Cable Terminations on Transformers

Connecting Principle, Function and Trend

PFISTERER Kontaktsysteme GmbH

Andreas Dobler

TRANSFORM Partner

Speaker
Andreas Dobler (M1972)
- born in Ludwigshafen/Rhein
- graduated from the University Kaiserslautern holding a degree of
electrical Engineering
- 1998-2004: ABB Energiekabel GmbH: Research & Development, later in
Product Management MV cable accessories
- since 2004: PFISTERER Kontaktsysteme GmbH
Product Management of pluggable cable accessories (CONNEX)
Product Manager of MV-CONNEX (since 2006)

Andreas Dobler, Pfisterer

07.06.2012

Page 2

Agenda

Connecting Principle
Medium Voltage
High Voltage

Function
Current Carrying Capability
Dielectric Strength
Mechanical Properties

3 worlds of a cable termination

Testing

Trends

Substitution of conventional terminations

Surge Arrester

Andreas Dobler, Pfisterer

07.06.2013

Page 3

Connecting principle - Medium Voltage (Um 52kV)

Air insulated

Outer Cone / Elbow Type

Inner Cone / Pluggable System

Bare bus bar and conductor

Polymer Housing

Metal enclosed / touch proof

Additional frame construction

needed

Connection of several cables per

phase on cable side possible

Connection of several cables per

phase on equipment side possible

Preventive action against animals

must be taken

Current rating limited

High current rating

Cable cross section up to

630mm feasible

Cable cross sections up to

800mm feasible

Low cost

Higher costs

Low cost

Andreas Dobler, Pfisterer

07.06.2013

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Connecting Principle - High Voltage (Um > 52kV)

Air insulated

Conventional Type / Wet Type

Dry Type / Pluggable Type

Bare bus bar and conductor

Epoxy insulator with oil filling

Metal enclosed / touch proof

Frame construction needed

Transformer compartment has to

be opened for assembly

Separation of cable system and

transformer in view of assembly
and testing

Preventive action against animals

must be taken

Relatively long assembly time

Integration of epoxy insulator in

transformer as an Interface

Space requirement very high

Dielectric test of cable system

only with additional effort feasible

Dielectric test of cable system

and transformer feasible

Medium flexibility

Low flexibility

Highest flexibility

Andreas Dobler, Pfisterer

07.06.2013

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Function of a cable termination

Main Functions of a Cable Termination

GIS or transformer compartment

Current Carrying Capability

Dielectric Strength

Mechanical Properties

Nominal

Field Controlling Elements

Compensation of Load Change

Short Circuit

Forces / Pressure

Fixation of cable

Andreas Dobler, Pfisterer

07.06.2013

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Function - HV - Cable Set Up

Conductor
Semi- conductive layer over conductor
Insulation XLPE or EPR
Semi- conductive layer over insulation
Semi- conductive crepe paper
Cable Shield
Metallic foil
Crepe Paper
Armouring

Outer Sheath

Andreas Dobler, Pfisterer

07.06.2013

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Function Size Determination

Size 0

Size 1

Size 2

Size 3 / 3S

Um

24kV

36kV

42kV

42 / 52kV

IN

250A

630A

800A

1250A

Cross Section *

70mm

240mm

400mm

800mm

Max. Diameter over

11,9mm / 23,5mm

20,1mm / 31,5mm

22,3mm / 36,0mm

34,6mm / 46,0mm

(36,0**)mm

(44,0**) mm

(55,0**) mm

conductor /
insulation

*valid only, if values comply to max. diameter over insulation / max. diameter over conductor
**diameter applicable only without capacitive voltage tap
Andreas Dobler, Pfisterer

07.06.2013

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Function Size Determination

Size 4

Size 5-S

Size 6

Size 6-S

Um

72,5kV

145kV

170kV

245kV

IN

2500A

2500A

2500A

2500A

Cross Section *

1600mm

1600mm

2500mm

2500mm

Max. Diameter over

50.4mm / 75mm

50.4mm / 76mm

64.9mm / 113.5mm

64.9mm / 113.5mm

conductor /
insulation
*valid only, if values comply to max. diameter over insulation / max. diameter over conductor

Andreas Dobler, Pfisterer

07.06.2013

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Function - Current Carrying Capability

