, field control inside and outside transformer is in one piece Pluggable bushings have two pieces. One integrated in the transformer (socket), the other consists of the conventional part and a plug connector Socket is permanently installed in the transformer and air and oil tight Bushing is connected by plugging in Connection is done automatically in the socket during the plugging process Conventional Socket

Short outage and installation time, maintenance free Approach: Compact pluggable accessories Dry Pluggable Transformer Bushing up to 345kV (Case study) Country: Germany Quantity: 3 substations

22 Short outage and installation time, maintenance free Approach: Compact pluggable accessories Dry Pluggable Transformer Bushing up to 345kV (Case study) Country: Germany Quantity: 3 substations Connection to an existing Overhead Line Connection to a cable system as part of the new substation. Task: Short shut down time. Change of connecting elements from OHL to cable without oil works at the transformer. Solution: Transformer equipped with sockets as an interface, exchange of connecting elements

23 Short outage and installation time, maintenance free Approach: Compact pluggable accessories Dry Pluggable Transformer Bushing up to 345kV (Case study) Country: USA Quantity: 3 Transformers 345kV. Task: Resilience Transformer

24 Short outage and installation time, maintenance free Approach: Dry type easy lift outdoor terminations Dry self supporting termination up to 170kV

Short outage and installation time, maintenance free Approach: Dry type easy lift outdoor terminations Dry self supporting termination (EST) up to 170kV Features and Application Dry type (NO liquid

25 Short outage and installation time, maintenance free Approach: Dry type easy lift outdoor terminations Dry self supporting termination (EST) up to 170kV Features and Application Dry type (NO liquid insulation) Easy installation on ground then lifting at final position Self-supporting properties Indoor and outdoor use with different pollution levels Perfect solution for earthquake regions Explosion poof

Short outage and installation time, maintenance free Approach: Dry type easy lift outdoor terminations Dry self supporting termination up to 170kV (Case

26 Short outage and installation time, maintenance free Approach: Dry type easy lift outdoor terminations Dry self supporting termination up to 170kV (Case study 1) Installation in USA, 170 kv, Very tough safety conditions within substation Lifting of terminations is done by skilled people from network operator

Installation in Austria, 110 kv, No scaffolding on tower Two overhead line systems;

27 Short outage and installation time, maintenance free Approach: Dry type easy lift outdoor terminations Dry self supporting termination up to 170kV (Case study 2) Installation in Austria, 110 kv, No scaffolding on tower Two overhead line systems; First system continuous energized Second system shut down for 6 hours during lifting. Very short outage time

study 3) BKK Norway 145kV, No scaffolding

28 Short outage and installation time, maintenance free Approach: Dry type easy lift outdoor terminations Dry self supporting termination up to 170kV (Case study 3) BKK Norway 145kV, No scaffolding on tower Minimum shut down time due to installation on ground

29 Trends and Challenges of HV Cable Systems Limited and expensive space for cable system and its substation Short outage and installation time, maintenance free More safety, easier installation and more reliability Higher power rating of cable systems

required No heavy special tools required No pre-defined shear positions in the

30 More safety, easier installation and more reliability Approach 1: Step less shear bolt connector Features and Application Easy installation, no special skills required No heavy special tools required No pre-defined shear positions in the screw Always optimal contact pressure For joints and termination One type for Al or Cu conductor

31 More safety, easier installation and more reliability Approach1: Step less shear bolt connector Always optimal contact pressure

32 More safety, easier installation and more reliability Approach 2: Easy to install joint housing vertical closing Pfisterer joint housing kV

mechanism Easy and safe closing by a slight rotation sealed by a double sealing system Filling caps

33 More safety, easier installation and more reliability Approach 2: Easy to install joint housing vertical closing Outer housing Fiber glass reinforced PP-housing with 6 mm wall-thickness Closing mechanism Easy and safe closing by a slight rotation sealed by a double sealing system Filling caps With two large filling ports ensure for an easy and efficient filling procedure. Sealed by a double sealing system too.

34 More safety, easier installation and more reliability Approach 2: Easy to install joint housing vertical closing Bonding outlet Extra strong bonding terminal for bonding cable cross sections up to 630mm 2

35 Trends and Challenges of HV Cable Systems Limited and expensive space for cable system and its substation Short outage and installation time, maintenance free More safety, easier installation and more reliability Higher power rating of cable systems

Higher power rating of cable systems Approach : Enamelled wires in cable systems To reduce the skin and proximity losses, each single copper wire is insulated against

36 Higher power rating of cable systems Approach : Enamelled wires in cable systems To reduce the skin and proximity losses, each single copper wire is insulated against each other by insulating coating Two main advantages: 1. Higher current rating of the cable 2. Less conductor cross section for same current rating saves money Thank you.

37 Higher power rating of cable systems Approach: Enamelled wires in cable systems Example calculation for enamelled wires: Current Carrying Capability Ratio C urrent inc reas e EN EN Cable type EN EN C urrent inc reas e Higher current carrying capability by using enamelled wires instead of standard conductors

38 Higher power rating of cable systems Approach: Enamelled wires in cable systems Example calculation for enamelled wires : Production Costs Ratio EN EN EN Cable type EN C os t inc reas e C urrent inc reas e C urrent inc reas e C os t inc reas e Less production costs for same or higher current carrying capabilities

Higher power rating of cable systems Approach: Enamelled wires in cable systems Until today the main disadvantage was a much longer installation time

39 Higher power rating of cable systems Approach: Enamelled wires in cable systems Until today the main disadvantage was a much longer installation time and higher installation costs as the insulating coating had to be removed from each single wire for a proper connection inside joints or terminations.

40 Higher power rating of cable systems Approach : Enamelled wires in cable systems Solution : Front contact connection system of for joint and termination Pfisterer type: FrontCon connecting system for enamelled conductor's

41 Thank You for Your Time

ECONOMICAL 36 kv CABLE SYSTEM FOR THE BELGIAN NETWORK

ECONOMICAL 36 kv CABLE SYSTEM FOR THE BELGIAN NETWORK J. Becker NEXANS BENELUX S.A. F. Musique ELECTRABEL S.A. ABSTRACT In order to tackle the deregulated market with confidence and in a realistic way,