Trends and Challenges of HV Cable Systems

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

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

It is all about evolution

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

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

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 62271-209 Transformer Dry type- no liquid insulation Same components as GIS No oil works at site Easy to install - pluggable EN 50299 /DIN VDE 0532-601 Application

Limited and expensive space for cable system and its substation Approach: Compact pluggable accessories / cable connectors An Universal Connection Interface Transformer Testing: IEC 60137 Housing: EN 50299 Cable termination GIS Testing: IEC 62271-203 Housing: IEC 62271-209 Testing: IEC 60840 and IEC 62067

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

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

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

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 / 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

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.

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 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

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

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 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 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 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

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

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 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 study 1) Installation in USA, 170 kv, Very tough safety conditions within substation Lifting of terminations is done by skilled people from network operator

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

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

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

More safety, easier installation and more reliability Approach1: Step less shear bolt connector Always optimal contact pressure 1 2 3 4

More safety, easier installation and more reliability Approach 2: Easy to install joint housing vertical closing Pfisterer joint housing 72-300kV

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.

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

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.

Higher power rating of cable systems Approach: Enamelled wires in cable systems Example calculation for enamelled wires: Current Carrying Capability Ratio 1.8 0 1.6 0 1.4 0 1.2 0 1.0 0 0.8 0 0.6 0 0.4 0 0.2 0 0.0 0 C urrent inc reas e 1200 1200 EN 1600 1600 EN Cable type 2000 2000 EN 2500 2500 EN C urrent inc reas e Higher current carrying capability by using enamelled wires instead of standard conductors

Higher power rating of cable systems Approach: Enamelled wires in cable systems Example calculation for enamelled wires : Production Costs Ratio 2.0 0 1.8 0 1.6 0 1.4 0 1.2 0 1.0 0 0.8 0 0.6 0 0.4 0 0.2 0 0.0 0 1200 1200 EN 1600 1600 EN 2000 2000 EN 2500 2500 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 and higher installation costs as the insulating coating had to be removed from each single wire for a proper connection inside joints or terminations.

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

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