-

Electrical Contacts are made at asperity peaks

5% rule 5% of the actual surface are current carrying

Oxide layer has to be broken

Line contact are therefore used for current
connections

Solutions
- Lamellas
- Spring Contact
- Al- Elast

Source: MultiContact
Source: Pfisterer

Source: BalSeal

- Tulip Contact
Current Carrying Capability

- others

Andreas Dobler, Pfisterer

07.06.2013

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Function - Current Carrying Capability

-

Contact System of a Cable Connector consists of

- Contact Cone
- Line Contact via Lamellas
- Allows movement of the conductor (load change)
- Contact to socket

- Tension Cone
- Line contact via grooves
- Contact between Cone and Conductor
- Thrust Piece

- Mechanical fixation
- base component to allow disassembly

Current Carrying Capability

Andreas Dobler, Pfisterer

07.06.2013

Page 11

Function - Dielectric Strength Field Control

Field grading techniques
1. without field grading
-

Applicable only below approx. 5kV

2. Geometrical grading

Usage in cable accessories

Homogeneous field distribution achieved by deflector

Standard for MV and HV cable accessories

3. Capacitive grading

Homogeneous field distribution by conductive layers of different

lengths/capacity

e.g. Oil / Air Bushing

4. Refractive Grading
-

field control by usage of a filled polymer with increased permittivity

5. Resistive Grading
-

field control by usage of a filled polymer with defined resistance

Dielectric Strength

Andreas Dobler, Pfisterer

07.06.2013

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Function - Dielectric Strength- Material Classification

Material

Description

Costs for
moulds

Usage

Main Disadvantage

Main Advantage

RTV

Room
Temperature
Vulcanizing

Low

Cable Accessories

- High level of
workmanship
- deflector has to be coated

- Cost effective for small volumes

- range taking

LSR

Liquid Silicone
Rubber

High

Cable Accessories

initial costs very high

- Volume conductive material can be

processed
- highly automated, range taking

Material of choice
HTV

High
Temperature
Vulcanizing

High

Insulators

initial costs very high

highly automated

EPDM

Ethylene
Propylene Dien
Monomer
(rubber)

High

Cable Accessories

Very High Shore Hardness

not range taking

Dielectric Strength

Andreas Dobler, Pfisterer

07.06.2013

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Function - Dielectric Strength - Forces

- Constant force required for electrical sealing.
- Silicone part gets widened

Overall length reduction due to

FV

inner stressing force

FF

spring force

FS

plug-in force

Dielectric Strength

Pges. pressure at the cable core

Pges. = f (FV, FF, FS)

Andreas Dobler, Pfisterer

07.06.2013

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Function - Mechanical Properties

Cable fixation (orange) during plugging

Cable must be straight and centered

- Integrated spring compensates movements due to

load change.

- Spring is getting pre-stressed during plugging

- Integrated cable clamp (green) is used for fixation
and positioning
- Cable weight is supported by an additional cable
clamp (blue)
Mechanical Properties

Andreas Dobler, Pfisterer

07.06.2013

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3 worlds of a cable termination

Transformer
Testing: IEC 60137

Dimensions: EN 50299

Cable Termination
Testing: IEC 60840 bzw. IEC 62067

GIS
Testing: IEC 62271-203
Dimensions: IEC 62271-209

Andreas Dobler, Pfisterer

07.06.2013

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Testing Routine Test

Visual Examination

Dimensional Examination

Material Test

Gas Tightness (Helium; < 4*10-7 bar cm/s)

Pressure Test (2*design pressure /1min)

X-Ray Test

Rated Power Frequency Voltage (275kV)

Partial Discharge (< 5pC at 2*U0)

Visual Examination

Sample Test

Temp. Shock Test (-40C +110C)

Andreas Dobler, Pfisterer

07.06.2013

Page 17

Testing Type Test

Type Test in view of a Cable Accessory

IEC 60840 (up to Um = 170kV)

IEC 62067 (up to Um = 170kV)

Type Test in view of a Transformer

Termination if defined as bushing
-

IEC 60137

Andreas Dobler, Pfisterer

07.06.2013

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Trends / Outlook - Flexibility

-

Flexibility even for HV equipment is becoming more and more important.

Pre-tested equipment is the standard.

Clear definition of scope of supply is mandatory.

Andreas Dobler, Pfisterer

07.06.2013

Page 19

Technical Trend Project

Pluggable Bushing Size 6 (170kV)
Technical data:
Max. operating voltage Um 170 kV
Nom. current IN 1250 A
Cantilever force (Cl. I) FB 1250 N
Temperature range - 20C* to 100C
Capacitive voltage tap

Test requirements acc. to IEC

Test cantilever force (Cl. I) FP 2500 N
Rated power freq. withst. Voltage UAC 325 kV
Rated lightning imp. withst. voltage BIL 750 kV
*other values on request
Andreas Dobler, Pfisterer

07.06.2013

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Technical Trend Project

Country: Germany
Quantity: 3 substations
Base Parameters: Refurbishment of
substation due to urbanization
scheduled within 5 years.
Connection to an existing Overhead
Line (OHL).
Connection to a cable system as part
of the refurbishment.
Task: Reduction of 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
Andreas Dobler, Pfisterer

07.06.2013

Page 21

Pluggable Bushing

Surge Arrester Size 5-S

Technical Trend - Flexbility

only for
testing

Andreas Dobler, Pfisterer

07.06.2013

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Technical Trend Substitution of conv. termination

Conventional type

Conventional

Assembly direct on the cable inside the equipment

Expansion box necessary if applied horizontally

Compartment has to be opened (Oil / Gas works

necessary)

Dry- Type Termination

Dry Type

Andreas Dobler, Pfisterer

Assembly of socket independent of cable termination

Final test of equipment in the factory without

additional Oil / Gas works at site

Clear definition of liabilities

Very compact

Reduction of assembly time

Maintenance free

Every position feasible

07.06.2013

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Technical Trend Substitution of conv. termination

Andreas Dobler, Pfisterer

07.06.2013

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Technical Trend - Offshore

Andreas Dobler, Pfisterer

07.06.2013

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Technical Trend Fully enclosed system, Protection

Lightning Overvoltages
-

Cause:

Atmospheric discharge

Duration:

Microseconds, e.g. 8/20

Magnitude:

> 5 Um

Can be limited by surge arresters (SA)

Positioning of Surge Arrester is crucial:

-

Due to travelling wave effects of fast

transient overvoltages,
surge arresters are effective only within
limited distance to arrester location

In other words: Do not install arresters too

far away from equipment to be protected!

Simplified calculation of the protective

zone (Details see IEC 60099-5, 60071-1,
60071-2).

Andreas Dobler, Pfisterer

xs =
xs
BIL
1.15
Ures
s
vtw

(BIL / 1,15) - Ures

2s

vtw

Protective zone
m
Basic insulation level
kV
Safety factor
Protection level of the arrester
kV
Front steepness of the overvoltage
kV/s
(usually about 1000 kV/s)
Speed of travelling wave:
300 m/s on overhead line (speed of light c")
200 m/s in cables
07.06.2013

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Technical Trend Fully enclosed system, Protection

GIS

Pluggable
AIS, Porcelain
AIS
Polymer Tube

Andreas Dobler, Pfisterer

AIS
Polymer Cage

07.06.2013

Page 27

Technical Trend Fully enclosed system, Protection

Minimum distance and thus maximum electrical protection of equipment

(e.g. GIS busbar, tansformer etc.) by integration of the arrester into the insulating system.

Fast installation and fast change after overload by pluggable connection.

No pressure vessel, no gas monitoring, no environment hazardous substances

by dry insulation made from elastomer material.

Pluggable solid state insulated surge arresters for high voltage combine the advantages of

GIS arresters
(maximum electrical protection)

Pluggable technology
(easy connection/disconnnection)

Solid state insulation

Andreas Dobler, Pfisterer

07.06.2013

Page 28

Technical Trend Projects

PLUG at Secondary Side

MV Connector at Primary Side (Germany)

Aluminum smelter (Irkutsk Russia)

Mobile Substation (Italy)

T- Joint Chemistry Plant, UK

Andreas Dobler, Pfisterer

07.06.2013

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The PFISTERER Group

Cable Systems
1921 founded by Karl Pfisterer
Turnover: 280 Mio. EUR
Employees: 1.500
Components

Family owned

Overhead Lines

Railway Catenary Systems

Andreas Dobler, Pfisterer

07.06.2013

Page 30

Thank You!

Contact details
Andreas Dobler
Produktmanager MV CONNEX
PFISTERER Kontaktsysteme GmbH
Rosenstr. 44
73650 Winterbach
Phone: +49 (0)7181 / 7005-340
mailto:andreas.dobler@pfisterer.de
http://www.pfisterer.de

Andreas Dobler, Pfisterer

07.06.2013

Page 31